PCI-7856 Master-Slave Distributed Motion and I/O Master Controller User’s Manual Manual Revision: 2.00 Revision Date: August 4, 2009 Part Number: 50-11163-1000 Advance Technologies; Automate the World.
PCI-7856 User’s Manual ii
PCI-7856 User’s Manual Table of Contents Table of Contents................................................................... iii List of Figures ......................................................................... v List of Tables......................................................................... vii 1 Introduction ........................................................................ 1 1.1 Specifications....................................................................... 3 1.
PCI-7856 User’s Manual 4.2.1 Digital I/O Module ............................................................... 28 4.2.2 Analog I/O Module .............................................................. 29 4.2.3 DIP Switch Setting .............................................................. 30 4.2.4 Wiring Diagram ................................................................... 31 4.2.5 Terminal Base Motion Control Module................................ 38 4.2.6 HSL-HUB/Repeater ......................
PCI-7856 User’s Manual List of Figures Figure 1-1: Figure 2-1: Figure 2-2: Figure 3-1: Figure 3-2: Figure 3-3: Figure 3-4: Figure 3-5: Figure 4-1: PCI-7856 Block Diagram ................................................. 2 PCI-7856 Mechanical Drawing ........................................ 6 LED Indicators on the PCI-7856 .................................... 10 Overview of an MNET Distributed Motion Control System .................................................. 12 MNET-4XMO-(C) Mechanical Diagram ....
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PCI-7856 User’s Manual List of Tables Table Table Table Table Table Table Table Table 3-1: 3-2: 4-1: 4-2: 4-3: 4-4: 4-5: 4-6: List of Tables MNET Specifications ..................................................... 13 MNET Motion Module Series......................................... 17 HSL Discrete I/O Module Series.................................... 26 HSL Discrete I/O Module Selection Guide..................... 26 HSL Analog I/O Module Series......................................
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PCI-7856 User’s Manual Preface Copyright 2009 ADLINK TECHNOLOGY INC. This document contains proprietary information protected by copyright. All rights are reserved. No part of this manual may be reproduced by any mechanical, electronic, or other means in any form without prior written permission of the manufacturer.
PCI-7856 User’s Manual Getting Service Contact us should you require any service or assistance. ADLINK Technology Inc. Address: 9F, No.166 Jian Yi Road, Chungho City, Taipei County 235, Taiwan קᗼխࡉؑ৬ԫሁ 166 ᇆ 9 ᑔ Tel: +886-2-8226-5877 Fax: +886-2-8226-5717 Email: service@adlinktech.com Ampro ADLINK Technology Inc. Address: 5215 Hellyer Avenue, #110, San Jose, CA 95138, USA Tel: +1-408-360-0200 Toll Free: +1-800-966-5200 (USA only) Fax: +1-408-360-0222 Email: info@adlinktech.
PCI-7856 User’s Manual ADLINK Technology Inc.
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PCI-7856 User’s Manual 1 Introduction Considering the advancement of the industrial machine automation field, designers not only use centralized control systems but also need a distributed solution to develop more complex machine applications. Distributed solutions provide many benefits such as lower maintenance, reduced wiring and a vast number of modules that are easy to integrate.
PCI-7856 User’s Manual MNET and HSL features: Flexible, comprehensive, extendable distributed motion and I/O solution based on PC architecture or embedded platform Convenient wiring for remote distributed motion & I/O modules, including multiple-axes motion control module, single axis motion control module, discrete I/Os and analog I/Os Space saving, reduced wiring and easier maintenance for cost saving Time-deterministic, fast scanning with hundreds of discrete I/O points (up to 2,016 poin
PCI-7856 User’s Manual 1.1 Specifications PCI Bus PCI local bus specification Rev. 2.1-compliant Master Controller Dedicated Motion Controller Motionnet ASIC master control (80 MHz external clock) Dedicated I/O Controller HSL ASIC master control (48 MHz External Clock) Interface Motionnet RS-485 with transformer isolation Half duplex communication 2.
