Ormec Model 20/40 Motion Controllers

Copyright Notice

Copyright 1990, 1991, 1993, and 1994 by Ormec Systems Corp. All rights reserved.

This manual and any software it may describe, remain the exclusive property of

Ormec Systems Corp. No part of either may be reproduced in any form without the

prior written permission of ORMEC.

Warranty

ORMEC extends no warranty with respect to the merchantability or fitness of this

product for any particular purpose. It is the customer’s responsibility to determine

whether it is suitable for the specific application and whether it meets the performance,

reliability, and safety requirements of that application. ORMEC reserves the right to

make improvements to the product as well as this documentation at any time without

notice.

Terms and Conditions of Sale

All products sold or otherwise provided by ORMEC are made available subject to

ORMEC’s published Standard Terms and Conditions of Sale.

UL Recognized Component

Generation III Model 20 and Model 40 Motion Controllers are now recognized under the

Component Program of Underwriters Laboratories Inc. in both the United States and

Canada. These new UL Recognized Units may be distinguished from previous units by

the UL trademark symbols shown below

This manual tells you about ORMEC’s Generation III Model 20 & 40 motion

controllers and accessories... providing a detailed description of the Generation

III hardware and information for installing, operating and "getting started" with

your new Generation III motion control system.

The manual is divided into the following chapters:

Chapter 1 Welcome introduces you to this manual and its organization.

Chapter 2 General Description provides an overview of the Generation III

product family. It includes descriptions of the Model 20 & 40

Motion Controllers, the DSP Axis Modules and compatible

servomotors and servodrives.

Chapter 3 Installation provides instructions on installing your unit. It also

provides a complete hardware description of the Generation III

controller interfaces, including detailed information on each

interface to the unit.

Chapter 4 Operation explains the powerup and initial configuration

approach utilized by Generation III.

Chapter 5 Getting Started provides detailed instructions on how to run

your Generation III unit for the first time.

Chapter 6 Product History provides a chronological revision history for

the Model 20/40 Motion Controllers and DSP Axis Modules.

Chapter 7 Specifications provides detailed specifications for the product.

These specifications include environmental, mechanical and

electrical interface specifications as well as references to the

interface schematics in the Appendixes.

Chapter 8 Terms & Mnemonics provides definitions for terms specific to

motion control and/or ORMEC’s motion control products.

Appendixes Appendixes contain detailed drawings which document the

Generation III dimensions, system interface, DSP Axis Module

interface, as well as associated interface cables and

accessories. See the Table of Contents for details.

NOTE: This manual concentrates on providing Generation III controller

hardware and cabling documentation. Detailed information on ORMEC’s

MotionBASIC® programming language is found in the on-line MotionBASIC®

Hypertext Software Manual. A diskette containing the MotionBASIC®

Hypertext Software Manual software is included at the end of this manual. A

hard copy is included in the MotionPROTM manual.

2.1 General Description

The ORMEC Generation III Model 20 & 40 Motion Controllers are industrially

hardened computers designed especially for high performance control of

automation using servomotors. They are fully compatible with ORMEC’s lines

of brushless servomotors and drives.

At the heart of both the Model 20 and 40 is a 12-Mhz Intel 80C186 main

processor. It is interfaced through dual-ported "shared memory" to DSP Axis

Modules which are controlled by Texas Instruments Digital Signal Processors

operating at 40 Mhz. This powerful architecture provides the foundation for

general purpose motion control programmed in ORMEC’s industrialized

superset of Microsoft BASIC called MotionBASIC®

. The combination of a main

processor from Intel’s premier family of microprocessors and Digital Signal

Processors for axis control provides speed and performance while maintaining

the ease-of-use associated with interpreted BASIC.

The Model 20 provides two PC-AT style I/O slots and is designed for systems

which have between 11/2 and 4 axes of motion control. For 11/2 to 2 axis

systems, the second slot can be used for various communications options such

as a video controller, a PLC network interface or additional serial interfaces.

