Physik Instrumente C-863 Mercury User manual

MS173E User Manual
C-863 Mercury™
DC Motor Controller
Release: 1.2.7 Date: 2008-04-24
This document describes the
following product:
C-863
DC Motor Controller, Single-Axis, Networkable
© Physik Instrumente (PI) GmbH & Co. KG
Auf der Roemerstr. 1 ⋅76228 Karlsruhe, Germany
Tel. [phone] ⋅Fax: [phone]
[email protected] ⋅www.pi.ws

Physik Instrumente (PI) GmbH & Co. KG is the owner of the following company names and
trademarks: PI®, PIMikroMove™, Mercury™, Mercury™ Step
The following designations are protected company names or registered trademarks of third
parties: Windows, LabVIEW
Copyright 2008 by Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Germany.
The text, photographs and drawings in this manual enjoy copyright protection. With regard
thereto, Physik Instrumente (PI) GmbH & Co. KG reserves all rights. Use of said text,
photographs and drawings is permitted only in part and only upon citation of the source.
Document Number MS173E, Release 1.2.7
C-863_User_MS173E127.doc
Subject to change without notice. This manual is superseded by any new release. The newest
release is available for download at www.pi.ws.

Declaration of
Conformity
according to ISO / IEC Guide 22 and EN 45014
Manufacturer: Physik Instrumente (PI)
GmbH & Co. KG
Manufacturer´s
Address: Auf der Römerstrasse 1
D-76228 Karlsruhe,
Germany
The manufacturer hereby declares that the product
Product Name: Single-Channel DC Motor Controller
Model Numbers: C-863
Product Options: all
complies with the following European directives:
2006/95/EC, Low-voltage directive (LVD)
2004/108/EC, EMC Directive
The applied standards certifying the conformity are listed below.
Electromagnetic Emission: EN 61000-6-3, EN 55011
Electromagnetic Immunity: EN 61000-6-1
Safety (Low Voltage Directive): EN 61010-1
April 24, 2008
Karlsruhe, Germany
Dr. Karl Spanner
President

About This Document
Users of This Manual
This manual is designed to help the reader to install and operate the C-863 DC Motor
Controller. It assumes that the reader has a fundamental understanding of basic servo systems,
as well as motion control concepts and applicable safety procedures.
The manual describes the physical specifications and dimensions of the C-863 DC Motor
Controller as well as the software and hardware installation procedures which are required to
put the associated motion system into operation.
This document is available as PDF file on the product CD. Updated releases are available for
download from www.pi.ws or by email: contact your Physik Instrumente Sales Engineer or write
[email protected].
Conventions
The notes and symbols used in this manual have the following meanings:
WARNING
Calls attention to a procedure, practice or condition which, if not
correctly performed or adhered to, could result in injury or death
CAUTION !
Calls attention to a procedure, practice, or condition which, if not
correctly performed or adhered to, could result in damage to
equipment.
NOTE
Provides additional information or application hints.
Related Documents
The software tools and any stages which might be delivered with C-863 DC Motor Controller,
are described in their own manuals. All documents are available as PDF files via download from
the PI Website (www.pi.ws) or on the included product CD. For updated releases or other
versions contact your Physik Instrumente Sales Engineer or write [email protected].
