Ormec Generation III 20 User manual

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Generation
GenerationGeneration III IIIIII
Model 20/40 Motion Controllers
Installation & Operation Manual
GN3-040f
Copyright (c) 1990-1994
Ormec Systems Corp.
All rights reserved
19 Linden Park
Rochester, NY 14625
[phone]
June 27, 1994

‘
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.

Generation III Table of Contents
Table of Contents
___________________________________________________________________________________
Welcome .................................................................. 1
General Description .......................................................... 3
2.1 General Description ................................................. 3
2.2 Model 20/40 Features ................................................ 4
Model 20 Model Number Description .................................. 4
Model 40 Model Number Description .................................. 4
2.3 Modular Construction ................................................. 5
2.4 DSP Axis Modules ................................................... 5
DSP Axis Module Model Number Description ............................ 5
2.5 Servodrive Compatibility ............................................... 6
2.6 Servomotor Compatibility .............................................. 6
MAC-A Series Motors ............................................. 6
MAC-B Series Motors ............................................. 6
MAC-C Series Motors ............................................. 7
MAC-E Series Motors ............................................. 7
Installation ................................................................. 9
3.1 Motion Controller Installation ........................................... 9
Receiving & Inspection ............................................ 9
Input Power - TB1 ............................................... 9
System Power Wiring & Interlocks - TB6 .............................. 10
Emergency Stop, No-Fault Interlock & I/O Power - TB6 ................... 11
Integral Discrete I/O - TB2 to TB5 ................................... 13
Extended I/O Connector - J3 ....................................... 15
Pamux I/O Expansion Connector - J3 ................................ 15
Serial Port Connector - J2 ......................................... 16
Keyboard Interface Connector - J8 .................................. 16
MotionDATATM Connectors - J4 & J5 ................................. 17
MotionDATATM Connector Pinout .............................. 17
MotionNETTM Port Connectors - J6 & J7 .............................. 18
MotionNetTM Connector Pinout ................................ 18
RS-422/485 Serial Communications with the MotionNETTM Port ........ 19
ModbusTM Communications .................................. 19
3.2 Memory Cards ..................................................... 19
Memory Disks .................................................. 19
MotionCARDTMs ................................................ 19
3.3 DSP Axis Modules ................................................. 20
Axis Addresses ................................................ 20
Setting Axis Addresses ........................................... 20
Model 20 Unit-ID and Axis Installation ................................. 21
Model 40 Unit-ID and Axis Installation ................................. 22
DSP Axis Interface Connectors - J11 & J12 ............................ 23
SAC-E Series Axis Interface ....................................... 25
SAC-S Series Axis Interface ....................................... 26
Pacer Encoder Axis Interface ....................................... 27
DSP I/O Header Connector - J10 ................................... 27
DSP I/O Header Connector - J10 (Old Version DSP) ..................... 29
page i GN3-040

Generation III Table of Contents
DSP Sensor Header Connector - J10 (for earlier model DSP Axis Modules) ..... 31
DSP Axis Module Configuration Jumpers .............................. 33
3.4 Video Display Adapter .............................................. 37
Analog Monitor Connector - CN1 .................................... 37
Digital Monitor Connector - CN2 ..................................... 38
Video Adapter VGA Installation ..................................... 38
Video Adapter Monochrome Installation ............................... 39
Video Adapter EGA Installation ..................................... 39
MDA/EGA Connector - J1 ......................................... 40
Video Adapter Installation ......................................... 40
3.6 GN3-422 Serial Communications Adapter ................................ 41
Device Configuration - Factory Default Settings Summary .................. 41
Device Configuration - Port 1 & Port 2 ................................ 41
Port Enable/Disable - Switches Port 1 & Port 2 position 8 .................. 42
Interrupt Request ................................................ 42
Driver Enable .................................................. 42
RS-232 and RS-422/485 Configuration ................................ 43
DB-9 Pin Description ............................................. 44
Use with the ITM-270s and/or AND-Series Alphanumeric Displays ............ 44
Device Configuration - Switches S1 & S2 .............................. 44
Port Enable/Disable - Switches S1 & S2, Pin 8 .......................... 45
Interrupt Request ................................................ 45
Driver Enable .................................................. 45
RS-232 and RS-422/485 Configuration ................................ 45
DB-9 Pin Description ............................................. 46
Use with the ITM-270s and/or AND-Series Alphanumeric Displays ............ 46
3.8 GN3-232 Serial Communications Adapter ................................ 47
Device Configuration - Header JP1 .................................. 47
Connector Pin Assignments ....................................... 47
Operation ................................................................. 49
4.1 Powerup ......................................................... 49
4.2 System Status LEDs ................................................ 50
4.3 Initial Configuration ................................................. 52
Getting Started ............................................................. 53
5.1 Test Run Preparation ............................................... 53
Motion Controller Checks ......................................... 53
Servomotor Checks .............................................. 54
Apply Control Power ............................................. 54
5.2 MotionPROTM Servo Development Software ............................... 54
5.3 Test Running Your System ........................................... 54
Product History ............................................................. 55
6.1 Model 20/40 (GN3-20 & GN3-40) History ................................. 55
6.2 DSP Axis Module (GN3-AQ & GN3-A2) History ............................ 56
Specifications .............................................................. 59
7.1 General Specifications .............................................. 59
7.2 Power Specifications ................................................ 59
Power Requirements ............................................. 59
Outgoing Power ................................................ 60
7.2 Battery Specifications ............................................... 62
7.3 Interface Specifications .............................................. 62
GN3-040 page ii