The Model 20 can provide 21/2 to 4 axes of control for many applications.

Examples of this are systems interfaced via ModbusTM or an MMI-840 Industrial

Terminal, which provides an 8-line by 40-character display.

The Model 40 provides four PC-AT style I/O slots and is designed for systems

which have between 21/2 and 8 axes of motion control.

Generation III motion controllers provide electronic gearing for a virtually

unlimited number of servomotors using ORMEC’s proprietary MotionDATATM

communications capability. This feature can be used to either closely

coordinate the motion of multiple servomotors with each other, or coordinate

some number of servomotors with the motion of an external pacer encoder.

2.2 Model 20/40 Features

• 80C186, 16-bit CMOS high integration microprocessor operating at 12 Mhz

• optional 80C187 math co-processor

• powerful MotionBASIC® programming with hypertext on-line manual

• powerful and easy to use MotionPROTM motion programming environment

on an IBM-PC or compatible

• 16-bit IBM-PC/AT style backplane for DSP Servo Modules and expansion

boards; Model 20 and 40 have 2 and 4 slots respectively.

• RS-232 Serial Port for program development and troubleshooting

• RS-422/485 communications port for either MotionNETTM or auxiliary serial

communications

• integral Watchdog Timer and Emergency Stop circuitry

• 22 built-in diagnostic LEDs

• dual PCMCIA standard memory card slots are standard on the Model 40

and optional on the Model 20

• 16 discrete I/O points for machine control use Opto-22 style modules

• optionally add 24 TTL level I/O points which are compatible with Opto-22

style I/O racks or the Opto-22 Pamux system

• Opto-22’s Pamux I/O system provides a combination of up to 512 optically

isolated digital and 12-bit analog I/O points

• IBM-PC/AT compatible keyboard interface is standard on the Model 40 and

optional on the Model 20

• optional EGA or monochrome video adapter for Operator Interface

• optional single or dual-channel RS-422 Serial Interfaces

2.2.1 Model 20 Model Number Description

GN3-20/1 Generation III Model 20, 115 VAC Input

Options:

1) for 230 VAC input, change the /1 to a /2

2) to add a math co-processor, add an M

3) to add an absolute encoder backup battery, add a B

4) to add MotionCARD/Memory Disk Support, add a C

5) to add an IBM/PC-AT Keyboard Interface, add a K

6) to add an extended I/O (Pamux) Interface, add an I

GN3-20/2MBCKI Generation III Model 20 with all options

2.2.2 Model 40 Model Number Description

GN3-40/1 Generation III Model 40, 115 VAC Input

Options:

1) for 230 VAC input, change the /1 to a /2

2) to add a Math co-processor, add an M

3) to add an absolute encoder backup battery, add a B

4) to add an extended I/O (Pamux) Interface, add an I

GN3-40/2MBI Generation III Model 40 with all options. Note that

MotionCARD/Memory Disk Support and a Keyboard

Interface are standard.

2.3 Modular Construction

• compact panel mountable steel enclosure (19.5"h x 6.0"w x 10.5"d)

• industrially hardened switching power supplies use either 115 or 230 VAC

power and include a built-in switch/circuit breaker as well as a line filter for

noise immunity

• isolated 24 VDC power supply for optically coupled discrete I/O is standard

2.4 DSP Axis Modules

There are two models of DSP Axis Modules including a dual axis unit, and a

single axis unit with an auxiliary pacer encoder interface. They both use a 40

Mhz Texas Instruments Digital Signal Processor (DSP) to provide axis control

algorithms. The DSP is interfaced to the main processor through a dual-port

RAM shared memory interface for maximum speed and flexibility. DSP Axis

Module features are overviewed below:

