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Motion MMI-8S User's Manual

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1. O FUSE O EE ON D L1 AC PLUG DC OK 1 SIDE PANEL END VIEW k 8 2 COHHECTOR CLEARENCE OPTIONAL 7 19 3 5 5 amp HANDLES FRONT PANEL FRONT VIEW 1 MOTION SYSTEM OB2 USER 2 OB1 HOME OBO ENABLE O SLY STP O DIR BSY OOOOOOOO o OOOOOOOO OOOOOOOO o 17 1B 1D 1E 07 0B 0D 0E NET ADDRESS msman wri 9 95 MS MiniStep translator driver card OPERATION AND INSTALLATION MANUAL FOR MS SERIES 5 25 5 5 415 968 6192 e 25 e e gt e 55 25 25 25 25 5 25 525 25 e e lt 5 20 e lt 5 5 gt 25 25 25 25 5 ds e 525 e 525 e 5 5 555 5 25 25 5 25 25 25 25 e 55 9 555 e 25 25 55 525 55 5 25 8 55 555 55 25 Ses 555 55 gt S 555 55 55 Ses 525 5 25 6 555 5 gt gt 555 Se 25 5 e 25 5 525 gt gt 25 5 e 5 5 25 55 26 525 gt 25 25 25 25 e e gt gt 5 25 25 55 9 gt e e 25 25 25 25 gt gt gt 25 e 525 e
2. 2132 31F1028 30 22 GUAGE WIRE Contacts for Connector Sets 093 SIZE 6 79 FEMALE SOCKETS LARGE TAB 02 06 1103 31F1027 22 18 GUAGE WIRE MALE PINS LARGE TAB 02 06 2103 31F1026 22 18 GUAGE WIRE FEMALE SOCKETS SMALL TAB 02 06 1132 31F1029 30 22 GUAGE WIRE MALE PINS SMALL TAB 02 06 2132 31F1028 30 22 GUAGE WIRE In general single wires use small tab contact double wires the large tab Tooling 105 RATCHET TOOL 062 DIA HTR 2262 11 01 006 30F338 MAKES PERFECT CRIMPS 105 RATCHET TOOL 093 HTR XXXX 11 01 006 30F338 MAKES PERFECT CRIMPS 13 HAND TOOL HT 1921 11 01 0015 31F1049 REQUIRES PRACTICE 12 EXTRACTOR 062 DIA HT 2285 11 03 0002 30F773 SPRING LOADED PUNCH OUT 12 EXTRACTOR 093 DIA Nylon Connector Designer Service Kit Contains male female housing assortment hand crimper pin extractor not as easy to use as spring extractor see above contacts and case 40 DESIGNER KIT 062 WM 072 30F774 40 DESIGNER KIT 093 of the above including custom cable sets are available from the factory Note When disconnecting grasp the mounting tabs not the wires and rock from top to bottom unseat the locking bump rather than SMCe to SMCe and then pull the connection apart The connections unseat easily with the right technique Contact factory for Heavy Duty Connectors with Metal Shells Retainers and Strain Reliefs SPECIFICATIONS MMI PARAMETER MIN MAX UNIT Power Motor supply voltage 12 40 VDC Current no motor 150 160 ma PWM
3. ABORT loop is used to remove all winding power to the motor during an out of bounds condition The ABORT feature can be used to provide hard limits emergency stop door inter locks and other safety features As the ABR input to the driver must be LO ground for the driver to step opening the loop will stop free the motor regardless of the control logic The diagram is typical of TMG Fail Safe Hard Soft limit loops LIMIT LOOP WIRING DIAGRAM CONTROLLER Right Left ABR MOTOR OUTPORT Limit Limit DRIVER Disabled during User Bi Switch Switch power up nc ne B 0 LO ENABLED RUN HI FREE NO CURRENT NOTE CONTRARY TO POPULAR PRACTICE IT IS UNWISE AND UNSAFE TO SENSE LIMITS AND OTHER SAFETY CONDITIONS THROUGH THE COMPUTER INPUTS PORTS All motion products regardless of their final intended form should initially incorporate home sensors and slip detection in order to prove correct positioning during product development particularly during software de bugging Typically a test routine is established which passes slip detection Any detrimental modification or code flaw will be flagged by this routine APPENDIX MOTOR CURRENT ADJUST PAGE 1 2 APPENDIX MOTOR CURRENT ADJUSTMENT MM 2 0 2 AMP MAX SERIES TO SET CURRENT ALIGN SLOT TO MARK CAREFULLY POT ADJUSTS PERCENTAGE OF MAX POWER 2 AMP x 50 1 AMP COIL IN GENERAL CURRENT TOO LOW MOTOR SLIP FROM REDUCED TORQUE CURRENT CORRECT
4. Enter the following commands Direct Mode at the prompt Motor E of SR4 0 is default Enter Command gt WOE Symbols used below lt Enter key Fx function key F9 the SMC returns position this indicates communication is OK p 2000 lt motor will move to position 2000 2000 steps CW F9 P returns P 0002000 position is 2000 0 lt motor returns to position 0 b 0 lt free motor E B O LED is out 4 Memory Commands F7 y where is memory byte pointer y 00000 after reset y 0 lt sets pointer to byte location 0 if required m 21 displays 21 command lines of memory F8 and type 21 CLEAR lt fill the memory with 0 s and carriage returns STOP commands YES lt yes wait till 0000 DONE F7 y 0000 F8 21 lt memory is cleared all zeros and carriage returns 42 bytes F6 load memory host goes to line 1000 returns p when done F7 yzxxxx last byte of program 0 lt set memory byte pointer to byte 0 F8 21 lt memory is loaded X sample motor test program in memory will run note that memory query F8 21 did not move the memory address pointer y 0000 F7 last address of program pointer did move with each line of program 0 lt reset to top of program X lt sample motor test program in memory will run ADWOD lt change SMC address prompt is now WOD lt Repeat the above with motor 2 for example Parameters Refer to the CY 545 MANUAL SECTIONS 1 12 Commands 16 see StepM
5. PROMS are also labeled with the current control selection HL shifts power HIGH 100 to LOW 25 during parking HM shifts power HIGH 100 to MED 60 during parking 5 CURRENT CONTROL DIAL The current dial sets the 100 power level of the driver outputs as required Refer to App C APPENDIX SECTION APPENDIX CABLE DIAGRAM FOR MMI SYSTEMS COLOR MOLEX PIN it 1 SENSOR 5 BLK T 2 SENSOR LED ANODE WHT 2 3 SENSOR LED GND GRY 3l 4 SENSOR OUTPUT PUR 4 5 USER GROUND BLU M 6 USER 5 VCC GRN 2 7 JOG SWITCH IN 8 USER 2 ORN 4 9 LIMIT LOOP IN RED M 10 LIMIT LOOP OUT BRN 2 11 USER 5 BLK 12 USER 5 WHT 13 BITS GRY 14 7 PUR 15 BIT3 BLU 16 BIT 4 GRN 17 BIT 1 same as 4 YEL 18 2 same as 8 ORN 19 USER GROUND RED 20 USER GROUND BRN C I CABLE 2 0 0 0 0 00 0 80 00000 0 0000 1 19 lt connector key 10 PIN 20 1 GND GND B2 0 01 B1 o 0 B3 B7 lo 5 VCC o o VCC 12 11 110 CONNECTOR 2 4 406 crm LEFT RIGHT 15 95 2 LIMIT LIMIT JOG GND 2 GND E Ie SPDT MON USERBIT USERBIT JOG SWITCH OUTPUT INPUT APPENDIX DESCRIPTION OF HOMING AND ABORT LOOP PAGE 1 2 HOMING A major advantage of a digital Open Loop step system is the ability to operate plus or minus zero steps no error Two conditions are required One is that the motor is suf
6. bipolar drive users as in figures C amp D Four lead bipolar motors may use larger wire since only half the windings are required in the given space of the motor body The paralleling in figure C is the equivalent of this to achieve lower winding resistance and thereby doubling motor efficiency The other alternative for the motor designers is to use a greater number of turns in the winding space This is shown by figures B amp D and results in more torque with a lower coil current but a subsequent loss of high speed torque Although step motors are often classified as bipolar or unipolar 2 phase or 4 phase these terms are more accurately applied to the types of electronic circuit used to drive the motor Bipolar drivers can drive 4 5 6 and 8 wire motors When the motor is described as unipolar the specifications are presented with the assumption that the motor will be driven with a unipolar drive Therefore the specifications must be translated to bipolar when the motor is used with a bipolar driver In general the translation is similar to a unipolar driver with dropping resistors in series with the center taps referred to as L over x R with R equal to the motor winding resistance For example a L over 4R unipolar driver has a resistor equal to 4 times the winding resistance In bipolar the L over R ratio is the ratio of the motor voltage to the supply voltage AL over 4R bipolar drive for example would be a 6 volt motor and a 24 volt power suppl
7. directly to the target device motion system until the detection of the terminator charactor carriage return by the 233 After detecting the terminator the 233 resets the address lines and waits for the next mode command If more than one controller is connected to the serial network invalid ID numbers and the serial data string are echoed to the next controller down the line If the ID is invaild for all controllers the entire message will return to the host CPU echo invalid Note that contary to normal CY545 procedure in a CY233 network system all SMC motor control commands MUST BE in LOWER case All 584 net commands must be in UPPER case With that said it may be observed that the SMC s respond to upper case as well Only during a query responce will the SR4 repeaters strip off the upper case characters A to F which are seen as hex control codes This will not cause a malfunction but may be confusing to the user WRITE MODE In general SR4 mode commands are prefixed to SMC motion commands which are then passed through to the motion systems Only two mode commands are used in this system the write W and the read R A write command consists of a mode character W an ID number two hex characters a command string motion system data string and a terminator carriage return The ID number consists of two characters the first or high byte is the system ID This identifies an MMI net controller card The system ID of a card is s
