Zub machine control MK1/100 Assembly Instructions

zub machine control AG · 2013
machine control AG
MK1/100
Mono axis compact control
Manual for installation
and hardware reference

Impress
zub machine control AG Manual MK1/100 · Hardware Installation Seite 2
MK1/100
zub machine control AG · Buzibachstrasse 23
CH-6023 Rothenburg
Telefon [phone]
Telefax [phone]
http://www.zub.ch
http://www.aposs.ch
[email protected]
zub machine control AG
All rights reserved. Reproducing or disassembling the computer algorithms in this program is
strictly forbidden. Subject to technical changes.
Issued June 2001
Monika Droeger, www.marketingdienstleistung.de
This manual is set in ITC MixageBQ.
To improve utilization of the printed manual and the on-line help with a variety of programs,
only special characters from the Symbol and Wingdings fonts were used.
APOSS is a registered trademark of Z&B GmbH.
IBM is a registered trademark of International Business Machines, Inc.
Microsoft, MS, MS-DOS, Microsoft NT, Windows and Wingdings are either registered
trademarks or trademarks of the Microsoft Corporation in the USA and other countries.
ITC MixageBQ is a registered trademark of the International Typeface Corporation.
VLT is a registered Danfoss trademark..
Impress
Address
Copyright
Editor
Trademarks

Table of Contents
zub machine control AG Manual MK1/100 · Hardware Installation Seite 3
MK1/100
MK1/100 1
Impressum............................................................................................................................................................................2
Table of Contents............................................................................................................................................................3
Hardware Installation 4
Connection and Initial Operation ........................................................................................................................4
Power Supplies and Communication Test...................................................................................................4
End Switch............................................................................................................................................................................5
Incremental Encoder ....................................................................................................................................................5
Motor Connection...........................................................................................................................................................6
Index Impulse of the Encoder and Reference Switch.........................................................................7
Program testing................................................................................................................................................................7
First steps towards programming......................................................................................................................7
Setting the Control Parameters............................................................................................................................8
Troubleshooting 9
Hardware Reference 10
Power Supply.................................................................................................................................................................10
CPU ........................................................................................................................................................................................10
COM Interface ...............................................................................................................................................................10
Axis Controller ...............................................................................................................................................................11
Encoder Inputs..............................................................................................................................................................11
Pin allocation of the connector for the encoder .................................................................................11
Reference Switch, Central Stop........................................................................................................................11
Control Inputs (Freely programmable)........................................................................................................12
Control Outputs (Freely programmable)...................................................................................................12
Display Elements.........................................................................................................................................................13
Operating Conditions ...............................................................................................................................................13
Mechanical Dimensions..........................................................................................................................................13
Index 14
Table of Contents

Connection and Initial Operation
zub machine control AG Manual MK1/100 · Hardware Installation Seite 4
MK1/100
For safe operation of the compact motor control MK1/100 it is necessary for the unit to be
connected and set in operation according to the VDE regulations.
Follow the steps described below and observe the warning messages.
How to use the APOS Software, please see software manual, chapter I 'APOS user interface'.
To supply the MK1/100 compact unit, you require two voltage sources which have the
following properties:
power supply 1 24 V ±25 %
min. output current3.5 mA
For the initial tests, you can connect the supply voltages and the end switch to the MK1/100,
and plug the 9-pin Sub-D jack on the front panel of the MK1/100 into the serial interface of
the computer.
Carry out the test without the motor and the encoder.
After the voltage turn-on, only the green Power LED should be lit. The red Error LED must
not be lit. In that case, no error is present.
In order to carry out the communication test with the computer, select the menu Execute →
Error State in the APOS program with the cursor keys and and the Enter key.
A window opens for the messages of the MK1/100. By turning the supply voltage of the
MK1/100 off and on, you receive the following initialization message on the monitor:
Z&B MOC-SDT SN Zx_xIL1? xxx. 19xx
Motor controller is initialized with 1 axis
It should be noted that approx. 5 seconds are required after turn-off before the green Power
LED is extinguished.
If you close the window by pressing ESC, an enquiry will appear, asking whether the possible
failure should be deleted. Answer this with J(for Yes) and a corresponding command is
transmitted to the MK1/100. If the command is not received, a time-out error message will be
displayed.
If the communication test was not completed successfully, find out about possible causes at
the end of this section.
Hardware Installation
Connection and Initial
Operation
! ! !
Power Supplies and
Communication Test
! ! !
Encoder
serial interface
end machine stop
PC
switch
1 2 3 4
1 2 3 4 5 6 7 8
+24 V GND
Power Error

