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PI Mercury C-862 Series User Manual

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MS 74E User Manual
C-862 Mercury™
DC-Motor Controller
Release: 8.5.2
Date: 2006-10-09
This document describes the
following product(s):
C-862.xx
DC-Motor Controller, Mercury™ Networkable
Single-Axis
© Physik Instrumente (PI) GmbH & Co. KG
Auf der Römerstr. 1 ⋅ 76228 Karlsruhe, Germany
Tel. +49 721 4846-0 ⋅ Fax: +49 721 4846-299
s ⋅ www.pi.ws
info@pi.w

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Summary of Contents for PI Mercury C-862 Series

  • Page 1 This document describes the following product(s): C-862.xx DC-Motor Controller, Mercury™ Networkable Single-Axis © Physik Instrumente (PI) GmbH & Co. KG Auf der Römerstr. 1 ⋅ 76228 Karlsruhe, Germany Tel. +49 721 4846-0 ⋅ Fax: +49 721 4846-299 s ⋅ www.pi.ws info@pi.w...
  • Page 2 The product complies with the requirements of the EMC Directive 89/336/EEC and CE markings have been affixed on the devices. Physik Instrumente (PI) GmbH & Co. KG is the owner of the following company names and trademarks: PI®, PIMikroMove®, Mercury™, Mercury™ Step...
  • Page 3 The software tools and any stages which might be delivered with C-862 DC-Motor Controller are described in their own manuals. All documents are available as PDF files via download from the PI Website (www.pi.ws) or on the included PI Motion CD. For updated releases contact your Physik Instrumente sales engineer or write info@pi.ws.

  • Page 4: Table Of Contents

    Contents Introduction Prescribed Use................5 Safety Precautions ..............5 Product Survey and Contents of Delivery ........6 Front and Rear Panel Elements ..........8 Quick Start System Description Firmware Version Notes............11 Control of Multiple Axes ............11 LED Status Indicators...............12 Default Values ................13 Cable Connections ..............14 Limit Sensors ................15 Position Reference Sensors.............15 DIP Switch Settings..............16...
  • Page 5 Contents Command Response Command Execution Mode Direct Mode ................29 Macro Execution Mode.............29 Working with Macro Commands Basic Macro Operation.............31 8.1.1 Defining a Macro ..............31 8.1.2 Executing (Starting) a Macro............ 31 8.1.3 Stopping a Macro ..............32 8.1.4 Limitations ................32 8.1.5 Macro #0 (autostart macro)............
  • Page 6 Contents Technical Data 13.1 Specifications ................79 13.2 Dimensions ................81 13.3 Motor-Connector Pin Assignment ..........82 13.4 I/O Connector ................83...

  • Page 7: Introduction

    Mercurys™ are designed to operate motorized PI stages. The starter package comes with all connecting cables, power supply and software necessary for immediate operation.

  • Page 8: Prescribed Use

    Introduction Prescribed Use Based on its design and realization, the C-862 Mercury™ Controller is intended to drive PI stages with analog or PWM DC motors. Observe the safety precautions given in this User Manual. Operation other than instructed here may affect the safeguards provided.

  • Page 9: Product Survey And Contents Of Delivery

    Mercury™ Controller (order# C-862.10) Power Supply (order# C-890.PS) Power supply line-voltage cables (German & US) RS-232 null modem cable for PC connection (order# C-815.34) PI Motion CD (software package) Network cable (order# C-862.CN) MS 74E User Manual (this document) C-862.10 Mercury™ Controller Unit C-862K003 Mercury™...
  • Page 10 Mercury™ Power Supply, 15 VDC C-890.P12 Mercury™ Power Supply, 12 VDC C-990.CD PI Motion CD including Mercury™ Software Tools All Mercury™ controllers are shipped with a Windows™ software application package. A power supply (C-890.PS) is included only in the C-862.00 set.

  • Page 11: Front And Rear Panel Elements

    Fig. 4: Rear view of C-862 Mercury™ Rear Labeling Element Type Purpose 12 to 15 VDC barrel connector Power supply, center + DIGITAL I/O digital input / output MOTOR sub-D 15(f) Motor /Stage connection www.pi.ws C-862 MS 74E Release 8.5.2 Page 8...

