Reliance electric PSC7000 User manual

Operating Instructions for
PSC7000 Control Card
Programmable Servo Controller
PSC7000
Instructions Manual 23030-10E
Reliance Electric Limited

Copyright©2015 Reliance Electric Limited, All rights reserved

Preface
Thank you for choosing the Programmable Servo Controller PSC7000.
The information contained in this manual is important for safe and reliable operation.
Carefully read and thoroughly understand this entire document before attempting to set up
and service the device. It should be used only for the purpose it is designed and directed.
Know the product’s application, limitations, and potential hazards. Failure to follow the
operating instructions may result in poor performance of the product or even cause severe
personal injuries.
Keep this instruction manual for future reference.
The product is manufactured and distributed by Reliance Electric Limited.
The version of the operating system is 1.08. This manual is based on information as of
November 2014.
For information on how to check the version of the Operating System, see Section 3.1 of this
document or Section 7.1 Property of the “PSC Terminal for PSC7000 Series Controllers
Operating Instructions Manual”.
The version of the PSC Terminal software is 1.08.
For information on how to check the version of the PSC Terminal, see Section 10.5 of the
“PSC Terminal for PSC7000 Series Controllers Operating Instructions Manual”.
Document Purpose
The manual provides detailed, step-by-step help and instructions for procedures for
-Operating PSC7000 through PSC terminal,
-Programming PSC7000, and
-Proper installation, configuration, operation and maintenance of the product.
Intended Reader
This instruction manual is primarily intended for use by qualified electrical personnel,
specifically trained and experienced in the installation, programming, operation and
maintenance of the product.
The product is manufactured and distributed by Reliance Electric Limited.
Copyright and Trademark
Copyright © 2015 Reliance Electric Limited. All rights Reserved
The information contained in this document is the property of the Reliance Electric Limited
and is protected by law, including without limitation the copyright laws of the United States
and other countries, and by international treaty provisions. No part of this document may be
reproduced, distributed, modified, posted to other Websites or transmitted in any form or by
any means, mechanical, electronic, photocopying, recording, or otherwise, for any purpose

without the prior written permission of Reliance Electric Limited.
Microsoft, Windows, the Windows logo are trademarks of Microsoft Corporation in the
United States, other countries, or both.
PICMG and the PICMG logo and Compact PCI and the CompactPCI logo are registered
trademarks of the PCI Industrial Computers Manufacturers Group.
CompactFlash is a U.S. registered trademark of SanDisk Corporation.
SERCOS interface is a trademark of the Interests Group SERCOS interface ve.V. of
Stuttgart, Germany.
Ethernet is a registered trademark of Xerox Corporation.
All other trademarks, product names, company names or logos used herein are the property
of their respective owners.
.
Limitation of Liability
Information in this document is subject to change without notice. Improvements and
enhancements to the product may occur without any formal notification.
Reliance Electric Limited assumes no responsibility or liability for any errors or inaccuracies
that may appear in the contents of this document.
The illustrations, charts, sample programs and circuit diagram used in this document are
intended only as reference views and may not match the actual configuration at your
worksite. Some adaptations and modifications may need to be applied to be tailored to meet
your specific needs.
The information contained herein is designed only for use with the product. Reliance Electric
Limited is not responsible for any use of this information as applied to other devices.
Reliance Electric Limited shall not be liable for any direct, indirect, incidental, consequential
or punitive damages or revenue, business interruption, loss of use of the product or any
associated products, equipment and software, loss or unavailability of information or data,
interoperability or compatibility issues, cost of capital, cost of any substitute products,
equipment, software, facilities or services, downtime costs, or claims of any party dealing
with you, arising from or in connection with the use of the product including software and
manual, misuse, or abuse of this product or unauthorized modification, repairs, or alterations
to this product, or failure to strictly comply with the instructions manual.