8. in fact are based on their hex decimal values from 0 to F hex Also as the active selection signal is a LOW or 0 volts the sequence is inverted For example all devices selected is a 0 zero code or address all bits are low No devices selected is F all bits HI 5 volts Therefore selection of the first device or E indicates 1 bit is LOW all others are HI Note that the codes for the individual motor controllers are therefore E motor 1 D motor 2 B motor 3 and 7 motor 4 The other codes allow selection of any combination of motors The BUSY codes correspond to these selections with the indicating all BUSY followed by A to O none busy in decending order Refer to PROGRAMMING section for examples of code selection CONTROLLER ID ADDRESS MSD HEX BINARY DNA C oC gt p 1111 1110 1101 1100 1011 1010 1001 1000 0111 0110 0101 0100 0011 0010 0001 0000 14 13 12 11 10 9 MN oC kA TABLE OF ID AND STATUS CODES OUTPUT ADDRESS LSD HEX N oC gt p mQ 1111 4110 1101 1100 1011 1010 1001 1000 0111 0110 0101 0100 0011 0010 0001 0000 BINARY FUNCTION READ BUSY CODE WRITE TO PORT 1 2 1 amp 2 3 3 amp 1 3 amp 2 38251 4 481 482 48281 483 48381 48382 4838281 READ BUSY CODE ASCII O lt H 1 BUSY M 2 BUSY etc L K J I H G F E D a LED DISPLAYS T
9. motor power supply chassis assemblies Home Sensor Pins 1 1 2 3 4 These pins power the optical home sensor circuit SEE APPENDIX A 8 Pin 1 is VCC 5 power 2 is VLED power pin 3 is GND ground and pin 4 is the HOME input from the sensor Abort Loop Pins P1 9 amp P1 10 12 These pins normally constitute the ABoRt Loop Safety limits System The driver enable is output from the controller to pin 12 CPU ABR and output to the loop from pin 10 to limit loop and returned from the loop to pin 9 ABR The ABR loop is NORMALLY CLOSED opening the loop for any reason FREEs the motors Never connect these signals to any potential or device except passive switches or relays Door locks and other safety switches may be inserted in the loop See Appendix B Spare Pins 1 6 5 7 8 These pins are used as required to provide VCC pin 6 and GND pin 5 to the chassis system Pins 7 and 8 are user pins which are generally jumped as required to the spare pins on the data connector See Appendix A 4 FULL HALF QUARTER STEP SELECT This series will operate either in FULL HALF step or QUARTER step only mode FULL HALF requires the FH PROM to be installed and the mode pin to be jumped either FULL or HALF with a dip clip jumper The jumper pins are located next to the top of the PROM socket See Appendix F In QUAD step mode the QD is installed and the mode pin is jumped to the QUAD pin Conversion is a field operation The
10. to hold off the host until for example a motion is completed In the MMI system the status of all four CTS signals is available as a single ASCII character This character is equal to a binary number consisting of two bytes The high byte is always 0010 4 hex the low byte consists of four bits each bit indicates the status of a channel s CTS signal Remember that the motion system MUST be in the Hand Shake Mode o 0a0h lower case only for the status function to be valid A typical command would be ROF if the response was the binary value would be 0010 fixed 1110 Refer to Code Table ECHO MODE In the MMI network system with two network cards it is necessary to engage the CY233 pass through echo all mode This allows commands originating in a motion channel SMC to be passed through successive SR4 cards down stream in the network loop A typical example is the SMC system query commands The J command format consists of a mode character J the ID number two hex characters the second is always F and the terminator carriage return A typical command would be JOF the 0 is the address of the first SR4 card and the indicates a SR4 only message J1F is the second card address Each SR4 in daisy chain network must be sent a J command during start up procedure ID AND STATUS CODES Refering to the following table note that the codes seem confusing in that they are not an orderly sequence of decimal numbers They
11. to the system and produce resonance In general resonance indicates except at the low 100 sps and mid frequency 1000 sps bands excessive power therefore reduce the driver current for smoother operation or wire the motor for softer response NOTES If a motor runs backwards with respect to software direction transpose the connections of ONE coil For MS series driver cards pins 2 amp 3 or 6 7 SMC MMI driver boxes pins 1 8 or amp 6 Five wire motors are really 6 wire motors with the center tap common The center tap must be connected to the motor supply voltage If phases 1 2 3 or 4 are crossed motor will not rotate hums For MS cards pin 1 is VMM for SMC MMI if connected pin 5 is VMM and pin 2 is GND Systems with pin 5 amp 2 connected are used to power external relays or solinoid valves The pins are keyed reversed Never attempt to connect any motor leads to pin 2 and only 5 wire center taps to pin 5 Pins 2 amp 5 are normally not connected and used to store the unused leads of 6 or 8 wire motors Typical Motor Winding Unipolar Drive only 172 motor shown 8 Wire Parallel Coils BB Best Speed Best Torque Fig C 8 Wire Series Coils mr mr Low Speed High Torque SMD SID HD Connector Bipolar Driver 5 Wire Motor Coils in Series Only speed amp torque Fig A 6 Wire Single Coils hn n nic 1 1 due Normal Speed amp Torque Fig
12. 00 is the time delay for the write cycle of the EEprom memory Line 1500 1800 is a sample homing routine with a limited number of re tries loop counter input test and message transmission are demonstrated in this program Line 2000 2510 assemblies keyboard entries and sends them to the MMI at the Enter key CR carriage return or enter key Note the special commands at line 2210 2270 which are created commands not part of the MMI command set Line 2600 2750 reads any incoming characters from the MMI and prints to the host display screen Line 2910 3000 closes the comm ports on Exit F5 or a computer error code other than ERROR 24 comm port is busy Line 3000 3150 writes zeros 545 stop command and carriage returns over the entire memory Clear command which erases the memory The opposite is the Load command which writes the memory Line 3300 3400 is the busy error routine Line 4000 are the help files Program Listings See MMIDEMO program Serial Cables XT TYPE CPU DB 25 IBM STYLE CONTROLLER DB 9S AT PIN 1 Frame Ground lt gt Shell solder PIN 2 TX Transmit gt PIN RX Receive PIN 3 RX Receive lt PIN2 TX Transmit PIN 5 CTS Clear PIN 8 DSR Ready PIN 7 Signal Ground lt gt 5 Signal 8 Frame DB 25 to DB 9 Adaptor TYPE CPU DB 9P IBM STYLE CONTROLLER DB 9S AT Note DB 9 Controller is wired as a Null
13. 047 Note that the memory is in pages of 256 bytes the CY545 does not allow Jump Test or Loop operations across page boundries The pointer command Y is used to move across boundries A feature of the 545 memory system the Auto Start function which recognizes special character flags in the first bytes of memory as a command to run the following program at power on is not used in the MMI Home Function This system uses an optical sensor to establish the starting reference or Home position at power on refer to the Home command H Lash Compensation is included in the home routine A major advantage of this system is Slip Detection which provides operation to zero steps See Installation and Test for a detailed home procedure Limit Loop Function The CW CCW Limits function of the 545 pin 4 amp 5 is not used in this system Instead the driver card will go free or ABoRt CURRENT OFF when the Limit Loop is opened Fail Safe Hard Soft limits This Limit Loop is enabled by User Bit 0 Refer to the Appendix B section of this manual Function The Cybernetic User Bits are available at the cable connectors and can be used as either inputs or outputs dependent on the command Note that an output can only drive LEDs such as those in Solid State relays or optical isolation An input can only be a passive switch or isolated relay contact across the User Bit and User ground Connecting any device at a different potential to this sy