  • Page 12: Quick Start

    C-862 Mercury controllers accept 12 to 15 V DC. Connecting a 24 VDC power supply (e.g. that from a C-663 stepper motor controller) may damage the C-862 units or the connected stages. Connect appropriate power to the controllers www.pi.ws C-862 MS 74E Release 8.5.2 Page 9...
  • Page 13 SC (select controller, p. 67) command in the autostart macro on that device (see p. 24) www.pi.ws C-862 MS 74E Release 8.5.2 Page 10...

  • Page 14: System Description

    PC’s COM port output stages. If there is a Mercury™ in the Network with a USB interface (e.g. C-663), this limitation can be circumvented by using it to connect to the host via USB. www.pi.ws C-862 MS 74E Release 8.5.2 Page 11...

  • Page 15: Led Status Indicators

    This indicates an internal busy mode in which communication is suspended. Some commands like UD (update: busy for about 0.5 seconds) and RM (busy for about 2 seconds) cause LED brightness fluctuations. www.pi.ws C-862 MS 74E Release 8.5.2 Page 12...

  • Page 16: Default Values

    Proper motion control parameter settings depend on the individual stage and drive connected. Once suitable parameters are found, they can be stored permanently using the UD (update) command. www.pi.ws C-862 MS 74E Release 8.5.2 Page 13...

  • Page 17: Cable Connections

    Controller. Irreparable damage could result. The C-862 sub-D-15 connector for the motor connection is compatible with all PI DC-motor stages and drives. Use the C- 815.38 Motor Cable for stage connection. Stepper motor drives use the same connector but are not compatible!

  • Page 18: Limit Sensors

    Each of the two switches will interrupt motion in a particular direction. If positioning equipment from PI is used, the limit switches or sensors are pre-wired for operation with Mercury™ controllers.

  • Page 19: Dip Switch Settings

    Fig. 6: slider up slider down Function of the 8-bit switch labeled "ADDRESS" Switch 1 to 4: Device address (0 to 15) Switch 5 and 6: Baud rate Switch 7 and 8: not used www.pi.ws C-862 MS 74E Release 8.5.2 Page 16...

  • Page 20: Address (Sw1-Sw4) And Baud Rate Setting (Sw5-Sw6)

    PC connection (order # C-815.34). 6 ON 7 ON 8 OFF 9 OFF 10 OFF Factory settings are 11 OFF shown in bold 12 OFF 13 OFF 14 OFF 15 OFF www.pi.ws C-862 MS 74E Release 8.5.2 Page 17...

  • Page 21: Internal Jumper Settings

    Normal operation mode: Jumper not Installed Jumper X1: Operating Mode Normal operation mode: Jumper at position closest to edge Firmware update mode: Jumper at position farthest from edge 3.10 Firmware Update Fig. 7: Firmware update program interface www.pi.ws C-862 MS 74E Release 8.5.2 Page 18...
  • Page 22 Start Button Wait about 3 minutes until data transfer has completed, Disconnect power Set jumpers back: reinstall jumper X3 and set jumper X1 back to right (outer) position 10 Update is now completed. www.pi.ws C-862 MS 74E Release 8.5.2 Page 19...

  • Page 23: Input / Output Lines

    The following commands handle the I/O lines: CN, CF, CP, TC, TA, WN, WF, XN, XF (for descriptions see command reference). www.pi.ws C-862 MS 74E Release 8.5.2 Page 20...

  • Page 24: Operating Notes

    Mercury™ controller connected. An address selection code consists of 2 characters: an ASCII decimal 1 followed by an ASCII “numeral” from 0-9 or A-F (decimal 48-57 and 65-70) for the device address of 0-15. www.pi.ws C-862 MS 74E Release 8.5.2 Page 21...

  • Page 25: Setting Motion Control Parameters

    Now try GH CR. The motor should return to the position it occupied when power was applied. Now for some really advanced programming: enter MR1000,WS100,TE CR. The motor should move 1000 counts www.pi.ws C-862 MS 74E Release 8.5.2 Page 22...

