Parker 6250 User manual

Compumotor Division
Parker Hannifin Corporation
p/n 88-013413-01B October 18, 1993
6250 Servo Controller
User Guide

To ensure that the equipment described in this user guide, as well as all the equipment connected to and used with it, operates
satisfactorily and safely, all applicable local and national codes that apply to installing and operating the equipment must be
followed. Since codes can vary geographically and can change with time, it is the user's responsibility to identify and comply with
the applicable standards and codes. WARNING:
Failure to comply with applicable codes and standards can result in
damage to equipment and/or serious injury to personnel.
Personnel who are to install and operate the equipment should study this user guide and all referenced documentation prior to
installation and/or operation of the equipment.
In no event will the provider of the equipment be liable for any incidental, consequential, or special damages of any kind or nature
whatsoever, including but not limited to lost profits arising from or in any way connected with the use of this user guide or the
equipment.
© Compumotor Division of Parker Hannifin Corporation, 1993
— All Rights Reserved —
The information in this user guide, including any apparatus, methods, techniques, and concepts described herein, are the
proprietary property of Parker Compumotor or its licensors, and may not be copied, disclosed, or used for any purpose not expressly
authorized by the owner thereof.
Since Parker Compumotor constantly strives to improve all of its products, we reserve the right to change this user guide and
equipment mentioned therein at any time without notice.
Compumotor
For assistance in the United States, contact:
Compumotor Division of Parker Hannifin
5500 Business Park Drive
Rohnert Park, CA 94928
Telephone: [phone]
Fax: [phone]
Important User Information
For assistance in Europe, contact:
Parker Digiplan
21 Balena Close
Poole, Dorset
England BH17 7DX
Telephone: [phone]
Fax: [phone]

6250 Servo Controller User Guide
Revision B Change Summary
The following is a summary of the primary technical changes to this user guide since the last version was released.
This user guide, p/n 88-013413-01B(released on October 18, 1993), supersedes 88-013413-01A.
Topic Description See Also
6250-ANI Analog Input Option
is Released New Option/Feature: The 6250-ANI option was released at the same time this user guide revision B was released. The -ANI option is a ±10V, 14-
bit analog input (with anti-aliasing filter) that is sampled at the servo update
rate (set with the SSFR command). One ANI input terminal is located on each
DRIVE connector. The input value can be transferred to the terminal with the
TANI command, or used in a assignment or comparison operation using the
[ANI] command (e.g., VAR1=1ANI). The TANI and [ANI] commands are
used only by the -ANI option, not the standard 6250.
Pg. 16, 54 &
68
Analog Voltage Override New Feature (see Program Debugging below) Pg. 67 & 95
Continuous Mode Clarification: While in the continuous mode (MC1), one of the factors that
can stop motion is if the load trips a switch for a general-purpose input that is
configured as a Kill input (INFNCi-C) or a Stop input (INFNCi-D).
Pg. 53
Drive Fault Monitoring Clarification: You must enable the input functions with the INFEN1
command before the drive fault input will be recognized. Also, be sure to set
the drive fault level (DRFLVL) appropriately for the drive you are using.
Pg. 19, 58 &
102
Encoders Clarification: The Compumotor E Series incremental encoders all have
the same cable color codes. Pg. 12 & 103
Error Handling Clarification: When an error occurs, the controller will GOTO or GOSUB,
depending on the error condition (an error resolution table is provided). Pg. 98
Homing Clarification: After the homing operation is successfully completed, the
absolute position register is reset to zero. Pg. 49
Inputs:
Debounce Time New Feature: The INDEB command has been included to allow you to set the debounce time for the 24 general-purpose programmable inputs and the 2
trigger inputs. The range is 1 - 250 ms, in even increments. The default
debounce time is 4 ms for the 24 inputs, and 25 ms for the trigger inputs.
Pg. 58 & 61
Power Input (AC) Correction: The power connection drawing was misleading by stating the
AC input power range was 100 - 120VAC; it is actually 85 - 240VAC. Pg. 5
Program & Command Buffer
Execution Control Clarifications:
Deceleration after a stop input or command—In all variations of the COMEXS
mode, upon receiving a stop input or stop command,
motion will decelerate at
the preset AD/ADA value
.
Resuming after a stop or pause—In the COMEXR1 & COMEXS1 modes, you can
resume program execution and/or motion with a !C command or the pause/
resume input (INFNCi-E)
only after the move in progress is completed .
Pg. 86
Pg. 60-61 &
86-87
Program Debugging New Features & Clarifications:
Simulating Analog Input Voltages: (new feature) A new feature called
Analog Voltage Override (enabled with the ANVOEN command and
programmed with the ANVO command) allows you to simulate a voltage on the
analog input channels (input channels 1 - 3 on the JOYSTICK connector).
Programming Error Messages: (clarification) The 6200 can display error
messages and/or a error prompt (?), depending on which error level is
selected with the ERRLVL command. The default error level (ERRLVL4)
displays both the message and the error prompt).
Identifying Bad Commands: (new feature) When the 6200 detects an error
with a command, you can issue the TCMDER command to find out which
command caused the error. This is especially useful when downloading a
program.
Pg. 67 & 95
Pg. 97
Pg. 97
Program Flow Control New Feature: The JUMP command was added to allow an unconditional
branch to another program and not return. The reason program control does
not return is because all nested IF, WHILE and REPEAT statements, loops,
and subroutines are cleared.
Pg. 88