14. 5 5 gt 55 25 25 25 25 gt 25 25 25 525 55 5 e gt 25 25 e 55 25 gt gt gt 25 e 525 e gt e 415 969 5629 FAX e 5 555 525 55 525 e gt 5 55 5 gt gt gt 25 e 555 e e gt gt gt 55 25 25 25 25 55 e 55 25 5 25 55 5 525 gt gt gt 55 55 525 525 5 SERVICE CENTER 1 800 424 STEP 25 Ses 525 5 gt gt 555 525 555 5 e 9 S 525 gt gt 25 555 525 525 5 555 25 gt 25 gt 255 gt PO BOX 4585 MOUNTAIN VIEW 94040 e 25 55 25 55 e 25 25 25 gt 25 gt gt e 25 2 5 55 25 5 5 TEL MS 2 0 STEP MOTOR TRANSLATOR DRIVER 2 AMPS PER COIL IN FULL HALF OR QUAD STEP Digital Inputs LS TTL quac STEP Pulse LO each step MOTOR DIRECTION COILA s GROUND LO CCW HI CW RETURNS PARK PRK MOTOR HI Park low Power LO Run high Power ABORT ABR r Free Motor Lo Enable Motor PROM CODES QD Quarter Step only FH Full or Half Step HL Park Power Shift 100 to 25
15. 6 Wire Series Coils P n n n ue De A Low Speed Torque Fig B 12345 678 vmm Card Connector O La MID ANT 2 0 Connector APPENDIX 1 2 APPENDIX PAGE 1 2 APPENDIX PAGE 2 2 APPENDIX PAGE 1 1 MOLEX WALDOM NYLON CONNECTOR SYSTEM USED BY THE MOTION GROUP The connectors used on Motion Group equipment are nylon connectors are manufactured by Molex and are refered to as 062 style pin diameter or 093 large driver motors only They are available from Newark Allied and Digi Key and come in 1 to 36 positions with locking and mounting tabs which snap in to punched holes on brackets or enclosures TYPICAL POLES TYPE PART NEWARK USED ON 5 84 10 4 062 MALE HOOD 03 06 2041 31F1004 HOME SENSOR ASSEMBLY 5 95 10 4 062 FEMALE RECT 03 06 1041 31F1005 HOME SENSOR CABLE 1 86 5 6 062 MALE HOOD 03 06 2062 31F1008 STEP MOTOR ASSY 2 07 5 6 062 FEMALE RECT 03 06 1061 31F1009 MOTOR OUTPUT 1 86 5 6 093 MALE HOOD 03 06 2062 31F1008 STEP MOTOR ASSY 2 07 5 6 093 FEMALE RECT 03 06 1061 31F1009 MOTOR OUTPUT Strain Relief Hoods are available on request Contacts for Connector Sets 062 SIZE 6 79 FEMALE SOCKETS LARGE TAB 02 06 1103 31F1027 22 18 GUAGE WIRE MALE PINS LARGE TAB 02 06 2103 31F1026 22 18 GUAGE WIRE FEMALE SOCKETS SMALL TAB 02 06 1132 31F1029 30 22 GUAGE WIRE MALE PINS SMALL TAB 02 06
16. HM Park Power Shift 100 to 50 See Appendix for P1 connector See Appendix for Limit Loop See Appendix C for Current Adjustment See Appendix D for Motor connection See Appendix E for Mechanical Card See Appendix F for Home Sensor See Appendix G for Opto Isolation Option See Appendix H for AC Input Option MS DRIVER CARD COIL B lt 40 6 to 24 VAC transformer 110 VAC INPUT SUPPLY OPTION POWER SUPPLY REQUIREMENTS 5 vdc TTL Logic 100 ma 5 to 40 vdc 10 to 2000 ma PRODUCT DESCRIPTION The 8 MS Series 1 8 2 stepper motor driver is switching constant current regulator which drives current pulses through the windings of a stepper motor All stepper motors are stepped or rotated by changing the direction of the current flow through the windings in a unique sequence Each change of current direction results in a step The driver contains two sections 1 the step generator and the 2 power drivers The step generator is a digital logic system which receives input commands from a controller typically a microprocessor and generates a series of step signals The power drivers receive the step signals and switch the phase of current in the motor windings The driver requires a minimum of four input signals 1 the step pulse STP 2 the direction level DIR 3 the power level PRK and the enable signal ABR The step pulse or step cloc
17. I letters followed by a space and a value if required Values without a suffix are 0 to 255 max Values with 16 suffix are 65535 64K max Values with 24 suffix are 16777215 16 Meg Add byte count is 64K max Bit is 0 to 7 ATTENTION Mis wiring of motor or power supplies WILL damage motor drivers IMMEDIATELY Motor coils A or B can be reversed motor will run in the opposite direction Pairs can be reversed pair A in coil B for example CROSS WIRING an A and B wire crossed WILL damage driver Allowing exposed motor leads to touch each other ground or power MAY damage driver Refer to Appendix D in the MS driver section for wiring schemes SMOKE POPPING ELECTRONIC ODOR OR FUSE FAILURE INDICATES DRIVER FAILURE Call the Service Center Do NOT change fuse or attempt repair without instructions ADDITIONAL DAMAGE CAN OCCUR Shorted drivers can easily be repaired by replacing the socketed driver arrays WARNING 1 NEVER connect or disconnect any of the motor leads power supply leads before disconnecting AC power Unit may be safely operated WITHOUT motor However pause 30 seconds after power off before reconnecting motor Bleed Down time NOTE An understanding of the Cybernetic Motion Controller and its Command Set is required in the following explainations Refer to the Cybernetic Micro Systems CY 545 OR 550 Step Motor Controller Manual Introduction The SMC motion control system cons
18. MMI 8S WIN MMIMAN1 WRI 02 02 MULTI AXES MOTION SYSTEM SECTION 1 SECTION 2 SECTION 3 SECTION 4 APPENDIX OPERATION AND INSTALLATION MANUAL INTRODUCTION SR4 NETWORK CONTROL SMC STEP MOTION CONTROL MMI MECHANICAL ASSEMBLY QUICK REFERENCE GUIDE PAGE 2 PAGE 6 PAGE 15 PAGE 27 PAGE 35 SERVICE CENTER 800 424 STEP om W PO BOX 669 CLOVIS 93613 0669 TEL 559 325 2727 FAX 559 325 7117 INTRODUCTION MMI Multi Axes Motion Controllers provide control of up to eight step motors Each motor controller is independent Each supports a home sensor limit safety loop and six bits of general purpose 1 input output In addition up to eight MMI motion controllers can be daisy chained together with simple DB9 serial cables for a total of 64 motors per serial port The MMI system consists of three major sub assemblies two SR4s Serial Repeater 4 channel network communication controller cards up to eight SMCs Step Motion Controller cards and the power supplies The MMI system is packaged in a 19 format enclosure suitable for 19 rack mount or free standing bench top applications During operation the SR4 net controllers send and receive commands from the host CPU using the RS 232 communication port There are 2 command sets one for the Cybernetics CY233 net controllers and the other for the Cybernetics CY545 550 SMC motor controllers The CY233 uses only 4 commands T
19. Modem pin to pin PIN 3 TX Transmit _ gt PIN 3 RX Receive PIN 2 RX Receive lt PIN 2 TX Transmit PIN 8 CTS Clear PIN 8 DSR Ready PIN 5 Signal Ground lt gt PIN 5 Signal amp Frame PIN 4 Ready PIN 4 DTR Ready Shell Frame Ground lt Shell Signal amp Frame pin to pin cable MAC DIN CPU DIN 8 EIA 422 CONTROLLER DB 9S AT PIN 5 RX In lt PIN 2 TX Transmit PIN 3 TX Out gt PIN 3 RX Receive PIN 2 CTS Hand In PIN 8 DSR Ready PIN 4 Signal Ground lt gt 5 Signal amp Frame PIN 8 In lt 1 DTR 7 PIN 4 DTR Shell Frame Ground lt gt Shell Signal amp Frame MAC to IBM Adaptor Cable The Controller Device signal DSR Data Set Ready is wired to the network CY233 status input CTS Cleared To Send When the controller is busy the DRS will set HI or or busy and pull CTS HI or not Clear To Send The host CPU should not send when the device is busy See Status Code Table If the host software ignores the CTS status signal and commands are sent to a busy motion controller the commands will be lost or jam the controller Typical indications of the host failing to obey the CTS are motion or homing stops when host program is run motor runs ba
20. SMOOTH ROTATION WITH NO SLIP OR RESONANCE CURRENT TOO HIGH EXCESSIVE NOISE SLIP MOTOR OVERHEATING ABOVE 85 C AND POOR RAMP PERFORMANCE BOARD EDGE MIN NOTE DRIVER WILL REDUCE CURRENT IF OPERATED CONTINUOUSLY AT SLOW PERCENTAGE OF RATES 200 PPS WITH MAXIMUM POWER CURRENT SET ABOVE 60 WARNING CONSTANT CURRENT AUTO PARKING BI POLAR DRIVERS DO NOT ATTEMPT TO MEASURE CURRENT WITHOUT SPECIAL INSTRUCTION APPENDIX D MOTOR WIRING SCHEMES PAGE 1 2 Performance of a stepper motor based system depends more on the electronic drivers used than it does on the motor itself A step motor both PM and Hybrid type is made to step by sequencing the orientations of the magnetic fields in two coils The UNIPOLAR drive method of is illustrated in the figure using just ONE coil of the motor Note that the center tap of the coil is connected to the positive motor supply voltage An electronic circuit represented by the switch then connects one end or the other to ground for current to flow from the center tap to the grounded end The most significant factor is that only one half of the coil is used at any given time and that the magnetic field intensity motor torque is proportional to the product of the number of turns in the coil and the current passing through the coil Motors designed for BIPOLAR drivers will often have only four leads However some manufactures will provide the motors in 8 wire versions to offer a performance choice for
