Ormec ORION User manual

ORMEC SYSTEMS CORP. [phone] Rochester, N.Y. 14625ORMEC SYSTEMS CORP. [phone] Rochester, N.Y. 14625
MotionBASIC Ver 4.x & MotionDESK 3.x Windows 95 or NT application
Using the direct mode window.
By pressing three key's < Shift + Alt + Letter >, a command will be automatically typed.
Troubleshooting example key group are ... < Shift + Alt + F > ... for Fault status.
<Alt+Shift+F> Fault Status
For troubleshooting a system, the most useful <Alt+Shift+ letter> is ... F ... for Fault status.
The following example shows the fault status after a machine has experienced a product jam
problem.
?USING”& 1st of & faulted. FAULT@:& AFAULT@:###
n1st of 5 faulted
ALARM@:##”;AXIS.FLT1@,AXIS.FAULT@,FAULT@,AFAULT@(AXIS.FLT1@),ALARM@(AXIS.FLT1@)
o
The first line provides the ERROR code, error message, and the program line number where
the error occurred. The second line prints the fault information.
System module .......... FAULT@, .............................{7} .... Axis Fault
Axis that failed 1st ..... AXIS.FLT1@ ........................ {2} .... Axis # two caused the failure.
DSP module .............. AFAULT@(AXIS.FLT1@) ..... 2 ..... See Servodrive ALARM@
Servodrive .................. ALARM@(AXIS.FLT1@) ..... 17 .... Motor Overload for E-Series drive.
<Alt+Shift+C> Will attempt to clear faults. You must enter a MODE@ value #.
AFAULT@=0:FAULT@=0:WAIT 300:MODE@=
Available Modes: 0=Disabled, 1=Pacer, 2=Standby, 3=Output, 4=Velocity , 5=Position
FAULT@ .....Unit Fault Code. Set of current fault(s) with a motion controller.
Code Fault Condition Code Fault Condition
1 ... RAM Checksum Error 7 ... Axis Fault occured
2 ... Battery Failure 8 ... User Machine Fault
3 ... Not used 9 ... String Space Fault
4 ... Internal Error 10 .. MB Extension Fault
5 ... DSP Axis Module Failure 11 .. Not used
6 ... E-Stop (or M-Stop) Input Open 12 .. Security Key Fault
13 .. DSP not Pentium Compatable
AXIS.FLT1@ . First Servo in the System that Faulted.
AFAULT@ ..... Axis Fault Code. Diagnostics determined at the DSP level.
Code Axis Fault Condition Code Axis Fault Condition
0 None 8 MotionDATA Error
1 Position Error > Max 9 Hi Axis Loop Rate
2 See Servodrive ALARM@ 10 Hi Pacer Loop Rate
3 Encoder Ch-A Open 11 No MotionDATA
4 Encoder Ch-B Open 12 Command Buffer Overflow
5 Command Overspeed 101 Motion Segment Overspeed
6 Pacer Overspeed 102 Missing Motion Table
7 Encoder Overspeed 901-999 are DSP Software Faults
ALARM@ .... Current servodrive alarm code.
DE & D - SERIES ALARM@ E - SERIES
No Drive Alarms ............. 0 - 7 ....... No Drive Alarms
Drive Unplugged ............... 10 ........ Drive Unplugged
Drive Overcurrent ............. 11 ........ Drive Overcurrent
Uncoded Alarm ................. 12 ........ Drive CB Tripped
Regeneration Fault ...........13 ........ Regeneration Fault
Hi Main DC Voltage .......... 14 ........ Hi Main DC Voltage
Motor Overspeed .............. 15 ........ Motor Overspeed
Uncoded Alarm ................. 16 ........ Lo Main DC Voltage
Motor Overload ................. 17 ........ Motor Overload
S - SERIES ALARM@ F - DRIVE
Normal operation................................. 0 - 7 ....... Normal operation
Drive Unplugged or Uncoded Alarm ...... 10 ........ Drive Unplugged or Uncoded Alarm
Drive Overcurrent .................................. 11 ........ Uncoded Alarm
Drive CB Tripped ................................... 12 ........ Drive Current Output Fault
Drive Overcurrent & CB Tripped ............ 13 ........ High Bus Voltage Fault
Uncoded Alarm with Motor Moving ........ 14 ........ Over Temp or RMS Current Limit
Drive Overcurrent & Motor Moving ......... 15 ........ Uncoded Alarm
CB Tripped & Motor Moving .................. 16 ........ Alarms 12 and 14
Overcurrent & CB Tripped & Moving ..... 17 ........ Alarms 13 and 14
TORQ
TACH
GND
CN3
CN2
CN1
DE-Series Servodrive
R
T
r
t
P
B
U
V
W
BUSPOWER
ORION Fault Codes for MotionBASIC 4.x
ORION - Rev E
Troubleshooting
DSP Module
GND
BUS+
BUS--
Ma
Mb
Mc
O.
