Addi-Data APCI-8001 Quick start guide

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

Copyright
The copyright for this manual belongs to ADDI-DATA GmbH.
These operating instructions consist of the OM, CM and PM parts and are only intended for use by the
operator and the operator’s staff. They include regulations and notes, which must not be
•duplicated
•published or
•otherwise distributed, either in part or in full.
Non-compliance with this could lead to criminal proceedings.
Warranty and liability
Warranty and liability claims for personal injury and damage to property shall be excluded, if they are
attributable to one or more of the following causes:
•Use of the board not in accordance with the regulations
•Improper installation, commissioning, operation and maintenance of the board
•Operation of the board in defective security installations or in improperly fitted or non-operational
security and protection appliances
•Non-compliance with the notes in the operating instructions regarding transport, storage, installation,
commissioning, operation, thresholds, maintenance of the board, standard software
•Arbitrary 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 licence.
•The standard software must only be used to set up the ADDI-DATA boards
•Reproduction of the software is forbidden (except for back-up and for exchange of faulty data
carriers)
•Disassembly, decompilation, decryption and reverse engineering of the software are forbidden.
•This licence and the software may be transferred to a third party if this party has acquired a board by
purchase, has agreed to all the conditions in this licence contract and the original owner does not
keep any copies of the software.
Trademarks
Borland C++ and Borland Delphi are registered trademarks of Borland Software Corporation.
MIPS is a registered trademark of Mips Technologies, Inc.
RM5231 is a registered trademark of PMC Sierra, Inc.
Microsoft, MS-DOS, Visual Basic, Visual C and Windows are registered trademarks of Microsoft Corporation.

The following risks result from the improper implementation of the
board and from use contrary to the regulations:
Personal injury
Damage to the board, the PC and peripherals
Pollution of the environment.
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:

CONTENTS 5
Warning! ............................................................................................................................................................3
1Introduction ..................................................................................................................................................8
2Intended use.................................................................................................................................................9
2.1 Special notes for the APCI-8001 and APCI-8008 ..........................................................................9
2.2 Special notes for the APCI-8008-STP-EVAI..................................................................................9
2.3 Limits of use.................................................................................................................................10
2.4 Users............................................................................................................................................10
2.4.1 Qualification.....................................................................................................................10
2.4.2 Personal protection equipment........................................................................................10
2.5 Handling the board.......................................................................................................................11
2.6 Important!.....................................................................................................................................11
3Installing and configuring the xPCI-800x TOOLSET software ..............................................................12
3.1 Scope of delivery of the xPCI-800x TOOLSET software .............................................................12
3.2 Installing the miniport (rnwmc device driver)................................................................................12
3.3 Installing MCFG............................................................................................................................12
3.4 Installing FWSETUP ....................................................................................................................12
3.5 Starting FWSETUP......................................................................................................................13
3.6 Creating a system directory..........................................................................................................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).........................................................................22
3.12.1.4 ANALOG PWM motor type (5).......................................................................22
3.12.1.5 STEPPER NDX motor type (6).......................................................................22
3.12.1.6 ANALOG/ANALOG motor type (7).................................................................22
3.12.1.7 Encoder Emulation motor type (8)..................................................................22
3.12.1.8 Piezo-Motor motor type (9).............................................................................22
3.12.1.9 PSM motor type (10) ......................................................................................22
3.12.1.10 ENDAT motor type (11+16)............................................................................23
3.12.1.11 INC_PULSE motor type (12)..........................................................................23
3.12.1.12 VIRTUAL motor type (13)...............................................................................23
3.12.1.13 GEOADD motor type (14)...............................................................................23

6
CONTENTS
3.12.1.14 UPDOWNSIGNALS motor type (15)..............................................................23
3.12.1.15 ANA_SIGN motor type (19)............................................................................23
3.12.1.16 CI / ANALOG and CD / ANALOG motor types (20+21) .................................24
3.12.1.17 STEPPER_ENDAT2_2 motor type (22).........................................................24
3.12.1.18 ETM motor type (23).......................................................................................24
3.12.1.19 ANA_SIGN_SSI motor type (24)....................................................................24
3.12.1.20 ANA_SIGN_ENDAT2_2 motor type (25)........................................................24
3.12.1.21SSI_PULSE motor type (26)...........................................................................25
3.12.2 The environment variable NumberAxis...........................................................................25
3.12.3 The environment variable SampleTime ..........................................................................25
3.12.4 The environment variable SZTSK?.................................................................................25
3.12.5 APCI-8001: Configuration of the analog input voltage ranges ........................................26
3.12.6 APCI-8008: Configuration of the analog input voltage ranges ........................................26
3.12.7 The environment variable FBCH?...................................................................................27
3.13 Special features for system parameters for servo and stepper motor axes ................................27
3.14 Additional installation information for Windows NT......................................................................28
3.15 Updating the xPCI-800x Flash firmware (PMON)........................................................................28
3.16 Trouble-shooting ..........................................................................................................................28
4How to install the motion control board in the PC .................................................................................29
4.1 Installing the xPCI-800x controller................................................................................................29
4.1.1 Installation under W98.....................................................................................................30
5Configuring and wiring the motion control board..................................................................................31
5.1 Installation, commissioning and replacement ..............................................................................31
5.2 Environment.................................................................................................................................31
5.2.1 Connector X1: 50-pin SUB-D male connector APCI-8001 / APCI-8008 .........................32
5.2.2 Counting for the 50-pin 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 assignment for connector X1, axis channel 3.............................37
5.2.5.2 Setpoint value channel for stepper motor axes APCI-8008 / APCI-8008.......37
5.2.5.2.1 Pin assignment for connector X1, axis channel 1.............................38
5.2.5.2.2 Pin assignment for connector X1, axis channel 2.............................38
5.2.5.2.3 Pin assignment for connector X1, axis channel 3.............................38
5.2.5.3 Analog outputs with the APCI-8008................................................................38
5.2.6 Pulse acquisition channels..............................................................................................39
5.2.6.1 SSI absolute encoder.....................................................................................39
5.2.6.2 Endat absolute encoder..................................................................................40
5.2.6.3 Incremental encoders with inverted signals (symmetrical circuitry) ...............40
5.2.6.4 Incremental encoders without inverted signals (asymmetrical circuitry) ........41
5.2.6.5 Optical decoupling of the pulse acquisition channels.....................................42
5.2.6.6 Pin assignment for the pulse acquisition channels with incremental encoders42
5.2.6.6.1 Pin assignment X1, channel 1...........................................................42
5.2.6.6.2 Pin assignment X1, channel 2...........................................................42
5.2.6.6.3 Pin assignment X1, channel 3...........................................................42
5.2.7 Pin assignment connector X1, Digital inputs (APCI-8001 / APCI-8008) .........................43
5.2.7.1 Basic wiring diagram of xPCI-800x digital inputs I1 … I13.............................43

