Giddings & Lewis MMC-A2 User manual

Giddings & Lewis
Controls, Measurement and Sensing
MMCTM
Hardware Manual
Part Number M.1300.7165
Version 12.0

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NOTE
Progress is an on-going commitment at Giddings & Lewis. We continually strive to offer the most
advanced products in the industry; therefore, information in this document is subject to change without
notice. The illustrations and specifications are not binding in detail. Giddings & Lewis shall not be
liable for any technical or editorial omissions occurring in this document, nor for any consequential or
incidental damages resulting from the use of this document.
DO NOT ATTEMPT to use any Giddings & Lewis product until the use of such product is completely
understood. It is the responsibility of the user to make certain proper operation practices are
understood. Giddings & Lewis products should be used only by qualified personnel and for the
express purpose for which said products were designed.
Should information not covered in this document be required, contact the Customer Service
Department, Giddings & Lewis, 660 South Military Road, P.O. Box 1658, Fond du Lac, WI 54936-
1658. Giddings & Lewis can be reached by telephone at (920) 921–7100.
M.1300.7165
Release 0201
© 1999, 2000, 2001 Giddings & Lewis, LLC

GIDDINGS & LEWIS MMC Hardware Manual TOC-1
Table of Contents: MMC Hardware Manual
1 Safety Precautions ............................................................................................. 5
1.1 System Safety ............................................................................................ 5
1.1.1 User Responsibility........................................................................... 5
1.1.2 Safety Instructions ............................................................................ 5
1.2 Safety Signs ............................................................................................... 6
1.3 Warning Labels .......................................................................................... 7
1.4 Safety First ................................................................................................. 8
1.5 Safety Inspection ........................................................................................ 8
1.5.1 Before Starting Operations ............................................................... 8
1.6 After Shutdown .......................................................................................... 8
1.7 Operating Safely ........................................................................................ 8
1.8 Electrical Service & Maintenance Safety .................................................. 9
1.9 Safe Cleaning Practices ............................................................................. 10
2 Introduction ....................................................................................................... 11
2.1 Overview .................................................................................................... 11
2.2 Major Components .................................................................................... 11
2.2.1 Machine Control Board .................................................................... 13
2.2.2 Motion Control Board ...................................................................... 13
2.2.2.1 Analog Servo board ........................................................... 13
2.2.2.2 SERCOS board .................................................................. 14
2.2.3 Option Modules ................................................................................ 15
3 Mounting the MMC Control ........................................................................... 17
4 Adding an Option Module to the MMC Control ........................................... 19
5 Dimensions and Mounting of MMC with Option Module Attached ........... 21
6 System Power and Environment Requirements ............................................ 23
6.1 General Power and Environment Requirements ........................................ 23
6.2 Control Cabinet Specifications .................................................................. 23
6.3 Power Distribution Diagram ...................................................................... 24
6.4 Notes for 24V Power Supply and MMC .................................................. 25
6.5 Grounding the System ............................................................................... 28
6.6 Controlling Heat Within the System .......................................................... 29
6.7 Handling an MMC ..................................................................................... 30
7 System Wiring Guidelines ................................................................................ 31
7.1 Recommended Signal Separation .............................................................. 31
7.2 Differential Devices for Analog and Encoder Signals ............................... 33
8 Starting an Operation ....................................................................................... 35
8.1 Connecting the MMC to the Application .................................................. 35
8.2 Troubleshooting ......................................................................................... 36
8.3 Diagnostics ................................................................................................. 37
8.3.1 Power-On Diagnostics ...................................................................... 37

TOC-2 MMC Hardware Manual GIDDINGS & LEWIS
8.3.1.1 Power LED ........................................................................ 37
8.3.1.2 Scan LED ........................................................................... 37
8.3.1.3 Diagnostic LEDs ................................................................ 37
8.3.2 Run-Time Diagnostics...................................................................... 38
9 MMC Connections to External Devices for Machine Control ..................... 39
9.1 PiCPro Port ................................................................................................ 39
9.2 Block I/O Port ............................................................................................ 40
9.3 User Port .................................................................................................... 41
9.4 General I/O Port ......................................................................................... 42
9.5 Power Connection ...................................................................................... 45
10 MMC Analog Servo Connections for Motion Control .................................. 47
10.1 Axis Connectors ......................................................................................... 47
10.2 Auxiliary I/O Connector ............................................................................ 52
11 MMC SERCOS Connections for Motion Control ......................................... 57
11.1 SERCOS Receive and Transmit Ports ....................................................... 57
11.2 Serial (Loader) Port ................................................................................... 58
12 Basic MMC Theory of Operation .................................................................... 59
12.1 Machine Control Board Operation ............................................................ 59
12.2 LEDs .......................................................................................................... 60
12.3 Diagnostic Error Codes .............................................................................. 61
12.4 MMC Machine Control ............................................................................ 62
12.5 Application in Flash ................................................................................... 62
12.6 General I/O Output Operation ................................................................... 63
12.7 Protecting from an Inductive Load ............................................................ 63
12.8 DC Output Theory of Operation (Axis Connector) ................................... 64
12.9 DC Input Operation (Axis, AUX, General Connectors) ............................ 65
13 Analog Servo Control Operation ..................................................................... 67
13.1 Analog Output Theory of Operation (Axis Connectors) ........................... 68
13.2 Encoder Theory of Operation (Axis and AUX Connectors) ..................... 68
13.3 Analog Input Operation (AUX Connector) ............................................... 70
14 MMC SERCOS Control Operation ................................................................ 71
15 Replacing the MMC Battery ............................................................................ 73
16 Specifications .................................................................................................... 75
A.1 - MMC Ethernet TCP/IP Module ............................................................ A.1-1
1 Introduction ................................................................................................ A.1-1
2 Connections ............................................................................................... A.1-2
2.1 The Ethernet Port.............................................................................. A.1-4
2.2 The RS232 COMM Ports ................................................................. A.1-4
3 LEDs .......................................................................................................... A.1-5
4 Firmware Update ....................................................................................... A.1-5
5 Theory of operation ................................................................................... A.1-6
6 Specifications Table ................................................................................... A.1-7
7 Useful Internet Links ................................................................................. A.1-8

