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Addi-Data APCI-8001, Commissioning Manual

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Addi-Data APCI-8001 Commissioning Manual Download Page 54

54 

CM

 

/

 

C

OMMISSIONING 

M

ANUAL 

 

 

External power supply: 

24 V power consumption depending on load of the digital outputs 

Design: 

Short plug-in boards, x8 multi-layer, 1 slot required 

PC power supply: 

3.3 V/0.8 A,  

  

Note: 3.3 V supply voltage is sometimes not provided by older  

  

motherboards.  

  

5V/1.0A, 

Cascading: 

APCI-8001: up to a total of 8 axes with OPMF option 

Controller software: 

PIDF (PID controller with forward compensation) 

Control times: 

1.28 ms (idle time approx. 0.05 ms) 

  

Optional approx. 0.3 ms to 4 ms 

Interpolation: 

2D .. 3D linear, 2D .. 3D circular, helical, asynchronous and  

  

synchronous interpolation with secondary axes 

Connectors: 

APCI-8001: 50-pin SUB-D connector complete peripheral 
connection 
10-pin FB connector with 3 potential-free relay points 
10-pin FB connector for CAN-Bus (Option),  
10-pin FB connector for Interbus (Option) 

Other options: 

Spline and CAD interpolation, electronic gear unit (e.g. Gantry axes), 
G-Code programming, velocity limitation at profile transition through 
look ahead, surface area processing, support of non-feed rate axes, 
scanner functionality, ELCAM functionality (cam plate control), flying 
saw, SSI absolute value encoder, PWM manipulated value outputs. 

Manufacturing: 

The board is manufactured according to DIN ISO 9001. 

Test: 

The board is tested according to CE directives.  

 
 

Summary of Contents for APCI-8001

Page 1: ...Manual revision 16 112018 www addi data com POSITIONING AND CONTOURING CONTROL SYSTEM APCI 8001 AND APCI 8008 COMMISSIONING MANUAL CM ...

Page 2: ...itrary changes to the board Arbitrary changes to the source code files Insufficient monitoring of parts which are subject to wear Catastrophes due to effects by foreign bodies or acts of God ADDI DATA software product licence Please read this licence carefully before using the standard software The customer is only granted the right to use this software if he she agrees with the conditions of this...

Page 3: ...ironment Protect yourself others and the environment Read the safety precautions yellow leaflet carefully If this leaflet is not enclosed with the documentation please contact us and ask for it Observe the instructions of this manual Make sure that you do not forget or skip any step We are not liable for damages resulting from the wrong use of the board Pay attention to the following symbols ...

Page 4: ......

Page 5: ...ectory 13 3 7 Setting up the MCFG project environment 14 3 8 Booting the xPCI 800x controller 15 3 9 Configuration errors 16 3 10 New calling of fwsetup exe 17 3 11 Entering and storing system data 18 3 12 Control system hardware environment variables 19 3 12 1 The environment variable MT MotorType 20 3 12 1 1 SSI motor type 2 21 3 12 1 2 INC PWM motor type 3 21 3 12 1 3 STEPPER SSI motor type 4 2...

Page 6: ...n SUB D male connector X1 33 5 2 3 Connector X1 78 pin SUB D female connector APCI 8008 STP EVAI 34 5 2 4 Counting for the 78 pin SUB D female connector X1 35 5 2 5 Setpoint value channels 36 5 2 5 1 Setpoint value channel for servo motor axes APCI 8001 APCI 8008 37 5 2 5 1 1 Pin assignment for connector X1 axis channel 1 37 5 2 5 1 2 Pin assignment for connector X1 axis channel 2 37 5 2 5 1 3 Pin...

Page 7: ...component mounting diagram bottom side 48 5 6 APCI 8008 component mounting diagram 49 5 7 APCI 8008 component mounting diagram bottom side 50 5 8 APCI 8008 STP EVAI component mounting diagram 51 5 9 APCI 8008 STP EVAI component mounting diagram bottom side 52 5 10 Technical data of APCI 8001 53 6 Settings and plans 55 6 1 Isolating output for power output stage 55 6 2 Determining the PIDF filter p...

Page 8: ...ning Manual and PM Programming and Reference Manual What devices belong to the xPCI 800x range The xPCI 800x range of products are third generation positioning and contouring control systems At present these include the APCI 8001 and APCI 8008 positioning and contouring control systems Other remarks Where the functions described in this manual do not apply for all xPCI 800x products this is marked...

