Parker ACR1505 Manual

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– ii –
User Information
Warning!
ACR Series products are used to control electrical and mechanical
components of motion control systems. You should test your motion system
for safety under all potential conditions. Failure to do so can result in damage
to equipment and/or serious injury to personnel.
ACR Series products and the information in this user guide are the proprietary property of Parker
Hannifin Corporation or its licensers, and may not be copied, disclosed, or used for any purpose
not expressly authorized by the owner thereof.
Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to
change this user guide and software and hardware mentioned therein at any time without notice.
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 the equipment or this user guide.
© 2003 Parker Hannifin Corporation
All Rights Reserved
Technical Assistance:Contact your local automation technology center (ATC) or distributor, or ...
North America and Asia
Parker Hannifin
5500 Business Park Drive
Rohnert Park, CA 94928
Telephone: [phone] or [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.parkermotion.com
Germany, Austria, Switzerland
Parker Hannifin
Postfach: 77607-1720
Robert-Bosch-Str. 22
D-77656 Offenburg
Telephone: [phone]
Fax: [phone]
Europe (non-German speaking)
Parker Hannifin
5500 Business Park Drive
Rohnert Park, CA 94928
Telephone: [phone] or [phone]
Fax: [phone]
E-mail: [email protected]
Internet: www.parkermotion.com
Italy
Parker Hannifin
20092 Cinisello Balsamo
Milan, Italy via Gounod, 1
Telephone: [phone]
Fax: [phone]
Technical Support E-mail
[e-mail]
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- iii -
Table of Contents
Important Information for Users ............................................................................................... viii
Change Summary ......................................................................................................................ix
Revision C Changes................................................................................................................ix
Revision B Changes................................................................................................................ix
Chapter 1 – Introduction............................................................................................................... 1
ACR1505 Products—Overview.................................................................................................. 2
ACR1505 Names..................................................................................................................... 3
Options..................................................................................................................................... 3
Compatible Parker Products ......................................................................................................3
Requirements............................................................................................................................. 4
Checking Your Shipment............................................................................................................ 5
Assumptions of Technical Experience ....................................................................................... 5
Technical Support ...................................................................................................................... 5
Chapter 2 – Hardware Configuration........................................................................................... 6
Overview—Configuring the Hardware........................................................................................ 7
Jumpers, Resistors, and Encoders............................................................................................ 7
Jumpers................................................................................................................................... 7
Resistor Packs......................................................................................................................... 8
Differential Encoders (Parker Drives and Encoders)............................................................... 8
Single-Ended Encoders (not recommended) ........................................................................ 10
Configuring the Voltage Jumpers and Resistor Packs.......................................................... 13
Encoder Input Connector (P1).................................................................................................. 14
Analog/Digital I/O—P2 Connector............................................................................................ 16
I/O Signal............................................................................................................................... 16
DAC Outputs.......................................................................................................................... 16
High Speed Outputs ..............................................................................................................16
Stepper Outputs..................................................................................................................... 16
P2 Connector......................................................................................................................... 16
Digital I/O—P3 & P4 Connectors ............................................................................................. 20
Input Signal............................................................................................................................ 20
Output Signal......................................................................................................................... 20
P3 Connector Pinout.............................................................................................................. 21
P4 Connector Pinout.............................................................................................................. 22
I/O Configuration Modes and the P3 Connector.................................................................... 23
I/O Configuration Modes and the P4 Connector.................................................................... 24
Address Jumper for Serial Communication.............................................................................. 25
Flash Bypass Mode...............................................................................................................25
Chapter 3 – Hardware Installation.............................................................................................. 26
Environment & Cooling............................................................................................................. 27
Weight ...................................................................................................................................... 27
Dimensions............................................................................................................................... 28
Connectors............................................................................................................................... 28
Hardware Installation................................................................................................................ 29
Precautions............................................................................................................................ 29
Installing the Hardware.......................................................................................................... 29
Installation Test ........................................................................................................................ 32
Chapter 4 – Troubleshooting...................................................................................................... 34
Troubleshooting Guidelines......................................................................................................35
First Troubleshooting Steps................................................................................................... 35
General Troubleshooting....................................................................................................... 36
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– iv –
Appendix A – Additional Specifications ................................................................................... 38
Hardware.................................................................................................................................. 39