Safety Precautions
The safety alert symbols and signal words are used throughout this manual to alert you to
potential personal injury hazards. Obey all safety messages that follow this symbol to avoid
possible injury or death.
The following symbols definitions describe the level of severity for each signal word:
WARNING
Indicates a potentially hazardous situation that could result in
death or serious injury.
CAUTION
Indicates a possible hazard which if not avoided may result in
minor to moderate injury. It is also used to alert against
unsafe practices that can result in property damage.
ATTENTION indicates installation, operation, maintenance or valuable information that is
not hazard related. It provides a tip, guidance, or advice, emphasizes important information,
or provides a reference to related information.
Safety Notice
The following symbols specify behavior or actions which are not permitted and an instruction
that must be carried out.
Prohibitions
Mandatory
Safety Ground
Before any use, be sure to read and understand all safety instructions and other information
for safe operation to reduce the risk of electrical hazard.An electrical hazard can be defined
as a dangerous condition where the user could make electrical contact with energized
equipment or a conductor, and from which s/he may sustain an injury from shock, receive
thermal burn, or blast injury.
ATTENTION

Use only attachments or accessories of the correct type and rating
specified by the manufacturer. Likewise, never use attachments or
accessories for any other products. Improper use of replacement
components may result in a fire, serious or fatal injury.
Do not use unit in explosive atmospheres, such as in the presence of
flammable liquids, gasses, or dust. The unit may produce sparks, which
can ignite flammable vapors, dust or fumes, and cause fire or explosion.
Operate unit only in well-ventilated areas that are free of flammable vapors.
Do not use unit in the presence of corrosive vapors, fumes, mists or
airborne dusts.
Do not forcibly bend, twist, pull, or place heavy objects on the cable. If
damaged, it can cause a shock hazard or short circuit that can lead to
electric shock, short circuit, or fire.
Do not exceed maximum recommended voltage.
Failure to heed this caution may result in a fire or serious bodily injury.
Do not start or operate unit unless all guards and protective covers are
properly assembled to unit. Opening or removing the guard and cover may
expose the user to dangerous voltages. There is a risk of electric shock
and burning.
Do not remove a faceplate untilAC power is disconnected, and the
capacitor is fully discharged. Dangerous voltages are present inside the
unit. Electrical shock can cause serious or fatal injury.
If damage, incomplete or missing components is found, do not use unit,
otherwise serious personal injuries may occur. Have unit repaired by an
authorized servicing electrician before using.
Do not touch unit, switches, or cables with wet hands. It can result in a
shock hazard.
Do not touch any circuit board, power device or electrical connection right
after power has been disconnected. Failure to observe this precaution
could result in severe bodily injury or loss of life.
Do not disassemble, modify unit.Altering unit in any way may create a
serious safety hazard, and result in electric shock, serious injury to the
user, explosion or fire.
In the event of a malfunction or abnormal situation such as heat
generation, abnormal odor, emission of smoke or unusual sound, shut
down unit immediately. Failure to heed this caution may lead to electric
shock or fire.
Turn off the power source and make sure that capacitors have been fully
discharged by using a voltage tester before starting any configuration,
wiring, or maintenance tasks. Be aware that the capacitors can retain
hazardous voltage even after the power is disconnected. Failure to
observe this precaution could result in electric shock or severe bodily
injury.
Only qualified personnel familiar with the construction and operation of this
product and hazards involved should install, adjust, operate or service the
device. Failure to follow the instructions and warnings could result in loss of
WARNING

life, serious bodily injury, or destruction of the device.
Ensure that all users are protected against electrical shock burns and other
potential electrical safety hazards as well as comply with regulatory
requirements.
The unit must be connected to ground terminal/protective earth to reduce
the risk of fire and electric shock. Use the dedicated ground terminal to
ground unit. Ground impedance and grounding points must comply with
the requirements of national and local industrial safety regulations and/or
electrical codes.
Use a protective earth conductor that can withstand high temperature or
dynamic stress that might be generated during unit installation. It should
have high impact strength and excellent resistance to abrasion. Failure to
heed this caution may lead to electric shock or fire.
The protective earth terminal and conductor should be physically durable
to ensure reliable operation and should also be able to withstand about any
imaginable combination of environmental conditions including temperature
extremes, humidity, dust, oil, radiation, corrosion, and so on. Perform
periodic inspection and preventive maintenance to check the status of
protective earth terminal and conductor and provide early correction of
weaknesses. Failure to heed this caution may lead to electric shock or fire.
The protective earth conductor connected to a unit must not be
instantaneously disconnected through switch operation or electronic
equipment. Electrical and mechanical connection should be constantly
maintained for the protective earth terminal. Failure to heed this caution
may lead to electric shock or fire.

