PI C-863 User manual

Physik Instrumente (PI) GmbH & Co. KG · Auf der Römerstr. 1 76228 Karlsruhe, Germany
Telephon [phone] · Telefax [phone] · E-Mail [email protected]s
MS205Equ
C-863 Mercury Controller
Short Version of the User Manual
Version: 2.0.0
Date: 22.03.2013
This document describes the following
product:

C-863.11
Mercury DC Motor Controller, 1 Channel,
with Wide-Range Power Supply
The detailed version of this user manual is
included as a PDF file on the product CD
and can be downloaded from our website.

Physik Instrumente (PI) GmbH & Co. KG is the owner of the following trademarks:
PI®, PIC®, PICMA®, Picoactuator®, PIFOC®, PILine®, PInano®, PiezoWalk®,
NEXACT®, NEXLINE®, NanoCube®, NanoAutomation®
The following designations are protected company names or registered trademarks of
third parties:
Microsoft, Windows, LabVIEW
© 2013 Physik Instrumente (PI) GmbH & Co. KG, Karlsruhe, Germany. The text,
photographs and drawings in this manual are protected by copyright. With regard
thereto, Physik Instrumente (PI) GmbH & Co. KG retains all the rights. Use of said
text, photographs and drawings is permitted only in part and only upon citation of the
source.
Original instructions
First printing: 22.03.2013
Document number: MS205Equ, BRo, version 2.0.0
Subject to change without notice. This manual is superseded by any new release. The
latest release is available for download (http://www.pi.ws) on our website.

1About this Document 1
1.1 Goal and Target Audience of this User Manual ...................................................1
1.2 Symbols and Typographic Conventions...............................................................2
1.3 Definition...............................................................................................................3
1.4Other Applicable Documents................................................................................4
1.5 Downloading Manuals ..........................................................................................5
2Safety 7
2.1 Intended Use ........................................................................................................7
2.2 General Safety Instructions..................................................................................7
2.2.1 Organizational Measures....................................................................8
2.2.2 Safety Measures during Installation ...................................................8
2.2.3 Safety Measures during Start-Up.......................................................9
2.2.4 Safety Measures during Operation.....................................................9
2.2.5 Safety Measures during Maintenance..............................................10
3Product Description 11
3.1 Features and Applications..................................................................................11
3.2 Model Overview..................................................................................................13
3.3 Product View.......................................................................................................13
3.3.1 Front Panel.......................................................................................13
3.3.2 Rear Panel........................................................................................14
3.4 Scope of Delivery ...............................................................................................15
3.5 Accessories ........................................................................................................16
3.6 Functional Principles ..........................................................................................17
3.7 Communication Interfaces..................................................................................18
3.8 Overview of PC Software ...................................................................................18
3.9 Stage Databases................................................................................................20
4Unpacking 21
5Quick Start 23
6Installation 29
6.1 Installing the PC Software..................................................................................29
6.1.1 Performing the Initial Installation ......................................................29
6.1.2 Installing Updates.............................................................................30
Contents