PCI-7856 User’s Manual Operating Temperature 0 to 60°C Storage Temperature -20 to 80°C Power Consumption +3.3 V @ 1.2 A (typical) +5 V @ 1.5 A (typical) 1.2 Supported Software Program Library ADLINK provides Windows WDM drivers and DLL function libraries for the PCI-7856. These function libraries are shipped with the board and they support Windows 2000/XP/Vista.
PCI-7856 User’s Manual 2 Installation This chapter describes how to install the PCI-7856. Please follow the steps below: Check what you have Check the PCB (Section 2.2, page 10) Install the software driver (Section 2.3, page 11) Understanding the I/O signal connections (Section 2.4, page 11) 2.
PCI-7856 User’s Manual 2.2 PCI-7856 Outline Drawing Figure 2-1: PCI-7856 Mechanical Drawing MRJ45 Connector: Motionnet connection port. HRJ45 Connector: HSL connection port. SW1: Card identification switch In addition to this User’s Guide, the package also includes the following items: PCI-7856: Distributed Motion & I/O Master board x1 All-In-One CD x1 If any of these items are missing or damaged, contact the dealer from whom you purchased the product.
PCI-7856 User’s Manual 2.3 Software Driver Installation Using the All-In-One CD with PCI-7856 package and execute the following steps: 1. Auto-run the ADLINK All-In-One CD. 2. Follow the installation steps of the installer. 3. After installation is completed, restart your Windows operating system. Note: The latest software can be downloaded from the ADLINK website: www.adlinktech.com. 2.3.
PCI-7856 User’s Manual 2.4 Signal Connection Signal connections of all I/O’s are described in this section. Refer to the contents of this chapter before wiring any cables between the PCI-7856 and any slave module. This section contains the following sections: Section 2.4.1: PCI-7856 connection with HSL and MNET slave modules Section 2.4.2: RJ45 Pin assignments and LED indication 2.4.
PCI-7856 User’s Manual 2.4.2 RJ45 Pin Assignment and LED Indicator The Motionnet master is the key component in charge of communicating with slave motion and I/O modules. The master sets commands to control slave motion controller or obtain the motion status from slave modules. The PCI-7856 provides two ports of Motionnet master connection for more flexibility wiring. The pin assignment of the MRJ45 connector on the PCI-7856 is listed as below: Pin No.
PCI-7856 User’s Manual The LED indicator on PCI-7856 provides Motionnet and HSL communication status. A red LED indicates Motionnet status and a green LED indicates HSL status. Before initialization of the PCI7856, the red LED and green LED will be off. LEDs will be blinking at a 1 HZ frequency after initialization of PCI-7856.
PCI-7856 User’s Manual 3 Motionnet Master-Slave Motion System Motionnet is an ultra-high-speed serial communication system proposed by NPM (Nippon Pulse Motor) with strong performance with MNET serial connection application. The maximum transfer speed is up to 20Mbps. The PCI-7856 is equipped with one MNET port to offer up to 256 axis control via serial connections. With an ADLINK MNET solution, we not only offer single axis configuration but also provide 4-axis control with interpolation functions.
PCI-7856 User’s Manual PCI-7856 Mitsubishi MR-J3 Series Panasonic A4 Series Yaskawa Sigma II, III Series MNET-4XMO-(C) (4-axes Motion Controller) Multi-drop Connection MNET Bus Via CAT5/5e Cable Figure 3-1: Overview of an MNET Distributed Motion Control System 12 Motionnet Master-Slave Motion System
PCI-7856 User’s Manual 3.1 MNET System Specifications Functions of MNET system can be classified as serial communications and motion control.
PCI-7856 User’s Manual 3.1.1 Wiring Cable This system guarantees enhanced quality for high-speed communication, and is designed to be connected with LAN cables suitable for 100BASE-T and 1000BASE-T. These cables have wellknown specifications, are cheap and easily obtained. Therefore, we do not include these items in our product lines and do not supply them. To select cables, make sure they meet the following specifications.
PCI-7856 User’s Manual 2. Minimum cable length The shortest cable must be at least 60 cm long. 3. Do not mix cables of different types and model in the same serial line. 4. Keep the total serial line length as short as possible. 5. If you are using shielded cables, do not connect the shield on both ends to the FG terminals. Connecting only one end of the shield on each cable will improve noise immunity. 3.1.2 MNET System Communication An MNET system communication block diagram is shown below.