  • Page 26: Networking

    Mercury™ controller connected. Alternatively, an SC (select controller, p. 67) command in the autostart macro (p. 33) of one of the Mercury™s can be used to select communication with that device. www.pi.ws C-862 MS 74E Release 8.5.2 Page 23...

  • Page 27: Address Selection Code

    0x39 (decimal 57) 10(A) 0x01 0x41 (decimal 65) 11(B) 0x01 0x42 (decimal 66) 12(C) 0x01 0x43 (decimal 67) 13(D) 0x01 0x44 (decimal 68) 14(E) 0x01 0x45 (decimal 69) 15(F) 0x01 0x46 (decimal 70) www.pi.ws C-862 MS 74E Release 8.5.2 Page 24...

  • Page 28: Command Types

    This feature makes it very easy to continuously execute the same command simply holding down the Enter key. Both uppercase and lowercase characters are valid, and spaces are allowed. www.pi.ws C-862 MS 74E Release 8.5.2 Page 25...

  • Page 29: Compound Commands

    Once this compound command is entered, it remains in the buffer until replaced by another non-blank line of input and can be re-executed by sending a carriage return CR alone (blank line). www.pi.ws C-862 MS 74E Release 8.5.2 Page 26...

  • Page 30: Single-Character Commands

    Macro n instead of being executed XN4 (Execute if ON) causes all base commands following it to be skipped unless digital input line 4 is ON (high). www.pi.ws C-862 MS 74E Release 8.5.2 Page 27...

  • Page 31: Command Response

    The reports are suppressed, however, if controller is put in the deselected state or the command is executing from a stored macro. www.pi.ws C-862 MS 74E Release 8.5.2 Page 28...

  • Page 32: Command Execution Mode

    Deselected controller receives address selection code. Consequently the running macro will be interrupted. Controller is power-cycled or reset with no Macro #0 defined Macro which called another macro terminates www.pi.ws C-862 MS 74E Release 8.5.2 Page 29...
  • Page 33 Command Execution Mode Macro terminates and no return to a calling macro is required To achieve a full understanding of how this works, see the EM command description. www.pi.ws C-862 MS 74E Release 8.5.2 Page 30...

  • Page 34: Working With Macro Commands

    "MR1000,WS100,MR-1000,WS100,RP5" is stored as macro 8.1.2 Executing (Starting) a Macro To execute (call up, run) the macro defined above, just issue the command EM3. Unlike MD# commands, EM# commands can be used anywhere in compound commands. www.pi.ws C-862 MS 74E Release 8.5.2 Page 31...

  • Page 35: Stopping A Macro

    If there is no need to return to the calling command, then macros may call macros without limitation. Example: MD1,EM2,EM3,EM4,EM5,EM6 www.pi.ws C-862 MS 74E Release 8.5.2 Page 32...

  • Page 36: Macro #0 (Autostart Macro)

    Pushbuttons The C-862.PB3 Pushbutton Box connects to the Mercury™ I/O connector and allows to apply a TTL signal at the input lines and indicate by LEDs the status of the output lines. www.pi.ws C-862 MS 74E Release 8.5.2 Page 33...

  • Page 37: Macros Under Pushbutton Control

    PC connected. Example 1: Autostart macro, initialization and “endless” loop functionality. [MC00] EM5,EM13 [MC05] BF,DP200,DI,DD200,SV80000,SA400000,FE2,WS100,DH ,SV250000 [MC13] EM14,EM15,EM16,EM17,WA20,RP,RP www.pi.ws C-862 MS 74E Release 8.5.2 Page 34...
  • Page 38 LEDs indicate the progression. Every 200 ms the speed is reset and the number of LEDs lit is changed accordingly. Note that the most significant bit for CP corresponds to the bottom LED. www.pi.ws C-862 MS 74E Release 8.5.2 Page 35...
  • Page 39 The desired mode is selected by pressing the corresponding button upon start-up; thereafter the buttons function as defined for the mode chosen, as can be seen from the macro descriptions. www.pi.ws C-862 MS 74E Release 8.5.2 Page 36...
  • Page 40 [MC30] XN4,MR-4000,WS50,WA20 These macros can be stored permanently in the Mercury™ Controller. The data file itself is an ASCII file and can be stored using the file manager of the Mercury™Move Software. www.pi.ws C-862 MS 74E Release 8.5.2 Page 37...
  • Page 41 If a button is just pressed, another macro is called. If not, Mercury™ goes to normal operation and waits for command input. www.pi.ws C-862 MS 74E Release 8.5.2 Page 38...
  • Page 42 Macro #21 If button #1 is pressed, the motor moves to position 100,000. The digital output pattern is set to 1 (LED #1 ON). The macro exits when the button is released. www.pi.ws C-862 MS 74E Release 8.5.2 Page 39...
  • Page 43 If button #4 is pressed, the motor moves -4000 steps, waits until the position is reached, then waits for another 20 ms and repeats the move as long as the button remains depressed. www.pi.ws C-862 MS 74E Release 8.5.2 Page 40...