6.1.3 Installing a Custom Stage Database................................................32
6.2 Mounting the C-863............................................................................................33
6.3 Grounding the C-863..........................................................................................34
6.4 Connecting the Power Supply to the C-863 .......................................................34
6.5 Connecting the Stage.........................................................................................35
6.6 Connecting the PC .............................................................................................36
6.6.1 Connecting to the RS-232 Interface.................................................36
6.6.2 Connecting to the USB Interface......................................................37
6.6.3 Setting Up a Daisy Chain Network...................................................37
6.7 Connecting an analog joystick - see detailed manual........................................38
6.8 Connecting digital in- and outputs - see detailed manual ..................................38
6.9 Connecting signal sources - see detailed manual..............................................39
7Start-Up 41
7.1 General Notes on Start-Up.................................................................................41
7.2 Adapting the DIP Switch Settings.......................................................................42
7.2.1 General Procedure ...........................................................................42
7.2.2 Controller Address............................................................................43
7.2.3 Baud Rate.........................................................................................44
7.2.4 Logic Level of the Limit Switches .....................................................44
7.2.5 Update Mode....................................................................................45
7.3 Switching on the C-863 ......................................................................................45
7.4 Establishing Communication..............................................................................46
7.4.1 Establishing Communication via RS-232 .........................................46
7.4.2 Establishing Communication via USB..............................................48
7.4.3 Establishing Communication for a Networked Controller.................49
7.5 Starting Motions..................................................................................................55
7.6 Recording the Step Response............................................................................60
7.7 Optimizing the Servo-Control Parameters..........................................................64
8Operation 67
8.1 Motion errors - see detailed user manual...........................................................67
8.2 Data Recorder - see detailed user manual.........................................................67
8.3 Digital output signals - see detailed user manual...............................................67
8.4 Digital input signals - see detailed user manual.................................................67
8.5 Analog Input Signals - see detailed user manual...............................................68
8.6 Joystick control - see detailed user manual .......................................................68
8.7 Controller Macros - see detailed user manual....................................................68
9GCS Commands 69
9.1 GCS Syntax for Syntax Version 2.0 - see detailed user manual........................69
9.2 Target and sender address - see detailed user manual.....................................69
9.3 Variables - see detailed user manual.................................................................69
9.4 Command Overview...........................................................................................70
9.5 Error Codes - see detailed user manual.............................................................74

10 Adapting Settings 75
10.1 Changing Parameters in the C-863....................................................................75
10.2 Creating or Modifying a Stage Type...................................................................78
10.3 Parameter Overview - see detailed user manual...............................................81
11 Maintenance 83
11.1 Cleaning the C-863.............................................................................................83
11.2 Updating Firmware - see detailed user manual..................................................83
12 Troubleshooting 85
13 Customer Service 91
14 Technical Data 93
14.1 Specifications......................................................................................................93
14.1.1 Data Table........................................................................................93
14.1.2 Maximum Ratings.............................................................................94
14.1.3 Ambient Conditions and Classifications ...........................................95
14.2 System Requirements ........................................................................................96
14.3 Dimensions.........................................................................................................96
14.4 Pin Assignment...................................................................................................97
14.4.1 DC Motor only...................................................................................97
14.4.2 I/O.....................................................................................................98
14.4.3 C-170.IO Cable for Connecting to the I/O Socket............................98
14.4.4 Joystick.............................................................................................99
14.4.5 C-819.20Y Cable for C-819.20 Joystick.........................................100
14.4.6 RS-232 In and RS-232 Out ............................................................101
14.4.7 Power Supply Connection 15-30 VDC ...........................................102
15 Old Equipment Disposal 103
16 EC Declaration of Conformity 105

1 About this Document
C-863 Mercury Controller MS205Equ Version: 2.0.0 1
In this Chapter
Goal and Target Audience of this User Manual ............................................................ 1
Symbols and Typographic Conventions........................................................................ 2
Definition........................................................................................................................ 3
Other Applicable Documents......................................................................................... 4
Downloading Manuals................................................................................................... 5
1.1 Goal and Target Audience of this User Manual
The short version of the MS205E user manual includes the following information on
the intended use of the C-863:
Product description and technical data of the C-863
Installation instructions for the C-863
Start-up instructions for the C-863
Command overview
Instructions for adapting settings
Cleaning instructions for the C-863
Overview for troubleshooting
In the detailed MS205E user manual, which is included as a PDF file on the product
CD, you can find all other information and instructions regarding operation and
maintenance as well as command and parameter descriptions. This short version
refers to information that is only included in the detailed version of the user manual.
It assumes that the reader has a fundamental understanding of basic servo systems
as well as motion control concepts and applicable safety procedures.
The latest versions of the user manuals are available for download (p. 5) on our
website.
If you have questions, contact our customer service department (p. 91).
1
About this Document