O.
O.
O.
O.
O.
O.
O.
O.
C3
C2
C1
Control Power
Torque Enabled
Drive Ready
RMS Current Limit
Over Tem erature
Current Fault
High Bus Voltage
Low Bus Voltage
Overs eed
AC Brushless
RESET
ALARM
IN
P
MP
ON ON
CN2 CN1
Alt+Shift+Key for MotionDESK 3.x
The "Alt keys" are provided to minimize typing at the
command line. MotionBASIC Ver 4.x -5.x By pressing this
group of keys, < Alt + Shift + Key >, a command will be
automatically typed in the Direct Mode Window:
Key I MOVE FOR_(Index) R Repeat
A REPEAT_ J MOVE AT_ (Jog) S MODE@ Status
B - K Show Servo Gains T Torque Status
C Clear Faults L - U _UNTIL_
D Dump Thread M MP.CONFIG V Velocity Status
E Error Status N Normalize Axes W WAIT_
F Fault Status O Clear Overtravel X AXIS.SET@={
G GEAR_ P Position Status Y
H HALT_ Q Error Stop (Quit) Z Axis Set Status

ORMEC SYSTEMS CORP. [phone] Rochester, N.Y. 14625ORMEC SYSTEMS CORP. [phone] Rochester, N.Y. 14625
ORION Quick Reference
Reset located on the system module is a reboot, like a PC key combination <Ctrl><Alt><Del>. Used
to restart the system instead of flipping the power switch. Avoid turning the power on and off frequently.
PB1 - Push Button one can be used at power up (boot-up) in two ways:
Inhibits a MotionBASIC®program from running at boot-up.
Load a MotionBASIC®program. At power up, if PB1 is held in, the controller checks for one of the following
program files in this order: PB1LOAD.ext on left slot PC Card first, System Card, right slot second.
Filename extension (.ext ) for MotionBASIC Ver 4.0 is (.MTP) , MotionBASIC Ver 3.2 is (.BAS).
PB1LOAD.ext on left PC Card will always OVERWRITE an existing PB1LOAD.ext on the System Card.
ORION ... Digital Signal Processor ... DSP
DSP Axis Identification The axis rotary switch determines axes number.
DSP Axis A # = DSP rotary switch # * 2 + 1, DSP Axis B # = Axis A # + 1
Cycle power if you change the DSP axis rotary switch, this will update AXIS.LIST@.
PRINT AXIS.LIST@ - will identify all of the servo axes found in the system at power-up.
Note: axis A number will be ODD, axis B number is EVEN.
DSP LED's - when lit, indicates the following:
DSP OK ...... Green ......... DSP card is operating properly. No software or internal faults.
MDATA ....... Green ......... MotionDATA - DSP is receiving MotionDATA communications.
DENB ..... Green ....... Drive Enabled - Axis torque is enabled for the respective axis.
AFLT ...... Red ........ Axis Fault on the respective axis.
SEN .... Yellow ...... Sensor hardware (ASEN or BSEN) is asserted (conducting current).
EXTZ .... Yellow ...... External ZREF sensor is asserted (conducting current) on the respective axis.