MMCRun MS139E Mercury™ Operating Software (native
commands)
Mercury™ Native DLL & LabVIEW MS177E Windows DLL Library and LabView VIs (native-
command-based)
Mercury™ Native Commands MS176E Native Mercury™ Commands
Mercury™ GCSLabVIEW_MS149E LabView VIs based on PI GCS command set
Mercury™ GCS DLL_MS154E Windows DLL Library (GCS commands)
PIMikroMove™ User Manual SM148E PIMikroMove™ Operating Software (GCS-based)
Mercury™ GCS Commands MS163E Mercury™ GCS Commands
PIStageEditor _SM144E Software for managing GCS stage-data database

Introduction
1Introduction 3
1.1 Overview.................................................................................... 3
1.2 Prescribed Use.......................................................................... 4
1.3 Safety Precautions .................................................................... 5
1.4 Unpacking.................................................................................. 7
1.5 Accessories............................................................................... 7
1.6 Software Interfaces.................................................................... 8
1.6.1 Native Command Set.................................................................8
1.6.2 GCS Command Set....................................................................8
1.6.3 Available Software......................................................................8
2Quick Start 11
2.1 Front and Rear Panel Elements.............................................. 11
2.2 Connecting Mercurys™ with the Host PC............................... 12
2.2.1 RS-232 from Host.....................................................................13
2.2.2 USB from Host..........................................................................13
2.3 Software Installation................................................................ 13
2.3.1 USB Driver................................................................................14
2.3.2 GCS Software...........................................................................14
2.3.3 Native-Command Software......................................................14
2.4 Starting Operation ................................................................... 15
3System Description 19
3.1 Control of Multiple Axes........................................................... 19
3.2 LED Status Indicators.............................................................. 19
3.3 Power-up Settings................................................................... 20
3.4 Cable Connections.................................................................. 20
3.5 Limit Signals............................................................................ 21
3.6 Reference Signal..................................................................... 22
3.7 Input/Output Lines................................................................... 22
3.8 DIP Switch Settings................................................................. 23
3.9 Firmware Update..................................................................... 24
4Manual Control 27
4.1 Joystick.................................................................................... 27
4.2 Pushbuttons............................................................................. 28
5Macros 29
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Introduction
6Troubleshooting 30
7Technical Data 33
7.1 Specifications .......................................................................... 33
7.2 Dimensions.............................................................................. 34
7.3 Connector Pinouts................................................................... 35
7.3.1 Motor-Connector.......................................................................35
7.3.2 I/O Connector...........................................................................36
7.3.3 Joystick Connector...................................................................36
7.3.4 Joystick Y-cable........................................................................37
7.3.5 RS-232 Connectors..................................................................37
7.3.6 USB Connector.........................................................................38
7.3.7 Power Connector & Grounding Screw .....................................39
8Disposal 40
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Introduction
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1Introduction
The Mercury™ DC motor controller is the perfect solution for cost-effective and
flexible motion control applications where a precision positioner is to be controlled
by a PC or PLC (programmable logic controller). The C-863 replaces the C-862
Mercury™ servo-motor controller and supplements the successful C-663
Mercury™ Step Stepper Motor Controller. These products are Mercury™ Class
controllers and as such share the same command sets and are internetworkable.
1.1 Overview
RS-232 and USB Host
Communication
Stand-Alone Capability
Network Capability for Multi-Axis
Applications
Compatible and Networkable
with all other Mercury™ Class
controllers, including Mercury™
Step
Joystick Port for Manual Control
Non-Volatile Macro Memory
Parameter Changes on-the-fly
Fig. 1: C-863.10 Mercury™ Controller
TTL Inputs for Limit & Origin Switches
Motor-Brake Control
Programmable I/O Lines
Multi-Axis Control, Combination of DC & Stepper Motors
The networking feature allows the user to start out with one Mercury™ controller
and add more units later for multiaxis setups.
The C-863 Mercury™ DC motor controller shares its native programming
language with its predecessor, the C-862 and with the Mercury™ Step stepper
motor controller. Up to 16 Mercury™ controllers (DC and stepper) can be daisy
chained and operated from one computer interface.

Introduction
Flexible Automation
The C-863 offers a number of features for performing automation and handling
tasks in research and industry in a very cost-effective way. Programming is
facilitated by the high-level mnemonic command language with macro and
compound-command functionality. Macros can be stored in the non-volatile
memory for later recall.
Stand-alone capability is provided by a user-programmable autostart macro to run
automation tasks at power up (no run-time computer communication required!).
For easy synchronization of motion with internal or external trigger signals, four
input and four output lines are provided. A joystick can also be connected for
manual control.
User-Friendly: Comprehensive Software Package and Two
Interface Options
Easy data interchange with laptop or PC is possible via the USB interface. To
facilitate industrial applications, an RS-232 interface is also standard.
The included software supports networking of multiple controller devices.