End Switch
zub machine control AG Manual MK1/100 · Hardware Installation Seite 5
MK1/100
You can now carry out a test of the end switch. After activation of the end switch, an error
must occur and the red Error LED must be lit.
In order to enquire about the error, open the error enquiry window as described above. The
error message "End switch reached" must appear. Delete the error message with ESC and J
(for Yes).
Switch off the power supply, before you connect the encoder to the MK1/100.
For error-free operation it is necessary for the encoder to be connected with the MK1/100 via
a shielded cable. In making the connection it is important to keep the cables as short as
possible and to route them as far away from power cables as possible. Encoders with TTL or
open collector outputs can be used, which have a supply voltage of 5 V.
The precise allocation of the encoder jack and the significance of the signals (temporal trends
and interrelationships) can also be found in the hardware reference section.
The encoder is mounted on the motor shaft. In order to test the encoder, it is necessary that
the motor shaft is able to move freely.
The motor must not be connected during this test.
In order to test the encoder in a simple way at first, carry out an APOS test program. Select
the APOS menu item File →Load.
With the keys Pos1 and End, select the document "DREHGTST.M“. You can also enter the
name of the document directly. The entry must be completed with the Enter key.
After the APOS program has been loaded, it must be started as follows:
Leave the Editor window with the ESC key. Then select the menu Execute →Start program
with the cursor keys and the Enter key. When the Enter key is pressed, the program is
processed.
In the output window, you will now see a new position value displayed every half a second.
After a full revolution of the motor shaft by hand, the position value should amount to four
times the encoder count per turn. For instance, if the encoder count per turn is 500, you
should receive a position value of ±2000. After a further revolution in the opposite direction,
the position value should be zero.
End Switch
Incremental Encoder
! ! !
! ! !
Encoder with
negative
index impulse
Encoder
Encoder with
positive
index impulse
Encoder
+ 5 V
track A
track B
/Index
GND
screen
+ 5 V
track A
track B
/Index
GND
screen
Z&B Werkbild: mk1drehb
to the encoder
to the encoder
bridge

Motor Connection
zub machine control AG Manual MK1/100 · Hardware Installation Seite 6
MK1/100
For the operation of the positioning system it is absolutely necessary that the encoder is
functional. If the test described above has resulted in improper functioning of the encoder
then this error must be remedied before the starting of operation can be continued.
See also troubleshooting at the end of this section.
Once the encoder function properly then it is possible to proceed with the connection of the
motor.
Switch off the power supply, before you connect the motor!
Moreover, the motor should be set in operation without any related mechanics: in case of
reversed polarity, it may happen that the motor turns at full speed in a random direction.
For this reason – and for safety purposes – the motors are to be fixed in place and existing
brakes are to be released.
Test the motor with the APOS program "MOTORTST.M". Inform you about File →Load and
→Execute in the section "Incremental Encoder".
After the program has been started, the motor will execute two small motion command
(forward and back) and then pause in a resting position.
No error should occur during the test and in the execution window the message "Program
completed without problems" should appear.
If the test is not completed successfully and the message "position error" appears, this may
have two causes:
1. there is no connection between the motor and the MK1/100.
2. the polarity of the motor does not coincide with signals A and B of the encoder. As a
result, the motor turns uncontrolled at top speed in one direction. To solve this problem,
you can reverse the poles of the motor or exchange the encoder signals A and B.
! ! !
Motor Connection
! ! !
! ! !
Encoder
serial interface
end switch
emergency
stop switch PC
reference switch
Z&B Werkbild: mk1drehm
Power Error
+24 V
GND