6250 User Guide Change Summary (continued)
Programming:
Troubleshooting problems Clarification: In Chapter 7, three resolutions were added to resolve the following problem situations:
• Start-up program (STARTP) will not run on power up
• Program execution stops at the INFEN1 command
• First time a program is run, the move distances are incorrect, but after
downloading the program a second time the move distances are correct.
Pg. 108-109
RMAs Clarification: If you need to return a Compumotor product to affect
repairs or upgrades, be sure to ship it to Suite D at the Rohnert Park
address.
Pg. 110
RP240 New Features and Clarifications:
Data Read Immediate Mode: (new feature) The DREADI1 command allows
continual input from the RP240 numeric keypad or the function keys (when
used in conjunction with DREAD and/or DREADF). Standard RP240 menus
should not be used in this mode. Data can be read into numeric variables
only. Do not assign the same variable to read numeric
and function key data.
Power-up (default) Mode: (clarification) On power up, the 6200 defaults to a
mode in which it controls the RP240 with the menu-driven functions listed on
page 50. To disable this menu, the power-up program (STARTP) must contain
the DCLEARØ command.
Pg. 91
Pg. 70
Software Revision 1.1
Released This version of the user guide was released at the same time that revision
1.1 of the 6250 software was released. n/a
Variable Type Conversion New Feature: The VCVT( ) command has been added to allow you to
convert between variables (numeric-to-binary and binary-to-numeric). Pg. 73

TABLE OF CONTENTS
Overview...........................................................................................................iii
Assumptions.................................................................................................................................iii
Contents of This User Guide.............................................................................................................iii
Installation Process Overview..........................................................................................................iv
Conventions.................................................................................................................................iv
Chapter 1: Introduction.......................................................................................1
6250 Description............................................................................................................................1
6250 Features...............................................................................................................................2
Chapter 2: Getting Started...................................................................................3
Inspect The Shipment.....................................................................................................................3
Bench Test...................................................................................................................................4
➀RS-232C Communications...............................................................................................4
➁Connect Power Cable .....................................................................................................5
➂Test Procedure .............................................................................................................5
Chapter 3: Installation........................................................................................7
Installation Precautions..................................................................................................................7
➀Mount the 6250 .........................................................................................................................8
➁System Connections..................................................................................................................9
Motor Driver Connections ....................................................................................................9
End-of-Travel Limit Connections ...........................................................................................11
Home Limit Connections......................................................................................................11
Encoder Connections .........................................................................................................12
Auxiliary +5V Output Connection...........................................................................................12
Output and Input Pull-up Connections....................................................................................12
Enable Input Connection .....................................................................................................13
Programmable Inputs & Outputs Connections..........................................................................13
Trigger Input Connections....................................................................................................14
RP240 Front Panel Connections............................................................................................15
Joystick and Analog Input Connections..................................................................................15
ANI Analog Input Connections (6250-ANI Option Only)..............................................................16
Extending 6250 System Cables ............................................................................................17
➂Installation Verification...............................................................................................................17
➃What's Next?............................................................................................................................19
Chapter 4: Servo Tuning......................................................................................21
Servo System Terminology ..............................................................................................................21
Servo Tuning Terminology....................................................................................................21
Position Variable Terminology...............................................................................................22
Servo Response Terminology...............................................................................................23
6000 Series Servo Commands..........................................................................................................25
Servo Control Techniques................................................................................................................26
Proportional Feedback Control (SGP).....................................................................................26
Integral Feedback Control (SGI)............................................................................................27
Velocity Feedback Control (SGV)..........................................................................................28
Velocity Feedforward Control (SGVF).....................................................................................28
Acceleration Feedforward Control (SGAF)...............................................................................28
Tuning Setup Procedure..................................................................................................................29
Drive Tuning Procedure (Velocity Drives Only).....................................................................................31
Controller Tuning Procedure.............................................................................................................32
Tuning Scenario.............................................................................................................................38
Target Zone (Move Completion Criteria) ..............................................................................................40