LabVIEW™ drivers and Windows DLLs allow for easy programming and
integration into your system. Mercury™ controllers can also be operated using
the PI General Command Set (GCS) via a DLL. PI-GCS allows interoperation of
different PI controllers such as piezo drivers and multi-axis servo-controllers with
minimal programming effort.
1.2 Prescribed Use
Based on its design and realization, the C-863 Mercury™ Controller is intended to
drive PI stages with DC motor or voice coil drives.
Observe the safety precautions given in this User Manual.
Operation other than instructed here may affect the safeguards provided.
C-863s conform to Measurement Category I (CAT I) and may not be used for
Measurement Categories II, III or IV. Other use of the device (i.e. operation other
than instructed in this Manual) may affect the safeguards provided.
C-863s meet the specifications of EN 61010 and are designed to operate under
normal ambient conditions at least as listed here. More stringent conditions given
in the specifications table on p. 33 are, of course, also met.
Indoor use
Altitude up to 2000 m
Temperature range 5°C to 40°C
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Introduction
Max. relative humidity 80% for temperatures up to 31°C, decreasing linearly
to 50% relative humidity at 40°C
Line voltage fluctuations not greater than ±10% of the line voltage
Transient overvoltages as typical for public power supply
Note: The nominal level of the transient overvoltage is the standing surge voltage according to the
overvoltage category II (IEC 60364-4-443).
Degree of pollution: 2
1.3 Safety Precautions
Read carefully the documentation of the included software components and of the
mechanics used also. Failure to heed warnings in this manual can lead to
accidents causing bodily injury, damage to equipment or loss of warranty
protection. Note that the C-863 does not contain any user-serviceable parts.
WARNING
All motion of the connected motors and mechanical stages is software
controlled, and software may fail. Be aware that motorized stages generate
large forces that may cause personal injury or other damage if mishandled.
! CAUTION
Install and operate the C-863 controller only after you have read the operating
instructions. Keep the manuals and any relevant Technical Notes readily
available. If lost or damaged, new copies can be downloaded from www.pi.ws
or obtained from PI.
! CAUTION
If operating different Mercury™ controllers, do not mix up the 12 V, 15 V and
24 V power supplies!
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Introduction
CAUTION !
Never connect a stepper motor to a C-863 DC motor controller. Irreparable
damage could result.
!
CAUTION
Do not enable a joystick axis here when no joystick is connected to the
controller hardware. Otherwise the corresponding controller axis may start
moving and could damage your application setup.
!
CAUTION
The voltage output on the “Motor +” and “Motor -“ pins can be as high as the
supply voltage used. If using a non-standard power supply for the Mercury™
and a motor that connects to these lines (i.e. without separate PWM
amplifier), make sure the motor’s operating voltage will not be exceeded.
!
CAUTION
Never connect the RS-232-IN and USB connectors of the same controller to a
PC at the same time, as damage may result.
!
CAUTION—Maintain Compliance
Because the unit is not grounded over the power supply, a grounding screw is
provided at the lower left corner of the rear panel for connecting the metal
case to a protective ground. Connection to a protective ground is required for
compliance with applicable standards.
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Introduction
1.4 Unpacking
Unpack the C-863 Mercury™ controller with care. Compare the contents against
the items covered by the order and against the packing list.
In C-863.10, the following components are included:
Mercury™ Controller (C-863.10)
Wide-range 15 V power supply (C-890.PS)
Power-supply line-voltage cable
RS-232 null-modem cable for PC connection (C-815.34, 3 m)
RS-232 straight-through networking cable (C-862.CN, 28 cm)
USB cable (type A to mini-B) for PC connection (14651) (EMI-suppression
ferrite no longer required)
Mercury™ Product CD with all software and manuals for Mercury™ Class
products
MS173E User Manual (this document) in printed form
If parts are missing or you notice signs of damage, contact PI immediately.
Save all packing materials in case the product need be shipped again.