  • Page 44: Software

    MMCRun Version 8.22 or higher MMCRun is a Windows operating software interface for Mercury™ Class controllers. It is now described in a separate manual, document number MS139E, available on the PI Motion CD (Release 9.60 or higher) www.pi.ws C-862 MS 74E Release 8.5.2...

  • Page 45: Mercury™ Joystick Control

    Joystick control is implemented with a separate host software program, MJoy. See the Mercury™ Joystick Software Manual (MS 88E) for details. www.pi.ws C-862 MS 74E Release 8.5.2 Page 42...

  • Page 46: Troubleshooting

    (c) There may be an autostart macro stored in the controller. Sending any command will interrupt the macro, unless that macro falsely addresses the controller (SC command, p. 67). Once interrupted, the macros can be examined or deleted. www.pi.ws C-862 MS 74E Release 8.5.2 Page 43...
  • Page 47 (command LH or LL) or not activated (command LN) (b)Non-PI stage limit signal not compatible with Mercury™’s limit signal input (e.g. insufficient current source or sink). Contact PI and stage manufacturer to discover who is at fault www.pi.ws C-862 MS 74E Release 8.5.2...

  • Page 48: Command Reference

    All commands are checked for acceptability before execution begins. MR, for example, must be followed by a minimum of 1 and a maximum of 9 digits to accommodate the allowable range of motion. www.pi.ws C-862 MS 74E Release 8.5.2 Page 45...

  • Page 49: Errors And Reports

    (see also chapter "Address Selection code" ). Address selection at power up If the Mercury™ should be powered up with enabled communication, there is a special command that can be used: www.pi.ws C-862 MS 74E Release 8.5.2 Page 46...
  • Page 50 (the controller would not execute it from the RS-232 input unless if were already selected, in which case the command would be unnecessary). Selecting more than one controller in a network at startup is not recommended. www.pi.ws C-862 MS 74E Release 8.5.2 Page 47...

  • Page 51: Commands In Alphabetic Order

    Report checksum Define d-term (derivative gain) Define home Define i-term (integral gain) Define integration limit Define p-term (proportional gain) Set Echo OFF Execute Macro Set Echo ON Find edge (find origin position ) www.pi.ws C-862 MS 74E Release 8.5.2 Page 48...
  • Page 52 Repeat from beginning of line Reset (like power-on reset) Set Acceleration Select controller Set maximum following error Stop motion smoothly and move back Set Velocity Tell analog input value Tell board address www.pi.ws C-862 MS 74E Release 8.5.2 Page 49...
  • Page 53 Wait channel ON Wait stop Execute if channel OFF Execute if channel ON Single Character 39 (0x27) Command: TP (Tell Position) Single Character 35 (0x23) Command: TC (Tell Channel) Single Character 37 (0x25) www.pi.ws C-862 MS 74E Release 8.5.2 Page 50...

  • Page 54: Motion And Sequencing Commands

    Stop motion smoothly and move back Define home Go home Motor on Motor off Move relative Move absolute Repeat from beginning of line Wait absolute time Wait stop Find edge (find origin position) www.pi.ws C-862 MS 74E Release 8.5.2 Page 51...

  • Page 55: Parameter Setup Commands

    Get integration limit Tell analog input value Tell board address Tell channel (digital input) Tell iteration number Tell status Tell macro contents none Tell Macro Zero none Tell programmed velocity Tell programmed acceleration www.pi.ws C-862 MS 74E Release 8.5.2 Page 52...