Power Consumption................................................................................................................. 39
Encoder Inputs ......................................................................................................................... 39
Analog I/O................................................................................................................................. 40
I/O Signal............................................................................................................................... 40
DAC Outputs.......................................................................................................................... 40
Stepper Outputs..................................................................................................................... 40
Watchdog Signal.................................................................................................................... 40
Digital I/O.................................................................................................................................. 41
Input Signal............................................................................................................................ 41
Output Signal......................................................................................................................... 41
High Speed Outputs ..............................................................................................................41
P3 & P4 Connector Specification—ACR1505....................................................................... 42
P3 & P4 Connector Specification—Mating Connector.......................................................... 42
Cables ...................................................................................................................................... 42
Fuses........................................................................................................................................ 42
P1 Connector......................................................................................................................... 42
P2 Connector......................................................................................................................... 42
P3 & P4 Connector................................................................................................................ 42
Appendix B – Breakout Box.......................................................................................................44
Breakout Box Overview............................................................................................................ 45
Checking your Shipment........................................................................................................ 45
Cables—ACR1505 Controller to RBC1505........................................................................... 45
Environment & Cooling............................................................................................................. 46
Weight ...................................................................................................................................... 46
Breakout Box Dimensions........................................................................................................ 47
Breakout Box to User Interconnect .......................................................................................... 48
COM1/COM2 Serial Port Connector Pinouts ........................................................................ 48
Drive Enable and Drive Reset ............................................................................................... 49
Drive Faults............................................................................................................................ 49
Axis Connectors..................................................................................................................... 50
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- v -
Table of Tables
Table 1 Ship Kit Items................................................................................................................ 5
Table 2 Jumper (JP1) Configuration for Encoder Voltage......................................................... 7
Table 3 Jumper (JP2) Configuration for Encoder Voltage......................................................... 8
Table 4 Resistor Packs and Voltage Jumpers........................................................................... 8
Table 5 Resistor Pack and Voltage Jumper Configuration...................................................... 13
Table 6 P1 MOTOR FEEDBACK Connector Pinout....................................................................... 15
Table 7 P2 ANALOG I/O Connector Pinout ................................................................................ 19
Table 8 Logic Polarities and I/O States.................................................................................... 20
Table 9 DIGITAL I/O Connector Pinout....................................................................................... 21
Table 10 DIGITAL I/O Connector Pinout..................................................................................... 22
Table 11 P3 Connector Pinout and I/O Mode Configuration.................................................... 23
Table 12 P4 Connector Pinout and I/O Mode Configuration.................................................... 24
Table 13 JP3 Jumper Configuration—Assigning a Serial Communications Address.............. 25
Table 14 Controller Weight....................................................................................................... 27
Table 15 Troubleshooting—Causes and Solutions.................................................................. 37
Table 16 Ship kit for RBC1505................................................................................................. 45
Table 17 Breakout Box Weight................................................................................................. 46
Table 18 COM1 Serial Port Connector .................................................................................... 48
Table 19 COM2 Serial Port Connector .................................................................................... 48
Table 20 DIP Switch SW1........................................................................................................ 49
Table 21 DIP Switch SW3........................................................................................................ 50
Table 22 Axis Connector Pinout............................................................................................... 50
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– vi –
Table of Figures
Figure 1 Differential, Open Collector Encoder with internal pull-up resistors ............................ 9
Figure 2 Differential, Line Driver Encoder with internal termination resistors.......................... 10
Figure 3 Single-Ended Encoder with internal pull-up resistors................................................ 12
Figure 4 Single-Ended Encoder with external pull-up and pull-down resistors........................ 13
Figure 5 P1 ENCODER INPUT connector, male drive connector pinout ...................................... 14
Figure 6 P2 ANALOG I/Oconnector, male drive connector pinout.............................................. 16
Figure 7 P2 ANALOG I/Oconnector—internal circuit diagram.................................................... 17
Figure 8 P2 STEPPER I/Oconnector—internal circuit diagram................................................... 17
Figure 9 P2 HIGH-SPEED OUTPUT connector—internal circuit diagram..................................... 17
Figure 10 Watchdog Signal—internal circuit diagram.............................................................. 19
Figure 11 P3 DIGITAL I/O connector diagram............................................................................. 21
Figure 12 P4 DIGITAL I/O connector diagram............................................................................. 22
Figure 13 Dimensions .............................................................................................................. 28
Figure 14 Connector, Jumper, and Fuse Locations................................................................. 28
Figure 15 Breakout Box Dimensions........................................................................................ 47
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Chapter 1 – Introduction – vii –
Warning!