1.5 Accessories
The following items are not included but can be ordered separately:
Order Number
C-815.38 Stage/motor cable, 3 m (sub-D 15 m/f)
C-862.CN2 Long straight-through networking cable for interconnecting
Mercury™ Class controllers, 180 cm
C-819.20 Analog joystick, 2 axes
C-819.20Y Y-cable for connecting 2 Mercurys™ to joystick
C-170.PB Pushbutton box with 4 buttons and 4 LEDs
C-170.IO Connector for I/O socket (p. 36), with cable, open end
C-663.PS 24 V power supply, primarily for use in systems with 24 V DC
motors not having PWM amplifiers; do not use with 12 V motors
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Introduction
1.6 Software Interfaces
The C-863 Mercury™ shares many features and commands with other Mercury™
class controllers from PI. It is possible to use either the Mercury™ native ASCII
command set or the PI General Command Set (GCS) to operate Mercury™ Class
controllers. The commands are used to set operating modes, transfer motion
parameters and to query system and motion values.
1.6.1 Native Command Set
The native ASCII command set is understood by the controller directly. It can be
used with virtually any terminal-emulator software and with MMCRun. Most native
Mercury™ commands begin with a two-letter mnemonic. The syntax of the native
commands and the detailed command descriptions can be found in the Mercury™
Class Native Commands software manual, MS176E.
1.6.2 GCS Command Set
GCS (General Command Set) is the PI standard command set, offering
compatibility between different controllers. With current Mercury™ firmware, GCS
command support is implemented by a Windows DLL which translates the GCS
commands to the native commands (for details, see the Mercury™ GCS DLL
manual, MS154E). The DLL has many command-oriented functions, making it
unnecessary to generate the GCS commands as ASCII strings. Most GCS
commands and the corresponding DLL function calls are characterized by a three-
letter mnemonic.
NOTES
Although the GCS DLL has a gateway for sending native commandsdirectly,
mixing native and GCS commands is not recommended. GCS move
commands, for example, may not work properly after the position is changed
by a native command.
GCS commands can be typed directly into the Command entry window of GCS-
compatible PI user-interface software, like PIMikroMove™(see the PIMikroMove™
manual on the product CD).
1.6.3 Available Software
With the C-863 DC Motor Controller, all motion of the connected motors and
mechanical stages is programmed or controlled by software. To offer maximum
flexibility, software interfaces at a number of different levels are provided and
documented. Most of the individual programs and driver libraries are described in
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Introduction
separate manuals. Updated releases are available on www.pi.ws or via email:
contact your PI Sales Engineer or write [email protected].
PITerminal is a Windows program which can be used as a simple terminal
with almost all PI controllers. It supports both direct and via-GCS-DLL
connection to Mercury™ controllers via RS-232 and USB (the USB link also
looks like a COM port to host software when the USB drivers are installed).
When the GCS-DLL connect option is used, command entered in the
Terminal window are actually sent to the GCS-DLL, where they are
interpreted as GCS commands. When the Connect button is used instead,
current Mercury™ firmware expects commands from the native command
set..
Native-Command-Set Software
MMCRun (operating software for Windows™ 95/98/2000/XP and NT) is an
operating software for C-863 and C-862 Mercury™, and C-663 Mercury™
Step controllers. MMCRun allows immediate operation of the motion
system. It features easy commanding and macro programming of Mercury™
class controllers. See the MMCRun Manual, MS139E, for a full description.
MMC410.DLL Windows DLL facilitates many interfacing operations and data
conversion tasks for programmers of custom applications. This DLL is based
on the native command set. (See the Mercury Native DLL and LabView
Manual, MS177, for details)
LabVIEW VIs: facilitate integrating Mercury™ class controllers in the
LabVIEW environment. Uses the native-command MMC410.DLL above.
(See the Mercury Native DLL and LabView Manual, MS177, for details)
GCS-Based Software**
PIMikroMove™ (application for Microsoft Windows platforms) is operating
software for this and many other PI controllers. With PIMikroMove™ you can
start your motion system—host PC, controller and stage(s)—immediately
without writing customized software. PIMikroMove™ offers motion control
displays and features that in many cases make it unnecessary to deal with
ASCII command formats. It also has a complete command input facility,
which lets you experiment with various GCS commands easily.