1 About this Document
2Version: 2.0.0 MS205Equ C-863 Mercury Controller
1.2 Symbols and Typographic Conventions
The following symbols and typographic conventions are used in this user manual:
NOTICE
Dangerous situation
If not avoided, the dangerous situation will result in damage to the equipment.
Actions to take to avoid the situation.
INFORMATION
Information for easier handling, tricks, tips, etc.
Symbol/Label Meaning
1.
2. Action consisting of several steps whose sequential order
must be observed
Action consisting of one or several steps whose sequential
order is irrelevant
 List item
p. 5 Cross-reference to page 5
RS-232 Labeling of an operating element on the product (example:
socket of the RS-232 interface)
Warning sign on the product which refers to detailed
information in this manual.
Start > Settings Menu path in the PC software (example: to open the menu,
the Start and Settings menu items must be clicked in
succession)
SVO?
Command line or a command from PI's General Command
Set (GCS) (example: command to get the servo mode).
Device S/N Parameter name (example: parameter where the serial
number is stored)
5Value that must be entered or selected via the PC software

1 About this Document
C-863 Mercury Controller MS205Equ Version: 2.0.0 3
1.3 Definition
Term Explanation
PC software Software that is installed on the PC.
Firmware Software that is installed on the controller.
Volatile memory RAM module in which the parameters are saved when the controller is switched
on (working memory).
Non-volatile
memory EEPROM memory chip (read-only memory), from which the default values of the parameters are loaded to the volatile memory when the controller is started.
Axis Also referred to as "logical axis". The logical axis reflects the motion of the stage
in the firmware of the C-863. For stages that allow motion in several directions
(e. g. in X, Y and Z), each direction of motion corresponds to a logical axis.
Stage Mechanical system connected to the C-863. For stages having just one motion
axis the designation "axis" is synonymous with "stage". Stages that allow motion
in several axes are also designated as "multiaxis stages". For these stages, a
distinction must be made between the individual axes.
In this manual, actuators, i. e. drive components without a moving platform (e. g.
precision linear actuators), are designated as stages as well.
Daisy chain Wiring diagram by which one controller is connected to the next in sequence
(series connection principle). Here the first controller is connected directly to the
PC. The additional controllers are always connected to the ones that precede
them so that a chain is formed. The signal to and from a controller goes to the
PC via the previous controllers.
Incremental
position sensor Sensor (encoder) for capturing changes of position or changes of angle. Signals from the incremental position sensor are used for axis position feedback. After
switching on the controller a reference point definition must be performed before
absolute target positions can be commanded and reached.
Control value The control value is the input for the PWM converter of the C-863. The PWM
converter converts the control value into the PWM signal for the stage.
Dynamics profile Comprises the target position, velocity, and acceleration of the axis calculated
by the profile generator of the C-863 for any point in time of the motion. The
calculated values are called "commanded values".
GCS PI General Command Set; command set for PI controllers. Piezo drivers and
servo controllers can be operated conjointly with minimal programming effort
thanks to the GCS.

1 About this Document
4Version: 2.0.0 MS205Equ C-863 Mercury Controller
1.4 Other Applicable Documents
The devices and software tools which are mentioned in this documentation are
described in their own manuals.
Description Document
Detailed user manual for the C-863.11 MS205E User Manual
Mercury GCS
LabVIEW driver library MS206E Software Manual
PI GCS 2.0 DLL for C-x63.11 MS212E Software Manual
GCS array
data format description SM146E Software Manual
PIMikroMove SM148E Software Manual
PIStageEditor
software for the management of stage
databases
SM144E Software Manual
PI Update Finder: Search and
download updates A000T0028 Technical Note
PI Update Finder: Updating PC without
Internet connection A000T0032 Technical Note
Adapting software that was written for
C-863.10 for use with C-863.11 A000T0029 Technical Note
INFORMATION
Model C-663.11 intended for operation with stepper motors is described in a
separate manual (MS208E).