Do not place electric heating element close to the unit.
The unit has openings for ventilation to protect it from overheating. Do not
block or cover any of the ventilation openings. Keep them clean to avoid
overheating.
Do not mount or use unit in a location where excessive vibration or impact
is present.
Do not drop, hit or subject unit to high impact or vibration.
Prevent metallic objects including nails and screws, conductive or
flammable foreign bodies from being entered in the unit.
Do not put anything on top. The area on top of the unit must be kept clear.
Prevent the user from being injured from falling objects.
Do not change the factory preset unless instructed to do so in the
instructions.
Do not use organic solvents such as alcohol, paint thinner, or benzene.
Failure to heed this caution may result in deformation of the device or
discoloration due to chemical reaction.
Do not touch the circuit board. It may result in damage, malfunction, or
deterioration of performance characteristics.
Do not touch any circuit board, reactor, resistor, heat dissipation fin or any
electrical connection areas. There is a risk of burning. Be aware that some
portions of the device have been heated to extremely high temperatures.
Only install unit in a humidity and temperature controlled environment that
meets the requirements given in the technical specifications. Do not
operate or store unit in a place subject to direct sunlight, high temperature,
heat and humidity.
Install the unit in a location that is well ventilated so that the heat generated
by the unit can be dissipated easily.
Prevent the buildup of static electricity. The unit is sensitive to Electrostatic
discharge (ESD). Sudden discharge of static electricity can cause damage
in power modules and integrated circuits.Astrong ESD susceptibility can
generate damage in the unit, or reduces its performance or even destroy it.
Provide appropriate measures on the prevention and control of ESD before
installing, wiring, operating, maintaining, inspecting or repairing the unit.
Electrical noise can affect the proper operation of unit. Take appropriate
measures to prevent electrical noise.
Be sure to provide an emergency stop circuit outside of the unit. This circuit
must disable the system in case of improper operation. Uncontrolled
machine operation can result if this procedure is not followed. Failure to
observe this precaution could result in bodily injury.
Properly wire unit. Use the appropriate size wire for connections. Failure to
observe this precaution could result in electric shock, short circuit, fire,
damage or destruction of unit.
Screws and fasteners can become loose during operation. Ensure the
screws are securely fastened. Regularly inspect and repair any loose or
missing fasteners.
When disconnecting the cord from the power supply, hold the plug body
and never pull out by the cord.
CAUTION

The unit should be used only for the purpose it is designed and directed.
Do not use for other than its intended connectors.
Be sure to turn off the power source before installing or uninstalling the
unit, starting any configuration, wiring, or maintenance tasks. Failure to
observe this caution could result in bodily injury or damage to the unit and
related equipment.
The protective earth conductor should be identifiable by color and shape
and distinguishable from all other conductors. Green and yellow striped
wire would be preferable.