PCI-7856 User’s Manual RAM usage, users are able to write data into a FIFO in the central device, and issue a send command using the same method. This communication will be sent and received automatically by interrupting the cyclic communication. A complete command delivering time depends on the number of MNET packets. One packet command can be delivered in one MNET scan (cycle) time.
PCI-7856 User’s Manual 3.2 MNET Motion Modules MNET motion slave module is a wire-saving solution. ADLINK offers three specific types of modules for connecting to Mitsubishi J3 servos, Panasonic A4 servos and Yaskawa Sigma II, III and V servos. Each module is easy and convenient to plug into the servo drivers. All of the servos can be connected serially through the recommended cable, greatly reducing wiring requirements.
PCI-7856 User’s Manual 3.2.1 Single Axis Motion Modules ADLINK offers three different types motion module which was used for three specific servos. 1. The MNET-J3 can control a servomotor when I/O signals from a Mitsubishi’s MR-J3 series servo driver CN1 are routed directly to this connector, CN4. 2.
PCI-7856 User’s Manual which include Mitsubishi J2S, Panasonic MINAS A4, Yaskawa Sigma II, III and V series and Delta ASDA A2 series.
PCI-7856 User’s Manual Figure 3-3: Outline of the MNET-J3 Assembly with MR-J3 Servo Driver 20 Motionnet Master-Slave Motion System
PCI-7856 User’s Manual Figure 3-4: Outline of MNET-MIA Assembly with a MINAS A4 Servo Driver Motionnet Master-Slave Motion System 21
PCI-7856 User’s Manual Figure 3-5: Outline of MNET-S23 Assembly with a Sigma II, III & V Servo Driver 22 Motionnet Master-Slave Motion System
PCI-7856 User’s Manual Motionnet Master-Slave Motion System 23
PCI-7856 User’s Manual 24 Motionnet Master-Slave Motion System
PCI-7856 User’s Manual 4 HSL Slave Modules The HSL is a master-slave network system, which features an innovative distributed architecture that modularizes the communication, I/O functions and signal termination. ADLINK provides slave I/O modules and terminal base to meet your particular applications requirement including discrete I/O, analog I/O, and motion control. As for motion control module, please refer to the HSL4XMO user manuals.
PCI-7856 User’s Manual 4.1 HSL Slave I/O Module 4.1.1 Discrete I/O Module ADLINK provides three series: DB, M and U series.
PCI-7856 User’s Manual 4.1.2 Analog I/O Module ADLINK provides an M series as follows. Series Model M HSL-AI16AO2-M-VV 16 2 2 (Leap number) HSL-AI16AO2-M-AV 16 2 2 (Leap number) 4 2 U Analog Input Analog Output Slave Index Occupation HSL-AO4 Table 4-3: HSL Analog I/O Module Series The selection guide is as follows.
PCI-7856 User’s Manual 4.2 General Specifications 4.2.1 Digital I/O Module Photo couple isolation 2500 VRMS Input impedance 4.7 kΩ Input Voltage +24 V* Input Current Discrete Input Operation Voltage (@ 24 VDC Power Supply) For NPN(1) -10 mA (2) +10 mA For PNP For NPN(1) ON: 11.4 VDC(Max.) OFF: 14.3 VDC (Min.) For PNP(2) ON: 12.6 VDC(Min.) OFF: 9.8 VDC (Max.) ON: 8.
PCI-7856 User’s Manual *Note: The HSL-DI16-UL supports 5 V, 12 V and 24 V, selected by jumper for each channel: 4.2.2 Analog I/O Module A/D Resolution Analog Input Input Range A/D Conversion Analog Output 16-bit (14-bit guaranteed) For VV type: ±10 V, ±5, ±2.5, ±1.
