USER`S MANUAL - Advanced Control Systems
Contents
1. Figure 2 2 Motor Connection To MCU 2 Unit 2 4 Power Connections Connect external power supply to motor power terminal block as indicated on the back panel of MCU 2 unit common ground to COM 12VDC to LV 36VDC to HV Connect power supply line cable to 115 VAC OUT connector on the back of MCU 2 unit Use supplied AC power cable to connect MCU 2 to AC line power 19 Advanced Control Systems MCU 2 2 5 Encoder Limits Connections When incremental encoder and limit inputs are utilized connect these devices per Fig 2 4 Busy Line TTL Compatible LO when stepping MCU 2 Enc Lim Connector External Inputs Encoder Inputs Incremental Figure 2 5 Encoders Limits Home Interconnect 20 Advanced Control Systems MCU 2 2 6 Communication Ports Connections Connect RS 232 Port of MCU 2 DB25 type connector to terminal or host computer serial port per connection diagram on Fig 2 5A or Fig 2 5B Pin 5 on MCU 2 is an output LO on Pin 5 indicates that MCU 2 is ready for new command HOST DB25 MCU 2 DB25 2 TX 3 Fig 2 5A DB25 to DB25 Communication Cable MCU 2 HOST DB25 DB9 S 2 ae 3 5 CTS Fig 2 5B DB25 to DB9 Communication Cable When there is more than one MCU 2 in the system they must be daisy chained via RS 485 communication ports and only one MCU 2 must be connected via RS 232 communication cable to the host RS 485 Standard defines drives and receivers for balanc2. 06 7 07 8 08 9 09 10 10 11 11 12 12 13 13 14 14 15 15 12 Advanced Control Systems MCU 2 1 7 Power Plan The requirements of the controller driver are separated from the requirements of the motor to provide isolation of electrical noise allow easy integration of heavy components into equipment and permit tailoring of electrical and mechanical arrangements The unit requires 115 VAC power at 60 Hz drawing up to 1 0 ampere This supplies the needs of displays logic communications and encoders Motor power consists of unregulated DC in two voltage ranges 10 to 15 and 36 to 42 Current draw can be up to 24 amperes depending on the motors used The motor power source should be able to supply and accept high current surges A 10 000 microfarad capacitor connected across each of the two voltages is adequate Back panel potentiometers are used to adjust motor torque after which they are locked Each motion axis has two torque potentiometers one marked HIl gh the other LO w High voltage pulse width torque or high speed torque or torque at speed is the adjustment for smooth operation of the motor at the highest speed required under equipment operating conditions This adjustment is at its minimum when the potentiometer is fully counterclockwise and at is maximum in the fully clockwise position Motor temperature is directly affected by this adjustment Low voltage current switching duty cycle torque or holding to
3. Holding JOG pushbutton depressed motor executes jog motion constant low speed of operation no ramping Holding SLEW pushbutton depressed motor goes into slew motion starts at base speed ramps up to slew speed Jog base and slew speed are to be preprogrammed using appropriate data enter instructions 4 3 Automatic Mode of Operation Host computer can be simulated by RS 232 Terminal either hand held CRT It must be set to correspond to communications parameters mode with internally generated line feed after receiving carriage return character This enables the operator to see all the control messages and responses Communication on RS 485 interconnect link is half duplex therefore communication on RS 232 line is simplex only one direction at a time The control program must operate on master slave principle when any of the MCU 2 units are responding Pin 5 of RS 232 connector goes LO In Normal Auto Mode all MCU 2s are in receive mode When host sends a message it is received and analyzed by all units At that time the units are not 39 Advanced Control Systems MCU 2 able to receive next message The host program should insert approximately 50mSec delay between consecutive commands or wait for a response 40 Advanced Control Systems MCU 2
4. executes index of 10000 steps in positive direction using preprogrammed base rate top rate and ramping index NOTE Base rate is stored in base rate register Data Block 01 contains top rate and ramping index Instruction 03107 Response 03 Function Motor 03 executes index of preprogrammed number of steps in preprogrammed direction NOTE Data Block 07 contains distance direction top rate and ramping index J Jog Rate Enter Examine Instruction 03J 500 Response 03 Function Rate 500 steps sec is entered into jog rate register for later use in manual jog mode NOTE Jog rate is usually set below start stop speed There is no ramping in manual jog mode Instruction 03J Response 03J 500 Function Jog rate is examined it is 500 31 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples K Rate Division Constant Enter Examine Instruction 03K 10 Response 03 Function Controller is programmed with rate division constant 10 All preprogrammed stepping and ramping rates are divided by 10 Instruction 03KI Response 03K 104 Function Rate division is examined it is 10 L Limit Function Instruction 03L Response 03 Function Motor 03 moves in positive direction at base speed until HI is recognized on limit input NOTE F and Q instructions are active in limit function M Motion Status Examine Instruction 03M Response O3M 00 Function Controller 03 responded w