Risk of damage and/or personal injury
The ACR1505 Controller cards described in this guide only contain user-
serviceable fuses. Attempting to replace any other internal component may
result in damage to the unit and/or personal injury. This may also void the
warranty.
Symbols Description
Protective Earth Ground
Functional Earth (Ground) Terminal
Shield, Frame, or Chassis Terminal
Caution Risk of Electrical Shock
Caution, Refer to Accompanying Documentation
Warning!
Do not install the ACR1505 in an AT motherboard. Doing this will permanently
damage the controller card.
The ACR1505 is only compatible with ATX motherboards, which supply both
+3.3 VDC and +5 VDC to the PCI bus.
If you are not sure which type of motherboard is in your computer, consult the
technical manual for your computer or the manufacturer.
Warning!
Do not install the ACR1505 in a computer that uses an AT power supply.
Doing this will permanently damage the controller card.
The ACR1505 is only compatible with ATX power supplies, which provide
both +3.3 VDC and +5 VDC to the PCI bus.
If you are not sure which type of power supply is in your computer, consult the
technical manual for your computer or the manufacturer.
Warning!
Do not connect external power to the ACR1505 through the ACRCOMM card.
Doing this will permanently damage the ACR1505.
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– viii –
Important Information for Users
Important Information for Users
It is important that motion control equipment is installed and operated in such a way that
all applicable safety requirements are met. It is your responsibility as an installer to
ensure that you identify the relevant safety standards and comply with them; failure to
do so may result in damage to equipment and personal injury. In particular, you should
study the contents of this user guide carefully before installing or operating the
equipment.
The installation, set up, test, and maintenance procedures given in this User Guide
should only be carried out by competent personnel trained in the installation of
electronic equipment. Such personnel should be aware of the potential electrical and
mechanical hazards associated with mains-powered motion control equipment—please
see the safety warnings below. The individual or group having overall responsibility for
this equipment must ensure that operators are adequately trained.
Under no circumstances will the suppliers of the equipment be liable for any incidental,
consequential or special damages of any kind whatsoever, including but not limited to
lost profits arising from or in any way connected with the use of the equipment or this
guide.
Safety Warning!
High-performance motion control equipment is capable of producing rapid
movement and very high forces. Unexpected motion may occur especially during
the development of controller programs. KEEP WELL CLEAR of any machinery
driven by stepper or servo motors. Never touch any part of the equipment while it is
in operation.
This product is sold as a motion control component to be installed in a complete
system using good engineering practice. Care must be taken to ensure that the
product is installed and used in a safe manner according to local safety laws and
regulations. In particular, the product must be positioned such that no part is
accessible while power may be applied.
This and other information from Parker Hannifin Corporation, its subsidiaries, and
authorized distributors provides product or system options for further investigation
by users having technical expertise. Before you select or use any product or
system, it is important that you analyze all aspects of your application and review
the information concerning the product in the current product catalog. The user,
through its own analysis and testing, is solely responsible for making the final
selection of the system and components and assuring that all performance, safety,
and warning requirements of the application are met.