Hardware Travel Limit Forward / Reverse. LED ON when there is an error,
With MotionBASIC Ver 3.2 axis motion is prohibited.
HTLF ...... Red when Jumper "J17" is ENABLED and NOT conducting current at TB9 or TB10.
HTLR ...... Red when Jumper "J17" is DISABLED and conducting current at TB9 or TB10.
ORION ... Discrete Input / Output board
Connecting External Field Power Supply at TB2
The ORION model number indicates if it has an internal field power supply or not.
The letter "F" = Internal Field supply, The letter "X" = NONE
WARNING: If ORION has an internal 24VDC power supply, DO NOT
connect another 24VDC supply to pins (+24, RTN) on TB2 or TB8
Discrete I/O Point - DIO@(number) ... number of the I/O point.
Read Input ................... PRINT DIO@(number)Zero=OFF, minus one (-1)=ON
Clear a Latched Input .... DIO@(number)=OFF
Write Output ................ DIO@(number)=ON or OFF or Set time in milliseconds.
Configure I/O point ...... IO.MODE@(number)="letter"
letters are: I = Input, O = Output, (for any point)
R = Rising,F = Falling (Only the first 16 points)
Trace Fuses On the Discrete I/O board is a Fuse Test socket "F1" and spare
holder. The below list of fuses are PRE-FUSED by the circuit board trace.
DO NOT USE A REPLACEMENT FUSE UNLESS THE TRACE IS OPENED!
Discrete I/O board: ...."F2" .... Extended Input /Output , +5VDC power.
System module trace fuses are located on the solder side (back) of board.
System module: "F1" ...... +5 VDC test at Interlock TB8 pin 7(+5) and pin 8 (R5)
System module: "F2" ...... E-Stop (12 to 24VAC)or(+12 to +24VDC) monitor voltage.
System module: "F3" ....+24 VDC test at Interlock TB8 pin 1(+24) and pin 3 (RTN)
The replacement fuse is Wickman 250V, 4Amps. Part # 19370-062K
ORION - Rev C
DSP OK
DENB
AFLT
SEN
EXTZ
HTLF
HTLR
A B
ID
Module
MDATA
901
Reset
PB1
Watchdog OK--
E-Stop OK--
No Fault--
+24 VDC--
MBX 1--
MBX 2--
User 1--
User 2--
MotionKEY Error--
Program Stopped--
Status
Development
Port
D 1 2
Serial Ports
SERIAL
1
J2
SERIAL
2
J3
SERIAL
D
J1
PC Card
Eject
8
System Card
Sending Serial
Receiving Serial
OK to Transmit
Ready to Receive
MS / NS
V+
CAN_H
SHIELD
CAN_L
V-
TB7
C
A
N
+24
E-Stop
RTN
No Fault
No Fault
SHIELD
+5
R5
I
N
T
E
R
L
O
C
K
TB8
S
Y
S
T
E
M
C
A
R
D
P
C
C
A
R
D
2
TB2
TB3
TB4
TB5
TB6
FUSE TEST
SOCKET
F1
LED
ON=OK
F2
EIO POWER FUSE
C
1-
1+
V
2+
2-
C
3-
3+
V
4+
4-
C
C
-
+
V
6+
6-
C
7-
7+
V
8+
8-
C
C
9-
9+
V
10+
10-
C
11-
11+
V
12+
12-
C
C
13-
13+
V
14+
14-
C
1 -
1 +
V
16+
16-
C
+24
V
+12
RTN
C
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
F
U
S
E
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
DIO 1-2
JP1
DIO 3-4
JP2
DIO -6
JP3
DIO 7-8
JP4
J 1
RN4
RN6
DIO
or
ESTOP
DIO
or
ESTOP
Discrete
Out ut s
have a
removable
fuse that
can be
tested
below.