5. 10 000 steps second using ramp data in data Block 00 Instruction 03825 Response 03 Function Controller 03 ramps to preprogrammed speed in data block 25 using direction and ramp index in data block 25 34 Advanced Control Systems MCU 2 NOTE Slew function enables the host controller to generate various velocity profiles The very first slew instruction defines the direction of rotation Speed can be changed by use of the three slew formats direction information is being ignored 3 5 Instruction Set Specifics and Examples U Unit Configuration Instruction 03UPEH Response 03 Function Controller 03 is programmed for even parity NOTE Even parity mode will become active on the next power reset Instruction 03UPOJ Response 03 Function Controller 03 is programmed for odd parity Instruction 03UPN Response 03 Function Controller 03 is programmed to ignore parity bit on receive and to transmit 0 for parity bit on transmit Instruction 03UA17W Response 03 03AW Response 03 Function Controller 03 new address is programmed to be 17 NOTE This new address becomes active on the next power reset Address select switch must be set to 0 NOTE 03A instruction must be executed for permanent store of new configuration before power OFF 35 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples V Velocity Data Enter Examine Instruction 03V08 5000 Response 03 Functi
6. 2 Performing motion function on command 3 Controlling un phased power to the motor which exerts a holding torque at standstill or zero speed 4 Transmitting stored information in various ways All of these functions have a discreet nature to them leading to the consideration of time throughout the controller driver This is a consideration throughout an entire machine Each element of each system must be reviewed at least briefly to make sure that the speed with which it operates is consistent with the speed of neighboring elements and the work performed by the machine 15 Advanced Control Systems MCU 2 1 10 Controller Driver Design A useful element with which to begin might be that of position As a motion stepping package the unit must keep track of the position of moving element s It does this with a counter for each axis which has a range of 8 388 606 This counter is driven up and down by signals from either of two sources If the motion system is equipped with an encoder the signals from the device are counted If no encoder is used signals are taken from the step control section of the unit itself If an encoder is used its signals are decoded then sent to the counter Connected to the counter on basic versions is the position display Control of the movement of the electrical motor lies in a step control section which emits a signal indicating clockwise or counterclockwise rotation and a pulse of proper d
7. BE DRIVEN TO THE MCU 2 VIA ONE OF THE 2 TWO BACK PANEL CONNECTORS 2 OPEN THE MCU 2 TOP COVER BY REMOVING THE 6 RETAINING SCREWS 3 IDENTIFY THE CCB 5 DRIVER BOARD WIRED TO THE CORRESPONDING MOTOR CONNECTOR 4 REMOVE BOTH TWO 2 FUSES ON THE CCB 5 DRIVER BOARD NOT CONNECTED TO THE STEPPING MOTOR IN STEP 3 ABOVE 5 REPLACE THE MCU 2 TOP COVER AND INSTALL THE 6 RETAINING SCREWS 6 FOLLOW THE REMAINING INSTALLATION INSTRUCTIONS IN THIS USER S MANUAL 17 Advanced Control Systems MCU 2 2 2 Internal Settings The MCU 2 is factory preset for the following operating parameters Operation without encoder Home switch input normally open Limit switches inputs normally closed Refer to table 2 1 for alternate jumper setting Remove top plate and move jumpers accordingly See also board pictorial JUMPER FUNCTION A1 A2 B1 B2 Encoder Inputs A2 A3 B2 B3 No Encoder Inputs A1 A2 A3 000 S amp Qs Figure 2 1 Board Pictorial 18 Advanced Control Systems MCU 2 2 3 Motor Connection Motor is to be connected via round motor connector on the back panel Refer to Fig 2 2 for pin assignment and proper stepping motor connection Refer to Motor Manufacturer data sheets for connection lead color codes or use an Ohm meter to determine the required motor lead configuration S 6S 639 Mating Plug Amphenol MS3106A 14S 6P 639 Cable Clamp Amphenol 97 3057 1007 639 Cable Boot Amphenol 9779 513 100 Connector
8. Constant Examine aaC c Distance Data Examine aaDdd n Examine Limits Home Inputs aaE bbb Jog Rate Manual Examine aaJ r_ Rate Division Constant Examine aaK 1 or aaK 104 Motion Status aaM bb Present Position Examine aaP n J Ramp Data Examine aaRdd k 1 Velocity Rate Data Examine aaVdd r Winding Motor Current Examine aaW b Velocity data for Slew function Ramp Index for Slew function Default Ramping Index Velocity data for Go function and Index function Ramp Index for Go function and Index function Note There are 80 data blocks Each block contains Velocity top rate Distance and Ramp index All this information is needed for motion execute commands Advanced Control Systems 25 MCU 2 3 4 Motion Execute Instructions MNEMONIC aaF aaG nJaa aaG n aaGdd aaH aaH _ aal no aal no aalddt aaL aaL Haa aaS aaS aaSdd aaS ro aaS ro RESPONSE DESCRIPTION MOTOR RESPONSE aa Finish Function Motor decelerates to Base Rate and stops Go Function Motor moves to n absolute aad position using rate and ramp data stored in Location 01 aa Go Function Motor moves to next position rate and ramp data stored at Location dd aa Home Function Motor moves at Base Rate to aa Home position in positive and negative direction aa Index Function Motor moves n steps in aa positive or negative using rate and ramp data store at Location 01 aa Index Function M