1 About this Document
C-863 Mercury Controller MS205Equ Version: 2.0.0 5
1.5 Downloading Manuals
INFORMATION
If a manual is missing on our website or if there are problems in downloading:
Contact our customer service department (p. 91).
The current versions of the manuals are found on our website. To download a manual,
proceed as follows:
1. Open the website http://www.pi-portal.ws.
2. Click Downloads.
3. Click the corresponding category (e. g. C Motion Controllers).
4. Click the corresponding product code (e. g. C-863.11).
An overview of the available file types is shown for the selected product.
5. If (0 Files) is shown in the Documents line, log in as follows to display and
download the documents:
a) Insert the product CD in the corresponding PC drive.
b) Open the Manuals directory.
c) Open the Release News (e. g. C-663.11_Releasenews_V_x_x_x.pdf) on
the CD of the product.
d) Find the user name and password in the User login for software
download section in the Release News.
e) In the User login area on the left margin in the website, enter the user
name and the password in the corresponding fields.
f) Click Login.
If Documents (0 Files) is still being displayed, no manuals are available:
−Contact our customer service department (p. 91).
6. Click Documents.
7. Click the desired manual and save it on the hard disk of your PC or on a data
storage medium.

2 Safety
C-863 Mercury Controller MS205Equ Version: 2.0.0 7
In this Chapter
Intended Use ................................................................................................................. 7
General Safety Instructions........................................................................................... 7
2.1 Intended Use
The C-863 is a laboratory device as defined by DIN EN 61010. It is intended to be
used in interior spaces and in an environment which is free of dirt, oil, and lubricants.
Appropriate to its design, the C-863 is intended for the operation of PI stages
equipped with DC motors or voice coil drives.
The C-863 is intended for closed-loop operation with incremental position sensors. In
addition, it can read and process the reference point and limit switch signals from the
stage connected.
The C-863 may only be used in compliance with the technical specifications and
instructions in this user manual. The user is responsible for process validation.
2.2 General Safety Instructions
The C-863 is built according to state-of-the-art technology and recognized safety
standards. Improper use can result in personal injury and/or damage to the C-863.
Only use the C-863 for its intended purpose, and only use it if it is in a good
working order.
Read the user manual.
Immediately eliminate any faults and malfunctions that are likely to affect
safety.
The operator is responsible for the correct installation and operation of the C-863.
Install the C-863 near the power source so that the power plug can be quickly
and easily disconnected from the mains.
Use the supplied components (power supply, adapter and power cord (p. 16))
to connect the C-863 to the power source.
2
Safety

2 Safety
8Version: 2.0.0 MS205Equ C-863 Mercury Controller
If one of the supplied components for connecting to the power source has to
be replaced, use a sufficiently dimensioned component.
2.2.1 Organizational Measures
User manual
Always keep this user manual next to the C-863.
If the user manual is lost or damaged, contact our customer service
department (p. 91).
Add all information given by the manufacturer to the user manual, for example
supplements or Technical Notes.
If you pass the C-863 on to other users, also turn over this user manual as
well as all other relevant information provided by the manufacturer.
Only use the device on the basis of the complete user manual. If your user
manual is incomplete and is therefore missing important information, property
damage can result.
Only install and operate the C-863 after having read and understood this user
manual.
Personnel qualification
The C-863 may only be started up, operated, maintained and cleaned by authorized
and qualified staff.
2.2.2 Safety Measures during Installation
Install the C-863 near the power source so that the power plug can be quickly
and easily disconnected from the mains.
Only use cables and connections that meet local safety regulations.
Connecting a stage with stepper motor to a DC motor controller can cause irreparable
damage.
Only connect to the C-863 a stage with DC motor or voice coil drive.
Connecting the USB and RS-232 interfaces of the controller to the PC at the same
time can damage the PC or the controller.
Connect either the USB or the RS-232 interface to the PC.