PIMikroMove™ uses the GCS DLL described below to command the
controller or controller network.
GCS LabVIEW drivers to communicate with the C-863 from the National
Instruments’ LabVIEW environment (not included) using the Mercury™
GCS-DLL (see MS149E for details).
** Software is based on the PI General Command Set and requires the Mercury GCS DLL to translate
the GCS commands into commands that can be understood by Mercury Class native-command
firmware.
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Introduction
GCS DLL (Windows DLL Library): The Mercury™ General Command Set
Dynamic Link Library (Mercury™ GCS DLL) is an intermediate layer
providing easy access to the controller from Windows programs. The use of
the DLL and the functions it contains is described in a separate manual
(MS154E). Most of the DLL functions correspond directly with the
commands of the PI General Command Set.
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Quick Start
2Quick Start
This Quick Start assumes that you wish to control one or more Mercury™ Class
controllers together from a single RS-232 or USB port on a host computer and are
connecting a motorized axis to each controller. Be sure to refer to the User
Manuals of all other hardware in the system.
2.1 Front and Rear Panel Elements
Fig. 2: Front view of C-863 Mercury™
Front
Labeling Element Type Purpose
RS-232 In Sub-D 9(m) Command routing (connects to PC or a
networked Mercury™ class controller)
RS-232 Out Sub-D 9(f) Command routing in network (connects to a
networked Mercury™ class controller)
Mini-B type USB Command routing (connects to host PC, do
not connect when RS-232 IN is connected)
STA LED
green Power and status
ERR LED
red/green Command error:
green: command OK
red: command error
Mode, Baud,
Addr 8-bit DIP switch Setting device number, RS-232 baud rate, limit-switch and firmware update modes (see
DIP Switch Settings, p. 23)
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Quick Start
CAUTION !
The voltage output on the “Motor +” and “Motor -“ pins can be as high as the
supply voltage used. If using a non-standard power supply for the Mercury™
and a motor that connects to these lines (i.e. without separate PWM
amplifier), make sure the motor’s operating voltage will not be exceeded.
Fig. 3: Rear view of C-863 Mercury™
Rear
Labeling Element Type Purpose
15-30 VDC Barrel connector Supply power input, center positive
I/O Mini DIN connector, 9-pin Digital I/O and analog input
Joystick Mini DIN connector, 6-pin Analog joystick (input)
DC Motor only Sub-D 15(f) Motor/stage connection (I/O): DC motor
only!
Screw & washer Protective ground connection
!
CAUTION
Never connect a stepper motor drive to a C-863 DC-motor controller.
Irreparable damage could result.
2.2 Connecting Mercurys™ with the Host PC
!
CAUTION
Never connect the RS-232-IN and USB connectors of the same controller to a
PC at the same time, as damage may result.
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Quick Start
Use either the RS-232 or the USB interface to connect the controller or controller
network to the host PC. Interconnect any additional Mercury™ Class controllers
being networked with straight-through RS-232 cables chaining from the RS-232
OUT to the RS-232 IN connectors of each in turn.
NOTE
Windows NT does not have USB support as standard. PI supports only the
RS-232 interface for Windows NT. Unless you manage to get USB interfacing
operational, the number of networkable devices may be limited to as few as 6
units by the current-sourcing capacity of the PC’s COM port output stages.
Power up the C-863 by connecting it to a suitable power supply. The C-863 is
ready for operation when the green power LED (STA) lights up.
2.2.1 RS-232 from Host
If you use RS-232, connect the C-815.34, RS-232 null-modem cable (F-F)
between the "RS-232 IN" socket to the desired COM port of the host computer.
2.2.2 USB from Host
When you connect via the USB interface for the first time, be sure you are logged
on the PC as a user having administrator rights. After the C-863 is powered up, a
message will appear saying that new hardware has been detected. Follow the on-
screen instructions and show the Hardware Wizard the \USB_Driver directory on
the Mercury™ CD.