Trace
Fuse
ORION ... System Module
5x7 Status Display After initialization, the ORION Status display will print
the MotionBASIC®Version and installed MBX's. Once a user program starts execution,
the display will be blank. When a user program terminates normally, the display will
revert back to the Direct Mode starburst. If a user program terminates due to an error
and enters direct mode, the program stopped led will be on and the display shows the
pertinent error code. Example: "E", "1" , "9" , "1" , "1" ... for ERROR 1911 Axis fault.
Status LEDs when lit indicates the following:
Watchdog OK ........ Green ........ Motherboard Processor is alive, flashes 1/sec.
E-Stop OK ........ Green ........ 24 Volts is present at Terminal Block TB8 E-Stop.
No-Fault ........ Green ........ The controller has no faults. FAULT@=0
+24 VDC ....... Yellow ........ Power is present at TB8 +24 and referenced to RTN.
MBX1 & MBX2 .. Yellow / Yellow . MotionBASIC®Extensions, Under MBX control.
User 1 / User2 .... Yellow / Red ... User LED's indication, Under program control.
MotionKEY Error ......... Red .......... MotionKEY is missing or insufficient credits.
Program Stopped ......... Red .......... MotionBASIC®program not running. In Direct Mode.
PC Card™ ATA The required system card (right slot) can contain all the
system executable programs, MotionBASIC®Extensions (MBX), user MotionBASIC®
program, and data files. An optional PC Card™ is used for storing user MotionBASIC®
program & data files. When the Green LED is ON or Flashing, it indicates that the
controller is accessing the PC Card™.
DO NOT REMOVE A PC CARD WHEN THE LED IS ON OR FLASHING.
FILES Display names of files currently stored on the booted SYSTEM Card™.
MB Ver 4.x MB Ver 3.2 ... MotionBASIC Versions have different drive names.
FILES "D:\*.*" FILES "1:\*.*" ... Display files stored in root dir on RIGHT PC Card™.
FILES "E:\*.*" FILES "2:\*.*" ... Display files stored in root dir on LEFT PC Card™.
.MTP .BAS ... Filename extension (.ext ) for below function.
AUTOLOAD.ext ..... File name which is designated to automatically load into the control-
ler from the left PC Card™ on power up. Filename allowed in the left PC Card™ slot ONLY.
PB1LOAD.ext ........ File loaded into the controller from the PC Card™ if the PB1 button
is held pressed during power up. PB1LOAD.ext in the left PC Card™ will always
OVERWRITE an existing PB1LOAD.ext on the System Card located in the right slot.
Serial Ports D=MotionPRO™ Development, 1= SRL1, 2=SRL2
WARNING: DO NOT connect the MotionPRO™ communications cable to J2 or J3
serial ports. This can cause damage to the ORION serial port or your computer port.
Sending Serial ... Yellow .... Transmitting a character on serial port.
Receiving Serial ... Yellow .... Receiving a character on serial port.
OK to Transmit .... Green .... Handshake from other devices has been established.
Ready to Receive ...Green .... Handshake from ORION.
E-Stop - (TB8 E-Stop) ORION controllers include an E-Stop monitor input, which
is indicated by a green "E-Stop OK" LED above. For normal operation, Emergency Stop
input power (+12 to +24VDC or 12 to 24VAC, referenced to TB8-RTN) is applied to TB8
E-Stop input. It is recommended that the input be interlocked with the servodrive main
power auxiliary contact. Should that current be interrupted, the "E-Stop OK" LED will go
off, causing a controller fault error. Error #1910: "E-Stop OK" Input Open.
No Fault-INTERLOCK (TB8 - No Fault, pins 4&5) ORION controllers have a "No
Fault relay", located on the system module. This relay is an isolated "normally-open"
output contact. As long as there are No Fault conditions in the controller (LED is ON), the
relay will be energized, holding the output contact closed. The power to the No Fault relay
is also hardware interlocked with both the E-Stop monitor input and Watchdog circuitry.
It is recommended that the No Fault relay be interlocked in series with the main contactor
coil. To reenergize this relay after a fault, "E-Stop OK" and "No Fault" LED's must be ON.
The "No Fault" LED is only an indicator and tells you the contact SHOULD be closed.