9. USER S MANUAL ray i pr E v 4 E m o BeEB eir Pei T T ml EE E Z B o E MCU 1 MCU 2 STEPPING MOTOR CONTROLLERS REVISION 1 1 ACS CS ADVANCED CONTROL SYSTEMS CORPORATION 35 Corporate Park Drive Pembroke Massachusetts 02359 PHONE 781 829 9228 FAX 781 829 9875 EMAIL support desk acsmotion com www ACSMotion com MCU 2 High Performance Intelligent Stepping Motor Controller Driver FEATURES Drives two four phase motors rated from 2 to 6 Amps per phase two motion stepping axes S S B S S S BS Oo Oo DU U Bi level driver switched holding current no resitors in motor circuits Speeds to 40 000 half steps per second use full dynamic range of motors Simple comprehensive manual controls with programmed resolution Communication by serial link using either RS 232c or RS 485 Can be controlled from a single host port Seven digit and sign position display by 0 56 inch LED in actual measuring engineering units not steps Accepts and displays limit and home switch inputs Computes times for accel decel rate changes in trapezoidal indexing functions using standard motion control variables Decodes encoder signals for position indication Non volatile memory for motion control unit variables ACCESSORIES AVAILABLE D O Power Supply Remote Controller Advanced Control Systems MCU 2 MCU 2 SPECIFICATIONS Instruction Set Overview Communication Posit
10. al from 00 to 99 and If not a valid address the instruction will be ignored is an ALL or Global axis address can replace any address decimal digit Advanced Control Systems MCU 2 Instruction Mnemonic Consists of on to tow non numeric characters from the list of commands If not of this list the unit will ignore the instruction Parameter Not required for all instructions Must be numeric Length depends on instruction Terminator Carriage Return character a non printing character terminates all commands An instruction is communicated to the unit When a terminator is received by the unit the unit communicates its response An important aspect of operation is the fact that a conversion constant can be entered which allows use of measuring engineering units instead of motor steps to be displayed The conversion constant is that number of motor steps which constitutes one measuring unit of position The default value of this parameter is 1 Advanced Control Systems MCU 2 1 4 Displays and Connectors Basic versions display the position of each axis on the front panel as a signed seven digit decimal number with decimal point floating Light emitting diodes immediately to the left of the sign indicate closure of limit switches or the home position switch Among the data to be entered via communication link with the host computer is that conversion constant which will result in positio
11. e uses Thus the MCU 2 can actually operate usefully without a host computer although normally we think of the unit as a computer peripheral The mode causing motor current to be turned off removes power from the motor windings thus removing torque except for a small value of residual motor torque In the automatic mode the MCU 2 follows the instructions of a host computer The unit has such computing power or intelligence however that depending on the physics of the equipment characteristics of the motors and encoders if used instructions chosen by the programmer and the supervisory program executed by the host computer very few instructions from the host to controller driver may be required This affects the amount of time the host must devote to developing and transmitting instructions for a motion stepping axis the other functions performed by the supervisory program of the host and the number of MCU 2 control drive units that can be supervised by a host An instruction is a character or group of characters that will be interpreted by the unit as a command An instruction is formatted as follows Start Character Axis Address Instruction Mnemonic Parameter Terminator Example 12G02 Axis with address 2 will index the motor to next position using parameter locations 02 is an instruction terminator Start Character All messages generated by the host computer must start with ASCII character Axis Address A decim
12. ed digital multipoint communication system The configuration of a system normally consists of several drivers several receivers and terminating resistor There can be up to 32 Driver Receiver pairs on a single balanced line By utilizing line repeaters the system can be expanded even more RS 485 is compatible with RS422 A Advanced Control Systems 21 MCU 2 RS 485 Connector N C Common Ground Data Bi directional Balanced Directional Control Balanced Output 100 Ohm to Gnd S N SSS SS RS Figure 2 6 RS 485 Pin Assignments 22 Advanced Control Systems MCU 2 SECTION 3 MCU 2 INSTRUCTION SET 3 1 Instruction Set Abbreviations and Notes Start Character aa Controller Address Range 00 to 99 is All Address b Status Indicator b 1 Winding Current On b 0 Winding Current Off c Conversion Constant Range 1 to 65535 dd Data Block Address Range 00 to 80 k Ramp Data Range 1 to 100 1 000 to 100 000 step sec r Rate Data 10 to 40 000 steps sec n Position or Step Count Data Range 8 388 606 to 8 388 606 4 Indicates carriage return character L 5 Motor is at zero speed sd Motor is ramping Dosli Motor is at speed G Controller is in OFF mode A Controller is in AUTO mode i M Controller is in MAN mode Onc Positive Direction Limit is not activated E Fina Positive Direction Limit is activated O Home Input is not activated E B Home Input is activated S ere Negative Direction Limit is n
