Industrial Indexing Systems EMC Series User manual

IB-11B045
EMC SERIES MOTION CONTROLLER JUNE 2008
16 AXIS
MOTION
CONTROLLER
WITH
ETHERNET
INSTRUCTION BOOK
Proprietary information of Industrial Indexing Systems, Inc. furnished for customer use only.
No other uses are authorized without the prior written permission of
Industrial Indexing Systems, Inc.
Revision - A
A
pproved By: AW 6/26/08
INDUSTRIAL INDEXING SYSTEMS, INC.

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 TABLE OF CONTENTS ii
TABLE OF CONTENTS
List of Illustration.................................................................................................................................................. iv
Introduction...........................................................................................................................................................v
SECTION 1 - OVERVIEW
SECTION 2 - DESCRIPTION
2.1 Components.........................................................................................................................2 - 2
2.1.1 Status Indicators.....................................................................................................2 - 2
2.1.2 Connectors .............................................................................................................2 - 2
2.2 Handling ...............................................................................................................................2 - 3
2.3 Mounting...............................................................................................................................2 - 3
SECTION 3 - EMERALD SPECIFICATIONS
3.1 General.................................................................................................................................3 - 1
3.2 Power Requirement.............................................................................................................3 - 1
3.3 SERCOS Interface...............................................................................................................3 - 1
3.4 Environment.........................................................................................................................3 - 1
3.5 Communication Ports...........................................................................................................3 - 2
3.6 5 Volt Digital I/O (J3)............................................................................................................3 - 2
3.7 Watchdog Protection............................................................................................................3 - 2
SECTION 4 - EMERALD WIRING
4.1 COM 1 & COM 2..................................................................................................................4 - 1
4.2 Ethernet................................................................................................................................4 - 1
4.3 5V Digital I/O........................................................................................................................4 - 2
4.4 Power and Watchdog Connector ........................................................................................4 - 3
4.5 SERCOS Interface TX/RX...................................................................................................4 - 4

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 TABLE OF CONTENTS iii
SECTION 5 - STATUS & ERROR CODES
5.1 Controller Status ..................................................................................................................5 - 1
5.2 SERCOS Status LEDs.........................................................................................................5 - 2
5.3 Ethernet Status Displays......................................................................................................5 - 3
SECTION 6 - CABLES AND ACCESSORIES
APPENDIX A - ETHERNET OPERATION BOARD
A.1 Ethernet Overview...............................................................................................................A - 1
A.2 EDE Setup For Ethernet Communication ..........................................................................A - 1
A.2.1 Select Ethernet For Connection Type ..................................................................A - 2
A.2.2 Ethernet EDE Configuration Screen.....................................................................A - 3
A.3 Ethernet Setup ....................................................................................................................A - 3
A.4 Global Parameters..............................................................................................................A - 4
A.5 Default Web Page...............................................................................................................A - 6
A.6 Sample XML Document...................................................................................................... A - 7
A.7 Sample Global Parameter .................................................................................................. A - 8
A.8 Sample Global Parameter Value........................................................................................A - 9
A.9 Sample Setting A Global Parameter Value......................................................................A - 10

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 LIST OF ILLUSTRATIONS iv
LIST OF ILLUSTRATIONS
SECTION 1 - OVERVIEW
SECTION 2 - DESCRIPTION
Figure 2.1 EMC Layout............................................................................................................2 - 1
Figure 2.2 Mounting.................................................................................................................2 - 3
SECTION 3 - EMERALD SPECIFICATIONS
SECTION 4 - EMERALD WIRING
Figure 4.1 COM 1 & COM 2....................................................................................................4 - 1
Figure 4.2 Ethernet ..................................................................................................................4 - 1
Figure 4.3 Digital I/O Connector..............................................................................................4 - 2
Figure 4.4 Power and Watchdog Connection.........................................................................4 - 3
Figure 4.5 Typical SERCOS Ring...........................................................................................4 - 4
SECTION 5 - STATUS & ERROR CODES
Figure 5.1 Controller Status.....................................................................................................5 - 1
Figure 5.2 SERCOS Status LEDs...........................................................................................5 - 2
Table 5.1 Module Status LED ................................................................................................5 - 3
SECTION 6 - CABLES AND ACCESSORIES
APPENDIX A - EHTERNET OPERATION BOARD

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 INTRODUCTION v
INTRODUCTION
This device is a single board motion controller based upon Industrial Indexing Emerald Series products and
herein will be referred to as the EMC (Emerald Motion Controller).
The EMC incorporates a Local PCI buss to support dual processor architecture. The on board MIPS
Processor’s primary function is to control motion of up to 16 Axis over the SERCOS InterfaceTM. A second
processor of type ARM has the task of supporting TCP/IP over Ethernet.
The EMC embodies a blend of open architecture features with a true real-time operating system. The result
is a state-of-the art performance and superior connectivity to other systems and network components.
The controller is programmed using our friendly Emerald Motion Programming Language (EML) and
powerful new Emerald Development Environment (EDE) software tools for the PC. The EML incorporates
easy to use motion commands to allow fast development of a servo application. The language has
commands which accommodate PLS’s (Programmable Limit Switches) from I/O, master/slave with
Camming, and much more motion and I/O control.