PCI-7856 User’s Manual 4.2.3 DIP Switch Setting ON 1 2 3 4 5 6 ON = 1 100000 address 1 010000 address 2 … … 011111 address 62 111111 address 63 OFF = 0 Please note the following: 1. The address (or slave index) ‘0’ is reserved. 2. HSL-DI32-M, HSL-DO32-M, HSL-DI32-DB, and HSLDO32-DB need two consecutive addresses that start from an odd number. For example, if the DIP switch is set as 3, it would occupy slave index 3 and 4. 3. HSL-AI16AO2-M-VV/AV needs two leap addresses at full duplex mode.
PCI-7856 User’s Manual 4.2.
PCI-7856 User’s Manual -P PNP Sourcing type sensor Input v+ Circuit LED IN Internal Circuits G -P Wet Contact Input v+ IN G 32 LED Internal Circuits HSL Slave Modules
PCI-7856 User’s Manual -N NPN Sinking Output -P PNP Sourcing Output HSL Slave Modules 33
PCI-7856 User’s Manual -R Relay Output LED NO.n Internal Circuit SSR Load COM.
PCI-7856 User’s Manual -Analog Input (Current Measure) Current Source IN(+) R ADC IN(-) R=125 Ohm %1 accuracy HSL Slave Modules 35
PCI-7856 User’s Manual Dimensions - DB: Daughter board form factor (100 mm X 78.
PCI-7856 User’s Manual - U-series slave I/O module (71.
PCI-7856 User’s Manual 4.2.
PCI-7856 User’s Manual Jumper Settings Since HSL is a serial transmition system, a terminator should be placed at the end of cable. Each TB has a jumper selectable terminator on board. Only the last module have to enable the terminator.
PCI-7856 User’s Manual HSL-TB32-MD Jumper Setting 40 HSL Slave Modules
PCI-7856 User’s Manual Dimensions -DB with HSL-TB32-U-DIN (126x120.1x107.
PCI-7856 User’s Manual -DB with HSL-TB64-DIN (168.7x120.1x107.3) mm -M module with HSL-TB32-M-DIN (128.5x85.
PCI-7856 User’s Manual -HSL-TB32-MD (129x107) mm HSL Slave Modules 43
PCI-7856 User’s Manual 4.2.6 HSL-HUB/Repeater HSL-HUB/Repeater including: HSL-HUB HSL-Repeater Feature 44 Linking style: Master to HUB, HUB to HUB, HUB to Slave Support T bracing connection / Star connection (Subsystem Concept) Support Max. 2.
PCI-7856 User’s Manual General Description Without HSL-HUB A B Add One More Master Controller With HSL-HUB Excellent Add One Mo re Master Controller Figure 4-1: HSL System Configuration HSL Slave Modules 45
PCI-7856 User’s Manual Jumper Settings FD / HD setting: JP*(0-3), JFH1 Half Duplex Full Duplex (default) FA HD JP FD HD FD HD JP FD HD JFH1 JFH1 3 M / 6 M / 12 M setting JBPS1 1 – 3 & 2 – 4 12 M 1 – 3 & 4 – 6 6 M (default) 3–5&2–4 3M 3 – 5 & 4 – 6 EXC 6 M (default) 46 HSL Slave Modules
PCI-7856 User’s Manual Dimensions HSL-HUB HSL-Repeaters HSL Slave Modules 47
PCI-7856 User’s Manual 4.2.7 Managing Slave Index in an HSL Network Before you proceed Before powering on the slave modules, users have to adjust the DIP switch. For this step, please refer to Section 4.2.3 to know how to do this. Please specifically note the following. 1. One master controller can connect up to 63 slave indexes. 2. The more compact slave address in HSL network, the much more efficient the HSL system can work. 3.
PCI-7856 User’s Manual The following examples are provided for user reference. All modules used are set in full duplex mode. Example 1 Provided you installed two HSL-DI16DO16-UD, two HSL-DI32MN, and an HSL-AI16AO2-VV with all slave modules in full duplex mode, you can have two conditions as follows: Condition 1 HSL-AI16AO2-VV×1 is in 6 Mbps. ADLINK suggests users can have the slave index configuration as follows.