13. h Overall Over Handles 14 6 inches Weight 12 pounds Several are available An A model has no position dis plays manual controls or rack mounting panel The single axis unit is also available 1 in an open frame without dis plays controls user connectors or convenience adjustment controls and 2 modular on a single sided printed circuit board with first stage heat sink only Open frame and board both have barrier terminal blocks for motor power connec tions and flat cable connectors for other connections OEM versions can be mounted in any orientation MCU 2 TABLE OF CONTENTS GENERAL NOTICES Warranty Assistance and Maintenance Agreements Documentation and Discrepancies Service Procedure SECTION 1 GENERAL INFORMATION Safety Features of the Unit Controls and Instructions Displays and Connectors Communication Standards Moving Elements Motors and Encoders Power Plan Dimensions and Mounting Motion Systems Overview 0 Controller Driver Design k k ee ee ee ee ee ee ee a ae k KD 9 d 9 QH R G M SECTION 2 INSTALLATION AND INTERCONNECTIONS 2 1 MCU 2 Motor Operation 2 2 Internal Settings 2 3 Motor Connections 2 4 Power Connections 2 5 Encoder Limits Connections 2 6 Communication Ports Connections SECTION 3 MCU 2 INSTRUCTION SET 3 1 Instruction Set abbreviations and Notes 3 2 Data Enter Instructions 3 3 Data Examine Instructions 3 4 Motion Execute Instructions 3 5 Instruction Set Spec
14. ifics and Examples SECTION 4 APPLICATION NOTES 4 1 Motor Current Adjustments 4 2 Manual Mode of Operation 4 3 Automatic Mode of Operation Advanced Control Systems MCU 2 SECTION1 GENERAL INFORMATION 1 1 Safety The use of electric motors and generators like that of all other utilization of concentrated power is potentially hazardous The degree of hazard can be greatly reduced by proper design selection installation and use but hazards cannot be completely eliminated The reduction of hazard is the joint responsibility of the user the manufacturer of the driven or driving equipment and the manufacturer of the motor or generator Standards Publication No ANSI C51 1 NEMA MG 2 Safety Standard for Construction and Guide for Selection Installation and Use of Electric Motors and Generators Available From National Electrical Manufacturers Association 2101 L Street N W Washington DC 20037 This manual should be completely read and understood prior to installing operating or troubleshooting the MCU 2 Observe all federal state and local safety standards that are pertinent to this piece of equipment Advanced Control Systems MCU 2 1 2 MCU 2 Features e The MCU 2 drives two four phase motors providing two motion stepping axes The MCU 1 drives one motor e Aproven design in the critical translator stage provides high power and high speed using conservative industrial voltages and other motor power sup
15. ion Displays Manual Controls As a motion stepping package the unit 1 needs information 2 performs motion functions 3 controls power and 4 stores information Because it operates with a host computer it must receive instructions to 1 enter needed variable information 2 call for execution of motion functions 3 request changes in power flow and 4 report stored information The unit accepts instructions expressed in standard stepping motor and motion control terminology In general the instructions of each type with the response produced by the controller driver are 1 Enter Data variables to which the unit responds accepted 2 Motion Execute for which the unit a responds accepted and then b performs the motion function 3 Output Control for which the unit a responds accepted and then switches motor current 4 Examine to which the unit responds by sending the requested variable either previously entered or computed and stored in the process of operation Protocol A controller driver operates as a slave under a master the host computer The host computer issues commands to which the controller driver responds Modes ASCII codes commands and responses are trans mitted asynchronously Standard baud rates are selected by convenience control up to 19 200 using RS 232c up to 300 000 using RS 485 Using standard CNC practice the position of each axis is expressed
16. ith 00 Code which means that the motor is at standstill Response O3M 10 Motor Ramping Response O3M 11 Motor at Speed 32 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples P Position Enter Examine Instruction 03P 5600 Response 03 Function Controller 03 position counter is preset to 5600 count or steps NOTE Sign has to always be in the message structure Position range is from 8 388 606 to 8 388 606 Instruction 03P Response 03P 5600 Function Position is examined it is 5600 Q Quit Function Instruction O38Qu Response 03 Function Motor 03 stops stepping immediately NOTE This instruction is operable for all automatic motion functions 33 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples R Ramp Index Enter Examine Instruction 03R08 5 Response 03 Function Controller 03 ramp index 5 into data block 08 NOTE Ramp index 5 represents 5 000 step sec ramping constant Range of ramp index is 1 to 100 Instruction 03R08W Response 03R08 5 Function Ramp index is examined it is 5 S Slew Function Instruction 03S Response 03 Function Controller 03 starts slew function in negative direction It ramps from base speed to preprogrammed speed in data block 00 NOTE Ramp index is also stored in data block 00 Instruction 03S 10000 Response 03 Function Controller 03 starts slew function in negative direction and ramps to