ii 6250 Servo Controller User Guide
Chapter 5: Basic 6250 Features.............................................................................43
Before You Proceed With This Chapter...............................................................................................43
6000 Series Software Reference Guide ..................................................................................43
Compumotor Bulletin Board Service.......................................................................................44
Basic Motion Control Concepts.............................................................................................44
Support Software...........................................................................................................................44
6000 DOS Support Disk.......................................................................................................44
Motion Architect®..............................................................................................................44
6250 Safety Features .....................................................................................................................45
Scaling ........................................................................................................................................46
Acceleration & Deceleration Scaling (SCLA/PSCLA) .................................................................46
Velocity Scaling (SCLV/PSCLV)............................................................................................46
Distance Scaling (SCLD) .....................................................................................................47
End-of-Travel Limits .......................................................................................................................48
Homing ........................................................................................................................................48
Positioning Modes..........................................................................................................................51
Preset Mode .....................................................................................................................52
Continuous Mode...............................................................................................................53
User Interface Options....................................................................................................................54
Programmable Inputs and Outputs ....................................................................................................55
Output Functions...............................................................................................................55
Input Functions .................................................................................................................58
Thumbwheel Interface.........................................................................................................63
PLC Interface....................................................................................................................65
Joystick Interface..........................................................................................................................65
-ANI 14-Bit Analog Input Option (6250-ANI Option Only)........................................................................68
RP240 Front Panel Interface ............................................................................................................68
Operator Interface Features.................................................................................................69
Using the Default Mode .......................................................................................................70
Host Computer Operation ................................................................................................................72
Variables (Binary, Numeric, and String) ..............................................................................................73
RS-232C Daisy-Chaining .................................................................................................................76
Chapter 6: Advanced 6250 Features........................................................................ 79
S-Curve Profiling............................................................................................................................79
X-Y Linear Interpolation...................................................................................................................81
Chapter 7: 6250 Programming Tips..........................................................................83
Creating Programs & Subroutines......................................................................................................83
Subroutines......................................................................................................................84
Stored Programs and Non-volatile Memory..............................................................................84
Automatic Program Execution ..............................................................................................85
Controlling Execution of Programs and the Command Buffer...................................................................85
Program Flow Control......................................................................................................................87
Unconditional Looping and Branching.....................................................................................87
Conditional Looping and Branching........................................................................................89
Program Interrupts.........................................................................................................................92
Program Debug Tools......................................................................................................................93
Trace Mode.......................................................................................................................93
Single-Step Mode...............................................................................................................94
Simulating Analog Input Channel Voltages ..............................................................................95
Simulating I/O Activation.....................................................................................................95
Programming Error Responses .............................................................................................97
Error Handling ...............................................................................................................................98
Chapter 8: Hardware Reference .............................................................................101
General Specifications....................................................................................................................101
I/O Pin Outs & Circuit Drawings.........................................................................................................102
Optional DIP Switch Settings............................................................................................................105
Chapter 9: Troubleshooting ..................................................................................107
Troubleshooting.............................................................................................................................107
Common Problems & Solutions .............................................................................................108
RS-232C Troubleshooting................................................................................................................109
Returning the System .....................................................................................................................110
Appendix A: Reducing Electrical Noise .....................................................................111
Appendix B: Alphabetical Command List....................................................................113
Appendix C: Index .............................................................................................. 117

Overview iii
O V E R V I E W
This user guide is designed to help you install, develop, and maintain your system. This
section is intended to help you find and use the information in this user guide.
Assumptions
To effectively use this user guide to install, develop, and maintain your system, you should
have a fundamental understanding of the following:
❏Basic electronics concepts (voltage, switches, current, etc.)
❏Basic motion control concepts (torque, velocity, distance, force, etc.)
❏Basic programming skills (any high-level language such as BASIC, Fortran, or Pascal)
Contents of This User Guide
Chapter Purpose
➀ Introduction Describes the 6250 and provides a brief account of its features.
➁ Getting Started Lists and describes the items you should have received with your
6250 shipment. A
bench test procedure is provided to verify the
system's basic functionality.
➂ Installation Provides instructions for mounting, wiring up, and testing the
6250 system. Complete all instructions in Chapter 3 before
tuning the 6250 in Chapter 4. Refer to the
6000 Series
Software Reference Guide for detailed descriptions of the
6000 Series commands used in Chapters 4 through 7.
➃ Servo Tuning Instructs you on how to tune the 6250 for your application.
Sample applications are provided. Complete all tuning
instructions before implementing motion features.
➄ Basic 6250 Features Describes the 6250's basic user features and instructs you on
how to implement them in your application. Sample applications
are provided.
➅ Advanced 6250 Features Describes the 6250's advanced user features (S-Curve Profiling,
Linear Interpolation) and instructs you on how to implement them
in your application. Sample applications are provided.
➆ Programming Tips Instructs you on how to implement the 6250's programming
language in your application.
➇ Hardware Reference Use the Hardware Reference as a quick-reference tool for 6250
electrical specifications, optional DIP switch settings (address &
baud rate), and I/O signal descriptions and circuit drawings.
➈ Troubleshooting Describes methods for isolating and resolving hardware and
software problems.
Appendices A: Reducing electrical noise in your application
B: Alphabetical listing of the 6250's commands
C: Index

iv 6250 Servo Controller User Guide
Installation Process Overview
➀Review this entire user guide. Become familiar with the user guide's contents so that you can
quickly find the information you need. At times you may want to refer to the 6000 Series
Software Reference Guide for detailed descriptions of the 6000 Series commands used in
this user guide.
➁Read Chapter 1, Introduction, and the user documentation for all peripheral system components
to develop a basic understanding of all system components, their functions, and
interrelationships.
➂Read Chapter 2, Bench Test, and verify that you have received all the proper components for
your system, and that all the items in your shipment have arrived without damage. Follow the
step-by-step bench test procedures to verify the 6250's basic operability, as well as the
functionality of the host computer (or terminal).
➃Complete the system configuration, mounting, and wiring instructions provided in Chapter 3,
Installation. Do not deviate from the sequence or installation methods
provided.
➄While in Chapter 3, be sure to use the Installation Verification procedures to check all the
system functions and features to ensure that you have completed the installation process
correctly.
➅After you successfully complete all procedures in Chapter 3, you will be ready to proceed to
Chapter 4, Servo Tuning, to tune the drive and the 6250 for your application. The tuning
procedures in Chapter 4 are based primarily on using the Servo Tuner option for Motion
Architect.
➆After successfully completing all procedures in Chapter 4, you may proceed to Chapters 5
through 7 to implement the 6250's user features in your application.
Conventions
Clockwise (CW, +) & Counter-clockwise (CCW, -) Directions
Clockwise
(CW, +) Counter-clockwise (CCW, -)
Throughout this user guide and the 6000 Series Software Reference Guide, you will
find references to the clockwise (CW) and counter-clockwise (CCW) direction of motion. The
CW or CCW direction is determined either by the direction the motor shaft (see illustration at
left), or by the sign (+ or -) of the commanded position (e.g., the D+8ØØØ distance command
indicates a 8,000-unit move in the clockwise direction). This convention is accurate only if
you connect the drive and encoder as described in Chapter 3.
6000 Series Commands
The command language conventions are provided in the 6000 Series Software
Reference Guide. Because some 6000 Series products have four-axis capability, the syntax
of the example commands in the Reference Guide shows data fields for all four axes; ignore
the third and fourth data fields when entering commands or reading status commands for the
6250.
Related Publications
❏6000 Series Software Reference Guide, Parker Hannifin Corporation, Compumotor
Division; part number 88-012966-01
❏Motion Architect User Guide,Parker Hannifin Corporation, Compumotor Division; part
number 88-013056-01
❏Current Parker Compumotor Motion Control Catalog
❏Schram, Peter (editor). The National Electric Code Handbook (Third Edition). Quincy, MA:
National Fire Protection Association