  • Page 56: Utility Commands

    Reset all parameters to default and perform a new start Select controller Update flash 12.2.7 Macro Commands Command Function Macro definition Execute Macro Reset (erase) macro Report macro contents Tell Macro Zero www.pi.ws C-862 MS 74E Release 8.5.2 Page 53...

  • Page 57: I/O Commands

    Single-Character Commands Char Command ASCII ASCII Report Comment decimal generated "?" 0x3F E:xxx Tell Position Error "(" 0x28 F:xxx Tell Following Error "%" 0x25 S:xxx Tell Status "#" 0x23 H00:xxx Tell Channel www.pi.ws C-862 MS 74E Release 8.5.2 Page 54...

  • Page 58: Command Reference In Alphabetic Order

    If you want to smoothly stop the motor, use the AB1 command instead. Example: www.pi.ws C-862 MS 74E Release 8.5.2 Page 55...
  • Page 59 The factory default power-up state is 0 V (brake on) With M-5x1.DD stages, the high signal on line #1 is required to enable the motor amplifier. www.pi.ws C-862 MS 74E Release 8.5.2 Page 56...
  • Page 60 2 high, channels 3 and 4 low, and so on. Command: CPnCR Parameter: n is interpreted as a decimal number representing the bit pattern for output channels 1 to 4. Report: none Example: www.pi.ws C-862 MS 74E Release 8.5.2 Page 57...
  • Page 61 Sets the current motor position to 0. DHCR Define Integral gain Sets the gain to be applied to the integral term in the PID algorithm. The primary function of this term is to overcome friction-induced static errors. www.pi.ws C-862 MS 74E Release 8.5.2 Page 58...
  • Page 62 If the EM command is executed in a macro, control will be returned to the command after EM unless the called macro itself calls another macro. www.pi.ws C-862 MS 74E Release 8.5.2 Page 59...
  • Page 63 Use this option when referencing M-500 series stages. n=3: Search starts in positive direction if the reference line input level is low. Otherwise the search starts in negative direction. Examples: www.pi.ws C-862 MS 74E Release 8.5.2 Page 60...
  • Page 64 Excessive Error condition. Go Home The Go Home command causes the motor to move to the currently defined zero position. Equivalent to an MA0 (Move to zero position) command. Example: www.pi.ws C-862 MS 74E Release 8.5.2 Page 61...
  • Page 65 The target is changed to the position at which the limit switch was encountered. Movement in the reverse direction is not affected. www.pi.ws C-862 MS 74E Release 8.5.2 Page 62...
  • Page 66 To define a macro, use MD followed by the desired macro number and a comma, and then write the command (base or compound command). Examples: www.pi.ws C-862 MS 74E Release 8.5.2 Page 63...
  • Page 67 When this command is issued, the motor no longer holds its position actively (servo-control is turned off) and may be moved freely. The MF command is used to prevent unwanted movement or to allow for manual positioning of the unit. The www.pi.ws C-862 MS 74E Release 8.5.2 Page 64...
  • Page 68 DH command to set the position to 0, then turn the motor/encoder one revolution. Now the TP command will report the number of encoder counts/ revolution. PI stages have incremental encoders with from 2000 to 4000 counts/ rev. Motor ON Returns the Mercury™...
  • Page 69 All values are restored to their defaults. If the autostart macro (Macro 0) exists, it will be executed. Remove Macro Zero Used to remove the autostart macro (macro 0) from the memory. www.pi.ws C-862 MS 74E Release 8.5.2 Page 66...
  • Page 70 TF command. For maximum system safety, use the SM command to limit following error to a value slightly above that required for normal operation. www.pi.ws C-862 MS 74E Release 8.5.2 Page 67...
  • Page 71 Sets the velocity of motion to SV40000CR 40,000 counts per second. Tell Analog Input Analog values can be read through the input channels 1 to 3 with a resolution of 8 bit. www.pi.ws C-862 MS 74E Release 8.5.2 Page 68...
  • Page 72 4 channels is reported as a hexadecimal number from 0 to F with each bit corresponding to the state of one of the channels.(LSB = ch. 1) Examples: www.pi.ws C-862 MS 74E Release 8.5.2 Page 69...
  • Page 73 Every 150 ms the actual distance from the target is reported. As with any RP loop, the output may be stopped by sending any character except a single-character command or address selection code. Report: "E:+0000000000" www.pi.ws C-862 MS 74E Release 8.5.2 Page 70...
  • Page 74 Displays all currently stored macro commands. If n = 0 or not specified, all macros (except the autostart macro) will be displayed. To display the autostart macro, use the TZ command. Since macros may be defined in any order, the TM www.pi.ws C-862 MS 74E Release 8.5.2 Page 71...
  • Page 75 The TS command reports the status of the system, its motion and limit switch states. Example: "S:04 A8 04 03 02 00" First hex digit holds bits 7 through 4, last hex digit holds bits 3 through 0, LSB is bit 0. www.pi.ws C-862 MS 74E Release 8.5.2 Page 72...
  • Page 76 Bit 7: Signal Lines Inputs Bit 0: Bit 1: Reference signal input Bit 2: Positive limit signal input Bit 3: Negative limit signal input Bit 4: Bit 5: Bit 6: Bit 7: www.pi.ws C-862 MS 74E Release 8.5.2 Page 73...
  • Page 77 (1 < n < 65,535) Measures and reports the number of encoder counts moved during the previous n milliseconds. If the parameter is omitted, the time period used is 1000 ms (1s). www.pi.ws C-862 MS 74E Release 8.5.2 Page 74...
  • Page 78 Tell Acceleration Reports acceleration value setting (not the current acceleration). This is the acceleration the controller will try to use at the beginning and end of a move. Command: TLCR "L:+0000170000" Report: www.pi.ws C-862 MS 74E Release 8.5.2 Page 75...
  • Page 79 Reports the copyright notice and revision level of the installed firmware. transmit: VECR Report: "(C)2000-42 DIVA Automation, Inc./PI GmbH Karlsruhe & Co. KG, Ver. 8.40, 13 Jan 2004" Wait Absolute (0 < n < 65,535) Inserts a wait period of n milliseconds before executing the next command.
  • Page 80 This command moves the motor for 5000 counts and waits for 1 second (default value, used if no number is specified) after the motor has completed the move before executing the TE command (Tell error) and reporting the error www.pi.ws C-862 MS 74E Release 8.5.2 Page 77...
  • Page 81 Execute if ON (range of n: 1...4) Execute the remainder of a command line only if input channel n is ON (+5V). Command: XNnCR Parameter: n indicates the input channel. Report: none www.pi.ws C-862 MS 74E Release 8.5.2 Page 78...