17. n being displayed in the measuring units of interest rather than in motor steps The height of each digit is 0 56 inches and the color of the display is red All units have a back panel on which are located connectors designed for multiple or repeated use These connectors are of different types depending on the kind of signal or power involved and safety considerations Motor Connectors are round mechanically shielded 6 pins RS 232 Connector is D type electrically shielded 25 pins RS 485 Connector is flat cable type 10 pins Encoder and Switch Connectors are flat cable type 10 pins Motor Power Input Supply Connector is a barrier terminal block 3 terminals 115 VAC Inlet Connector is three pronged mechanically shielded In addition basic units have a 115 VAC outlet connector which is three pronged mechanically shielded Power to this connector is on when the front panel switch is on Again excepting certain OEM versions all units have convenient controls for configuring the unit to a particular equipment arrangement a task that may have to be done more than once but is not done repeatedly These controls are all screwdriver actuated Communication Mode Switch detent type 16 position Axis Address Switch detent type 16 position Motor Torque Potentiometers with locking nuts 10 Advanced Control Systems MCU 2 1 5 Communication Standards The unit communicates with a host computer by ASCII codes
18. nd selected and located for safety are 1 round type high current motor conectors for each axis 2 a 25 pin D type connector for the RS 232C communication standard 3 a 10 pin flat cable connector for the RS 485 communication standard and multi unit chaining 4 10 pin flat cable connectors for encoder limit switch and home switch signals for each axis 5 a motor power barrier terminal block 6 a 115v AC inlet connec tor and 7 a switched 115v AC plug Basic to the translator circuitry of the controller driver the unit operates four phase DC stepping motors with six or eight leads The maximum rated current per phase is six amperes Providing for bidirections movement of an axis the unit requires a dual channel pulse output incremental encoder with output signals phased in quadrature and a signal level of 5 volts TTL The architecture of the power system separates the require ments of the control drive as to displays logic communi cation and encoders from the requirements of the motors The unit requires 115v AC power at 60 HZ drawing up to 1 0 ampere Motor power needed consists of unregulated DC in two voltage ranges 10 to 12 and 36 to 42 Current draw can be up to 24 amperes depending on the motors used The motor supply should be able to supply and ac cept high current surges Width Over Heat Sinks Depth Behind Front Panel 17 1 inches 13 0 inches Height sss his 3 5 inches Dept
19. on Controller 03 data block 08 is programmed for velocity rate 5000 step sec NOTE Velocity range is 10 to 40 000 steps sec Instruction 03V00 2000 Response 03 Function Controller 03 data block 00 is programmed for 200 steps per second NOTE Data Block 00 is used for slew function 3 5 Instruction Set Specifics and Examples W Winding Motor Current Examine Instruction 03W 0 Response 03 Function Controller 03 shuts off motor current Instruction 03W 1 Response 03 Function Controller 03 turns on motor current NOTE This is also motor phases reset motor phases are turned on is a preset known state 36 Advanced Control Systems MCU 2 Instruction 03W Response 03W 14 or O83W 0 Function Motor current is examined NOTE 1 response indicates the current is on Z Zero Position Counter Instruction 03Z Response 03 Function Controller 03 position counter is set to zero NOTE This instruction is the same as 03P 04 37 Advanced Control Systems MCU 2 SECTION 4 4 1 Motor Current Adjustments The MCU 2 is to be adjusted to achieve the best performance of the selected stepping motor The LO potentiometer adjustment on the back panel of the MCU 2 controls idle motor winding current or holding torque It can be adjusted in the range of 2 to 6 Amp The HI potentiometer adjustment controls the running torque as well as compensates for motor resonances Procedure 4 11 Power
20. on the front panel as seven red decimal digits with sign and decimal point For each axis the closure of switches located on the equipment to mark plus and minus limits and home position is indicated by the lighting of red LEDs If an encoder is used its position is shown The position of an axis without an encoder is derived from the motion execute instructions issued to that axis and the operation of any manual controls affecting that axis For direct operator control the front panel has 1 an on off switch for operation of the controller driver 2 a unit mode switch for each axis selecting auto matic operation under the host computer man ual operation from the front panel and off turning off the motor current and 3 pushbuttons for each axis operating in manual mode to set position display to zero and slew and jog at the entered rate in plus and minus directions d Advanced Control Systems Convenience Controls User Connectors Motor Requirements Encoder Requirements if used Power Requirements Physical Dimensions OEM Versions To configure the unit for a particular equipment arrange ment the back panel has 1 a screwdriver actuated com munication mode switch for the communication standard and baud rate 2 a screwdriver actuated address switch for each axis and 3 two screwdriver actuated potenti ometers with locking nuts for each axis setting motor torque Mounted on the back panel a