➀ Introduction 1
C H A P T E R ➀
Introduction
This chapter describes the 6250's basic functions & features.
6250 Description
The Compumotor 6250 is a stand-alone, two-axis servo controller. The 6250 provides
sophisticated two-axis control of any standard ±10V analog input servo drive system.
The 6250 implements a dual processor approach, comprising a microprocessor for executing
high-level motion programs and a digital signal processor (DSP) for high-speed, sophisticated
servo control. This dual processor approach allows commands to be executed faster.
Using the 6000 Series Programming Language, you can program the 6250 via a PC or a
dumb terminal. User programs are stored in the 6250's battery-backed RAM.
The 6250 also provides operator interface capabilities when used with the Compumotor
RP240 Front Panel.
The 6250 comes standard with support software for the Microsoft®Windows™ and DOS
operating environments:
❏Motion Architect®is an innovative, easy-to-use Microsoft®Windows™ based programming
aide to help you easily create and implement complex motion programs. The Servo Tuner
option, a special add-on module sold separately, allows you to visually gather data and tune
your controller/drive system. For more information, refer to the Motion Architect User
Guide.
❏The 6000 DOS Support Disk contains a DOS-based program editor and terminal emulator package.
Also included are sample 6000 Command Language programs.
Additional 6250 features are listed below in the 6250 Features section.

2 6250 Servo Controller User Guide
System Hardware Block Diagram
Joystick Interface
Motor #1
Drive #1
Up to 2 Axes of control
RS-232C
Interface
6250
Computer
or
Dumb Terminal
Operating System
------------
Microprocessor
68000 - 12MHz
Battery-backed
RAM
for
user programs
- CW & CCW End-of-travel
- Home
Limits
Motion
Chip
Axis #1
Motion
Chip
Axis #2
Front Panel
Interface
Limit
Connections
- ±10V Analog Output
- Shutdown Output
- Drive Fault Input
- Enable Input
- 2 Positon Latch Inputs
- 24 Prog. Inputs
- 24 Prog. Outputs
- 2 Auxiliary Prog. Outputs
Drive Interface
I/O
RP240
Front Panel
Motor #2
Drive #2
Encoder
#1
Encoder
#2
I/O
Connections
Joystick
- Inc. Encoder Interface
- Position Latch
- Output on Position
Dual Port RAM
DSP
6250-ANI
Option
Optional ±10V,
14-bit Analog Input
6250 Features
❏1 to 2 axes of optically isolated —10V analog interface servo control
❏Servo feedback from incremental encoders. Analog feedback available with the
6250-ANI option.
❏Controls servo drives in the velocity or torque mode
❏Fast digital signal processor (DSP) for sophisticated servo control (digital
Proportional, Integral, and Velocity feedback, plus acceleration and velocity
Feedforward—PIV&F)
❏S-curve motion profiling
❏Motion Architect®is standard
❏Teach Mode
❏Windows™-based visual data gathering and tuning aide available when using
the Motion Architect®Servo Tuner option
❏DOS Support Disk provided
❏40,000 bytes of non-volatile memory for storing programs & paths
❏Capability to interrupt program execution on error conditions
❏2-axis linear interpolation standard
❏Variable storage, conditional branching, and math capability
❏Program debug tools — single-step and trace modes, breakpoints, and
simulation of I/O
❏Internal power supply
❏Direct interface to RP240 Front Panel
❏Operates stand-alone or interfaces to PCs & PLCs
❏3-wire, RS-232C interface to PC or dumb terminal
❏1.2 MHz pre-quadrature encoder feedback pulse frequency
❏I/O capabilities (all I/O are isolated):
•±10V analog control output (both axes )
• Shutdown output (both axes)
• Drive Fault input (both axes)
• Incremental encoder input (both axes)
• CW & CCW end-of-travel limit inputs (both axes)
• Home limit input (both axes)
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD-
CMD+
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD-
CMD+
DRIVE 1
DRIVE 2 ENCODER 2
+5V
A+
A-
B+
B-
Z+
Z-
GND
SHLD
AUX
ENCODER 1
+5V
A+
A-
B+
B-
Z+
Z-
GND
SHLD 2-AXIS SERVO
CONTROLLER
STATUS
Compumotor
Rx
Tx
GND
SHLD
+5V
OUT-P
IN-P
RP240
POWER
6250
P
R
O
G
R
A
M
M
A
B
L
E
I
N
P
U
T
S
P
R
O
G
R
A
M
M
A
B
L
E
O
U
T
P
U
T
S
J
O
Y
S
T
I
C
K
+5V
GND
Rx
Tx
SHLD
EARTH N/A
NEUT LINE
GRN
RED
: READY
: RESET
1CW
1CCW
1HOM
GND
2CW
2CCW
2HOM
GND
SHLD
LIM 1/2
DRIVE1 OFF
DRIVE2 OFF
TRG-A
TRG-B
GND
OUT-A
OUT-B
GND
ENBL
6250 Front Panel
• 3 8-bit analog inputs for joystick control and variable input
• 2 (trigger) inputs — use for hardware position latch (±1 count accuracy)
• 24 programmable inputs (Opto-22™ compatible)
• 24 programmable outputs (Opto-22™ compatible)
• 2 auxiliary programmable outputs that can be configured for accurate output on position within ±1 count
❏6250-ANI Option offers two ±10V, 14-bit analog inputs (one per axis) with anti-aliasing filter.