Index Impulse of the Encoder and Reference Switch
zub machine control AG Manual MK1/100 · Hardware Installation Seite 7
MK1/100
At every revolution, the encoder delivers a index impulse. Together with the reference switch,
this impulse helps with the establishment of the absolute zero.
In order to detect the index impulse, it is necessary that the signals A and B and /Index are
simultaneously low. This can be expressed in the following logical equation:
Detected_index impulse = /A * /B * Index
In order to enable the MK1/100 to detect the index impulse, the MK1/100 must be informed of
the count per turn of the encoder.
In APOS, select the menu Init →Axis param.
In order to set the axis parameters, the MK1/100 must be turned on.
When the Enter key is pressed again, a window opens, in which you can specify the encoder
count per turn. You can close the window again by pressing the Enter key several times.
As there are certain differences between the encoders from different manufacturers, we re-
commend that you test the detection of the index impulse. This can be achieved with the help
of the "NULLTST.M" APOS program. In the illustration "Motor connection", the wiring of the
reference switch has also been displayed.
You may carry this test out without any connected mechanics, provided that the reference
switch can be activated.
After the "NULLTST.M“ program has been started, the shaft of the motor must turn until the
reference switch is closed. After this, it should turn in the opposite direction until the reference
switch is opened and then the index impulse is detected.
If the message "Zero impulse not found" is displayed in the execution window, read about the
possible causes of the error and the corresponding steps to be taken at the end of this
section.
In order to facilitate initial installation, the delivery parameters are set so that movement to the
reference switch after switching on the unit is not absolutely programmed. The software end
switch is also disconnected. Before final integration in a mechanical system it is absolutely
essential that these parameters are set in order to avoid damage to the unit or the system.
After the compact unit has been connected as described above, some of the enclosed demo
programs can be started for initial testing. As far as possible, these tests should be carried out
without connected mechanics (see above).
For instance, in order to establish the basic operability of the data transmission circuit, the
assembly and the programming surface, load the demo program Motortst.M via File →Load
and start it with Execute →Start program (entire program is run in full) or with Execute →
Trace program (program is run line by line, after pressing the Enter key each time).
As a further test, the outputs 1 to 2 can be addressed (by entering APOS commands under
the menu item Online. They are set and reset. They were set and reset. The inputs 1 to 4 can
be read (direct mode) and the end switch can be checked. During a step-by-step program
run, the signal level can be monitored with a suitable measuring device. However, this only
functions if the open collector outputs are connected to a resistor.
The programming of the compact unit is carried out using the APOS software on the PC. The
program supports the development of the user's own movement programs and on-line
testing with the connected drive unit.
Index Impulse of the
Encoder and Reference
Switch
! ! !
! ! !
Program testing
First steps towards
programming

Setting the Control Parameters
zub machine control AG Manual MK1/100 · Hardware Installation Seite 8
MK1/100
The programs are started in exactly the same way as in the previous example.
The demo programs contain a commentary which explains which commands are being
performed and what should happen. In general, all position specifications in the programs are
given in units in multiples of four of the encoder resolution (hereinafter referred to as qc =
quadcounts). For instance, if a encoder with 512 lines is being used, the command
POSR 2048 (= 4 * 512) causes a relative movement of a single revolution. Similarly, a
command POSA 512 means that the motor will be located at a quarter revolution from the
machine's zero calibration. If a encoder with a division of 1,000 lines is being used, the same
results are achieved with the commands POSR 4000 or POSA 1000 respectively. See also
the explanatory notes to the parameters.
This section describes the simple procedure for empirically determining the control
parameters. The values determined in this matter have proven to be sufficient in most
applications; in order to make setting the parameters easier we also offer the program OPAL.
In order to be able to perform the adjustment tests described here the drive must be able to
run, with a normal load, a test distance that is long enough so that the majority of the distance
can be run at the necessary top speed. If the motor is driven at load torque's which differ
greatly (e.g. movements with and without tools), different control settings must be determined
for the various loads and the parameters of the control unit are to be set accordingly in
subsequent application programs.
The control algorithm of the PID filter used is described by the following formula:
u (n) = KP* e(n) + KI∑e(n) + KD[ e(n') - e (n'-1)]
u (n) = Correction factor in n e (n) = Control error in n
n = Sample cadence n' = Sample cadence for differential
factor
KP= Proportional factor KI= Integration factor
KD= Differential factor KILIM = Integration limit factor
For the initial connection of the system it is advisable to set a very low value for the
proportional factor, e.g. KP= 1 (KI , KDand KILIM = 0); thus it is certain that the cycle of the
closed loop control circuit is correct. Now KPcan be set to values ranging from 20 to 200
(typical values) in order to check the basic functions of the system. The values are set
individually, with the aim that vibration-free operation is possible. Then it is possible to begin
with the setting of the other filter parameters.
The setting of the filter parameters directly in the application is necessary since the mechanical
systems can change sufficiently due to fluctuations in temperature, etc., to make an accurate
model recording impossible. However, since it is easy to change the filter parameters, only a
small amount of effort is required. Various methods can be used to empirically determine the
optimal filter values. The method described in the following section is most suitable to make
the settings without having any measured values on hand.
In order to logically comprehend how the settings are made, it is necessary to first understand
the functions of the various filter parameters. The proportional factor KP causes a gain, the
differential factor KDdampens, the integral factor KIeliminates constant positioning errors.
KDand KIare set to zero, and KPis increased until an overcorrection becomes visible. Reading
of the speed over time can be made over the measurement of the motor voltage. By
increasing KDa reduction in the overcorrection can be observed. With ITERATION KPand KD
Setting the Control
Parameters