21. op rate into data block 00 i e execute command aaVO0 r Set manual mode Using one of the slew pushbuttons ramp motor to the top speed and adjust HI pot from maximum CCW to a position that allows the motor to run smoothly This should occur at one half to three quarters potentiometer setting Run the motor for 20 minutes at the slew rate to ensure that the motor does not 38 Advanced Control Systems MCU 2 overheat Readjust the HI and LO controls a small amount for smooth ramping Do not turn up the HI pot to compensate for too high a ramp setting Motor and load inertia may mandate a slower ramp rate 4 14 Repeat step 4 13 for 2nd axis 4 15 Ifthe motor falls out of sync i e stalls it may be necessary to change ramp data Todo this you must choose a lesser value for aaR00 You may also want to ensure that an extra margin of torque exists for the high speed setting Slew at maximum speed with motor load in place Using a gloved hand carefully apply an additional load to the motor shaft If the motor immediately stalls you can advance the HI torque setting a small amount until additional motor shaft load is required to stall motor 4 2 Manual Mode of Operation In manual mode of operation the front panel pushbuttons are operative The unit does not accept serial port motion execute commands Pushing CLEAR pushbutton sets position counter and display to zero Short push of JOG pushbutton executes single step
22. ot activated ere Negative Direction Limit is activated For example OOAS Limits and home inputs are not activated controller is in auto mode and motor is at speed MCU 2 does not respond to All Address MCU 2 does not respond to unrecognized addresses 23 Advanced Control Systems MCU 2 MCU 2 responds with aa when address is recognized but structure of the instruction is wrong 3 2 Data Enter Instructions MNEMONIC DESCRIPTION RESPONSE aaAW Accept Data to NVRAM aa aaB r Base Rate Enter aa aaC r Conversion Constant Error aa aaDdd n Distance Data Enter aa aaJ rtD Jog Rate Manual Enter aa aaK 1 aaK 10 Rate Division Constant Enter aaP n Position Enter aaRdd k Ramp Data Enter aa aaVdd r Velocity Rate Data Enter aa aaW b Winding Motor Current On b 1 on Off b 0 aa aazZ Zero Current Position aaV00 r Velocity Data for Manual and immediate Slew Enter aaR00 k Ramp Data for Manual and immediate Slew Enter Unit Configuration Instructions aaUPEJ Set Even Parity aa aaUPOW Set Odd Parity aaUPNJ Set No Parity aa aaUVaa Set Unit Address to aa aa aaPRESJ Preset NVRAM to Default Conditions aa 24 Advanced Control Systems aa aa aa aa aa aa MCU 2 3 3 Data Examine Instructions MNEMONIC aaBu aaC aaDdd aaEJ aaJ Iaa aaM aaP aaRdd aaVdd aaW Data Block 00 Data Block 01 DESCRIPTION RESPONSE Base Rate Examine aaB r 1 Conversion
23. otor moves preset number of steps using data stored at Location dd aa Limit Function Motor moves at base rate to aa positive or negative limit switch aa Quit Function Motor stops stepping immediately aa Slew Start Function Motor ramps in selected aa direction from Base rate using rate and ramp data stored in Location dd aa Slew Function Motor ramps to next rate using rate and ramp data stored in Location dd aa Slew Function Motor ramps in selected aa direction using ramp data stored in Location 00 and for speed using immediate data provided for instructions 26 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples A Accept Data to NVRAM Instruction 03A Response 03 Function Controller with address set to 03 will copy all data from volatile memory into nonvolatile storage It responds with 03 Instruction 3Au No Response Function All Controllers with second address digit equal 3 will memorize data Instruction 0 AW No Response Function All Controllers with first address digit equal 0 will memorize data NOTE is a global address character and can be used on any instruction No response is generated B Base Rate Enter Examine Instruction 03B 400 Response 03 Function Controller loads base rate registers with base rate of 400 steps per second and responds with its own address and carriage return character NOTE Base Rate is starting and stopping ra