➁ Getting Started 3
C H A P T E R ➁
Getting Started
The information in this chapter will enable you to:
❏Verify that each component of your 6250 system has been delivered safely and configured
properly
❏Bench test the 6250's power and RS-232C interface to the host computer/terminal
Inspect The Shipment
If you need to return
any or all of the 6250
system components,
use the return
procedures in Chapter
9, Troubleshooting .
You should inspect your 6250 shipment upon receipt for obvious damage to its shipping
container. Report any damage to the shipping company as soon as possible. Parker
Compumotor cannot be held responsible for damage incurred in shipment. The items listed
below should be present and in good condition.
Part Part Number
6250 main unit (w/ship kit)
Ship kit: 6250 Servo Controller User Guide
6000 Series Software Reference Guide
Motion Architect®diskettes
Motion Architect Servo Tuner diskette (optional)
Motion Architect User Guide
DOS Support Disk
DOS Support Disk Quick Reference
8-foot AC power cord
6250 (or 6250-ANI, if so ordered *)
88-013413-01
88-012966-01
95-013070-01
95-013070-02
95-013714-01
88-013056-01
95-012266-01
88-013258-01
71-009039-01
* The 6250-ANI is an optional version of the 6250 which provides two ±10V, 14-bit analog inputs. If you ordered a
-ANI option, check the serial tag on the side of the 6250's chassis; it should say 6250-ANI.
Pre-Wired Connections
You should receive your 6250 with the following connections on the AUX connector prewired
(from the factory):
+5V supplies power to OUT-P and IN-P.
This provides power to the output and input pull-ups.
If this connection is broken, the 6250's
analog command output signal is held
to zero volts (independent of the DSP
and microprocessor).
AUX
Rx
Tx
GND
SHLD
+5V
OUT-P
IN-P
TRG-A
TRG-B
GND
OUT-A
OUT-B
GND
ENBL
❏Output and input pull-ups
(OUT-P and IN-P) connected
to the +5V power supply (+5V)
❏Enable input (ENBL)
connected to ground (GND)

4 6250 Servo Controller User Guide
Bench Test
This section leads you through step-by-step instructions to bench test your 6250 system.
This is a temporary (bench top) configuration; the permanent installation will be performed in
Chapter 3, Installation. In this section, you will complete the following tasks:
➀RS-232C Communications
➁Connect Power Cable
➂Test Procedure
➀RS-232C Communications
To communicate with the 6250, your computer or terminal must have an RS-232C serial
port.
The 6250 uses a three-wire implementation of standard EIA RS-232C signals.
Computer-to-
Terminal
Conversion
If you are using an IBM/compatible computer, you must use a terminal emulator software
package to communicate with the 6250. The 6250 comes standard with Motion Architect®
for Windows™ and the 6000 DOS Support Disk; both provide a terminal emulator and
program editor (refer to the Motion Architect User Guide or the 6000 DOS Support
Disk Quick Reference for installation and other user information). You may also use
communication programs such as Crosstalk™, PC-Talk™, and PROCOMM™.
Set
Communication
Parameters
Make sure your computer or terminal is set to the following communication parameters. You
can configure these parameters by using one of the terminal emulation software packages listed
above in Computer-to-Terminal Conversion. If you are using Motion Architect®or the 6000
DOS Support Disk, verify that the baud rate, data bit, parity, and stop bit parameters are set as
follows:
❏Baud Rate: 9600*
❏Data Bits: 8
❏Parity: None
❏Stop Bits: 1
❏Full Duplex
❏XON/XOFF: Enabled
* If your terminal is not capable of 9600 baud, use the 6250's auto-baud function to automatically
set the 6250's baud rate equal to the terminal's baud rate. Refer to Optional DIP Switch Settings
in Chapter 8 for instructions.
Terminal
Connections The Receive Data (Rx), Transmit Data (Tx), and Ground (GND) signals are on the 6250's AUX
connector (shown below). The ground (GND) connection on the connector is signal ground or
common as opposed to earth ground (SHLD).
NOTE
If you intend to daisy chain multiple 6250 servo controllers, do not attempt the daisy-chain
connections now. Daisy-chain instructions are provided in Chapter 5, Basic 6250 Features .
Tx
Rx
GND
Computer or
Terminal
(Serial Port)
AUX
Rx
Tx
GND
SHLD
+5V
OUT-P
IN-P
TRG-A
TRG-B
GND
OUT-A
OUT-B
GND
ENBL
Standard 25-Pin
COM Port Pin Outs:
Pin 2 = Transmit (Tx)
Pin 3 = Receive (Rx)
Pin 7 = Ground (GND)
Standard 9-Pin
COM Port Pin Outs:
Pin 3 = Transmit (Tx)
Pin 2 = Receive (Rx)
Pin 5 = Ground (GND)