• Texas Instruments TMS-320C25 DSP operating at 40 Mhz

• direct digital loop control with up to 5 Khz servo update rates provide wide

loop bandwidth for high positioning accuracy and response

• quadrature feedback 4x decoding with positioning rates to 1.2 MBit per

second

• position, velocity or torque mode control

• total elimination of analog drift errors and extremely quiet loop operation

using direct digital processing of both position and velocity loops with 32 bit

intermediate calculation accuracy

• software controlled position, speed, and current limits

• velocity and acceleration feedforward for minimum tracking errors and

response times

• fully compatible with ORMEC torque mode servodrives through the

individual Axis Interface Connectors

• pacer encoders for electronic gearing are interfaced through any of the DSP

Axis Modules’ interface connectors

• proprietary MotionDATATM communications from DSP to DSP allows tightly

coordinated multi-axis motion

• servodrive remote enable and reset functions are provided by optically

coupled outputs

• open feedback wire detect provided on all differential quadrature feedback

inputs

• failsafe servodrive alarm detection using optically isolated input

• servodrive alarm decoding is provided by three optically isolated inputs

• shared memory data interface to main processor

• writable control store for DSP program storage is loaded from the main

processor at powerup

2.4.1 DSP Axis Module Model Number Description

GN3-DSP-AQ Single Axis DSP Module with Pacer Encoder Interface

GN3-DSP-AQ/A Single Axis DSP Module with Pacer Encoder Interface

with 4-channel 12-bit A/D converter option

GN3-DSP-A2 Dual Axis DSP Servo Control Module

GN3-DSP-A2/A Dual Axis DSP Servo Control Module with 4-channel

12-bit A/D converter option

2.5 Servodrive Compatibility

ORMEC’s SAC Series current mode servodrives provide the following features

and benefits:

• operation on unisolated standard line voltages of either 115 or 230 VAC

• wide range of output power from 50 watts to 6.1 kilowatts

• high peak torque (current), typically three times rated current for a few

seconds and twice rated torque for up to a minute

• wide current loop bandwidth for high positioning accuracy and response

• safety and diagnostic protection features include servo bus overvoltage,

undervoltage, overload, overcurrent, open phase detection, loss of feedback

detection, main circuit breaker trip, excess regeneration or drive CPU failure

• diagnostics provided by a seven segment LED Alarm Indicator with codes

transmitted to the DSP Axis Module through the Axis Interface Cable

• fully compatible with our MAC Series AC Brushless Servomotors

2.6 Servomotor Compatibility

The MAC Series AC Brushless Servomotors provide exceptional performance

as overviewed below:

• continuous torque from 1.6 lb-in to 560 lb-in RMS, conservatively rated

• peak torque from 4.2 lb-in to 935 lb-in

• maximum speeds from 1,500 to 4,500 RPM

• high torque inertia ratios of the motors mean more delivered power for high

performance applications

• durable construction includes no brushes, high thermal efficiency frame and

rugged bearings

• built in position transducer, with up to 24,000 counts per revolution

• low torque ripple, particularly compared with other brushless motors

2.6.1 MAC-A Series Motors

• Maximum Speed: 4,000 RPM

• Continuous stall torques: 10 to 110 lb-in

• Peak Torques: 26 to 257 lb-in

• Peak Acceleration: greater than 50,000 rad/sec2 (even the largest unit)

• Rated Power: 0.43 to 4.2 HP

• Position Encoder Resolution: 6,000 cts/rev (1500 linecount)

• compatible S-Series servodrives use three phase 230 VAC incoming power

• Optional multi-revolution absolute encoders available

2.6.2 MAC-B Series Motors

• Maximum Speed: 2,500 RPM

• Continuous stall torques: 10 to 330 lb-in

• Peak Torques: 26 to 675 lb-in

• Peak Acceleration: up to 28,888 rad/sec2 (largest unit is 5,315 rad/sec2

)

• Rated Power: 0.21 to 6.1 HP

• Position Encoder Resolution: 24,000 cts/rev (6000 linecount)