21. Trademark protection are the following MINI STEP QUAD STEP AUTO PARK DIAL POT MMA PRINTER PORT DRIVER THE MOTION GROUP information is transfered to the customer for their own uses upon the purchase of a TECHNOLOGY TRANSFER AGREEMENT and is limited to those items listed in the agreement Contact the Customer Service Center for TT details equipment purchased from THE MOTION GROUP includes a 100 26 warranty for parts and labor This warranty may be revoked at any time and the purchase refunded at the discretion of THE MOTION GROUP
22. ated in three modes FULL step or HALF step and QUAD step only In each of these modes the output power control PRK is controlled by an external microprocessor PRK is used to reduce driver and motor heating during non step periods THEORY OF OPERATION The unique element in the driver is the current regulator device referred to as the driver chip This driver has three main inputs 1 the phase control F 2 current control 10 3 current control 11 The outputs of a driver are the connections to a single motor winding Internally an output section contains four power transistors configured in an H bridge with two pair sourcing current and two pair sinking current The motor winding is connected across the bridge If one source transistor at one end of the winding and one sink transistor at the other end are turned on then current flows through the winding Alternately if the other pair is on then the current will flow through the windings in the opposite direction The D C Supply is connected to the top positive and bottom negative of th H bridge transistor pairs An external resistor typically 1 ohm or less is inserted in series between the negative of the H bridge and the negative of the power supply negative so that the total winding current flows through the resistor When full winding current flows the small voltage 400 mv across the resistor is fed back to the comparator section and turns off the H bridge transistors Afte
23. ce after the correct number of turns of the motor For example a 10 turn screw should cause linear travel of 1 inch every 2000 steps 200 step rev motor If rather than commanding the motor controller to go in 2000 step increments the controller moves to absolute positions such as 2000 4001 6003 7999 ect the error is eliminated This technique requires a control system which carries a map with each individual machine The EEPROM memory is suitable for this purpose APPENDIX DESCRIPTION OF HOMING AND ABORT LOOP PAGE 2 2 SUPER HOMING In high resolution systems two sensors are used The first sensor the home sensor is mounted to the motion platform in the typical configuration The second sensor the index sensor is located as an index detector on the motor shaft The index can be either a disk with a tab or along pin During the homing operation the motor is stepped backwards until the first sensor is blocked The motor however continues to rotate until the second or index mark is detected The system is now homed to the step TMG systems with Super Homing use two identical PHOTO LOGIC sensors wire ORed together so that both must be blocked before the home signal is detected The H or home command of the motion controller will operate with either single or double sensors HOME LIMIT LIMIT SWITCH SWITCH LEFT SENSOR gt CW RIGHT SENSOR NO side view TAB ABORT LOOP FUNCTION In TMG systems the
24. ckwards at high speed forever or only part of a memory routine is completed It is the responsibility of the host software to check status for not busy before sending commands to the selected device SECTION 4 MMI Mechanical Assembly The MMI assembly consists of the SR4 network controllers the SMC CY 5 4 controller amp MS 2 0 motor drivers all DC power supplies and an AC power entry The DC power supplies provide 5 TTL computer VCC and 40 motor VMM The VCC supply is over current protected In addition A 1 amp AC fuse protects the entire assembly NOTE NEVER REPLACE THE FUSE FUSE FAILURE INDICATES DRIVER FAILURE The green chassis lamp indicates VMM motor power on The neon lamp in the power switch indicates that AC power is present to the MMI The MMI has six pin motor connectors see Appendix D IEC power connector network serial connectors refer to serial cable section and LED status indicators The 20 pin Cl cable connectors provides access to the spare 1 0 lines limit loop home sensor and VCC power ground Refer to Appendix A POWER SUPPLY WIRING DIAGRAM FILTER SOCKET ac Er LIHE 2000UF 470 EARTH FILTER posts 250v 26 34 NOTE NEVER REPLACE FUSE FAILURE INDICATES DRIVER DAMAGE VIN IMMIAMMIMECH1 MMIMECHANICALDRAWNG sid rnin 19 RACK MOUNT OR FREE STANDING ASSEMBLY 17 WIDE X 3 5 HIGH X 8 DEEP BACK PANEL REAR VIEW 17
25. current to the motor coils between 100 power and park power When PRK is LO Ovdc the unit produces FULL power If PRK is HI 5vdc or floating the units outputs at PARK power On units so equipped PARK power may be preset at the medium MED power level PARK condition is used to reduce power supply requirements and motor dissipation during non step periods Any load which can be moved by the motor at full power can be firmly PARKed at low power The motor will free wheel only if the ABORT ABR line is HI Abort Control Input ABR P1 9 see next The ABR input must be LO to step If the input is HI or disconnected the driver control output will output zero current NOTE the driver is not OFF power is still being regulated to the zero condition The motor will free wheel ABORT is normally only used in stand by position loss may occur in series with safety switches limits or other emergency stop conditions Other Signals CPU ABR and HOME P1 10 12 amp P1 4 16 Pin 12 is the normal input to P1 9 when the ABoRt Loop is used Pin 4 16 is the output signal HOME back to the controlling device Spare Inputs P1 18 88 P1 20 7 Pins 18 and 20 can be used for other signals to from the card See Chassis Signals connector Pin 20 is normally keyed on free standing cards 3 Chassis Signals P1 1 to 9 amp P1 2 to 10 These signals are normally used to provide for a convenient method of cabling the driver between the controller and the
26. d as a single unit as required during service Note Do not attempt any procedure or remove any screws other than instructed no user service is possible to the interior assemblies SERVICE ACCESS Remove the top cover see following procedure and access the interior of the MMI only 1 to adjust the motor current factory preset to 1 amp coil 2 to set the network address clips factory preset to 0 amp 1 3 to observe the network LED displays during programming as required TOP COVER REMOVAL PROCEDURE 1 Remove only the four 4 corner 6 32 slotted head screws holding the black top cover the cover edges will be retained by the front and rear panels 2 Pressing against the rear portion of the cover at the raised bevel with the thumbs slide the cover fully forward while keeping the cover edge under the lip of the front panel The rear lip of the cover will be exposed Do not attempt to remove by sliding front to rear 3 Using care not to bend the cover lift up both rear corners of the cover slightly above the rear panel Pull the cover towards the rear and lift off 4 Replacement is the reverse of the above OPERATION The CY233 microprocessor is used as an address controller for the multiplex system When mode command followed by a valid ID number is received by the 233 233 s address lines select a multiplex channel The remaining serial data motion command string is passed through the multiplexer
27. elected with the jumper switches located on the controller card Valid ID numbers are from 0 to F hex 1 to 16 net controllers The second or low byte selects any combination of the four channels within a controller Valid channel numbers are from 0 to F hex Note that F selects no motor channels and is used only to send the Status request to the CY233 and not the motion systems A typical example of a message to a SMC axes would be WOEp 1000 lt This example directs SMC axis E motor 1 of SR4 0 to move to position 1000 The write command is also used to request information query from the motion systems Only one motion channel can be requested to return information at a time In a typical motion system with a CY545 motion controller the question mark command is used to query the system Do not program the motion system EEPROMS to respond with information without a query command first Slave mode only A typical command would be WOE p lt This requests motor 1 to return its current position READ MODE A read command consists only of a mode character R the ID number two hex characters note that the second character is always F and a terminator carriage return The read command is only used to read the status of the SMC motion systems from the SR4 net controller STATUS When a motion system is busy it can not respond normally to the host computer The BUSY also refered to as the CTS or cleared to send signal is used