If the equipment is used in any manner that does not conform to the instructions
given in this user guide, then the protection provided by the equipment may be
impaired.
The information in this user guide, including any apparatus, methods, techniques, and
concepts described herein, are the proprietary property of Parker Hannifin or its
licensors, and may not be copied disclosed, or used for any purpose not expressly
authorized by the owner thereof.
Since Parker Hannifin constantly strives to improve all of its products, we reserve the
right to modify equipment and user guides without prior notice. No part of this user
guide may be reproduced in any form without the prior consent of Parker Hannifin.
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Chapter 1 – Introduction – ix –
Change Summary
Revision D Changes
This document, 88-021610-01D, supercedes 88-021610-1C. Changes
associated with ACR1505 User Guide revisions, and document clarifications
and corrections are as follows:
Topic Description
High Speed outputs Added specifications for High-Speed Outputs,
added to P2 Connector pinout.
Revision C Changes
This document, 88-021610-01C, supercedes 88-021610-1B. Changes
associated with ACR1505 User Guide revisions, and document clarifications
and corrections are as follows:
Topic Description
Specifications Added specification for vibration under section
titled Environment & Cooling.
Connectors Corrected connecter labels for Figure 14.
Revision B Changes
This document, 88-021610-01B, supercedes 88-021610-1A. Changes
associated with ACR1505 User Guide revisions, and document clarifications
and corrections are as follows:
Topic Description
Breakout Box Corrected part numbers under section titled
Checking your Shipment.
Breakout Box Corrected number of pins on the Digital I/O
headers. See Digital I/O Cables.
Breakout Box Corrected dimensions (reversed) in illustration.
See Breakout Box Dimensions.
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CHAPTER ONE
Introduction
Chapter 1 – Introduction
IN THIS CHAPTER
• ACR1505 Products—Overview.............................................................2
• Compatible Parker Products.................................................................3
• Requirements........................................................................................4
• Checking Your Shipment ......................................................................5
• Assumptions of Technical Experience..................................................5
• Technical Support.................................................................................5
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– 2 – ACR1505 User’s Guide
ACR1505 Products—Overview
The ACR1505 is a PC-bus based controller in the ACR family of high-
performance motion controllers. As a half-length 32-bit PCI card, the
ACR1505 can run up to four servo drives or stepper drives with up to four
encoders.
The 1505 controller has 16 fixed inputs, 16 fixed outputs, and an additional
16 configurable I/O points. In addition, the ACR1505 also provides an
expansion slot to accommodate the ACRCOMM module, which lets you add
serial communications to the ACR1505.
The ACR1505 transmits and receives data through its Dual Port Memory,
accessible on the PCI bus. The Windows™ Plug and Play interface
automatically configures the dual port memory address range.
Another feature lets users instruct a program on the ACR1505 to interrupt the
host computer through the PCI bus. This advanced feature lets users create
programs that signal the host computer to perform additional actions. (The
interrupt is automatically configured through the Windows™ Plug and Play
interface.)