• compatible S-Series servodrives use three phase 230 VAC incoming power

• Optional multi-revolution absolute encoders available

2.6.3 MAC-C Series Motors

• Maximum Speed: 1,500 to 2,000 RPM

• Continuous stall torques: 290 to 560 lb-in

• Peak Torques: 570 to 945 lb-in

• Peak Acceleration: up to 4,488 rad/sec2 (largest unit is 4,337 rad/sec2

)

• Rated Power: 4.1 to 8.2 HP

• Position Encoder Resolution: 24,000 cts/rev (6000 linecount)

• compatible S-Series servodrives use three phase 230 VAC incoming power

• Optional multi-revolution absolute encoders available

2.6.4 MAC-E Series Motors

• Maximum Speed: 4,000 or 4,500 RPM

• Continuous stall torques: 1.6 to 23 lb-in

• Peak Torques: 4.2 to 59 lb-in

• Peak Acceleration: up to 62,000 rad/sec2 (largest unit is 17,900 rad/sec2

)

• Rated Power: 0.07 to 0.9 HP

• Position Encoder Resolution: 6,000 cts/rev (1500 linecount)

• Compact & inexpensive

• compatible E-Series servodrives use single phase incoming power at 115 or

230 VAC (depending on model)

• Optional multi-revolution absolute encoders available

3.1 Motion Controller Installation

3.1.1 Receiving & Inspection

ORMEC Motion Controllers and their associated accessories are put through

rigorous tests at the factory before shipment. After unpacking, however, check

for damage which may have been sustained in transit. The bolts and screws

should all be tight, and motor output shafts should rotate freely by hand. Check

the motion controller and any of the accessories for bent or broken components

or any other physical damage before installing.

3.1.2 Panel Mounting & Environment

Panel mounting data is available in the Specifications Section and Appendix A.

The motion controller’s environment should be maintained as follows:

• Temperature should be between 0 and 55C.

• If the electrical panel is subjected to vibration, mount the unit on shock

absorbing material.

• Avoid use in corrosive atmospheres which may cause damage over time.

• Select a location with minimum exposure to oil, water, hot air, high

humidity, excessive dust or metallic particles.

• The proper mounting orientation for the motion controller is vertical on a

panel using the mounting holes (4) on the base plate.

3.1.3 Input Power - TB1

Motion Controllers are available to operate on either 115 VAC or 230 VAC

power (50/60 Hz). A servodrive control power output is provided at terminals r

and t which is interlocked with the integral switch/circuit-breaker on the top of

the unit. Use of this feature as illustrated in Appendix B eliminates the need

for additional switches and/or circuit breakers, and assures that servodrive

power will be disabled whenever power is removed from the Motion Controller.

To use this feature, the input voltage selected must match the voltage for

the selected servodrive’s control power. All ORMEC servodrives are

available with 230 VAC control power; some of the lower power E-Series are

also available with 115 VAC control power.

Input power connections are made on terminal block TB1, located on the top of

the unit. The label near TB1 indicates the input voltage of the unit. Copper

wire with an 80o

C temperature rating, 10 AWG maximum, is recommended for

terminal block TB1 wiring. The maximum terminal block screw torque is 5 inlbs. Connections to TB1 are described below:

_________________________________________________________________________________

Symbol Name Description

L1, L2 Input Power Single-phase 115 or 230 VAC, +10%, -15%, 50/60 Hz, with a switch and two 10 amp

circuit breakers (one in each line). In most installations, these terminals would be

wired with 14 gauge wire. The maximum continuous input power requirement of the

Model 20/40 is 175 watts. Maximum servodrive control power for E-Series is 30 watts

per axis; S-Series is 60 watts per axis. If external fusing is required in the power feed

to the Model 20/40, 10 amp slow-blow fuses are recommended.

FG Frame Ground Connect to the enclosure chassis and earth ground, preferably with AWG 8 or larger

braid.

r, t Servodrive Single-phase 115 or 230 VAC, +10%,-15%, 50/60 Hz. This output power is

Control Power switched by the power switch and 10 amp circuit breakers in the Model 20/40. In

most installations, these terminals would be wired with 14 gauge wire.