28. er to Appendix A for details This system is self contained and can operate independently or under the direct command of a host computer In Memory Mode the host computer is used to teach the system by sending a string of commands which are stored for later execution in the on board memory of the controller card In Direct Mode the host commands are executed immediately by the CY545 A combination of these two modes is also possible typically macro command strings are loaded to memory and then executed as required by the host See Appendix A for cable See Appendix D for motor wiring See Appendix B for homing limits See Appendix E for driver card See Appendix C for current adjust See Appendix F for home sensor SMC BLOCK DIAGRAM The SMC system consists of motor driver card and motion controller card Refer to specific section for details SMC Cable Connector REFER TO APPENDIX LED Display SR4 NET CONTROL Motor Output REFER TO APPENDIX D CI CABLE CONNECTOR wed gnd home gnd Chassis Cable jog B2 limit loop limit loop VEC B5 B7 Userl O Cable B3 B4 B 1 B2 gnd gnd JOG CONNECTOR MOTOR CONNECTOR 1 2 3 6 070 vcc jog B2 COIL 2 5 COIL 34 A 1 4 B REFER TO APPENDIX A pin 2 amp 5 are not used Molex Connector pin numbers are REFER TO embossed on back of nylon housing APPENDIX D Hardware Configuration The SMC controller card contains the CY 545 mo
29. fer to the unit label for the VMM maximum of that model TS1 8 P1 13 amp 14 1 6 If the optional 5vdc TTL supply is not installed then an external 150ma digital supply is connected to the TS1 8 VCC connections TS1 5 is provided for ground return TS1 8 is protected by a 6 8vdc TRANSORB The VCC is ALSO common through the digital control connector P1 13 amp 14 The 5vdc can be furnished by 1 the computer or controller power supply only or both If the system power is not controlled by one switch always isolate the driver systems with a diode in the VCC connection In any case controller VCC and driver VCC MUST BE COMMON or other interface connections are required opto isolation GND 1 4 amp 5 P1 19 3 5 In all cases ground is COMMON to all grounds digital VCC analog VMM chassis ground and green wire ground AC power ground If a dual VMM amp VCC supply is used then an identical and equal ground lead is connected 2 each wires to TS1 4 and 5 Always bridge the supply returns and connect to chassis If separate supplies are used connect the VMM supply and ground to the TS1 connector Connect the driver VCC P1 13 amp 14 and ground P1 19 from the driver to the controller bus Connect the VCC supply to the controller bus IN ALL CASES ANY VCC BETWEEN THE CONTROLLER AND IN THE DRIVER MUST BE COMMON OR ELSE OPTICAL ISOLATION IS REQUIRED In all cases connect chassis ground green wire ground or earth to the driver or
30. ficient for the load in normal operation and second that a reference position commonly called the home position be consistently established during initialization of the system When step motors are rotated by counting clocking out a number of steps in theory the motion will take place zero steps The exact mechanical position of the motor can vary by the motor step accuracy typically 3 of one step non cumlative A proof of zero step operation is first to reference a starting positon of the motor or home During homing the motor is stepped backwards into a switch reversed and then stepped forward until the switch opens The point of interest is not the exact mechanical position but rather on which step the switch changed state For that reason only high resolution PHOTO LOGIC optical beam switches are used TMG systems SLIP DETECTION After the motor is home the controller position counter is reset to the home position typically position 1 one step out of the sensor The motor is then stepped CW to any position To slip detect the system the motor is returned to position 1 If the sensor remains open then the motor is stepped to positon 0 If the sensor closes the system is operating zero steps error free Note that a single step lost slip will always result in at least a movement of 4 full steps away from the correct position Open loop systems are slip detected at regular intervals to prove continuing sl
31. frequency MD10A 18 24 Khz Motor current MS2 0 0 05 2 0 Amp Step pulse input Voltage 0 5 0 VDC Sink surrent 12 20 ma Pulse high 1 uSec Pulse low 1 uSec Rise time 0 5 uSec Fall time 0 5 uSec Frequency 500 KHz Logic 1 volts 418 20 VDC Direction input Voltage 0 5 0 VDC Sink current 12 20 ma Logic 1 volts 418 20 VDC Note The step pulse input must be a logic 1 high during direction input change Environmental Operating temperature 20 50 Humidity non condensing 0 95 Shock 100 G Altitude 30 000 FT Mechanical Weight 3 Ib Dimensions 2 x 8 5 x 11 0 Mounting hole centers 2 625 x 8 250 Mounting screw size 6 32 x 1 2 max SERVICE CENTER GROUP 800 424 STEP is motiongroup com PO BOX 669 CLOVIS 93613 0669 TEL 5593252727 FAX 559 325 7117 PURCHASE AGREEMENT Purchase of any item from THE MOTION GROUP represents a agreement between THE MOTION GROUP and the customer Therefore the customer agrees that all information contained in the included documentation drawings and software is the exclusive property of THE MOTION GROUP and that the customer is bound to prevent dissemination of this information to unauthorized parties The above mentioned information represents the Intellectual Property of THE MOTION GROUP and is thereby protected by the Copywrite Act of 1988 In particular the firmware tables artworks and design drawings are specifically copywrite protected Also included under
32. he CY545 has 26 commands refer to the CY545 Motion Controller manual for details The CY number refers to the model of microprocessor used in this system MMI 8S TURNKEY MOTION SYSTEM COMPONENTS MOTION IN MINUTES PLUG AND GO SYSTEM Features CY 545 550 RS232 SERIAL NETWORK gt NET IN NET OUT NET CONTROL POWER SUPPLY SECTION J STEP III MOTOR 6 PIN MOLEX HOME 4 PIN SENSOR MOLEX A JoG L PIN CONECTOR MOLEX u TYPICAL 1 0 DEVICE CONNECTIONS IEC POWER CORD 6 L Sensing User Gnd switch input must be passive contacts only OUTPUT SOLID STATE RELAY AC or DC User AC In 19 Controlled RACK Output MOUNT User Bit AC Out Lo On AC must be zero crossing SOFTWARE USER 1 0 e CONNECTOR DISK 10 PIN IDC MANUALS 2 PIN NT LIMIT NC RIGHT MMI MOTION SYSTEM COMMUNICATION BLOCK DIAGRAM HOST CPU SERIAL OUT IH SYSTEMS 4 PER HET 050 233 COHTROLLER LIMITS Vo MOTION SYSTEMS 4 PER HET ID 1 COHTROLLER CY 233 HET COHTROLLER POWER HEXT MMI SYSTEM UP 8 MMI SYSTEMS AC OR DC OR TERMINATION PER HOST SERIAL PORT DANGER SUDDEN AND UNEXPECTED MOTION CAN OCCUR DUE TO PROGRAMMING ERRORS STAY CLEAR OF THE MOTORS WARNING It is the user s responsibility to insure that commands are not sent to busy systems The motion systems can indicate they are busy but have no way to block incoming commmunica
33. he displays are used with the test software program to verify and demonstrate correct operation of the MMI They are located on each SR4 card inside the MMI L1 OUT1 INDICATES TRANSMIT DATA TO CHANNEL 1 L2 OUT2 2 L3 OUT3 3 L4 OUT4 4 L5 OUT DATA INDICATES TRANSMIT DATA FROM HOST CPU L6 IN1 INDICATES RECEIVE DATA TO HOST CPU 1 L7 2 4 2 L8 5 3 L9 4 4 L10 ADO INDICATES MOTION CHANNEL ADDRESS 1 L11 AD1 i 2 112 AD2 3 L13 AD3 4 ID JUMPER SWITCH The ID jumper switch assigns the ID number to SR4 card The switch consists of 3 rows of 4 posts The center row is jumpered high or low according to the required number The rows are labeled J2A high posts J2B signal and J2C low posts All posts must be jumpered If addition MMI units are used their addresses must be set according to their position in the daisy chain LSB 1248 1248 1248 MSB J2C ground 0 J2B address J2A 0000 00 00 card edge clips shown set for 0000 10 0 0010 10 42 1001 or ID 8 9 PROGRAMMING The MMI is in general transparent to the connected motion systems and requires only that the three byte address be pre fixed to the existing commands The demonstration software furnished with the MMI is intended to exercise the entire unit and to allow transmitting commands one at a time or in complete strings in order to verify operation of the system or to create a complete simulation of the application Thi