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 1 - 1
SECTION 1 - OVERVIEW
This manual is organized so that information is easy to find and easy to use. It begins by detailing how to
identify the EMC Controller and its options. This section is followed by a general description of the product
and its components. Next, a comprehensive hardware specification is provided followed by connector wiring
diagrams. The section that follows documents the controller status displays. Sections on EMC installation
guidelines and cables drawings round out the manual.

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 2 - 1
SECTION 2 - DESCRIPTION
The Emerald EMC product is a SERCOS Master servo motion controller, with the ability to command up
to 16 SERCOS Slave Devices. The application program that operates the controller is created on a PC
using the EDE software tools and sent to the controller via an RS-232 link or Ethernet.
NOTE
All commands used by the EMC are part of the Emerald
Motion Language (EML). Refer to the Emerald Development
Environment (EDE) PC tools online help for detailed
information on the commands and their proper usage.
The external connections that exist on the EMC are shown in Figure 2.1, and consist of 2 RS-232 ports,
Ethernet, SERCOS Transmitter and Receiver, Digital I/O, as well as a Hardware Watchdog and power
connections.
Figure 2.1 - EMC Layout

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 2 - 2
2.1 COMPONENTS
2.1.1 STATUS INDICATORS
NOTE
For indicator status information, refer to Section 5 - Status
& Error Codes.
1. Controller Status Display - This single seven-segment LED display with decimal point provides
status information of various operating conditions.
2. SERCOS Phase LEDs - This group of 4 LEDs indicates the status of the SERCOS InterfaceTM.
3. SERCOS - Error LED - This LED indicates poor Fiber Optic reception.
4. Ethernet Status LEDs - Functional indicators for Ethernet.
2.1.2 CONNECTORS
NOTE
For proper pinouts for each connector refer to Section 4 -
Emerald Wiring.
1. COM 1 - This 6-pin RJ-11 connector is an RS-232 serial communication port. It uses a custom
protocol to communicate with the EDE software tools on a PC. This port also facilitates firmware
download.
2. COM 2 - This 6-pin RJ-11 connector is an RS-232 serial communication port. It can be used to
communicate with the IIS OPI-50 or similar RS-232 type device. The protocol is selectable
through the EML programming language. This port does default to the custom protocol for
communicating with the EDE software tools on a PC.
3. P4 - This 8-pin RJ-45 connector is for Ethernet.
4. J4 - This 10-pin header is a high-speed master encoder pulse input.
5. P3 - This connector is used to connect the required 24VDC external power supply. This
connector also provides a normally open hardware watchdog output for external monitoring of the
EMC operation. The watchdog output contact will be closed when the Motion Application is
executing.
6. RX - This SMA style interface port is the SERCOS Fiber Optic Receiver. This is return connection
for SERCOS Interface Ring.
7. TX - This SMA style interface port is the SERCOS Fiber Optic Transmitter. This connection is the
start of the SERCOS Interface Ring.

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 2 - 3
2.2 HANDLING
This is a static sensitive product. While handling this unit you should were a static discharge device such
as a wrist strap, foot straps, or other static discharge device approved within your facility. Remember to
always handle the product only when required.
2.3 MOUNTING
In Figure 2.2 there are seven locations for mounting the EMC. The mounting base should tie back to
earth ground of the system as the mounting points on the EMC are electrically tied to the earth
connection on the 24V input connector.
Hardware requirement:
Standoffs - Type M3 or #4 with a minimum of 10mm or 0.375” length.
Screws - Type M3 or #4 with a maximum head diameter of 6mm or 0.25”.
Washers - Maximum diameter of 6mm or 0.25”.
Figure 2.2 - Mounting

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 3 - 1
SECTION 3 - EMERALD SPECIFICATIONS
3.1 GENERAL
Weight 5.8 lbs / 2.2 Kgs
Dimensions Width 12.0 in (304.8 mm)
Height 6.5 in (165.1 mm)
Thickness 1.25 in (20.32 mm)
3.2 POWER REQUIREMENT
Supply Voltage 24 volts DC +10%, Class 2 power supply
Supply Current 1.0 amps max.
3.3 SERCOS INTERFACE
Interface Version V01.02
Topology Multi drop fiber optic ring
Transmission
Rates 2, 4, 8 and 16 MB/second
3.4 ENVIRONMENT
Storage
Temperature -10 to 70°C/14-158°F
Operating
Temperature 0 to 55°C/32-131°F
Humidity 35 to 90% Relative Humidity, non-condensing
Shock and
Vibration 1 G or less
Operating
Conditions Free of dust, liquids, metallic particles and corrosive gases.
Use in a pollution degree 2 environment.