2 Safety
C-863 Mercury Controller MS205Equ Version: 2.0.0 9
The output voltage on the Motor + and Motor -pins of the DC Motor only socket can
be as high as the supply voltage provided by the power supply. Stages without PWM
amplifier are connected to these pins and can be damaged by output voltage that is
too high.
Connect a power supply whose output voltage does not exceed the
permissible operating voltage of the stage.
Unsuitable settings made to the servo-control parameters of the C-863 can cause the
stage to oscillate. Oscillations can damage the stage and/or the load affixed to it.
Secure the stage and all loads adequately.
2.2.3 Safety Measures during Start-Up
When the system settings in the non-volatile memory are changed, the original
settings will be lost. Unfavorable settings can cause stage oscillation, worse settling
behavior and reduced positioning accuracy.
Only change the internal system settings for the C-863 in the non-volatile
memory when necessary.
Contact our customer service department (p. 91) if you are not sure whether a
change to the system settings is necessary.
Selecting an incorrect stage type in the PC software can cause damage to the stage.
Make sure that the stage type selected in the PC software matches the stage
connected.
2.2.4 Safety Measures during Operation
Unsuitable settings made to the servo-control parameters of the C-863 can cause the
stage to oscillate. Oscillations can damage the stage and/or the load affixed to it.
If the stage is oscillating (unusual operating noise), immediately switch off the
servo mode or disconnect the C-863 from the power source.
Only switch on the servo mode after you have modified the servo-control
parameter settings of the C-863; see "Optimizing Servo-Control Parameters"
(p. 64).
The collision of a moving part at the end of the travel range, or with an obstacle, as
well as high acceleration, can cause damage to or considerable wear on the
mechanical system.
Prevent motions in open-loop operation.

2 Safety
10 Version: 2.0.0 MS205Equ C-863 Mercury Controller
If motions in open-loop operation are necessary:
−Set the control value with the SMO command so that the axis moves with
low velocity.
−Stop the axis in time. For this purpose, use the #24, STP or HLT
command, or set the control value to zero with the SMO command.
Do not disable via parameter setting the evaluation of the limit switch signals
by the C-863.
Check the function of the limit switches at about 10 % to 20 % of the
maximum velocity.
In the event of a malfunction of the limit switches, stop the motion
immediately.
Ensure that the end of the travel range is approached at low velocity.
If the moving part or the load mounted on it collides with an obstacle, switch
off the motor.
If possible, adjust the soft limits in the software used for commanding motion
to your mechanical system.
Determine the maximum velocity for your application.
If no joystick is connected to the C-863, activating the joystick in the software can
cause unintentional motion of the axis connected.
Activate the joystick in the software only if a joystick is actually connected to
the C-863.
If the servo mode is switched off, e. g. after a motion error occurs, the brake of the
stage can be deactivated by command. Deactivating the brake can cause the stage to
move unintentionally.
Secure the stage against unintentional motions before you deactivate the
brake by command!
2.2.5 Safety Measures during Maintenance
The C-863 comprises electrostatic sensitive devices.
Do not open the case of the C-863.
Before cleaning, disconnect the C-863 from the power source by pulling the
power plug.

3 Product Description
C-863 Mercury Controller MS205Equ Version: 2.0.0 11
In this Chapter
Features and Applications........................................................................................... 11
Model Overview........................................................................................................... 13
Product View ............................................................................................................... 13
Scope of Delivery ........................................................................................................ 15
Accessories ................................................................................................................. 16
Functional Principles ................................................................................................... 17
Communication Interfaces........................................................................................... 18
Overview of PC Software ............................................................................................ 18
Stage Databases......................................................................................................... 20
3.1 Features and Applications
The Mercury DC motor controller is the perfect solution for designing cost-efficient and
flexible positioning systems in which a precision stage is to be controlled with a PC or
a programmable controller. In addition to the C-863, the Mercury line comprises the
successful C-663 Mercury Step stepper motor controller. The controllers of the
Mercury line use the same command sets and can be networked with each other.
The product features of the C-863 include:
RS-232 and USB interfaces
Stand-alone operation
Daisy chain networking for multi-axis operation
Compatible and networkable with all Mercury line controllers, including
Mercury Step
Joystick connection for manual operation
Non-volatile macro memory
Parameter changing during operation
TTL inputs for limit and reference point switches
Control signal for motor brake
Programmable in-/outputs
3
Product Description