34. ip free operation CENTER HOME AND CONTIGUOUS SLIP DETECTION If the home sensor is located at the center of axis motion and a step bar is mounted along the entire motion path then the home position can be verified each time the system crosses the center line A stepped bar is thin strip with a left high SMCe and a right low SMCe The high to low edge is the center line LASH COMPENSATION A major advantage of steppers is in their repeatability which is typically less than 01 96 because the digital controls are not affected by temperature aging voltage or adjustment This allows errors such as lash and distortion to be zeroed out Lash compensation adds or subtracts steps at each change of direction or because of other forces to take up the lash error Lash compensation is accomplished during the slip detection process When the system is slip detected the first time the sensor will not close at position 0 because of the lash home LED remains off At this point the system is single stepped CCW until the sensor closes home LED is on The number of CCW steps is the lash compensation value The system is re homed and the counter loaded with this value see At home command The motor is then moved some number of steps CW returned to position 1 sensor open and finally position 0 sensor closed The system is zero steps Screw distortion error occurs when the screw pitch which is so many turns per inch does not move the correct distan
35. ists of two basic elements the controller card and the MS driver card The controller card CY5 4 contains the Cybernetic CY 545 or CY 550 Step Motor Controller and a 2K character EEPROM non volatile for storing application routines Refer to the Cybernetics 545 manual for a description of the 545 microprocessor and its High Level command set 26 characters and symbols All actions of this system are controlled by these commands Two of the eight User Bits of the 545 USRB 0 7 are assigned to a specific function The remainder are for general purpose Input and Output functions I O such as controlling relays or valves output and reading switches input The command set of the Cybernetic 545 contains instructions such as Test Wait Delay Loop which are used along with the motion instructions to provide a wide range of machine operations The SMC system can also be discribed as a mini PLC with motion The Step pulses and the Direction signal from the CY5 4 controller are connected to the motor driver Additionally the Stop PWR LED signal shifts the driver from Park power to Full power A Home Sensor channel is also part of the system Each system includes a cable controller interface cable This 20 pin cable is divided into two sections The I O section contains 5 v power and ground as well as six User Bits The Chassis section connects the Home Sensor User Bit 2 Jog Switch and Limit Loop signals back to the controller Ref
36. k to the input of the driver will cause a corresponding change of the output current resulting in one step one unit of motor rotation The direction input is a digital level signal which controls the direction of motor rotation If the signal is true High the motor rotates in CW direction if the signal is false LOw the motor rotates in CCW direction In addition to the step and direction inputs the driver will accept an output power control input This digital input PARK controls the amount of current delivered to the motor windings either run power or park power If the signal is or floating the driver is at reduced current if LO the driver is at full current The enable signal ABoRt sets the current to either off or on If the signal is HI or floating the driver is FREE no current if LO the driver is enabled In addition to the digital input signals the MS driver also requires a power supply input of unregulated D C voltage The driver functions to control the current furnished by the D C supply The combination of a D C supply and the MS driver is referred to as a current regulated power supply or constant current motor driver The driver regulates the current through the motor winding by rapidly switching on and off the D C voltage This technique is referred to as switch mode or chopper stabilized regulation The driver also requires 5 TTL logic supply for the digital sections OPERATIONAL MODES The driver can be oper
37. m at a time is selected for setup commands and then up to four motors can be directed to execute Go simultaneously When requesting information from a SMC motor system only one of the eight can be selected When a motor system is performing an operation its Busy signal is input to the SR4 s status register To monitor the busy status of the SMCs a Read command address again consisting of three bytes is sent to the net controller The SR4 will return an ASCII character equal to a binary number This number indicates the status of all four SMCs Refer to the net ID address table in this manual The host to MMI serial port is wired with standard RS 232 IBM type DB 9 connectors Each MMI has two connectors The first goes to the host computer and the second to the next MMI controller in the daisy chain The last controller s second connector must terminated with the loop jumper DB9 plug The MMI normally operates in standard RS 232 format using ASCII character mode at 1200 baud which supports the EEPROM memorys on the motor cards Optional baud rates up to 57K baud are possible Parity is none 8 data bits and 1 stop bit HARDWARE DESCRIPTION The MMI network control contains two CY233 SR4 cards generally refered to as 0 and 1 which is their binary address Each card controls four SMC motor systems and includes status LEDs and jumber posts dip clips for setting its ID number The cards are mounted to a single rail and can be remove
38. mp Comments Command A val 24 B bit 4 16 H bit 4 L cnt N num 24 O mode P val 24 Q R val S val T bit add W bit X Y add 16 Z cnt 16 add 0 number plus minus forslash command message CONTENTS Introduction Hardware Configuration Displays amp Controls Installation amp Test Programming amp Listings Serial Cable Diagrams PAGE 17 19 20 21 25 26 CY 545 COMMAND SET SUMMARY In the MMI network system all letter commands must be in lower case Function set position counter to At value set or clear B User Bit set Continuous stepping mode Delay for value in milliseconds Enter commands to user mem First starting speed of motor motor Goes the number of steps Home motor on bit Initialize 545 software reset Jump to address on mem page Loop to address for count value Number of steps see Go set mOdes of CY controller moves to an absolute Position Quit Enter commands to mem set Ramp top speed of motor Slope acceleration of F to R jump to add unTil Bit matches Wait at add until Bit matches eXecute commands at Y add set mem address counter to Y Zillion Loops to add for cnt value end of program or stop program set CW direction for Go move set CCW direction for Go move negate prefix for Bit commands send back command val to host send back message to host Note Commands are lower case ASCI
39. neral Purpose User Bit Reset To hardware reset or stop the system cycle the AC power switch located on the rear panel Software Configuration This system is a serial device directed by ASCI character commands It is configured exactly as described in the Cybernetics controller manuals except for differences as noted in this manual Special Commands are created to simplify use of the Basic program Reserved and Special Software Commands CLEAR Writes 0 s and CR s to memory LOAD F6 Loads memory Not same function as Basic key EXIT F5 Required to close comm port close file and clear error traps not use comma to separate elements of 545 commands T L and M XX Comma isa Basic symbol use space instead HP LED command string is not used C Continuous Step Mode is normally not used with the CY545 unless motion can be terminated with an external Abort signal Refer also to the CY550 which is an advanced version which has a larger selection of on the fly software commands Special Aspects of Some Commands W The Wait command causes the 545 to wait at the instruction therefore incoming stop commands will not be processed Use a T command in a jump to itself L Z These loop instructions assume that the first pass of a routine before reaching the loop command was the 1st loop pass In general the loop count must be one less than required Also see J amp T below T H W O These command