Table of Contents
1 Outline ...................................................................................................................... 1-1
2 Mechanical Structure................................................................................................2-1
2.1 PSC7000 Control Card.........................................................................................2-1
2.2 External Devices...................................................................................................2-2
3 Description of Motherboard Chassis........................................................................3-1
4 Specifications............................................................................................................4-1
4.1 Motherboard Chassis............................................................................................4-1
4.2 DSP Module (DSPM-1A/DSPM-2A).....................................................................4-2
4.3 PG Module (MCIM-1 / MCIM-2)............................................................................4-3
4.4 SERCOS Module (SRCS-1).................................................................................4-4
4.5 PG Module Terminal Block ................................................................................... 4-5
4.6 Dimensions........................................................................................................... 4-5
4.6.1 Motherboard including Modules ........................................................................... 4-5
4.6.2 Terminal Block of PG Module and Cable.............................................................. 4-6
4.7 Installation Dimensions.........................................................................................4-7
4.8 External Wiring for PG Modules........................................................................... 4-8
4.9 Installation of PSC7000........................................................................................4-8
4.9.1 Selection of Installation Site and Environment..................................................... 4-8
4.9.2 Mounting in Control Cabinet................................................................................. 4-9
4.9.3 Wiring in Control Cabinet.................................................................................... 4-11
5 Mounting and Dismounting Modules........................................................................5-1
5.1 Mounting............................................................................................................... 5-1
5.2 Dismounting..........................................................................................................5-3
6 Battery Change.........................................................................................................6-1
6.1 DSPM-1A.............................................................................................................. 6-1
6.2 DSPM-2A.............................................................................................................. 6-3
7 CompactFlash (CF) Memory Card...........................................................................7-1
7.1 Out line of CF Memory Card................................................................................. 7-1
7.2 Appearance...........................................................................................................7-2
7.3 Inserting CF Memory Card................................................................................... 7-2
7.4 Removing CF Memory Card................................................................................. 7-3
7.5 Saving into CF Memory Card...............................................................................7-3
7.6 Download from CF Memory Card.........................................................................7-3
8 Connection to PSC Terminal....................................................................................8-1
8.1 USB Cable............................................................................................................ 8-1
8.2 DCS Programming Cable..................................................................................... 8-2
9 Connection of PG Module and External Wiring ....................................................... 9-1
9.1 PG Signal Inputs................................................................................................... 9-3
9.2 Mark & Origin Point Signal Inputs ........................................................................9-4
9.3 Analog Signal Input...............................................................................................9-5
9.4 Other Terminals of PG Module Terminal Block..................................................... 9-5
9.5 Applicable Wires for PG Module........................................................................... 9-6
10 Programming.......................................................................................................... 10-1
10.1 System Variables................................................................................................10-1
10.1.1 Counter Variable (CHn_COUNTER!）............................................................... 10-1
10.1.2 Latch Variable..................................................................................................... 10-2
10.1.3 Pulse Rate Multiplication (CHn_MULT!)............................................................. 10-3
10.1.4 Input Logic Variable............................................................................................ 10-4
10.1.5 Input Selection Variables.................................................................................... 10-5
10.1.6 Analog Output Variable (CHn_ANALOG_OUT!).............................................. 10-11
10.1.7 Latch Signal Status Input Variables (CHnZZZ@, CHnMRK@, CHnORG@).. 10-12

10.1.8 System Switch Variable (AUTORUN@)........................................................... 10-12
10.1.9 Battery Status Variable (BATTERY@).............................................................. 10-12
10.1.10 Battery Status Warning Variable (BTYWAR@)................................................ 10-12
10.1.11 SynchroCard Synchronizing Status Variable (SYNC1_LOCKED@)............... 10-12
10.1.12 SynchroCard Interval Variable (SYNC1_MILLISECONDS)............................. 10-12
10.1.13 Autorun Permission Variable (AutorunPermission@) ..................................... 10-12
10.2 How to Use System Variables..........................................................................10-12
10.3 List of System Variables ...................................................................................10-13
10.4 Wire-Breaking Detection of PG Module (MCIM-2 Only) ..................................10-17
11 Error Code.............................................................................................................. 11-1
11.1 PSC7000 System Error...................................................................................... 11-1
11.1.1 Internal Errors..................................................................................................... 11-1
11.1.2 Basic Task Program Errors................................................................................. 11-2
11.1.3 CF Memory Error Codes .................................................................................... 11-3
12 Troubleshooting......................................................................................................12-1
13 Appendix.................................................................................................................13-1
13.1 PSC Series .........................................................................................................13-1
13.2 Restrictions on PSC Option Cards.....................................................................13-2
13.3 External Wiring for Controllers............................................................................13-2

1-1
1 Outline
The PSC7000 Control Card is an integrated controller system, combining all the primary
functions into one unit. The user can implement servo control on PSC7000*1) by
programming inverter operation patterns. The PSC7000 provides SERCOS module as
well as input/output circuits required for servo control including feedback input (response
from motors) and analog output.
*1) The PSC controller manages the respective assembled cards (power supply card, DIO, AIO and
network) mounted in the backplane through PSC bus.
Fig.1-1 PSC7000 Control Card Fig.1-2 PSC7000 (Configuration Example)
There are three slots in which the following modules can be attached or removed:
DSP Module:
The DSP module contains a DSP processor to run servo control program and is
indispensable to operate the PSC7000 Control Card.
PG Module:
The PG Module provides 5 channels for incremental pulse encoder input (hereafter,
PG input) and 5 channels for analog output, respectively.
SERCOS Module:
It is SERCOS master module to enable SERCOS communication with inverters.
The PG module, mounted in the PSC7000 Control Card, provides five independent
channels. Each of the channels has its respective input and output circuits as
described below. Each PG module can control up to five independent shafts. The
PSC7000 Control Card can accommodate two PG modules to manage ten shafts.
PG input: Two phase pulse with 90 degree phase difference, Z pulse.
Latch input into the mark and origin signals, respectively
+/-8V or +/-10V analog output