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Chapter 2 – Hardware Configuration – 3 –
ACR1505 Names
The following helps explain the meaning of ACR1505 part numbers:
Controller Type........................................ACR1505
PC Bus....................................................PC = PCI Bus Card
Encoder Inputs........................................E0 = 0 Encoder Inputs
E4 = 4 Encoder Inputs
Motion Outputs........................................D4 00 = 4 Analog Outputs
with encoders
S4 00 = 4 Stepper Outputs
without encoders
S4 ENC = 4 Stepper Outputs
with Encoders
D2 S2 = 2 Analog Outputs &
2 Stepper Outputs
with encoders
Analog Inputs..........................................A0 = 0 Analog Inputs
A8 = 12-bit Analog Inputs
AA = 16-bit Analog Inputs
Digital I/O ................................................0 = 48 TTL Digital I/O
Expansion I/O..........................................0 = 0 Expansion I/O
1 = Add 64 Digital I/O
2 = Add 128 Digital I/O
3 = Add 192 Digital I/O
4 = Add 256 Digital I/O
Options For the latest additions, see our website at www.parkermotion.com
Compatible Parker Products
Drives......................................................Aries, Dynaserv G2, Gemini GT,
Gemini GV, E-AC/E-DC, OEM750,
OEM770T, and Zeta
Software..................................................AcroView
Motors.....................................................SE/SM Series, BE Series,
NeoMetric Series, J Series,
MaxPlus Rotary, MaxPlus Linear,
LXR Linear Series, SL Linear
Series, ILM Linear Series
1505
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– 4 – ACR1505 User’s Guide
Requirements
The ACR1505 is a PCI compatible motion controller card for your personal or
industrial computer.
Operating System...................................Windows 98SE, Windows NT 4.0,
Windows 2000, or Windows XP
Motherboard............................................ATX, with 32 bit PCI bus
version 2.1 or 2.2
Power Supply..........................................ATX
Processor................................................Pentium 200 MHz, minimum
Memory...................................................64 MB, minimum
Warning!
Do not install the ACR1505 in an AT motherboard. Doing this will permanently
damage the controller card.
The ACR1505 is only compatible with ATX motherboards, which supply both
+3.3 VDC and +5 VDC to the PCI bus.
If you are not sure which type of motherboard is in your computer, consult the
technical manual for your computer or the manufacturer.
Warning!
Do not install the ACR1505 in a computer that uses an AT power supply.
Doing this will permanently damage the controller card.
The ACR1505 is only compatible with ATX power supplies, which provide
both +3.3 VDC and +5 VDC to the PCI bus.
If you are not sure which type of power supply is in your computer, consult the
technical manual for your computer or the manufacturer.
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Chapter 2 – Hardware Configuration – 5 –
Checking Your Shipment
Inspect your shipment carefully. You should have received one or more of
the following:
Controller Ship Kit
Part Name Part Number
Strain Relief Connector XCN085
P2 Connector XCN086
ACR SDK Compact Disc 95-021500-01
Table 1 Ship Kit Items
Assumptions of Technical Experience
The ACR1505 is designed for industrial applications. To effectively install and
troubleshoot the ACR1505, you must have a fundamental understanding of
the following:
• Motion control applications
• Electromechanical actuators
• Electrical concepts such as voltage, current, switches, etc.
• Serial Communication (RS-232 or RS-422) depending on which
communications protocol you are using (applicable only if using the
ACRCOMM module).
Technical Support
For solutions to your questions about implementing the ACR1505, first refer
to this manual. If you cannot find the answer in this documentation, contact
your local Automation Technology Center (ATC) or distributor for assistance.
If you need to talk to our in-house Application Engineers, please contact us
at the telephone numbers listed on page ii.
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CHAPTER TWO
Hardware
Configuration
Chapter 2 – Hardware Configuration
IN THIS CHAPTER
• Overview—Configuring the Hardware ..................................................7
• Jumpers, Resistors, and Encoders.......................................................7
• Encoder Input Connector (P1) ............................................................14
• Analog/Digital I/O—P2 Connector.......................................................16
• Digital I/O—P3 & P4 Connectors........................................................20
• Installation Test...................................................................................32
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Chapter 3 – Hardware Installation – 7 –
Overview—Configuring the Hardware
Before installing the ACR1505, you must configure the card for your specific
application.
The ACR1505 is capable of handling line driver encoders, and either +5 VDC
or +12 VDC open collector encoders (not recommended).
The ACR1505 ships with resistor packs installed, which supply termination
resistance for line driver encoders. In addition, the pull-up jumpers are
configured for +5 VDC.
Warning!