40. of COMMANDS refer to the back cover of the CY 545 manual either stored in the external memory Memory Mode or sent from the host computer Direct Mode The third mode Programming Mode is when commands are sent from the host and written into the external memory Computer Test Procedure 1 LOAD and RUN the Demo program which will down load self tests Refer to lines 500 1000 of the listings 2 Verify the time delay is correct for the host computer During testing the system will return the network status characters or other query information ROFO status or P 000000 position for example If the returns are in segments P 00 00 00 with multiple line feeds between characters the host computer is too fast for the comm card Exit the program F5 refer to line 120 and increase the timebase T value for the host computer Re start shift F5 the program Note the serial delay routine GOSUB 2500 at Line 2500 is multiplied by itself use small increases When set correctly the display will have no vertical segments but also have no excessive delay in responding to querys NOTE If the message system is busy or not connected appears enter Ctrl Break The system IS NOT connected to COMM 1 RESET the MMI and correct the serial cabling The MMI system should when the MMIDEMO bas is run lite B 0 motors enabled lite DIR direction BUSY lite off and return status none busy to the display 3 Motor Commands NOTE
41. otor and Home 17 Rate Tables 19 good sample program sections 13 14 15 not used Typical commands will duplicate the down load with different values of R S and F used in order to determain the best parameters for moving the motor Refer to the Rate Tables Repeat Step 3 with different parameters Resonance Resonance feed back oscillation between the motor rotor and the motor coils is a vibration which affects the motor behavior Typical symptions are shuttering dropping steps jumping back and forth hard running and excessive noise unpleasent All step motors exibit resonance at approximately 100 full step sec Low Frequency and at 1000 full steps sec Mid Frequency This behavior is affected by motor load power and speed The normal procedure is to start at a speed F command above the low point and ramp through the mid point S command to a higher speed R command To determine the resonance points set F and S to the lowest value and R above mid freq Move the motor sufficent steps to reach top speed Note the points during this acceleration where the motor exhibits abnormal behavior these are the low frequency nodes The motor will stall at the mid freq point Resonance can be reduced by less power decoupling the motor and load isolating couplers not metal to metal higher speeds faster acceleration and or smaller step angles Programming The software program used with the MMI SR4 SMC system is only a Serial Drive
42. r routine The main purpose of the program is to send and receive commands between the host and the MMI microprocessors The motion control software firmware command set is contained only in the CY545 The QBASIC serial driver contain examples of typical operations required by the host computer software such as opening the comm serial port sending receiving characters loading the 545 memory handling the Busy status and diagnostic capability Included in the sample program are routines of 545 commands which exercise the motion system during manufacturing tests Two types of routines are demonstrated 1 downloading a string of commands from a keyboard file and 2 loading a string of commands to EEprom memory The sample listing is commented and contains information about how to operate a 545 system It is helpful to read the listing even for non computer types Line 0 20 defines the variables and create symbols for control characters Line 30 100 assigns the Basic function keys for common functions Line 120 creates the time delay used between characters so that fast computers do not get ahead of the serial card and the MMI Line 130 defines the serial port as the ACTIVE device PRINT ZACTIVE sends characters to the active port Line 200 400 creates the introduction screen display Line 500 999 is the down load test routine which is sent to the 545 when this program is first run Line 1010 1410 is the Self Test program The GOSUB 25
43. r a fixed time off to allow the transistors to settle and the feed back voltage to dissipate the bridge again turns on and current builds up in the winding until the voltage across the sense resistor again trips the comparator The digital phase input level HI or LO selects which pair turns and corresponds to the direction of current flow through the winding The current controls 10 and 11 select one of four comparators zero low medium or full The output is therefore a series of current pulses equal in amplitude and separated by the period of fixed time off The value of the current sense resistor is pre selected to produce a current amplitude equal to that of the current rating of the motor winding 10 and 11 select a comparator other that FULL then the sense resistor feed back voltage trips at less than full current The reference voltage of the comparators is also available as an input to the device By externally controlling this reference input the output current can be varied between zero and full i e microstepping The driver card contains three sections 1 the step generator which controls the digital levels of the phase F inputs 2 the drivers and 3 the Auto Park gate which if installed controls the output current digital input PRK automatically The step generator is a counter PROM configured as a four eight sixteen step counter The outputs of the counter are combined through PROM gates into two outputs
44. s are followed by a numeric value in Hexdecimal which is desinated by the H following the value The decimal and the hex values for 0 to 7 are the same and the H can be omitted H Homing is a single step operation The Busy signal is not continuously set during homing but cycles every step It is best therefore that homing is executed from memory J T Any Jump or Test operation which includes L amp Z commands must not cross the memory page boundry which is ever 256 bytes 256 512 768 1024 etc Use the Y for global jumps Installation and Test Procedure 1 Connect AC power cord 2 Connect motors verify that driver current is correct for motors See Appendix C for current adjustment and Appendix D for motor wiring 3 Connect cable Limit Loop must be closed for motor to run 4 Connect the serial cable and turn on computer system 5 Connect the AC power and turn on power switch or supplies Verify that AC power is present DC lamp motor power is SMC LEDs are off except for BUSY Refer to lines 500 1000 of the listings in this manual These tests prove that the MMI system is operating correctly Typically a motor will run back and forth several times Observe the LED indicator lites while the tests are running and note that each action of the system can be monitored and that this self test is the series of commands listed between the quotes in lines 500 1000 All actions of the system are the result
45. s software is a simple terminal program whose listings contain important notes All users should read the listing for this general information about system operations Refer to the sample program in the Installation and Operation section of this manual NETWORK CONFIGURATION DAISY CHAIN BLOCK DIAGRAM 8 CABLES SR 4 HOST CABLE NETWORK ASSEMBLY P5 1 GROUND 08955 GROUND BLACK P5 2 TXD DATA IN 0895 3 LOOP INPUT GRAY P5 3 GROUND DBSP 5 GROUND PURPLE P5 4 RXD DATA OUT DBSP 3 LOOP OUTPUT YELLOW P5 5 5 0895 8 CTS ALWAYS NOT BUSY RED 0895 2 LOOP DBSP 2 LOOP WHITE JUMPER HOST CABLE ASSY DB9P DEVICE CABLE ASSY 4 EA CARD P5 1 45 VDC P5 2 TXD DATA IN asispa P5 3 GROUND P5 4 RXD DATA OUT P5 5 CTS NOT BUSY CTS BUSY NETWORK CABLING DIAGRAM MMI 1 H P PINS S SOCKETS HOST SERIAL PORT TERMINATOR SR 4 CARD 8 CABLE PINOUTS 5 2 5 8 8 8 63 3 00 8 CARD 4 40 CHANNEL CONNECTORS FOUR P1 P2 P3 P4 TYPICAL PLACES aca 0 P1 1 5 VDC 25 IN o P1 2 TXD DATA OUT 4 5 X 2 0 03 0 P13 SYSTEM GND 1 4 RXD DATA IN 0 P1 5 CTS BUSY CARD ADDRESS 15 SWITCH 9 LSD 0 MSD c5 HOST CONNECTOR P5 1 SYSTEM GND 5 2 TXD DATA OUT P5 3 SYSTEM GND P54 RXD DATA IN P555 5 VDC CTS o E o SECTION 3 STEP MOTION CONTROLLER ASSEMBLY ALSO REFER TO Cybernetic Micro Systems CY 545 Step Motor Controller Manual MMIDEMO program Software Listings a