3 Product Description
12 Version: 2.0.0 MS205Equ C-863 Mercury Controller
Multi-axis operation of DC and stepper motors
The C-863.11 Mercury DC motor controller has the same command set as the C-
663.11 Mercury Step stepper motor controller. Up to 16 Mercury controllers (for DC
and stepper motors) can be networked and operated via the same computer interface.
Mercury networks are flexible and can also be expanded later on.
Flexible automation
The C-863 presents a number of performance characteristics that make cost-effective
implementation of automation and processing tasks in both research and industry
possible. With the easily understandable programming language macros can be saved
in the non-volatile memory.
A programmable start-up macro makes stand-alone operation possible: The automatic
execution of internal instruction cycles is even performed without external
communication upon switching-on.
Four I/O lines each are used at any one time to easily synchronize motion cycles with
internal or external events. A joystick can be connected for manual control.
User-Friendly: Comprehensive software package and two
interfaces
The controller has a USB interface for easy data exchange with laptop or PC. An RS-
232 interface is also available standard.
The software provided enables the networked operation of multiple controllers.
LabVIEW drivers and a program library make programming system integration easier.
The Mercury controllers can be actuated with the PI General Command Set (GCS)
directly. With PI GCS different PI controllers, like piezo controllers and servo
controllers, can be operated conjointly with minimal programming effort.

3 Product Description
C-863 Mercury Controller MS205Equ Version: 2.0.0 13
3.2 Model Overview
In addition to the C-863.11 DC motor controller the C-663.11 model for stages with
stepper motor is also part of the Mercury controller model series.
INFORMATION
The hardware of the C-863.11 DC motor controller is identical to the hardware of the
C-863.10 DC motor controller. The two models differ in their firmware and use
different command sets. The C-863.10 and the C-863.11 cannot be networked
together.
By installing the appropriate firmware a C-863.10 can be converted into a C-863.11.
If you want to convert a C-863.10 into a C-863.11, contact the customer service
department (p. 91).
If you want to use software that you have written for the C-863.10 with the C-
863.11, read A000T0029 Technical Note.
For further questions contact our customer service department (p. 91).
3.3 Product View
3.3.1 Front Panel
Figure 1: C-863 Mercury DC motor controller, front view
Labeling Type Function
RS-232 In Sub-D 9(m)
(p. 101) Serial connection to the PC or to the previous controller in a daisy chain network; do not connect to the PC if the USB interface is
already connected.
RS-232 Out Sub-D 9(f)
(p. 101) Serial connection to the subsequent controller in a daisy chain network
Mini-USB
type B Universal serial bus for connecting to the PC; do not connect if
RS-232 In is already connected.

3 Product Description
14 Version: 2.0.0 MS205Equ C-863 Mercury Controller
Labeling Type Function
STA LED
green/off Controller state:
Green: C-863 is ready for normal operation
Off: C-863 is not connected to the supply voltage or is in
firmware update mode (selection via DIP switch 8)
ERR LED
red/off Error indicator:
Continuously lit: Error (error code ≠0)
Off: No error (error code = 0)
The error code can be queried with the ERR? command. The query
resets the error code to zero and the LED is switched off.
Mode, Baud,
Addr 8-bit DIP
switch (p. 42) Setting the device address, the baud rate for communication with the PC, the limit switch signal logic and the update mode.
3.3.2 Rear Panel
Figure 2: C-863 Mercury DC motor controller, rear view
Labeling Type Function
15-30 VDC Barrel
connector
socket (input)
(p. 102)
Connection for the supply voltage
I/O Mini-DIN
socket,
9-pin (p. 98)
Digital in-/outputs:
Outputs: Triggering external devices
Inputs: Use in macros or as switch signals
Analog inputs:
Use in macros or for scanning processes
Joystick Mini-DIN
socket,
6-pin (p. 99)
Analog joystick
Inputs for signals from the joystick axes and buttons
Output for the supply voltage of the joystick