GIDDINGS & LEWIS MMC Hardware Manual TOC-3
B.1 - MMC DeviceNet Module ......................................................................... B.1-1
1 Introduction ................................................................................................ B.1-1
2 Connections ............................................................................................... B.1-2
2.1 The DeviceNet Port .......................................................................... B.1-3
2.2 The Configuration (RS232) Port ...................................................... B.1-3
3 LEDs .......................................................................................................... B.1-4
4 Theory of Operation ................................................................................... B.1-5
5 Specifications ............................................................................................. B.1-6
C.1 - Breakout Boxes, Centurion Connector Cables and Flying Lead Cables C.1-1
1 Breakout Boxes and Cables ....................................................................... C.1-3
1.1 Breakout Box and Cables for Axis Connector ................................. C.1-3
1.1.1 Breakout Box for Axis Connector ..................................... C.1-4
1.1.2 Cable - Breakout Box to MMC Axis Connector ............... C.1-5
1.2 Breakout Box and Cables for Auxiliary I/O Connector ................... C.1-6
1.2.1 Breakout Box for AUX I/O Connector .............................. C.1-6
1.2.2 Auxiliary I/O Connector Breakout Box with Encoder Isolators C.1-9
1.2.3 Cable - Breakout Box to AUX I/O Connector ................... C.1-12
1.3 Breakout Box and Cables for Block I/O Connector ......................... C.1-15
1.3.1 Block I/O Connector Breakout Box ................................... C.1-15
1.3.2 Cable - Breakout Box to Block I/O Connector .................. C.1-17
1.4 Breakout Box and Cables for User Port Connector......................... C.1-18
1.4.1 User Port Connector Breakout Box ................................... C.1-18
1.4.2 Cable - Breakout Box to USER PORT Connector ............ C.1-20
1.5 Breakout Box and Cables for General I/O Connector ...................... C.1-21
1.5.1 Breakout Box for GEN I/O Connector .............................. C.1-21
1.5.2 Cable - GEN I/O Connector to Breakout Box ................... C.1-23
2 Cables from Centurion Drives to MMC Axis Connector .......................... C.1-25
2.1 Cable - DSM J1 Connector to MMC Axis Connector...................... C.1-25
2.2 Cable - MicroDSM J1 to MMC Axis Connector ............................. C.1-27
3 Flying Lead Cables to MMC Control ........................................................ C.1-29
3.1 Flying Lead Cable to MMC Axis Connector ................................... C.1-29
3.2 Flying Lead Cable to MMC AUX I/O Connector............................ C.1-30
3.3 Flying Lead Cable to MMC BLK I/O Connector............................. C.1-33
3.4 Flying Lead Cable to MMC USER PORT Connector ..................... C.1-34
3.5 Flying Lead Cable to MMC GEN I/O Connector ............................ C.1-35
D.1 - MMC Profibus Module ............................................................................ D.1-1
1 Introduction ................................................................................................ D.1-1
2 Connections ............................................................................................... D.1-2
2.1 The Profibus Port.............................................................................. D.1-3
2.2 The Configuration (RS232) Port ...................................................... D.1-3
3 LEDs .......................................................................................................... D.1-4
4 Theory of Operation ................................................................................... D.1-5
5 Specifications ............................................................................................. D.1-6

TOC-4 MMC Hardware Manual GIDDINGS & LEWIS
E.1 - CE and EMC Guidelines ......................................................................... E.1-1
1 Background on EMC (Electromagnetic Compatibility) Compliance ........ E.1-1
2 Background on Low Voltage Compliance ................................................. E.1-1
3 RFI Emission and Immunity ...................................................................... E.1-2
4 Classes of EMC Operating Environments ................................................. E.1-3
5 Conformance with the EMC Directive ...................................................... E.1-4
6 Conformance With the Low Voltage Directive ......................................... E.1-4
7 Changes to the PiC Products ...................................................................... E.1-4
7.1 Changes Affecting the User.............................................................. E.1-5
8 Using EMC and Non-EMC Modules ......................................................... E.1-8
9 Declarations of Conformity ....................................................................... E.1-9
Index ............................................................................................................ IND-1