Generation III Table of Contents
Serial Port - J2 ................................................. 62
MotionDATATM Interface J4 & J5 ..................................... 62
MotionNETTM Interface J6 & J7 ..................................... 62
DSP I/O Header - J10 ............................................ 63
DSP Axis Interface Connector - J11 &J12 .............................. 65
7.4 Mechanical and Environmental Specifications .............................. 66
Terms & Mnemonics ........................................................ 67
APPENDIXES
A Model 20/40 Installation Diagram A-1
B System Wiring Diagrams
System Wiring with S-Series Servodrive(s) B-1
System Wiring with E-Series Servodrive(s) B-2
C Model 20/40 Interface Diagrams
Power Panel Layout Diagram (Model 20/40 - Top View) C-1
I/O Panel Layout Diagram (Model 20/40 - Front View) C-2
Interface Panel Layout Diagram (Model 20 - Bottom View) C-3
Interface Panel Layout Diagram (Model 40 - Bottom View) C-4
Integral Discrete I/O and Interlock Interface Schematics C-5
Extended Discrete I/O (or Pamux Interface) Schematics C-6
MotionNET and Serial Port Interface Schematics C-7
MotionDATA Interface Schematic C-8
D DSP Axis Module Interface Schematics
Axis A Input Circuitry D-1
Axis A Output Circuitry D-2
Axis B Input Circuitry D-3
Axis B Output Circuitry D-4
Component Location Diagram D-5
Axis A Input Circuitry (Old version DSP) D-6
Axis A Output Circuitry (Old version DSP) D-7
Axis B Input Circuitry (Old version DSP) D-8
Axis B Output Circuitry (Old version DSP) D-9
Component Location Diagram (Old version DSP) D-10
E DSP Interface Cables & Accessories
CBL-AE/NN E-Series Axis Interface Cable E-1
CBL-AS/NN S-Series Axis Interface Cable E-2
CBL-AET/NN E-Series to Terminal Block Axis Interface Cable E-3
CBL-AST/NN S-Series to Terminal Block Axis Interface Cable E-4
TBC-D25/NN Axis Terminal Block E-5
CBL-AT/NN DSP to Axis Terminal Block Cable (Old version DSP) E-6
CBL-AR3/NN DSP Axis Terminal Block Cable (ver. 3.0 and later) E-7
CBL-QE25/NN EDR-25S Pacer Encoder Axis Interface Cable E-8
CBL-DSP-IO/NN DSP I/O Cable & Terminal Block E-9
CBL-DSP-TB/NN DSP Sensor Terminal Block & Cable (Rev A) E-10
CON-2Q DSP Axis Interface Connector E-11
page iii GN3-040

Generation III Table of Contents
F Serial and I/O Interface Cables
CBL-SER/PC Serial Coil Cord to IBM-PC F-1
CBL-SER/AT Serial Coil Cord to IBM-AT F-2
CBL-MOD8/NNN Shielded 8-wire modular cable F-3
CON-MOD8-ITM Connector from CBL-MOD8 to ITM-270 F-4
CBL-ITM-PWR/NN ITM-270 Power Cable F-5
CBL-EIO/NNN Extended I/O Cable F-6
CBL-DIO/N Extended I/O Cable to MIO-002-24 I/O Rack F-7
CBL-422-ITM/NNN Cable from GN3-422 to ITM-270 F-8
CON-422-MOD8 Connector from GN3-422 to CBL-MOD8 F-9
CBL-422-TL/NNN Cable from GN3-422 to Tinned Leads F-10
CBL-ITM-TL/NNN Cable, ITM-270 to Tinned Leads F-11
CON-MOD8-TB Connector, CBL-MOD8 to Terminal Block (Old version) F-12
CON-MOD8-TB2 Connector, CBL-MOD8 to Terminal Block F-13
G Motor and Encoder Interface Cables
CBL-SMACE/NN Encoder Cable, MAC-E Series Motors G-1
CBL-SMAC/NN Encoder Cable, MAC-S Series Motors G-2
CBL-SMAC1/NN Motor Cable for E007-015, A010-015 & B025-080 G-3
CBL-SMAC2/NN Motor Cable for MAC E016-030 & A030-055 G-4
CBL-SMAC3/NN Motor Cable for MAC E002-003 & B010-020 G-5
CBL-SMAC4/NN Motor Cable for MAC A110 G-6
CBL-SMAC5/NN Motor Cable for MAC B110 G-7
CBL-SMAC6/NN Motor Cable for MAC B200, B330 & C290 G-8
CBL-SMAC7/NN Motor Cable for MAC C410 & C560 G-9
CBL-SMACF/NN Motor Fan Cable for MAC-C560 G-10
H Model 20/40 Internal Wiring
Model 20/40 Internal Wiring H-1
Model 20/40 Motherboard Locators H-2
Model 20/40 Internal MotionDATA Cabling H-3
Memory Disk Installation H-4
GN3-040 page iv

Generation III Welcome
Chapter 1
Welcome
___________________________________________________________________________________
1.0 Welcome
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.
GN3-040 page 1

Generation III Welcome
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.
page 2 GN3-040

Generation III General Description
Chapter 2
General Description
___________________________________________________________________________________
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.
GN3-040 page 3