46. stem through the User Bits WILL damage the User port opto isolation is required The standard cable is the 20 pin which provides limits and home sensor signals access to the User Bit I O lines and VCC power amp ground Refer to Appendix of this manual Other Functions The Jog function pin 6 is available at the Jog connector of the Cl Cable see Appendix A External thumbwheel pin 12 is not used Instead refer to the I O Path option for thumbwheel operation or stand alone PLC mode Note that the CW CCW inputs are available in this system as the Emergency Stop option Also the Inhibit Abort pin 8 is not used in this system This Abort is not the same as the driver abort ABR Reserved User Bits BO Enable Driver must be LO to step BO LED will be ON B1 Bit 1 is always the Home Sensor Bit 6 Is the Busy Bit CTS See mOde Command LED Status Displays OFF Logic High or true Low or false pin refers to CY 545 pinout BZ Indicates the inverse of pin 27 User Bit 6 Off Ready On Busy DR Indicates the polarity of pin 2 direction LO CW ST Indicates the polarity of pin 1 step LO Step pulse PW Indicates the polarity of pin 3 stop LO z Stepping SW Indicates the polarity of pin 6 slew LO Ramp speed BO Indicates the polarity of pin 21 User Bit 0 LO Enable all drivers B1 Indicates the polarity of pin 22 User Bit 1 LO Home Sensor blocked B2 Indicates the polarity of pin 23 User Bit 2 Ge
47. supply grounds COIL A COIL B TS1 2 amp 3 TS1 6 amp 7 none A pair of motor windings are connected across each coil connection Bipolar motors have FOUR leads two pair Unipolar motors with SIX leads can be used provided a coil end and a center tap are connected unused wires MUST be INSULATED and cut off or tied back NEVER attempt to connect the center taps of unipolar motors to VMM except in the case of FIVE wire motors NEVER insert dropping resistors in the power supply leads or winding leads NEVER insert caps or coil filters across the windings 2 INPUT SIGNALS Digital Inputs 1 12 20 8 11 19 See Appendix A Step Input CLK P1 15 The step clock 5vdc TTL compatible inputs to the clock pin of a 74191 type counter The 74191 toggles on a LO to HI transition The Step CLK MUST be normally HI 5vdc and go LO only long enough to toggle th counter 100us to 1ms Refer to TTL data books for max min clock conditions A pull up resistor 4 7k is installed on the step clock input Refer to AUTO PARK for additional requirements of the clock inputs Direction Input DIR P1 17 The direction level inputs to the 74191 counter The input is pulled up by a 4 7k resistor Setting the input HI or LO reverses the direction of motor rotation Motor rotation with respect to the state of the direction input may be reversed by reversing the motor winding pairs Current Control Input PRK P1 11 The current control signal shifts the output
48. tion controller EEprom memory memory latches 2 each RS 232 receiver driver LED status lites and standard crystal 11 MHZ Refer to the Rate Table in the CY545 manual Serial Format The SMC is connected as a RS 232 serial device and communicates with the host computer through SR4 network The serial format is configured in the following manner ASCII characters 1200 Baud 8 data bits no parity and one stop bit The CTS Clear To Send feature of the 545 User Bit 6 is used as the hardware hand shake to control communication between the host and the 545 When the 545 is busy it will set the CTS signal to the SR4 status register as a request to hold off transmission During operation from memory or when homing the CTS function is not 100 busy pulses on off each instruction This is to allow interruption of routines by the host computer sending a stop command 0 or CR If other data is sent incorrect operation will result To set the SMC 100 busy during operations 1 disable the CTS function with the Mode command User Bit 6 will set Hl or busy 2 As the last instruction in the memory routine re enable the CTS NOTE the correct Mode command to defeat the CTS is 080h the correct Mode command to enable the CTS is o 0 0 Any hex value starting with a letter must be preceded by a zero Memory Format The memory is configured as 2K bytes of EEPROM RAM is optional It is not possible to access memory above address 2
49. tions which will either be lost or jam lock up the system In some cases the system may begin uncontrolled motion ATTENTION CONTRARY TO POPULAR PRACTICE IT IS BEST TO READ THIS MANUAL BEFORE ATTEMPTING TO OPERATE SYSTEM IT WILL SAVE TIME AND PRODUCE BETTER FASTER RESULTS SECTION 2 SR4 Serial Repeater 4 channel Assembly CONTENTS PAGE Introduction 7 Hardware Configuration 8 Service Access 8 Table of ID and Status Codes 11 Displays amp Controls 12 Mechanical Assembly 14 WRITE READ ECHO ENTER SR4 CY 233 COMMAND SET SUMMARY Ac Rs Send commands to the motion system Read status busy of the motion systems Used to set SR 4s into pass through mode Carriage Return terminates commands INTRODUCTION In the MMI system two SR4 controllers are used Each can control up to four SMC systems During operation a three byte net command address consisting of three bytes is prefixed to a motion control command string When the selected SR4 detects its address a serial path is connected to the addressed SMC by a 1 to 4 serial data multiplexer The motion command is then passed to the SMC The command terminator character carriage return resets the multiplexer Each motor command string must start with a net controller address The controller address compares to the setting of the SR4 address switches in the MMI The multiplex code selects any combination of the four output paths to the SMCs For example one motor syste
50. which control the phase inputs F of the two driver IC s Each step clock causes the step counter to toggle one step and the PROM decodes a pair of phase commands to the drivers which cause a winding current direction change resulting in a one step rotation of he motor The direction input input directly to the counter directs the decode to produce a CW or CCW rotation INSTALLATION AND OPERATION Before operating the MS amp MM series that the input connections are correct for that mode Refer to the installation wiring diagrams found in the back of this manual Locations of jumpers and signals are identified on the bottom SMCe of the unit circuit board The configuration of the MS series requires attention to four areas step size jumper and PROM type power supply voltage motor winding connection and current control dial pot setting Refer to driver label for maximum current and voltage limits of the particular model Refer to the Appendix section in the rear of this manual for details 1 POWER SUPPLY amp MOTOR CONNECTIONS Signal Name Terminal Strip TS1 Data Connector P1 VMM TS1 1 none In general the MS series requires an unregulated source of D C voltage connected to VMM The current output must equal 1 414 the full rating of one motor winding The voltage can be between 12 and 45 volts D C maximum The higher voltage is required only for higher step rates In general do not use a regulated power supply as performance is reduced Re
51. y Performance would be similar to the L 4R torque curve of a unipolar motor The figures identify the various connection options when using a bipolar driver with 6 or 8 wire motors A SINGLE COILS Identical to unipolar specification if the supply voltage equals the specified motor voltage Normal connection of a bipolar driver to 6 wire motor amp D SERIES COILS This configuration will produce torque greater than the unipolar specification indicates To stay within the power wattage rating of the motor reduce the unipolar specified current by 30 depending on the duty cycle of the system park time Note that the torque curve of this configuration is conSMCerably fore shortened as this motor is now the same as a motor with a rating of twice the voltage slower motor C PARALLEL COILS When this configuration is driven at the unipolar current the motor will perform identical to the specification but the motor will dissipate only one half the power it is twice as efficient When the current is increased by 1 414 to drive the motor at it s full power rating the motor torque is increased by approximately 60 Note that this torque curve is extended by four times high speed system Resonance vibration of a step motion system depends on the speed and power range of the motor Fast windings A amp C are quicker and may break into resonance easier than slow B amp D Power windings B amp D may deliver excessive power torque

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