Safety Precautions
GIDDINGS & LEWIS MMC Hardware Manual 5
1 Safety Precautions
READ AND UNDERSTAND THIS SECTION IN ITS ENTIRETY
BEFORE UNDERTAKING INSTALLATION OR
ADJUSTMENT OF MMC CONTROL EQUIPMENT
The advice contained in this section will help users to operate and maintain the
equipment in a safe manner at all times.
PLEASE REMEMBER THAT SAFETY IS EVERYONE'S RESPONSIBILITY
1.1 System Safety
The basic rules of safety set forth in this section are intended as a guide for
the safe operation of equipment. This general safety information, along with
explicit service, maintenance and operational materials, make up the
complete instruction set. All personnel who operate, service or are involved
with this equipment in any way should become totally familiar with this
information prior to operating.
1.1.1 User Responsibility
It is the responsibility of the user to ensure that the procedures set
forth here are followed and, should any major deviation or change
in use from the original specifications be required, appropriate
procedures should be established for the continued safe operation
of the system. It is strongly recommended that you contact your
OEM to ensure that the system can be safely converted for its new
use and continue to operate in a safe manner.
1.1.2 Safety Instructions
1. Do not operate your equipment with safety devices bypassed
or doors removed.
2. Only qualified personnel should operate the equipment.
3. Never perform service or maintenance while automatic con-
trol sequences are in operation.
4. To avoid shock or serious injury, only qualified personnel
should perform maintenance on the system.

Safety Precautions
6 MMC Hardware Manual GIDDINGS & LEWIS
5. ATTENTION - DANGER TO LIFE
Do not touch the main power supply fuses or any components
internal to the power modules while the main power supply
switch is ON. Note that when the main power switch is OFF,
the incoming supply cable may be live.
6. GROUNDING (Protective Earth)
The equipment must be grounded (connected to the protective
earth connection) according to OEM recommendations and to
the latest local regulations for electrical safety. The ground-
ing (protective earth) conductor must not be interrupted inside
or outside the equipment enclosures. The wire used for equip-
ment grounding (connection to protective earth) should be
green with a yellow stripe.
7. If there is any doubt at all as to the safety of the equipment,
you should set the main power switch to OFF and contact
your OEM for advice.
1.2 Safety Signs
The purpose of a system of safety signs is to draw attention to objects and
situations which could affect personal or plant safety. It should be noted that
the use of safety signs does not replace the need for appropriate accident
prevention measures. Always read and follow the instructions based upon
the level of hazard or potential danger.

Safety Precautions
GIDDINGS & LEWIS MMC Hardware Manual 7
1.3 Warning Labels
Hazard warning
When you see this safety sign on a system, it gives a warning of a hazard or
possibility of a hazard existing. The type of warning is given by the pictorial
representation on the sign plus text if used.
The safety color is black on a yellow background with a black symbol. To
ignore such a caution could lead to severe injury or death arising from an
unsafe practice. If voltage levels are included in the text they must indicate
the maximum level of the hazard in normal or fault condition.
Danger, Warning, or Caution warning
Hot Surface warning
Danger Electric
Shock Risk
Symbol plus DANGER, WARNING or CAUTION: Thes
e
notices provide information intended to prevent potential
personal injury and equipment damage.
Hot Surface

Safety Precautions
8 MMC Hardware Manual GIDDINGS & LEWIS
1.4 Safety First
Giddings & Lewis equipment is designed and manufactured with
consideration and care to generally accepted safety standards. However, the
proper and safe performance of the equipment depends upon the use of sound
and prudent operating, maintenance and servicing procedures by trained
personnel under adequate supervision.
For your protection, and the protection of others, learn and always follow
these safety rules. Observe warnings on machines and act accordingly.
Form safe working habits by reading the rules and abiding by them. Keep
these safety rules handy and review them from time to time to refresh your
understanding of them.
1.5 Safety Inspection
1.5.1 Before Starting Operations
1. Ensure that all guards and safety devices are installed and
operative and all doors which carry warning labels are closed
and locked.
2. Ensure that all personnel are clear of those areas indicated as
potentially hazardous.
3. Remove (from the operating zone) any materials, tools or
other objects that could cause injury to personnel or damage
the system.
4. Make sure that the control system is in an operational condi-
tion.
5. Make certain that all indicating lights, horns, pressure gauges
or other safety devices or indicators are in working order.
1.6 After Shutdown
Make certain all controlled equipment in the plant is safe and the associated
electrical, pneumatic or hydraulic power is turned off. It is permissible for
the control equipment contained in enclosures to remain energized provided
this does not conflict with the safety instructions found in this section.
1.7 Operating Safely
1. Do not operate the control system until you read and understand the
operating instructions and become thoroughly familiar with the system
and the controls.
2. Never operate the control system while a safety device or guard is
removed or disconnected