___________________________________________________________________________________

3.1.4 System Power Wiring & Interlocks - TB6

Both Motion Controllers provide integrated emergency stop and fault interlocks

through terminal block TB6. Also provided on TB6 are terminals for the

+24 VDC I/O power supply provided in the unit; the internal +5 VDC power

supply; and also the input connections to the I/O Power Bus.

System wiring diagrams for standard ORMEC servodrives, which include the

recommended safety and fault interlocks for a typical system, are provided in

Appendix B. The primary features of these system wiring diagrams are:

• Servomotor power, called Main Power, is switched by the Main Power

Contactor.

• For the Main Power Contactor to be enabled, both the E-Stop Pushbutton

and the No Fault Relay must be closed.

• For the No Fault Relay to be closed, three conditions must be satisfied:

1) there must be no computer diagnostic faults, including powerup

diagnostics, run-time diagnostics and the watchdog timer function;

2) there must be 24 volts applied to the ES input at TB6; and

3) there must be no drive faults from any standby or active servodrives.

• Pressing the normally-open E-Stop Reset Pushbutton as shown provides

the 24 volts to the ES input, and as long as the other conditions are

satisfied, the Model 20/40 will close the No Fault Relay contact.

• Assuming the E-Stop Pushbutton is closed, the Main Power Contactor will

be enabled, and its auxiliary contact, MP-AUX, will close maintaining the

required 24 volts at the ES input.

• If a fault occurs in the Model 20/40, or any of the servodrives which are in

Output, Torque, Velocity or Position control modes, the normally-open

No Fault Relay contact will be opened, removing Main Power by disabling

the Main Power Contactor.

There are many acceptable variations of these System Wiring Diagrams, which

can provide different features such as 24 VDC or 115 VAC operation of the

E-Stop Pushbutton; 115 or 230 VAC operation of the and Main Contactor coil

for motor power. If using a variation, it should incorporate the primary features

as described above and in Appendix B. Contact the ORMEC Service

Department with any questions you may have in this area.

Copper wire with an 80o

C temperature rating, 12 AWG maximum, is

recommended for terminal block TB6 wiring. The maximum terminal block

screw torque is 5 in-lbs.

Before applying power, refer to Test Run Preparation in Chapter 4.

3.1.5 Emergency Stop, No-Fault Interlock & I/O Power - TB6

The Emergency Stop, No-Fault Interlock, and I/O power connections are made

at a "pluggable" terminal block on the Discrete I/O board. This terminal block is

located at the lower left of the front of the unit under the removable cover. See

Appendix C-5 for a description of fuses F1-F19 on the DIO Board as well as

the ORMEC and Littelfuse part numbers.

Description

V TB6-1 I/O Power Bus The I/O Power Bus connects all terminals labelled V and C

which are distributed on the Integral Discrete I/O terminal

blocks TB2-TB5. Its purpose is to facilitate field wiring of

discrete I/O without requiring additional terminal blocks.

This connection is to the voltage side of the I/O Power Bus,

and would normally be either:

1) connected to TB6-2 if the user decides to use the

internal +24 VDC isolated power supply to provide power

to the I/O Power Bus, or

2) connected to 115 VAC if the user decides to use 115

VAC for the I/O Power Bus.

24 TB6-2 +24 VDC Power This fully isolated +24 VDC power supply rated at 2.0 A is

provided for Emergency Stop and Servodrive interlocks, as

well as user I/O.

It would normally be used to:

1) power the Emergency Stop Reset Pushbutton;

2) power +24 VDC discrete inputs for operator inputs, limit

switches, PLC interfaces, etc; and

3) power an MMI-840 Operator Interface Terminal (1/4 amp

max) if one is used.

It would not normally be used to power 24 VDC coil outputs,

and if intending to use it for this purpose, the user should

watch power requirements carefully and use noise prevention

measures such as flyback diodes across each coil.