PCI-7856 User’s Manual Condition 2 HSL-AI16AO2-VV×1 operates at 12 Mbps. We recommended that you use the provided slave index configuration. Item DIP Switch Index Occupation in HSL HSL-DI32-M-N #1 1 1, 2 HSL-DI32-M-N #2 3 3, 4 HSL-DI16DO16-UD #1 5 5 HSL-DI16DO16-UD #2 6 6 There is another example of a compact composition. The scan time needs 30.33 µs x 6 at 6 Mbps, full duplex mode. You may connect these modules with one master controller.
PCI-7856 User’s Manual Example 2 Provided you installed two HSL-DI16DO16-UJ, one HSLDI16DO16-M-NN, two HSL-DO32-M-N and one HSLAI16AO2-VV with all slave modules in full duplex mode, you can have the following conditions: Condition 1 The HSL-AI16AO2-VV module operates in 6 Mbps. We recommended that you use the provided slave index configuration.
PCI-7856 User’s Manual The scan time needs 30.33 µs x 7. You may connect these modules with one master controller. The HSL-AI16AO2-M-VV module connects to another master controller. The management table below is for reference. Group 2 DIP Switch Index Occupation in HSL HSL-AI16AO2-M-VV 1 1, 2 Refer to the illustration below. Group 1 6 Mbps Group 2 12 Mbps The cycle time of the first master controller is 30.33 µs x 7, while the cycle time of second master controller is 15.
PCI-7856 User’s Manual 5 MotionCreatorPro 2 After installing the hardware, it is necessary to correctly configure all cards and double check the system before running. This chapter gives guidelines for establishing a control system and manually testing the PCI-7856 to verify correct operation. The software provides a simple yet powerful means to setup, configure, test, and debug a motion control system that uses PCI-7856.
PCI-7856 User’s Manual 5.1 Execute MotionCreatorPro 2 After installing the software drivers for the PCI-7856 in Windows, the MCP2 program can be located at \MCP2.exe. Double click this file to run the program. 5.2 About MotionCreatorPro 2 Before running MotionCreatorPro2, the following should noted. 1. MotionCreatorPro2 is a program written by BCB 6.0, and is available only for Windows with a screen resolution higher than 1024x768. It cannot be run under DOS. 2.
PCI-7856 User’s Manual 5.3 MotionCreatorPro 2 Form Introducing 5.3.1 Main Window The main menu appears after running MotionCreatorPro 2. Refer to the following illustrations for a description of the available functions: File\Exit: Close and then exit this program. A C B A. Icons for operation modes. Some will be active when a filed bus / motion item in the tree view was selected and some will be active when an axis item is selected.
PCI-7856 User’s Manual Movement Button Description Single Movement Single Axis movement (PTP), include absolute and relative function. Home Return Movement Home return movement. Interpolation Interpolation function. Sampling Sampling function, it can select source and drew its profile. 2D Movement Execute 2D motion movement Field Bus Button 56 Function Function Description Field Bus Connect Connect Motionnet / HSL module. Please select baud rate at button right side and connect.
PCI-7856 User’s Manual B. All automation products found by MotionCreatorPro2. The tree view can displayed both motion axes and field bus I/O. ICON Function (Yellow) Warning Description Servo Warning (Red) Alarm Servo Alarm (Black) Normal (Servo OFF) No Error and servo off (Green) Normal (Servo ON) No Error and servo on C. Board information about software, firmware and hardware version.
PCI-7856 User’s Manual 5.3.2 HSL Distributed I/O Manager This page can be used to test the HSL system and slave modules. After executing the I/O management page, the main operation window shown below will appear. You can select the module for testing in the tree list of left window. The corresponding ID will also appear with each module. For example, the following figure shows the management pane for the HSL-AI16AO2-VV module.
PCI-7856 User’s Manual B C A Operation Instructions: A. Tree view of whole HSL and Motionnet modules B. Digital input presentation and digital output control C. Check the communication status of each module.
PCI-7856 User’s Manual 5.3.3 Motionnet Distributed Motion Manager The Motionnet manager offers motion operations that include single axis operation, homing return operation, axis parameter setting, etc. Parameters Management B C A Operation Instructions: A. Parameter type display B. Parameter values of all axes C. Parameter management button for load/save parameters to flash or users’ file. You must use set to card to make this table active.