➁ Getting Started 5
➁Connect Power Cable
The 6250 is shipped with an 8-foot power cable that is prewired and keyed. Attach the power
cable to the 6250's POWER connector as illustrated below.
WARNING
DO NOT APPLY POWER
TO THE 6250 UNTIL
INSTRUCTED TO DO SO
IN THE FOLLOWING
TEST PROCEDURE.
POWER
EARTH N/A
NEUT LINE
Compumotor
2-AXIS SERVO
CONTROLLER
85 - 240VAC
If you have a power source other than
85-240VAC, refer to Chapter 8 for
specifications on alternative input power.
Protective
Rubber
Boot
➂Test Procedure
Use the following procedure to test the 6250's power and RS-232C connections. In Chapter 3,
Installation, you will test the analog output, end-of-travel and home limits, encoders, RP240,
joystick, and programmable I/O.
➀Apply power to the 6250 by plugging the power cable into a grounded power source.
CAUTION
The earth ground connection must be made by plugging into a grounded receptacle
or by physically connecting the green wire to earth ground.
➁Watch the LEDs on the 6250. The STATUS LED should be green, indicating the 6250 is ready
for operation. The other two LEDs should be red because the drives are not yet enabled with the
DRIVE11 command.
If the STATUS LED is red, or if none of the LEDs illuminate, check your power source and cable
connections. If these connections seem correct, disconnect power and consult Chapter 9,
Troubleshooting.
➂If you are using the 6000 DOS Support Disk, go to the Set-up menu and move the cursor down
to CHECK OUT and press ENTER to automatically verify the communication interface to the
6250.
If the interface is not successful (Device not Ready message will flash on the screen), refer
to the RS-232C troubleshooting procedures in Chapter 9, Troubleshooting.
➃Initiate the terminal emulator in Motion Architect or in the 6000 DOS Support Disk (refer to
the Motion Architect User Guide or the 6000 DOS Support Disk Quick
Reference if necessary). You could also use your own terminal emulator package.
Press the RETURN key. The cursor should move down one or two lines each time you press the
RETURN key. If the cursor does not move as described, refer to the RS-232C troubleshooting
procedures in Chapter 9, Troubleshooting.

➂ Installation 7
C H A P T E R ➂
Installation
The information in this chapter will enable you to:
❏Mount all system components properly
❏Connect all inputs and outputs properly
❏Verify that the complete system is installed properly
To ensure proper installation, you should perform all the bench test procedures in Chapter 2,
Getting Started, before proceeding with the permanent installation process in this chapter.
Installation Precautions
To help ensure personal safety and long life of system components, pay special attention to
the following installation precautions.
WARNING
Always remove power to the 6250 before performing wiring installation or changing DIP switch
settings.
Heat & Humidity
Operate the 6250 system at an ambient temperature between 32°and 122°F (0°to 50°C). Keep
the relative humidity below 95%.
Electrical Noise
For more information
on electrical noise,
refer to Appendix A.
Minimize the potential for electrical noise before installing the 6250, rather than attempting to
solve such problems after installation. You can prevent electrical noise by observing the
following installation precautions:
❏Do not route high-voltage wires and low-level signals in the same conduit.
❏Ensure that all components are properly grounded.
❏Ensure that all wiring is properly shielded.

8 6250 Servo Controller User Guide
Airborne Contaminants
Contaminants that may come in contact with the 6250 should be carefully controlled.
Particulate contaminants, especially electrically conductive material such as metal shavings,
can damage the 6250.
Follow Installation Procedure
To ensure proper installation of the 6250 system, this chapter is organized in logical, linear
steps. Deviating from this prescribed format may result in system problems.
➀Mount the 6250 Servo Controller
➁Perform system connections
➂Perform the system test
➀Mount the 6250
The 6250 should be installed in an enclosure that will protect it from atmospheric
contaminants such as oil, metal, moisture, and dirt. Refer to the National Electrical
Manufacturers Association (NEMA) specifications that pertain to your particular operating
environment. The drawing below illustrates the 6250's dimensions.
4.20 (106.68)
2.70 (68.58) 0.75 (19.05)
10.80
(274.32)
10.00
(254.00)
Provision for #10
Mounting Screws
(4 Plcs.)
0.80 (20.32)
11.60
(294.64)
0.60 (15.25)
9.61 (244.10)
inches (millimeters)
Panel Layout
If you mount the 6250 in an enclosure with other equipment, be sure to maintain at least 2
inches of unrestricted air-flow space around the chassis. The maximum allowable ambient
temperature directly below the 6250 is 122°F (50°C). Fan cooling may be necessary if
adequate air flow is not provided.
➁System Connections