Incorrect jumper or resistor configuration may damage the feedback device
and ACR1505.
Warning!
Do not install the ACR1505 in an AT motherboard. Doing this will permanently
damage the controller card.
The ACR1505 is only compatible with ATX motherboards, which supply both
+3.3 VDC and +5 VDC to the PCI bus.
If you are not sure which type of motherboard is in your computer, consult the
technical manual for your computer or the manufacturer.
Jumpers, Resistors, and Encoders
Some versions of the ACR1505 include the encoder option. Before
connecting feedback devices, configure the following for each device you
want to connect:
• Jumpers JP1 and JP2
• Resistor packs RP1 through RP4
Jumpers The ACR1505 can supply +5 VDC or +12 VDC to each encoder. Use Table 2
and Table 3 to determine the correct jumper configurations. For the location
of the jumpers, see Figure 14 on page 28.
Factory Default........................................JP1 & JP2 configured for +5 VDC
for standard Parker encoders
Jumper (JP1)
Encoder +5 VDC +12 VDC
0 Pins 1 & 2 Pins 2 & 3
1 Pins 4 & 5 Pins 5 & 6
Table 2 Jumper (JP1) Configuration for Encoder Voltage
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– 8 – ACR1505 User’s Guide
Jumper (JP2)
Encoder +5 VDC +12 VDC
2 Pins 1 & 2 Pins 2 & 3
3 Pins 4 & 5 Pins 5 & 6
Table 3 Jumper (JP2) Configuration for Encoder Voltage
Resistor Packs
The ACR1505 comes with termination resistor packs installed. If using open
collector or single ended encoders (not recommended), you must replace the
packs. For more information, see “Differential Encoders (Parker Drives and
Encoders)”.
For the location of the resistor packs, see Figure 14 on page 28.
Factory Default........................................Termination resistor packs are
installed for differential line-driver
encoders
Encoder Resistor Jumper
0 RP1 JP1
2 RP2 JP2
1 RP3 JP1
4 RP4 JP2
Table 4 Resistor Packs and Voltage Jumpers
Differential Encoders (Parker Drives and Encoders)
Parker encoders are differential line-driven (balanced pair). You can use the
supplied 8-pin, isolated, termination resistor packs. No additional
modifications should be necessary.
Differential, Open Collector
For differential open collector encoders, replace the factory supplied
termination resistor packs with common, 8-pin, 1 KΩpull-up resistor packs.
This supplies pull-up voltages necessary for each signal on the encoder input
channels.
Depending on the application, you might need to pull up to +5 VDC or +12
VDC. Five volt DC provides faster response times, but has lower noise
immunity. It may be necessary to use +5 VDC with high frequency
applications—encoder rates higher than 1 MHz. Twelve volt DC provides
higher noise immunity, but has slower response times.
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Chapter 3 – Hardware Installation – 9 –
Warning!
When using open collector encoders, replace the terminating resistor packs
(factory installed) with common, 8-pin, 1 KΩpull-up resistor packs.
Warning!
When using pull-up resistor packs (necessary with open collector encoders),
the ACR1505 is not able to detect encoder failures. An encoder fault can
occur, but the ACR1505 Controller is unable to notify the user.
For a wiring schematic, see Figure 1.
1. On the ACR1505, remove the termination resistor packs:
a. Insert a small, standard screwdriver underneath one end of
the resistor pack.
Gently rock the screwdriver to loosen the resistor pack. Use
caution to not damage the socket. Repeat this action at the
opposite end of the resistor pack.
b. Using a thin pair of needle nose pliers, firmly grip the resistor
pack in its center. Lift the resistor pack straight up.
2. Insert the following type of resistor packs.
• For +5 VDC encoders, install common 1 KΩ, 8-pin pull-up
resistor packs.
• For +12 VDC encoders, install common 2.2 KΩ, 8-pin pull-up
resistor packs.
Figure 1 Differential, Open Collector Encoder with internal pull-up resistors
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