CONTENTS 7
5.2.7.2 Basic wiring diagram of xPCI-800x digital inputs I14 … I16...........................43
5.2.8 Pin assignment connector X1, digital outputs (APCI-8001 / APCI-8008)........................44
5.2.8.1 Basic wiring diagram of the xPCI-800x digital outputs O1..O8.......................44
5.2.9 APCI-8001 pin assignment connector P5, release relay.................................................44
5.2.10 Connection and wiring instructions..................................................................................45
5.2.10.1 Earth and current supplies..............................................................................45
5.2.10.2 Potential equalisation .....................................................................................45
5.2.10.4 Fitting shields..................................................................................................45
5.3 Using several xPCI-800x controllers in a PC ...............................................................................46
5.4 APCI-8001 component mounting diagram...................................................................................47
5.5 APCI-8001 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
6Settings and plans .....................................................................................................................................55
6.1 Isolating output for power output stage........................................................................................55
6.2 Determining the PIDF filter parameters........................................................................................55
6.2.1 Speed controllers.............................................................................................................55
6.2.2 Current amplifier..............................................................................................................56
6.2.3 Voltage amplifier..............................................................................................................56
6.2.4 Stepper motor power amplifiers ......................................................................................56
6.2.4.1 Stepper motor system without position feedback...........................................56
6.2.4.2 Power amplifier with step/direction setpoint value input and position control.56
6.2.5 Pre-control.......................................................................................................................56
6.2.5.1 Determining the coefficients...........................................................................57

8
CM /COMMISSIONING MANUAL
1 Introduction
What is this
manual for?
This manual describes how to commission all the necessary system components for
using the xPCI-800x positioning and contouring control system. The complete
manual is made up of three parts: OM (Operating Manual), CM (Commissioning
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 clearly. In this case, the corresponding function only applies
for the product indicated.

CM /COMMISSIONING MANUAL
9
2 Intended use
The xPCI-800x motion control boards (APCI-8001 and APCI-8008) form the interface between industrial
process, automation and drive technology and a personal computer (PC).
The board is suitable for use in a PC that has been fitted with free PCI slots. The PC is subject to EU
directive 898/336/EEC and must satisfy the corresponding EMC protection requirements.
Products which satisfy these requirements carry the symbol.
2.1 Special notes for the APCI-8001 and APCI-8008
Data exchange between the APCI-8001 and APCI-8008 boards and the peripherals takes place via a
shielded cable. This cable must be connected to the 50-pin SUB-D male connector of the APCI-8001 or
APCI-8008.
The APCI-8001 or APCI-8008 also has digital outputs for processing 24 V signals. An external 24 V supply
voltage is required to operate these outputs.
The PX8000 screw terminal board enables connection of the 24 V supply voltage via a shielded cable.
The use of the APCI-8001 or APCI-8008 in combination 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 connector shell.
2.2 Special notes for the APCI-8008-STP-EVAI
The board APCI-8008-STP-EVAI enables the user to control 6 stepper axes with encoder verification.
For this purpose, the board is equipped with 16 digital inputs and a maximum of 8 digital outputs.
The inputs and outputs are shared for all 6 axes. Hardware latch inputs are:
I11 for axis 1
I12 for axis 2
I13 for axis 3
I14 for axis 4
I15 for axis 5
I16 for axis 6
The outputs are optional. The +24 V supply at pin 59 of X1 is required only if digital outputs are used. At the
respective pins (digital outputs), also CNC ready relays or analog inputs can be made available.
The corresponding configuration is fitted ex works. The external components are connected via a 78-pin
SUB-D female connector (X1). The OPMF-8008 cannot be used for this board version.

10
CM /COMMISSIONING MANUAL
The scope of software is more or less identical to that of the other xPCI-800x boards. However, an
interpolation is only possible with the first 4 axes. The SMLA and SMLR commands can be called up for axes
5 and 6 as well, but only as single-axis traversing commands.
2.3 Limits of use
By using the boards in a PC, the resistance to interference and emission values of the PC may change.
Increased emissions or reduced resistance to interference can mean that the conformity of the system is no
longer 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 Qualification
The following activities must only be executed by trained electronics employees:
•Installation
•Commissioning
•Operation
•Maintenance
2.4.2 Personal protection equipment
Please note the national regulations regarding:
•Accident prevention
•Installation of electrical and mechanical equipment
•Electromagnetic compatibility (EMC).