➂ Installation 9
This section describes procedures for the following 6250 system connections:
❏Motor Drivers
❏End-of-travel and home limits
❏Encoders
❏Auxiliary +5VDC output
❏Output pull-up (OUT-P)
❏Programmable inputs and outputs (including auxiliary outputs OUT-A and OUT-B)
❏Trigger inputs (TRG-A and TRG-B)
❏RP240 Front Panel
❏Joystick and analog inputs
❏ANI analog inputs (6250-ANI option only)
❏Extending cables
Refer to the bench test procedures in Chapter 2 for the following connections:
❏Power
❏RS-232C communications
Refer to Chapter 5 for connection procedures on the following:
❏PLC
❏Thumbwheels
❏RS-232C daisy-chain
NOTE
Refer to Chapter 8, Hardware Reference , for system specifications and detailed I/O circuit
drawings and signal descriptions.
Motor Driver Connections
Before you connect the drives to the 6250, configure your drives and connect the motors
according to the user documentation for your drives.
CAUTION
Before connecting to your Motor/Drive system, be sure that power is not applied to the 6250.
The 6250 provides a standard ±10V analog control signal for use with any servo drive. The
following table lists the 6250's motor driver connector pin outs; with this information you
can connect the drives to the 6250's 9-pin screw terminal connectors as illustrated below. I/O
circuit drawings are provided in Chapter 8, Hardware Reference.
Pin # Name In/Out Description
1 SHLD ----- Shield—internally connect to chassis (earth) ground.
2 COM ----- Signal common for shutdown.
3 SHTNC OUT Shutdown relay output to drives that require a closed contact to disable the drive.
The shutdown relay is active (disabling the drive) when no power is applied to
the 6250. When the 6250 is powered up, the shutdown relay remains active until
you issue the DRIVE11 command.
Shutdown active (DRIVEØØ): this output is internally connected to COM.
Shutdown inactive (DRIVE11): this output is disconnected from COM.
4 SHTNO OUT Shutdown relay output to drives that require an open contact to disable the drive.
The shutdown relay is active (disabling the drive) when no power is applied to
the 6250. When the 6250 is powered up, the shutdown relay remains active until
you issue the DRIVE11 command.
Shutdown active (DRIVEØØ): this output is disconnected from COM.
Shutdown inactive (DRIVE11): this output is internally connected to COM.
5 DFT IN Drive fault input. Set active level with the DRFLVL command.
6 AGND ----- Analog ground.
7 ANI IN ±10V, 14-Bit analog input (available only with the 6250-ANI option).
8 CMD- OUT Command signal return.
9 CMD+ OUT Command output signal (±10V signal).

10 6250 Servo Controller User Guide
<<WARNING>> SAFETY FIRST <<WARNING>>
If your drive does not have a shutdown input, install a manual emergency-stop switch for the drive's power supply.
Connections to Compumotor and Digiplan Servo Drives
6250
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD-
CMD+
ENCODER 1DRIVE 1
APEX Series
Drive
Reset
Gnd
Vel Int Enable
Enable In
Fault Out
Gnd
Command+
Command–
Tach Output
Gnd
+15V
Gnd
-15V
CHA+
CHA–
CHB+
CHB–
CHZ+
CHZ–
Gnd
+5V
A+
A–
B+
B–
Z+
Z–
GND
SHLD
APEX Series Drive
A+ (pin 13)
A– (pin 14)
SRVON (pin 23)
Voc (pin 24)
B+ (pin 29)
B– (pin 30)
Z+ (pin 43)
Z– (pin 44)
VIN (pin 49)
AGND (pin 50)
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
6250
A–
A+
SHTNO
+5V
B+
B–
Z+
Z–
CMD+
CMD–
NOTE:
Apex Series A+ connected to 6250’s A–
Apex Series A– connected to 6250’s A+
1
815
6250
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD–
CMD+
DRIVE 1
BL Drive
User I/O Connector ENCODER 1
+5V
A+
A–
B+
B–
Z+
Z–
GND
SHLD
9
NOTE: These connections will work only if
BL jumper LK2 is set to position B
(not the factory default position).
BL Drive
V2 (pin 1)
V1 (pin 2)
GND (pin 4)
RST (pin 5)
+15V (pin 6)
FT (pin 9)
AOP (pin 10)
AOP (pin 11)
BOP (pin 12)
BOP (pin 13)
ZOP (pin 14)
ZOP (pin 15)
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
6250
CMD–
CMD+
GND
COM
SHTNO
DFT
A–
A+
B+
B–
Z+
Z–

➂ Installation 11
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD-
CMD+
DRIVE 1 ENCODER 1
+5V
A+
A-
B+
B-
Z+
Z-
GND
SHLD
Dynaserv Drive
DN1
(50-pin Honda Connector)
1
18
19
33
50
6250
Dynaserv Drive
A+ (pin 13)
A– (pin 14)
SRVON (pin 23)
Voc (pin 24)
B+ (pin 29)
B– (pin 30)
Z+ (pin 43)
Z– (pin 44)
VIN (pin 49)
AGND (pin 50)
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
6250
A–
A+
SHTNO
+5V
B+
B–
Z+
Z–
CMD+
CMD–
NOTE:
Dynaserv A+ connected to 6250’s A–
Dynaserv A– connected to 6250’s A+
6250
OEM670
Drive
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD–
CMD+
DRIVE 1
1
13 25
14
OEM670 Drive
CMD+ (pin 1)
CMD– (pin 2)
FAULT (pin 9)
ENABLE (pin 10)
GND (pin 11)
GND (pin 16)
↔
↔
↔
↔
↔
↔
6250
CMD+
CMD–
DFT
SHTNO
COM
AGND
6250
PLB1
UD2 & UD5 Drives
(UR3, UR4 or UR8 Rack)
G1
G2
VEL2
VEL1
SCREEN
0V
FAULT
EXT.DIS
LSW1
LSW2
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD–
CMD+
DRIVE 1
18V AC
0V
18V AC
+15V
0V
–15V
0V
RESET
READY
PSU FAULT
PL9 1
UD2 & UD5 Drives
+15V, LSW1 & LSW2
VEL2
VEL1
0V
FAULT
EXT.DIS
↔
↔
↔
↔
↔
↔
6250
SHTNO
CMD–
CMD+
AGND
DFT
COM
NOTE: These connections will
work only if UD2/5 jumper LK1 is
set to the 0V position (not the
factory default position). If a drive fault occurs, you must cycle power to the drives, unless you control RESET
(PL9 pin 8 on UR4 & UR8 racks, PL4 pin 8 on UR3 rack) with one of the 6250’s
general-purpose outputs. For additional instructions on detecting and reacting to UD
rack faults, contact the Compumotor or Digiplan Applications Department.