Setting the Control Parameters
zub machine control AG Manual MK1/100 · Troubleshooting Seite 9
MK1/100
can be increased further until the desired reaction can be observed or until the stability limit is
reached. Here KIand KILIM can also be used to eliminate any constant position errors which
may possibly occur.
Error Reason Solution
After switching on the voltage
the green network LED does
not light up.
The voltage supply is not in
order.
Check the connection of the
connecting cables. Measure the
voltage. It should be 24V ±25%.
After switching on the power
supply the red error LED is lit.
The end switch is not
connected.
Connect the end switch to the
MK1/100.
No communication between
the PC and the MK1/100..
Wrong interface
Wrong cable assignment
Set the correct interface on the
PC with the APOS program.
Use the original cable or check
the cable assignment.
The encoder does not function. Wrong cable assignment.
Encoder needs higher supply
voltage than 5V
Check the connections.
Use an encoder with 5V supply
voltage.
Connect external supply voltage
to the encoder (only for
encoders with open collector
outputs)
Display of the wrong position. The signals A and B of the en-
coder are not displaced by 90°.
Adjust the encoder (if possible).
The index impulse can not be
detected.
The requirement that the A,
B and /index signals are simul-
taneously low has not been ful-
filled.
Connect the /A- and /B-signals
of the encoder to the MK1/100,
provided they exist (instead of A
and B).
The motor is running
uncontrolled at the highest
speed.
The polarity of the motor does
not correspond to the A and B
signals of the encoder.
Reverse the polarity of the motor
or exchange the A and B signals
of the encoder with one another.
Troubleshooting

Power Supply
zub machine control AG Manual MK1/100 · Hardware Reference Seite 10
MK1/100
Control circuit (Control voltage
UBS
) +24 V DC ±25 %, 35 mA
Micro processor 80C32, 8 bit, 24 MHz
Operating system memory 64 kB EPROM
Program memory 128 kB RAM = ca. 20.000 positioning commands;
Application program memory 128 kB EEPROM
Signal transfer to RS232 standard
Baud rate 9600 bit/s
Data format 8 bit
Stop bit 1
Parity none
Signals RxD, TxD, GND
Hardware handshake signal none
Software handshaking XON/XOFF
Type 9-contact D-SUB
Pin allocation 5: GND
7: RxD
8: TxD
Hardware Reference
Power Supply
CPU
COM Interface
MK1/100
-RS232
MK1/100
-RS232
GND
= Ground
RxD
= Received Data
TxD
= Transmitted Data
Z&B Werkbild: mk1com
GND
TxD
RxD
GND
TxD
RxD
PC
PC