Page 9: ...mbination with external screw terminal boards requires technical installation in a closed switch cupboard Check the screen attenuation measure of PC housing and cable shield before commissioning the device Use of the standard ST8001 cable satisfies the minimum requirements metallised connector shells shielded cable cable screen folded back over insulation and screwed down on both sides with the co...

Page 10: ...r ensured EMERGENCY STOP functions must not be taken over by any of the above mentioned modules The EMERGENCY functions must be protected separately This protection must not be influenced by the boards and the PC The board must remain in its anti static packaging until it is installed The warranty claim becomes invalid if the identification numbers are deleted or changed 2 4 Users 2 4 1 Qualificat...

Page 11: ...installing or removing any modules ensure that the PC and the external power supplies have been switched off If this instruction is ignored the board or computer could be destroyed The manufacturer shall not be liable for damage which could result from the use or implementation of its products The manufacturer shall not be liable for errors of any type which may be contained in these manuals The m...

Page 12: ... contains the file rnwmc inf This file has to be specified as an installation file for the plug play installation and accordingly in the device manager Thus the current hardware driver version will be installed For earlier operating systems the INF file of the respective directory has to be indicated In addition the Miniport driver needs to be installed using ksetup exe 3 3 Installing MCFG Call th...

Page 13: ... set for the control system for parameterising the specifications of the control system You will find further information in section 3 12 3 6 Creating a system directory Create a file for storing the most important system files In this folder generate a system dat file using one of the 3 methods outlined below By creating a new file using the sysgen exe help program from the Toolset sub directory ...

Page 14: ... type to be selected from the Toolset software This also applies to the SYSTEM DAT file but where applicable this file may as well be adapted through conversion using sysconv exe 3 7 Setting up the MCFG project environment Start the mcfg exe application In the File Project Parameter menu update the entries according to the system directory you have selected see above Save the project settings via ...

Page 15: ... the xPCI 800x controller Open the dialogue box Tools System Boot Press the Boot System button After a few seconds the System Booted check box must be marked and the Online Mode entry should appear in the header line of the mcfg application ...

Page 16: ...have booted the control system this is caused by the following The system file system dat and system data selected in the project which are stored residually in the flash memory of the xPCI 800x controller control system are different This error can be cleared through a storage procedure as described in the next section ...

Page 17: ... the monitor window data about the started operating system variant RWMOS ELF are listed These are first the software options available in the booted RwMos variant Then the operating system version with creation date and information about the hardware equipment of the control variants here ACEX EP1K50 This display is to be noticed when errors occurs by booting or during the operation You can find ...

Page 18: ...he header line of the mcfg exe application mcfg exe File System Data enter the axis parameters for the respective axes Save the new system data using the File Save command During the save process the different parameters are stored residually in the flash memory of the xPCI 800x controller If a configuration error was displayed this must not be displayed again after the system data has been stored...

Page 19: ...le until all the variables have been listed in the monitor window From RWMOS ELF V2 5 3 37 andmcug3 dll V2 5 3 25 on in the PCAP programming environment environment variables of the control can be read out Hereto the function getEnvStr is available However in this way the setting of environment variables is not possible Important note The status of the environment variable is an important characte...

Page 20: ...xis with analog manipulated variable output and actual value acquisition through analog input 8 Encoder emulation With this axis type an incremental signal is output as manipulated value Encoder simulation The axis must also be defined in mcfg as stepper motor axis 9 Piezo motor This motor type is optimised for driving Piezo motors of the Nano Motion Company 10 PSM Axis with digital performance fi...

Page 21: ...th this motor type an SSI absolute value encoder can be used for the acquisition of actual values This type is valid for stepper and servo axes For the configuration of the SSI parameters the environment variables SSIF and SSIP can still be set These have to be set in an axis specific way The character represents the axis index 0 7 With SSIF the clock frequency can be reduced for reading the encod...

Page 22: ...type with analog manipulated variable output and analog actual value acquisition For this also the environment variable FBCH Section 3 12 7 can be set to assign an analog actual value channel to an axis 3 12 1 7 Encoder Emulation motor type 8 Stepper motor type Yet the command value is not output as a step or directional signal but as an emulated incremental encoder signal For this option a specif...