12 6250 Servo Controller User Guide
6250
18V AC
0V
18V AC
+15V
0V
–15V
0V
RESET
READY
PSU FAULT
UD12 Drive
(UR4 Rack)
G1
G2
VEL2
VEL1
SCREEN
0V
FAULT
EXT.DIS
LSW1
LSW2
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD–
CMD+
DRIVE 1
11
PLnC
PL9A
UD12 Drive
+15V, LSW & LSW2
VEL2
VEL1
0V
FAULT
EXT.DIS
↔
↔
↔
↔
↔
↔
6250
SHTNO
CMD–
CMD+
AGND
DFT
SHLD
If a drive fault occurs, you must cycle power to the drives, unless you control RESET
(pin 8 on the PL9 connector) with one of the 6250's general-purpose outputs.
For additional instructions on detecting and reacting to UD rack faults, contact the
Compumotor or Digiplan Applications Department.
NOTE: These connections will
work only if UD12 jumper LK3 is
set to position A (not the factory
default position).
6250
SHLD
COM
SHTNC
SHTNO
DFT
AGND
ANI
CMD-
CMD+
ENCODER 1DRIVE 1
Z Drive
+5V
A+
A–
B+
B–
Z+
Z–
GND
SHLD
1
13 25
14
ENABLE+
ENABLE–
RTI+
RTI–
RTO+
RTO–
GND
Tx
Rx
GND
CHA+
CHA–
CHB+
CHB–
CHZ+
CHZ–
ANALOG+
ANALOG–
I/O [1]
INDEXER CONNECTOR
To 6250 Logic Gnd
To 6250 Programmable Output
Pin #7 and #19 are FAULT RESET+ and FAULT
RESET– respectively. These connections are required
if you need to clear a drive fault via the 6250. Activate
the output for no longer than 140ms. If you choose not
to make these connections, you will have to manually
reset the Z Drive anytime a drive fault occurs.
Z Drive
ENABLE+
ENABLE–
GND
GND
CHA+
CHA–
CHB+
CHB–
CHZ+
CHZ–
ANALOG+
ANALOG–
Indexer Connector
DRIVE FAULT (pin 9)
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
↔
6250
SHTNO
COM
AGND
GND
A–
A+
B+
B–
Z+
Z–
CMD+
CMD–
DFT
NOTE:
Z Drive CHA+ connected to 6250’s A–
Z Drive CHA– connected to 6250’s A+

➂ Installation 13
End-of-Travel Limit Connections
The 6250 provides CCW and CW end-of-travel limit inputs for both axes via the LIM 1/2
connector. End-of-travel inputs serve as safety stops that prevent the load from crashing into
mechanical stops and damaging equipment or injuring personnel. The drawing below
illustrates typical end-of-travel limit switch connections.
Normally-closed switches*
End-of-Travel Limits
* LHLVL command changes
active level of switches
1CW
1CCW
1HOM
GND
2CW
2CCW
2HOM
GND
SHLD
LIM 1/2 NOTE
Motion will not occur until you do one of the following:
❏Install limit switches
❏Disable the limits with the LH command
❏Change the active level of the limits with the
LHLVL command
Use of hardware
(and software) end-
of-travel limits is
discussed in detail in
the End-of-Travel
Limits section in
Chapter 5.
Mount normally-closed switches such that the load forces them to open before it reaches the
physical travel limit (leave enough room for the load to stop). When the load opens
the limit switch, the motor comes to a halt. The actual stopping distance depends on motor
speed and the Hard Limit Deceleration (LHADA and/or LHAD) setting. The motor will not be
able to move in that same direction until you clear the limit (close the switch) and execute a
move in the opposite direction (or you can disable the limits with the LH command, but this
is recommended only if the motor is not coupled to the load). Use the TLIM or TAS
commands to check the status of the limit switches.
<< CAUTION >> RUNAWAY << CAUTION >>
If a runaway occurs (motor starts moving, usually at the fastest possible velocity, due to servo
instability), the 6250 will shut down the drive if the maximum encoder position error (set with the
SMPER command) is exceeded before an end-of-travel limit (either hardware of software) is
encountered. However, if the maximum encoder position error is not exceeded by the time the
limit is encountered, the 6250 may not be able to stop the motor.
Home Limit Connections
Use the Home input to establish a home position or zero position reference point. The home
input (TTL compatible) is used for homing the motor. The encoder's Z channel pulse can be
used in conjunction with the home switch to determine the home position. To use the
encoder's Z channel, the HOMZ command must be enabled.
Homing is discussed
in detail in the
Homing section in
Chapter 5.
The 6250 is shipped configured for use with normally-open home switches. You can, if you
wish, reverse the home input polarity (to use normally-closed switches) with the HOMLVL
command. The most common way to use the home switch is to mount it at a home reference
position. The drawing below illustrates typical home limit switch connections to the 6250.
1CW
1CCW
1HOM
GND
2CW
2CCW
2HOM
GND
SHLD
Normally-open switch*
Home Limit
* HOMLVL command changes
active level of switch
LIM 1/2 CAUTION
Compumotor cannot guarantee proper homing
performance with the home and end-of-travel limit
inputs tied together.