24. ply characteristics e Available stepping rates are up to 40 000 half steps per second eight step input sequence also called half step mode use the full mechanical speed range of the motors e Programmable reduction of stepping rates by factor of ten e No dropping resistors are used meaning that there are no resistors in motor circuits All necessary tuning of the unit motor system is done with screwdriver actuated adjustments of the unit e Communication is by serial link which provides great flexibility in system architecture Electrical standards are RS 232C and RS 485 e If anincremental encoder is used on a motion stepping axis the MCU 2 will decode the signals from the encoder to provide position information e MCU 2 performs indexing functions without depending on a host computer This means that an axis can be driven a specified distance starting at a specified base speed accelerating to and decelerating from a specified top speed at a specified ramp and stopping from the base speed This substantially frees the host computer e In addition to stopping stepping of a motion axis upon closure of a limit switch the MCU 2 responds to inquiries from the host computer as to the status open or closed of either of the limit switches or the home position switch e Each axis has an address with the number of available addresses allowing up to 100 motors to be controlled from a single host computer serial port e On instruc
25. rque is the adjustment for rated idle current in the motor winding when at standstill or zero speed This adjustment is at its minimum when the potentiometer is fully counterclockwise and at its maximum in the fully clockwise position Motor temperature is directly affected by this adjustment 13 Advanced Control Systems MCU 2 1 8 Dimensions and Mounting Dimensions and weight of basic versions are Width Over Heat Sink 17 1 inches Depth Behind Front Panel 13 0 inches Height 3 5 inches Depth Overall Over Handles 14 6 inches Weight 12 pounds Basic versions have a front panel designed to allow the MCU 2 to be mounted on a standard 19 inch rack In addition the front panel has two handles mounted on it to make movement between locations easy OEM versions can be mounted in a wide variety of ways 14 Advanced Control Systems MCU 2 1 9 Motion Systems Overview The motion requirements of a machine are considered to form a system distinct from other systems within the machine With the other systems the motion system is directed by a computer of some kind In relation to this computer the motion system is subordinate the relationship being that of a master and slave or host can guest hence the general use of the term host computer As a motion stepping package the controller driver is a key element in a motion system It performs several functions 1 Receiving information from various sources
26. te when motor accelerates to or decelerates from higher speeds Base rate should be set below start stop rate of motor load combination from accurate positioning 27 Advanced Control Systems MCU 2 Instruction 03Bi Response 03 Function Examination of base rate base rate is 400 steps sec 3 5 Instruction Set Specifics and Examples C Conversion Constant Enter Examine Instruction 03C 200 Response 03 Function Controller loads conversion constant register with value 200 NOTE Conversion Constant is used to display calculations Number of steps is divided by conversion constant and displayed For example to move load linearly for one inch motor has to execute 200 steps Conversion Constant should be 200 in order to display Conversion Constant is 1 to 65535 in unite increments Instruction 03C Response 03C 200 Function Examination of Conversion Constant it is 200 D Distance Data Enter Examine Instruction 03D12 3500 Response 03 Function Controller with address 03 loads positive direction and count of 3500 into memory block 12 28 Advanced Control Systems MCU 2 Instruction 03D12W Response 03D12 3500 Function Controller 03 Data Block 12 contains 3500 distance position information NOTE Count of 3500 can be number of steps when used by instruction or absolute position when used by G instruction 3 5 Instruction Set Specifics and Examples E Examine Limits Home Inpu
27. tion the unit will store data entered in a nonvolatile memory which retains the information even when the supply voltage to the control drive is removed e Basic MCU 2 versions have a position display for each axis consisting of seven digits and sign in conjunction with a conversion constant Advanced Control Systems MCU 2 communicated from the host computer Position is shown in large bright numerals in engineering units e Basic MCU 2 versions have a three position mode switch and just five spring loaded push button switches for each axis With speed rates and acceleration deceleration ramp factors communicated from the host computer the manual controls can be simple and comfortable for the operator and appropriate to the physics of the equipment e MCU 1 is the basic versions of the single axis unit Advanced Control Systems MCU 2 1 3 Controls and Instructions The MCU 2 operates in one of three modes automatic manual and motor current off depending on the setting of the switch on the front panel In the manual slew mode push buttons on the front panel set the position display to zero and slew and jog at the entered rates in positive or negative directions Thus there are five 5 push button controls for each axis If no value has been entered for any or all of the numeric values needed jog or slew rate or ramp factor including the case where the unit has never been connected to at host computer the default values will b