Page 23: ...and pulse output are available for the corresponding axis 3 12 1 12 VIRTUAL motor type 13 With the help of virtual axes the track velocity can be calculated in cartesian coordinates The real axes can participate in this interpolation as Non Feed Rate axes Thus a constant track velocity is guaranteed in axis systems with non cartesian design Virtual axes are compiled in RWMOS ELF without relation t...

Page 24: ...ive manipulated variable output an environment variable SIGNOUTPOS can be defined and for negative manipulated variable output an environment variable SIGNOUTNEG with the attached representing the axis index In the SIGNOUT value the digital output is specified in a bit coded form output 1 1 output 2 2 output 3 4 output 8 128 etc Here also none or more outputs can be specified Example 2nd axis posi...

Page 25: ...s 3 Normally this value is set for operation and is only to be modified with values which are supported by the hardware and software configuration of the control 3 12 3 The environment variable SampleTime Through this environment variable the scan time control cycle time and interpolation cycle time of the control is set in microseconds The values are between 100 and 5000 The default value is 1280...

Page 26: ...can be configured Here the configuration cannot be set individually for each channel but for all analog inputs together Unlike the APCI 8001 there is no longer a unipolar operating mode with the APCI 8008 Instead the analog inputs have a 16 bit resolution Value Voltage range 5VB 5 V bipolar 5 V 5 V 10VB 10 V bipolar 10 V 10 V Examplel set AD7606RNG 5VB Further information about the use of analog i...

Page 27: ...eters Stepper operating mode selection Encoder slits or step pulses motion parameters Pulses steps no electronic quadrupling Filter parameter kp motor specific parameters 0 04 is set by the system any other value will lead to instable control behaviour Note as of mcfg exe version 2 5 0 45 kp can no longer be edited for stepper motors You require rwmos elf firmware version 2 5 0 4 or later What nex...

Page 28: ...tart Run regedit Change the HKEY_LOCAL_MACHINES System CurrentControlSet Control Session Manager Memory Management SystemPages key which should usually have the value 0 to the value 10000 hex or higher Reboot the PC 3 15 Updating the xPCI 800x Flash firmware PMON If it is necessary to update the Flash firmware on the xPCI 800x controller Start the fwsetup application Open the Pmon Download page Se...

Page 29: ...D seen from the board holder Must be lit up D28 PC supply voltage 3 3 V 2nd LED seen from the board holder Must be lit up D32 Flashes showing that the monitor program is running 1st LED on the side facing away from the board holder Must flash when the PC is switched on APCI 8008 D50 PC supply voltage 5 V 1st LED seen from the board holder Must be lit up D51 Internal supply voltage 3 3 V 2nd LED se...

Page 30: ...he following message is displayed The driver is not written for the selected hardware etc This happens because Win98 overwrites the Sub Vendor ID of the board and therefore does not recognize it Confirm this message with OK Then confirm it with Yes and install it Now the device must be correctly registered in the device manager under Multifunction boards Please note that for Windows 98 the Minipor...

Page 31: ...y isolated from the logic supply and have a shared earth reference potential This means that incidents from the peripheral electronics are almost completely suppressed As the xPCI 800x board is fitted with a microprocessor module you should avoid installing it in an environment subject to severe electromagnetic interference Otherwise this could lead to an uncontrolled process behaviour by the micr...

Page 32: ...used this voltage must be supplied externally 18 SERVO2 PULSE2 Setpoint value 2 stepper 2 19 AGND2 PULSE2 Setpoint value 2 stepper 2 20 CHA2 CLKSSI2 ENDATCLK2 Actual value 2 21 CHA2 CLKSSI2 ENDATCLK2 Actual value 2 22 CHB2 DATSSI2 ENDAT_Data2 Actual value 2 23 CHB2 DATSSI2 ENDAT_Data2 Actual value 2 24 NDX2 SIGN2 Actual value 2 stepper 2 25 NDX2 SIGN2 Actual value 2 stepper 2 26 O1 Digital outputs...

Page 33: ... 48 I15 49 I16 50 GND D Reference potential for all signal sources These include digital inputs and outputs and the transmitter actual value GND D must be connected with the earth potential of the external device electronics 5 2 2 Counting for the 50 pin SUB D male connector X1 34 1 Top 18 35 2 19 36 3 20 37 4 21 38 5 22 39 6 23 40 7 24 41 8 25 42 9 26 43 10 27 44 11 28 45 12 29 46 13 30 47 14 31 ...