  • Page 82: Technical Data

    The RS-232 output stages of some PCs may not be capable of driving more than 6 units; if the network contains a unit with USB (e.g. C-663), use it to interface to the PC to circumvent this limitation. www.pi.ws C-862 MS 74E Release 8.5.2 Page 79...
  • Page 83 ASCII format, compound & macro command capability (non-volatile EEPROM); GCS (via DLL) User operating software MMCRun, PIMikroMove® Software drivers GCS (PI General Command Set) DLL, LabView™ drivers, native Mercury™ DLL Supported functionality Start-up macro Internal safety features Watchdog timer Miscellaneous Operating temperature range 0 to 50°C...

  • Page 84: Dimensions

    Technical Data 13.2 Dimensions Decimal places separated by commas in drawings. Fig. 12: C-862 Mercury dimensions www.pi.ws C-862 MS 74E Release 8.5.2 Page 81...

  • Page 85: Motor-Connector Pin Assignment

    Negative limit signal (input) Positive limit signal (input) Reference signal (input) Limit GND Encoder: A(+) / ENCA (input) Encoder: A( - ) (input) Encoder: B (+) / ENCB (input) Encoder: B ( - ) (input) www.pi.ws C-862 MS 74E Release 8.5.2 Page 82...

  • Page 86: I/O Connector

    Part Numbers Connector at controller: 3M part number: 10214-52B2JL Connector at cable: 3M part number: 10114-3000VE I/O Cable (order# C-862.IO), Pin Assignment Fig. 13: Pin, wire colors and signals Fig. 14: Cable connector www.pi.ws C-862 MS 74E Release 8.5.2 Page 83...

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