PCI-7856 User’s Manual Single Movement A B C D Operation Instructions: A. Command, feedback, error and target position information. Command and feedback speed information. The minimum speed value may limit by speed calculation cycle time for low speed display. B. Optional operation setting and button. The repeat mode check box can be used in relative and absolute mode. The axes will move between two positions or forward/ backward distance cyclically.
PCI-7856 User’s Manual C. Operation buttons and setting for 3 modes. You can switch operation between relative, absolute and velocity modes. The parameters of each mode must be set before operations such as position 1 and 2, forward/ backward distance and forward/backward velocity. Remember to set MaxVel before executing relative and absolute mode. When using jog mode, the other three modes will be disabled. D. Motion status, I/O status and interrupt status display area.
PCI-7856 User’s Manual Home Return A B C D E F MotionCreatorPro 2 63
PCI-7856 User’s Manual Operation instructions: A. Speed parameter of homing profile, please refer to the figure of area F. B. Modes setting of homing function, you can select one of items in pull down menu C. Command and position information when homing. After the home is done, the command counter will be reset to zero at the edge of ORG ON when VA speed. D. Operation button for start homing or stop/abort homing function E. Motion and I/O status when homing F.
PCI-7856 User’s Manual Interpolation A B C MotionCreatorPro 2 65
PCI-7856 User’s Manual A B C 66 MotionCreatorPro 2
PCI-7856 User’s Manual Operation Instructions: A. Interpolation axes selection and operation parameter settings including center position in ARC mode or target position in Linear mode. The arc angle parameter can be larger than 360. B. Absolute or relative interpolation mode selection. In ARC mode, it relates to the center position. In Linear mode, it relates to the target position. C. Command and position information. In Arc mode, only two will be active.
PCI-7856 User’s Manual NVRAM Write/Read Window The PCI-7856 equipped with 32 KB of NVRAM. By using the write/ read window, you can access and store the data in this non-violated memory directly.
PCI-7856 User’s Manual 5.
PCI-7856 User’s Manual 70 MotionCreatorPro 2
PCI-7856 User’s Manual 6 Scan Time Table 6.1 Full Duplex Mode Slave Index No Cycle Time under 2.5 Mbps Cycle Time under 5.0 Mbps Cycle Time Cycle Time under 10 Mbps under 20 Mbps Base Unit 60.67 μs 30.33 μs 15.17 μs 15.17 μs < 3(*) 182.00 μs 91.00 μs 45.50 μs 45.50 μs 5 303.33 μs 151.67 μs 75.83 μs 75.83 μs 10 606.67 μs 303.33 μs 151.67 μs 151.67 μs 20 1.213 ms 606.67 μs 303.33 μs 303.33 μs 30 1.820 ms 910.00 μs 455.00 μs 455.00 μs 40 2.427 ms 1.213 ms 606.67 μs 606.
PCI-7856 User’s Manual 72 Scan Time Table
PCI-7856 User’s Manual 7 HSL-HUB/Repeater Information 7.1 Transfer Rates Tranfer rates recommended total extension distance and the number of inserted HSL-HUB/Repeater Transmission Rate Number of Inserted Hubs (Repeater) Basic Configuration 1 2 3 4 5 6 7 3 Mbps 300 m 600 m 900 m 1.2 km 1.5 km 1.8 km 2.1 km 2.4 km 6 Mbps 200 m 400 m 600 m 800 m 12 Mbps 100 m 200 m 300 m 400 m 500 m 600 m 700 m 800 m 1 km 1.2 km 1.4 km 1.6 km 7.
PCI-7856 User’s Manual Full duplex / 6Mbps Number of inserted Hubs (Repeater) Slave Index Number 3 (Min.) 30 63 (Max.) Basic Configuration (0) 91.00 μs 910.00 μs 1911.00 μs 1 164.00 μs 1640.00 μs 3444.00 μs 2 236.00 μs 2360.00 μs 4956.00 μs 3 308.00 μs 3080.00 μs 6468.00 μs 4 380.00 μs 3800.00 μs 7980.00 μs 5 452.00 μs 4520.00 μs 9492.00 μs 6 524.00 μs 5240.00 μs 11004.00 μs 7 596.00 μs 5960.00 μs 12516.