Page 34: ...ls CH4 27 Puls CH4 46 Sign CH4 66 Sign CH4 8 CHA CH4 28 CHA CH4 47 CHB CH4 67 CHB CH4 9 Puls CH5 29 Puls CH5 48 Sign CH5 68 Sign CH5 10 CHA CH5 30 CHA CH5 49 CHB CH5 69 CHB CH5 11 Puls CH6 31 Puls CH6 50 Sign CH6 70 Sign CH6 12 CHA CH6 32 CHA CH6 51 CHB CH6 71 CHB CH6 13 D Inp 01 33 D Inp 02 52 D Inp 03 72 D Inp 04 14 D Inp 05 34 D Inp 06 53 D Inp 07 73 D Inp 08 15 D Inp 09 35 D Inp 10 54 D Inp 11...

Page 35: ...male connector X1 59 20 Top 78 39 58 19 77 38 57 18 76 37 56 17 75 36 55 16 74 35 54 15 73 34 53 14 72 33 52 13 71 32 51 12 70 31 50 11 69 30 49 10 68 29 48 9 67 28 47 8 66 27 46 7 65 26 45 6 64 25 44 5 63 24 43 4 62 23 42 3 61 22 41 2 60 21 40 1 Bottom interlocking ...

Page 36: ...xe TOOLSET program Channel Jumper Position Mode 1 J1 J2 1 2 Stepper 2 3 Servo 2 J3 J4 1 2 Stepper 2 3 Servo 3 J5 J6 1 2 Stepper 2 3 Servo Component mounting diagram components side of the APCI 8001 applies to the APCI 8008 to a limited extent C2 8 Interbus P2 U25 R22 D3 D8 D2 D7 D1 C3 0 C31 U3 1 C3 2 U2 6 R3 8 U28 R39 R37 R41 R42 C37 C33 C29 U30 R44 U29 U27 R46 R45 U34 ISP IO C R U24 U22 C25 C24 R...

Page 37: ...isolated from the APCI 8001 APCI 8008 and has reference potential AGND2 19 AGND2 Setpoint 2 Reference potential for SERVO2 This potential is electrically isolated from the APCI 8001 APCI 8008 system electronics Note Jumpers J3 and J4 must be bridged in position 2 3 so that the signals listed in the table are available at connector X1 5 2 5 1 3 Pin assignment for connector X1 axis channel 3 Pin Nam...

Page 38: ...must be bridged in position 1 2 in order for the above mentioned signals to be available at connector X1 5 2 5 3 Analog outputs with the APCI 8008 With the APCI 8008 a total of 4 analog outputs with 16 bit resolution each are available The first 3 of these outputs are used as manipulated value outputs for axis channels 1 3 see previous chapters However all 4 analog outputs are also led to connecto...

Page 39: ...he number of the respective axis channel starting from 0 SSIF X X Numerical value for SSI frequency in Hz Permitted values 100 000 to 4 000 000 Default value 500000 Note With bigger cable lengths the SSI frequency must be reduced in order to compensate the signal runtimes is the number of the respective axis channel starting from 0 SSIP X X Numerical value for the number of SSI bits Permitted valu...

Page 40: ...n RWMOS ELF with the option optionEndat must be used The available RWMOS ELF options can be verified in the fwsetup program on the Monitor tab when the control unit is booted Example Info running MCU 3000 APCI 8001 option1k5 optionPCI optionRESOURCE optionENDAT For the connection of the Endat interface the pins with the designation ENDATCLK for the Endat clock signals and ENDAT_Data for the Endat ...

Page 41: ...t pin 4 X1 CHB1 J11 8000 J9 8008 Bridged Do not connect pin 6 X1 Unbridged Connect pin 6 X1 NDX1 J15 8000 J8 8008 Bridged Do not connect pin 8 X1 Unbridged Connect pin 8 X1 2 CHA2 J9 8000 J13 8008 Bridged Do not connect pin 21 X1 Unbridged Connect pin 21 X1 CHB2 J12 8000 J12 8008 Bridged Do not connect pin 23 X1 Unbridged Connect pin 23 X1 NDX2 J18 8000 J11 8008 Bridged Do not connect pin 25 X1 Un...