1-2
The PSC7000 requires application program to implement servo control. Through the
PSC7000 terminal, it is necessary to program applications and download the applicati
on program in the PSC7000 controller. The PSC7000 terminal (MH-5009, B40881030
KXX) is software that must be installed on the computer beforehand.
The DSP module contains flash memory to store downloaded program. Data stored in the
flash memory is maintained when the power is turned off or the PSC7000 Control Card is
dismounted from the PSC backplane.
The battery for the DSP module is used to keep nonvolatile variables (NVMEMDEF and
NVLOCAL), and values that change in real time as well.
The application program can be stored on the optional CompactFlash (CF) Memory Card as
well. Further, the application program in the CF Memory Card can be downloaded into the
PSC7000 controller by using a system switch.
When the current PSC7000 Control Card is replaced with a new one, the same application
program can be downloaded to the PSC7000 controller without intervention of the PSC
terminal.
The PSC7000 Control Card is the enhanced version of the PSC5000 Control Card.
It is compatible with each control card of PSC series (PSC3000, PSC4000 and PSC5000)
with the same dimensions and enables programmable servo controller, combined with the
power supply card, backplane and some types of option cards.
Major functions of the PSC7000 Control Card:
The PSC7000 Control Card provides a total quality solution with the following functions:
High speed processing capability:
Calculates 150 MFLOPS through DSP.
Increase in the number of control shafts:
Controls up to 10 shafts of motors when two PG modules are mounted on the PSC7000.
Enhanced flexibility of signal feedback:
Enables communication through SERCOS interface module as well as conventional PG
signal feedback.
Further, the following functions are supported for productive user interfaces:
USB2.0:
Enables high speed communication with a computer and reduces upload and download
time of application program during programming or maintenance.
CF Memory Card:
Ensures reliability for consistent performance with a small, fast, removable mass storage
device.
Dot matrix LED display:
Displays the status of the PSC7000 Control Card. In the event of a failure, an error code
appears.

2-1
2 Mechanical Structure
2.1 PSC7000 Control Card
The PSC7000 Control Card consists of the following components:
マザーシャーシ
ＤＳＰモジュール
マＤＳＰ
ＰＧモジュール
マＤＳＰ
サーコスモジュール
マＤＳＰ
ブランクパネル
Fig. 2-1 Components of PSC7000 Control Card
Depending on your choice and intended use, the controller can be created in combination
with the above modules. The modules are mounted in the slots in the lower part of the
PSC7000 Control Card (compliant with CompactPCI Standard). The DSP module must be
inserted into Slot 3.
Table 2-1 Components for PSC7000 Control Card
Name
Type (Drawing No.)
Part No.
Descriptions
Motherboard
Mother Chassis
(WR-D4008)
B40843301XXX
Modules depending on
the intended use are
mounted in the slots.
DSP Module
DSPM-1A (S-D4031)
B40843705XXX
Mounted in Slot 3
(rightmost)
DSPM-2A
(S-D4041)*1
B40843610XXX
PG Module
MCIM-1 (WR-D4009)
B40843708XXX
Mounted in Slot 1 or 2
MCIM-2 (S-D4043)*2
B40843612XXX
SERCOS Module
SRCS-1 (S-D4039)
B40843609XXX
Mounted in Slot 1 or 2
Blank Panel
Blank Panel
(MB-D4017A)
B40133003AXR
Mounted in open slot
*1: DSPM-2Ais the advanced version of DSPM-1A.
*2: MCIM-2 is the advanced version of MCIM-1.
Motherboard Chassis
SERCOS Module PG Module DSP Module Blank Panel