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 3 - 2
3.5 COMMUNICATION PORTS
COM 1 Classification: RS-232
Data Transfer: EMC Packet protocol
Protocol: 38400 baud, 1 stop bit, 8 data bits, No parity
COM 2 Classification: RS-232
Data Transfer: EMC Packet protocol (default), Programmable
Protocol: Configurable
P4 Classification: Ethernet (CAT5)
Data Rate: 10/100MHz
Protocol: TCP/IP
Fiber Optic
Transmitter/
Receiver
Classification: SMA style - SERCOS compatible Fiber Optics
SERCOS: Data Transfer and Protocol are define by the SERCOS
Specification (IEC-61491 or EN-61491).
3.6 5 VOLT DIGITAL I/O (J3)
Outputs Four optical Isolated sinking outputs.
Internal pull-ups to 5V I/O Supply.
Sink current capability 100 mA.
Inputs 2 optically Isolated inputs.
5V ± 10% @ 15 mA max.
3.7 WATCHDOG PROTECTION
Contact Type Relay normally open dry contact
Rating Up to 28 VAC/VDC, 0.5 Amp Maximum

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2004 PAGE 4 - 1
SECTION 4 - EMERALD WIRING
This section details the pinouts of the external connectors on the EMERALD controller.
4.1 COM 1 & COM 2
The ports are used for communication and use RJ-11 connectors to interface to respective devices. The
port 1 & port 2 pinouts are shown in Figure 4.1.
Figure 4.1 - COM 1 & COM 2
4.2 ETHERNET
The RJ-45 connector (shown in Figure 4.2 with an RJ-45 plug) is used to connect workstations, hubs,
and switches through unshielded twisted pair cable. The RJ-45 connector accepts four-pair Category 3
or Category 5 UTP cable. Only two pairs are used for 10BASE-T wiring.
Figure 4.2 - Ethernet
PIN ASSIGNMENT OF P4
1 Output Transmit Data +
2 Output Transmit Data -
3 Input Receive Data +
6 Input Receive Data -
4,5,7,8 Not used

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2004 PAGE 4 - 2
4.3 5V DIGITAL I/O
Figure 4.3 - Digital I/O Connector

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2004 PAGE 4 - 3
4.4 POWER AND WATCHDOG CONNECTER
The 24-volt, Class 2 power supply is to be used to power this device.
The pinouts of the WD/24V connector are shown in Figure 4.4.
Figure 4.4 - Power and Watchdog Connection

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2004 PAGE 4 - 4
4.5 SERCOS INTERFACE TX/RX
The SERCOS InterfaceTM is a multi-drop fiber-optic ring with 1 Master Controller command multiple Slave
devices. The EMC acts as the Master Controller in this arrangement.
Figure 4.5 - Typical SERCOS Ring

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 5 - 1
SECTION 5 - STATUS & ERROR CODES
5.1 CONTROLLER STATUS
Figure 5.1 - Controller Status

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 5 - 2
5.2 SERCOS STATUS LEDS
{
OFF
Ï
FLASHING
z
ON
{
{
{
SERCOS PHASE 3
Ï
{
{
{
SERCOS PHASE 2
Ï
{
{
{
SERCOS PHASE 1
Ï
SERCOS PHASE 0
Ï
Ï
Ï
Ï
SERCOS PHASE 4
Figure 5.2 - SERCOS Status LEDs
{
{
z
PH2
PH3
PH4
PH
1
{

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 5 - 3
5.3 ETHERNET STATUS DISPLAYS
STATE LED IS STATE DESCRIPTION
DL3 Off No link (idle)
Link DL3 On Valid link exists
DL4 Off Not receiving
RCV DL4 On Receiving Data
DL5 Off Not transmitting
Xmit DL5 On Transmitting data
DL6 Off 10 meg Baud link
100M DL6 On 100 meg Baud link
Table 5.1 - Module Status LED

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 6 - 1
SECTION 6 - CABLES AND ACCESSORIES
DRAWING NUMBER DESCRIPTION
C-752YYY SERCOS Fiber Optic Cable, External
C-753YYY SERCOS Fiber Optic Cable, Internal
C-822YYY Adaptor Cable
C-987YYY Modular Data Cable

INDUSTRIAL INDEXING SYSTEMS, Inc. IB-11B045
EMC SERIES MOTION CONTROLLER USER’S GUIDE
JUNE 2008 PAGE 6 - 2