Page 42: ...ncremental signal track B 7 NDX1 Reference signal track 0 8 NDX1 Inverted reference signal track 0 5 2 6 6 2 Pin assignment X1 channel 2 Pin Name Function 20 CHA2 Incremental signal TTL square wave pulse trains track A 21 CHA2 Inverted incremental signal track A 22 CHB2 Incremental signal track B with 90 electrical phase shift to track A 23 CHB2 Inverted incremental signal track B 24 NDX2 Referenc...

Page 43: ...al input 11 45 I12 Digital input 12 46 I13 Digital input 13 47 I14 Digital input 14 and faster hardware latch input to save the actual position of axis channel 1 48 I15 Digital input 15 and faster hardware latch input to save the actual position of axis channel 2 49 I16 Digital input 16 and faster hardware latch input to save the actual position of axis channel 3 5 2 7 1 Basic wiring diagram of xP...

Page 44: ...e APCI 8001 corresponds to X6 on the APCI 8008 relay points are provided for the CNC ready request and amplifier release These are normally open contacts After the PC is switched on all relays are switched off after a reset action or an error The release relay is activated for the respective selected axis channel by using the cl command for PCAP and the CL command for SAP Note Depending on the con...

Page 45: ...cquisition encoder setpoint value generation and the digital input output logic This separation offers maximised protection of the various modules prevents earth loops and circuits and provides a high level of immunity to interference from interfering signals which are often spread from the drives via signal and earth connections 5 2 10 2 Potential equalisation Since the above mentioned supply zon...

Page 46: ...e that is installed in the PC can be selected Then for this and all following devices the command InitMcuSystem3 must be called newly If necessary also each control must be booted separately In this case it must be considered that for each device in the system global data structures e g tsrp must be declared separately When calling a device the data structures especially TSRP that are declared for...

Page 47: ...CM COMMISSIONING MANUAL 47 5 4 APCI 8001 component mounting diagram ...

Page 48: ...48 CM COMMISSIONING MANUAL 5 5 APCI 8001 component mounting diagram bottom side ...

Page 49: ...CM COMMISSIONING MANUAL 49 5 6 APCI 8008 component mounting diagram ...

Page 50: ...50 CM COMMISSIONING MANUAL 5 7 APCI 8008 component mounting diagram bottom side ...

Page 51: ...CM COMMISSIONING MANUAL 51 5 8 APCI 8008 STP EVAI component mounting diagram ...

Page 52: ...52 CM COMMISSIONING MANUAL 5 9 APCI 8008 STP EVAI component mounting diagram bottom side ...

Page 53: ...422 or TTL Incremental encoder evaluation x4 32 bit with sign 5 0 MHz 20 MHz after quadrupling SSI encoder evaluation 1 32 bit gray binary codes variable frequency 30 kHz 10 MHz Encoder supply External auxiliary voltage depending on encoder type 5 30 V Setpoint value outputs for servo power transformers 16 bit DA converter 10 V 5 mA potential free Setpoint value outputs for stepper motor transform...

Page 54: ...cal asynchronous and synchronous interpolation with secondary axes Connectors APCI 8001 50 pin SUB D connector complete peripheral connection 10 pin FB connector with 3 potential free relay points 10 pin FB connector for CAN Bus Option 10 pin FB connector for Interbus Option Other options Spline and CAD interpolation electronic gear unit e g Gantry axes G Code programming velocity limitation at pr...

Page 55: ...rimental settings when the motor axis is connected you must remember that the system may vibrate at considerable amplitudes and with high accelerations Any danger to persons or the machine itself must be prevented by appropriate precautionary measures Furthermore a system which initially appears to be stable may start to oscillate due to excitation Possible protective measures are an EMERGENCY STO...

Page 56: ...ler with an amplification of kp 0 04 and a forward compensation All other filter parameters are automatically set to 0 The controller parameters are automatically set by the system It is not possible for the user to make any settings Although this seems to be an open loop system the control loop must still be closed with CloseLoop when the axis is handled Here the actual value is the number of ste...

Page 57: ... characteristics coincide in good approximation after the preset profile has been run After every modification to the parameters you must select the Clear Position and Update Filter menu items so that the new parameters can be applied When using a current amplifier first set the acceleration pre control kfca so that the acceleration ramps for the setpoint and actual speed coincide Then set the vel...

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