2-2
2.2 External Devices
The following devices are provided for the PSC7000 controller.
Terminal Block for
PG Module
Cable for PG Module
PSC
256
PSC
512
CompactFlash Memory
Card （256MB, 512MB）
PSC Terminal（CD-ROM）
USB Cable
Battery for DSPM-1A
Module (for replacement)
Battery for DSPM-2A
Module (for replacement)
LAN cable
Network HUB
Fig. 2-2 Peripheral Devices for PSC7000 Controller

2-3
Table 2-2 Peripheral Devices for PSC7000 Control Card
Device
Model
Part No.
Descriptions
Terminal block
for PG module
PS7XW-10080
B40365705XXX
Relays external wires
connected to PG module.
Installed in the control cabinet.
Cable for PG
module
MB-D5021
B40174015XXR
Connects between PG module
and terminal block.
CompactFlash
Memory Card
256MB
MB-D4014
B40882301XXX
Stores data including user
application program.
CompactFlash
Memory Card
512MB
MB-D4015
B40882302XXX
Stores data including user
application program.
PSC terminal
(CD-ROM)
MH-D5009
(CD-ROM)
B40881030KXX
Software tool to perform
programming and maintenance
on PC.
USB cable
B type cable
certified by USB-IF
－
Connects between the
PSC7000 controller and PC.
DCS programming
cable
M-82170
B40884015XXX
Connects between the
PSC7000 controller and PC.
Battery for
DSPM-1Amodule
(for replacement)
Battery
(BR-AGC2P)
B40370861XXX
Backs up memory of DSPM-1A
module.
Battery for
DSPM-2Amodule
(for replacement)
CR2032
(FDK or MAXELL)
-
Backs up memory of DSPM-2A
module.

2-4

3-1
3 Description of Motherboard Chassis
The motherboard chassis of the PSC7000 Control Card is mounted on Slot 0 for a PSC
base unit. Depending on the intended use, modules can be applied to slot 1, slot 2 and slot 3,
respectively.
The DSP module must be inserted into slot 3 (rightmost). The following figure shows the
location and name of the components of the motherboard.
Fig.3-1 Motherboard Composition
Dot Matrix LED indicator
System switch
UP/DOWN button
CPU OK LED
BAT OK LED
Terminal connector
CF Carfd insertion connector
Access LED

3-2
Dot Matrix LED indicator
The status indicator shows the error status of the PSC7000 Control Card when a failure
occurs in a system. For details about errors, see Chapter 12 Error Codes. It also shows
the current status of the PSC7000 Control Card when a specific operation (e.g.
download from CF Memory Card) is processed. For details about CF MemoryCard, see
Chapter 7 CompactFlash (CF) Memory Card.
When the power supply is turned on, the indicator will display “Int…”, “vX.XX”and
“PSC7”sequentially. “VX.XX”indicates the version of the operating system for the
PSC7000 controller.
System switch
The system switch sets up the AUTORUN of the tasks at startup of the PSC7000
controller.
The tasks will not automatically run if the switch is turned in the up position.
The tasks will automatically run or the system will be reset if the switch is turned in the
neutral position.
To start and initialize the PSC7000, hold the switch down for at least 3 seconds.
To download and execute the user task from CF Memory Card, release the switch while
the CF Memory Card remains inserted. For details about the CF Card, see Chapter 7
CompactFlash (CF) Memory Card.
Terminal connector
The terminal connector connects between the PSC controller and the PSC terminal by
using a USB cable.APSC terminal and USB cable are separately sold. For details, see
Chapter 8 Connection to PSC Terminal.
UP button
The UP button allows you to look up the last four errors that have been displayed on the
Dot Matrix LED indicator.
DOWN button
The DOWN button is used to scroll down to the most recent error.
CPU OK LED
The CPU OK LED indicator light turns on when the DSP module of the PSC7000
Control Card is properly running. If the indicator light is off, see Chapter 12
Troubleshooting.
BAT.OK LED
The BAT.OK LED indicator light turns on when the voltage of the battery in the DSP
module goes over a certain value. If the indicator light is off, see Chapter 12
Troubleshooting.
Access LED indicator
The access LED indicator light stays on while the PSC7000 controller is accessing the
CF Memory Card. Do not remove the CF Memory Card while the light is on.