NOTE
The USB drivers will make the USB interface appear to all software on the
host PC as a new COM port. That port will be present only when the controller
is connected via USB and powered-up. Even when using USB, it is necessary
to set the baud rate consistently on the PC and all connected devices.
With current firmware, it may be necessary to power-cycle the controller while
the host PC is on to establish communication with it.
2.3 Software Installation
It is most convenient to test the system with PI software, even if custom software is
planned later. PIMikroMove™ , MMCRun or PITerminal can be used (on the
product CD). For more information on these programs see Section 1.6, p. 8.
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Quick Start
This section describes the procedures necessary to install the various programs.
2.3.1 USB Driver
If using the USB interface, the USB driver must be installed as described in the
section on connecting the USB interface, Section 2.2.2 above.
2.3.2 GCS Software
If you wish to use any of the GCS-based software, the Windows Setup installation
procedure must be run. Proceed as follows:
1 Be sure to log in with administrator privileges and insert the CD in the host
PC.
2 Insert the Mercury™ CD; if the Setup Wizard does not start automatically,
start Setup from the root directory of the CD.
3 Follow the on-screen instructions. You can choose between typical and
custom installation. Components covered by typical are LabVIEW™
drivers, DLLs and PIMikroMove™. Typical is recommended.
2.3.3 Native-Command Software
The Windows Setup routine can also be used to install the native-command-based
software. Setup puts it in subdirectories of the installation directory and adds the
MMCRun and the Mercury™ firmware update programs to the PI program group
under Start→Programs→PI→Mercury
If using only the native-command software, it is possible to bypass the Setup
Wizard as follows:
1 Insert the CD in the host PC; administrator privileges are not required.
2 If the Setup Wizard starts automatically, close or ignore it
3 Open a Windows Explorer and go to the CD drive
4 Copy the contents of the Mercury_Native_Software directory to a directory
on the host PC.
5 Access the programs you need from that directory. To start the MMCRun
host software, for example, go to that directory, open the MMC_Run
subdirectory and double-click the MMCRun “.EXE” file there.
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Quick Start
2.4 Starting Operation
1 Make sure each controller is set to a suitable device address. The factory
default setting of the address DIP switches is all ON, corresponding to
device number 1. Each Mercury™ Class controller in a network must be
set to a unique address. See ”DIP Switch Settings,” p. 23 for details on
setting device numbers.
2 If there are to be additional controllers in the network, chain them from
RS-232 Out to the RS-232 In of successive units.
Use C-862.CN straight-through RS-232 cables (M-F) between the units.
Between the first controller and the PC use either the USB cable or the
null-modem RS-232 cable, but not both. Each controller on the network
must be set to the same baud rate (DIP switches 5 and 6 on the C-863)
and it must be the same as that assumed by the host software.
! CAUTION
Never connect a stepper motor drive to a C-863 DC motor controller.
Irreparable damage could result.
! CAUTION
The voltage output on the “Motor +” and “Motor -“ pins can be as high as the
supply voltage used. If using a non-standard power supply for the Mercury™
and a motor that connects to these lines (i.e. without separate PWM
amplifier), make sure the motor’s operating voltage will not be exceeded.
3 Connect each motorized axis to the corresponding controller.
CAUTION
! Always respect the power supply voltage markings. Never connect a 24 V
power supply to an old (black) C-862 Mercury™
4 Connect a protective ground to the grounding screw on the rear panel
5 Connect power to each of the controllers. If there are C-862 (black)
Mercurys™ in the system, be especially careful when connecting the
power supplies.
6 The status LED (label STA) will glow green for normal operation.
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Quick Start
7 Start the PI host software you wish to use and set it up for the stage(s)
connected to your system. The sample screen shots that follow are from
PIMikroMove™, though MMCRun can be used instead; more details on
the host software operation are given in the respective software manual.
NOTE
A USB connection will appear as an extra COM port when the controller is
connected, powered up, and the USB drivers are installed.
The baud rate used by the host must be the same as that set on the DIP
switches, even if the USB interface is used!
Fig. 4: PIMikroMove™ Start up Controller screen, Step 1 with “extra” COM port for
USB connection being selected
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