Axis Controller
zub machine control AG Manual MK1/100 · Hardware Reference Seite 11
MK1/100
Number of axis processors 1
Control algorithm
u(n) = k e(n)+k e(n)+k [ e(n' )- e(n'-1)]
pi d
∗ ∗ ∗
∑
u(n) = Output size
e(n) = Control error in n
n’= Sample cadence differential factor
KP= Proportional factor
KD= Differential factor
KI= Integration factor
Maximum positioning path ±1 billion quadcounts
(500-series Encoder ca. 536000 revolutions
1000-series Encoder ca. 268000 revolutions)
Number 3 (A, B, Index)
Input frequency max. 180 kHz (per channel)
(500-series Encoder max. 21600 rpm
1000.series Encoder max. 10800 rpm
Input voltage low
U
EL
0 …0.8 V
Input voltage high
UEH
2.6 V …6 V
Input current
I
ELow
0 mA
Input current
IEHigh
2.5 mA …9 mA
Pull-up-Widerstand
Rup
1 k internal
Number 1
Logic central stop low active
reference high = reference point high active
UB
24 V DC ±25 %
Input voltage low,
UEL
–3 V …+5 V DC
Input voltage high,
U
EH
+13 V DC …
U
B
Input current low,
IEH
–0.1 mA …+0.1 mA
Input current high,
IEH
< 1 mA
Axis Controller
Encoder Inputs
Pin allocation of the
connector for the
encoder
Refere
n
ce Switch,
Central Stop
1
2
3
4
5
6
7
8
9
Pin
allocation
01
+5 V (supply encoder)
02
signal A
03
signal B
04
05
GND (supply encoder)
06
07
Index input for encoder with positive index pulse
08
signal /Index
09
/Index output (for 8) for encoder with positive index
pulse
Z&B Werkbild: mk1dre-k

Control Inputs (Freely programmable)
zub machine control AG Manual MK1/100 · Hardware Reference Seite 12
MK1/100
Number 4
Logic positive (high active)
UB
24 V DC ±25 %
Input voltage low,
UEL
–3 V …+5 V DC
Input voltage high,
UEH
+13 V DC …
UB
Input current low,
I
EH
–0.1 mA …+0.1 mA
Input current high,
I
EH
< 1 mA
Number 2
short-circuit proof
Logic positive connecting to GND
APOS program sample: OUT 1 1
means output 1 after GND switched by
U
B
Maximum load current
I
AN
100 mA
Voltage drop 1.8 V for
I
AN
Switching frequency maximum 200 Hz for ohmic load
Defined output condition 200 ms after connecting the power supply
Zero current = 0,5 mA (not connecting)
Control Inputs
(Freely
programmable)
Control Outputs (Freely
programmable)
user
compact unit
U
B (24 V)
input
controller
D
– in case with
inductive load
any output
U
B
+24 V
load
D
user MK1/100

Display Elements
zub machine control AG Manual MK1/100 · Hardware Reference Seite 13
MK1/100
Number 2
LED 1 (green) Power
internal logic supply connected
LED 2 (red) Error has occurred
Operating temperature 0°C …50°C
Storage temperature –20°C …+70°C
Relative humidity < 75 % without dew
Design housing with brackets for easy assembly
enclosers for 19" systems (option)
Width 105 mm; with brackets 130 mm
for 19" systems 3 HE
Height 54 mm inclusive cooling facility
for 19" systems 11 TE
Depth 160 mm
Weight ca. 775 g
Display Elements
Operating Conditions
Mechanical Dimensions

Mechanical Dimensions
zub machine control AG Manual MK1/100 · Index Seite 14
MK1/100
A
Anschrift.............................................................................2
Axis Controller............................................................11
C
Central Stop.................................................................11
COM Interface...........................................................10
Communication Test................................................4
Connection ...................................................................... 4
Control Inputs.............................................................12
Control Outputs........................................................12
control parameters.................................................... 8
Copyright .......................................................................... 2
CPU....................................................................................10
D
Display Elements......................................................13
E
Encoder Inputs..........................................................11
End Switch ...................................................................... 5
F
First steps towards programming .................8
H
Hardware Reference ............................................10
I
Impressum.......................................................................2
Incremental Encoder ...............................................5
Index Impulse of the Encoder..........................7
Index Impulse of the Reference Switch....7
Initial operation............................................................. 4
Inputs
Control inputs ......................................................12
Encoder....................................................................11
M
Mechanical Dimensions......................................13
Motor Connection ..................................................... 6
O
Operating Conditions ...........................................13
Outputs...........................................................................12
P
Pin allocation of the connector for the
encoder ....................................................................11
Power Supplies............................................................ 4
Power Supply.............................................................10
Program testing........................................................... 7
programming................................................................. 8
R
Reference Switch....................................................11
S
Setting the Control Parameters.......................8
T
Table of Contents.......................................................3
Trademarks..................................................................... 2
Troubleshooting .......................................................... 9
Index