28. transmitted in bit serial fashion over a single transmission line The rates at which data can be transmitted and received in bits per second are COMMUNICATION MODE BAUD RATE SWITCH SETTING 300 Parity Ignored 600 Sa os 1200 2400 4800 9600 19 200 Spare 300 Parity Programmed 600 sa 10 1200 11 2400 12 4800 13 9600 14 19 200 15 Spare GO 0 l O Qn E GM GO Each ASCII code is transmitted by sending a start bit eight data bits and a stop bit This means each code in transmission is ten bits Parity can be preprogrammed to be even odd or ignored 11 Advanced Control Systems MCU 2 1 6 Moving Elements Motors and Encoders The fundamental motor specification is that of a four phase DC stepping motor with six or eight leads and a rated phase current of six amperes or less This is the type of digital motor found in commercial applications The encoder specification is for a dual channel pulse output incremental encoder with output signal phased in quadrature and a signed level of 5 volts TTL Transistor Transistor Logic This is the kind of encoder used for digitizing motion in commercial applications In the architecture of a motion system an address must be assigned to each motion axis The following table relates the back panel axis address switch to the logical address used for communication Address Switch Setting Address 0 00 or Preprogrammed for any value up to 99 1 01 2 02 3 03 4 04 5 05 6
29. ts Instruction 03E Response O3E 000AS Function Controller 03 responded with OOOAS code which means that both limit input and home input are not activated controller is in automatic mode and motor is at speed F Finish Function Instruction 03F Response 03 Function Motor 03 starts decelerating and will stop when reaching base rate NOTE Deceleration rate is equal to the last acceleration rate 29 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples G Go Function Instruction 03G 30000 Response 03 Function Motor 03 executes index to absolute position 30000 steps using preprogrammed base rate top rate and ramping index NOTE Base rate is stored in base rate register Data Block 01 contains the top rate and ramping index Instruction 03G15 Response 03 Function Motor 03 executes index to absolute position stored in data block 15 NOTE Data Block 15 contains also top rate and ramping index for this particular move F and Q functions are enabled H Home Function Instruction 03H Response 03 Function Motor 03 finds home position moving in positive direction NOTE Motor moves at base rate in positive direction until LO is recognized on home input If it find positive limit first it reverses direction 30 Advanced Control Systems MCU 2 3 5 Instruction Set Specifics and Examples I Index Function Instruction 031 10000 Response 03 Function Motor 03
30. up the unit Turn mode switch to Manual for one motor Adjust corresponding LO pot for required holding torque This is done by rotating the motor shaft back and forth by hand while slowly turning the LO speed pot from extreme CCW to CW At approximately one third of the pots rotation there will be a noticeable increase in motor shaft resistance This is the point at which you stop turning the potentiometer i e you have reached the setpoint for the LO speed and holding torque It is important that you locate the pot setpoint at exactly the shaft resistance needed to provide a minimum holding torque required Actuate the jog pushbutton and ensure that the jog function operates the motor smoothly It may be necessary to provide a small increase in the LO speed pot to remove any missteping that may occur due to insufficient LO speed torque WARNING The motor temperature should not become too hot to touch about 65 deg c High motor temperature indicates the LO pot is set too high This will cause damage to both the motor and the MCU 2 output transistors Allow unit to sit powered up for 20 minutes to check motor temperature It is important to note that low voltage motors typ 1 2 to 5 0 volts require less LO and HI pot adjustment They also require more careful adjustment as their low winding impedance can result in higher MCU 2 output and motor currents 4 12 Repeat step 4 11 for 2nd axis 4 13 Set automatic mode Enter your t
31. uration voltage and rise and fall time to actuate the driver The number of pulses and interval between each of them determine the distance of movement of the load and its speed at all times while moving The step control also controls the state of holding of idle current when the motor is at standstill or zero speed Pulses from the step control are counted for position display if no encoder is used Power to the motor is modulated by an electronic drive which translates the information received from the step control into electric power for an electro magnetic mechanical device the motor The MCU 2 uses a proven bi level design which operates on conservative voltages appropriate to commercial machinery and provides excellent overall performance Storage of variables without depending on power is done by a nonvolatile memory under the direct control of the central processor 16 Advanced Control Systems MCU 2 SECTION 2 INSTALLATION AND INTERCONNECTIONS 2 1 MCU 2 Motor Operation The MCU 2 Driver Controller is designed to operate 2 stepping motors Running only 1 motor can cause damage to the channel not connected to a motor if the channel is powered up The board level fuses to the channel not connected to a motor must be manually removed If you plan to run a single motor with the MCU 2 follow the instructions below WARNING DO NOT SUPPLY POWER TO THE MCU 2 DRIVER CONTROLLER UNTIL THIS PROCESS IS COMPLETE 1 CONNECT THE MOTOR TO
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