UMAC Guide PUB-0001-06 12000 NE 60th Way Vancouver, WA 98682 Voice 360.253.4810 Fax 360.253.4818 www.appliedmotionsystems.com
2007 Applied Motion Systems, Inc. All rights reserved. No part of this document may be photocopied, reproduced, stored in a retrieval system, or transmitted, in any form or by any means, whether electronic, mechanical, or otherwise without the prior written permission of Applied Motion Systems, Inc. No warranty of accuracy is given concerning the contents of the information contained in this publication. To the extent permitted by law, no liability (including liability to any person by reason of negligence) will be accepted by Applied Motion Systems, Inc., its subsidiaries, or employees for any direct or indirect loss or damage caused by omissions from or inaccuracies in this document. Applied Motion Systems, Inc. reserves the right to change details in this publication without notice. Windows is a trademark and Microsoft, MS-DOS, and Windows NT are registered trademarks of Microsoft Corporation. Other product and company names herein may be the trademarks of their respective owners. Applied Motion Systems, Inc. 12000 NE 60th Way Vancouver, WA 98682 Voice (360) 253-4810 Fax (360) 253-4818 www.appliedmotionsystems.com Table 1 Revision History Revision Date Description 01 23 February 2007 Initial release. 02 6 March 2007 Updated screenshots. 03 22 March 2007 Moved Download the Compiled Code before Download and Restore the Configuration File and minor editorial changes throughout. 04 13 April 2007 Updated the Downloading and Restoring a Configuration procedure. 05 31 October 2007 Added the About the PMAC section. 06 20 November 2007 Added /Pro2 terminology throughout the document. Revised the Establishing Communications section. Added the Configuring a Spare ControlNet UMAC Board section. UMAC Guide Page 2 of 34 PUB-0001-06
Contents 1 Introduction... 4 1.1 Using This Guide... 4 1.2 Our Service Ethic... 4 1.3 Typographic Conventions... 4 2 PEWin32PRO/PRO2 and Your UMAC Controller... 6 2.1 Required Tools... 7 2.1.1 Cautions... 7 2.2 Summary of Uploading and Saving a Configuration... 8 2.3 Summary of Downloading and Restoring a Configuration... 8 2.4 Establishing Communications... 9 2.4.1 Before You Begin... 10 2.4.2 Select and Test the Desired PMAC Device... 10 2.5 PEWin32Pro/Pro2 Functions... 15 2.6 Uploading and Saving a Configuration... 16 2.7 Downloading and Restoring a Configuration... 18 2.7.1 Prepare the Processor... 18 2.7.2 Download the Compiled Code... 22 2.7.3 Download and Restore the Configuration File... 24 2.7.4 Verify the Downloads... 28 3 Controller Operation and Programming Details... 29 4 Configuring a Spare ControlNet UMAC Board... 30 UMAC Guide Page 3 of 34 PUB-0001-06
1 Introduction Thank you for purchasing an Applied Motion Systems machine control and drive system. 1.1 Using This Guide In this guide, we describe how to reconfigure a UMAC controller. We assume that users of this manual are system technicians, engineers, and/or managers. We assume you are trained on safety standards. Throughout this guide we refer to you as the operator, technician, user, or manager of the drive or control system. We are the designers of the system at Applied Motion Systems, Inc. 1.2 Our Service Ethic If you have questions about this system that are not answered in this guide, please contact us at (360) 253-4810. We will do our best to answer your questions quickly and accurately. If you have suggestions for system improvement or a new feature, please let us know. We will make every effort to put your idea to work on your machine. Thank you again for selecting AMS. We look forward to serving you. 1.3 Typographic Conventions The following table explains the typographic conventions used throughout this guide. Table 2 Typographic Conventions Convention To indicate a selection sequence, directories and subdirectories are boldfaced and separated by a pipe ( ). Example Go to Control Shear Control. In this example, first select the Control directory, followed by the Shear Control select button on the Control directory page. Hyperlinks are blue and underlined. See Appendix D on page 76. UMAC Guide Page 4 of 34 PUB-0001-06
Table 2 Typographic Conventions (Continued) Convention Status messages and control and select buttons are capitalized. Placeholders are italicized. Example Selecting START RESOLVER TEST enables the selected motor and starts the resolver test. The file naming convention for event files is evyymmdd.evt. For example, a file named ev070214.evt is the event log for February 14, 2007. Select and open the configuration file for your shop (Your_Shopname.p7k). UMAC Guide Page 5 of 34 PUB-0001-06
2 PEWin32PRO/PRO2 and Your UMAC Controller The UMAC and PMAC are both high-performance motion controllers. Your system may have either controller, or both. We have provided a description of both controllers in this section for your reference. However, we use the terms UMAC and PMAC interchangeably in this guide unless otherwise noted. The process for configuring either motion controller is identical. AMS has made every effort to minimize the possibility of corruption of the application software and parameter settings stored in the UMAC. In the event that this does happen, or a hardware failure of the main UMAC CPU board occurs, you must download a complete backup configuration to your spare UMAC CPU board. To do this, you can use any Windows-compatible PC loaded with the UMAC Executive software, PEWin32Pro or PEWin32Pro2. Note: PEWin32Pro and PEWin32Pro2 are the two latest executive version releases from Delta Tau. Both are similar in look and functionality, but where differences occur, this guide provides instructions both versions. Note: The executive software can also be used to upload the current configuration from the UMAC CPU for archival purposes. If modifications are ever made to the software running in the UMAC, it is important to save the changes in a backup configuration file. Then, should a spare UMAC CPU board need to be restored, an accurate configuration is available to download. In this section, we provide instructions for: PEWin32Pro/Pro2 Functions on page 15 Uploading and Saving a Configuration on page 16 Downloading and Restoring a Configuration on page 18 In addition, we have provided abbreviated versions of the procedures for Uploading/Saving a Configuration and Downloading/Restoring a Configuration on page 8. About the UMAC The UMAC is a high-performance motion controller that is capable of managing up to 32 drives. The UMAC resides in a 3U rack and is often linked to a supervisory PLC via an industrial network such as ControlNet, Ethernet, or a local ISA bus to allow high-speed data transfer. This ongoing transfer of information allows control and adjustment of various parameters that can be changed through the HMI. The UMAC runs control software/code much like a PLC. Along with this program code, the UMAC also has memory definitions, axis-specific parameters, and set-up variables, which are also similar in structure to a PLC. UMAC Guide Page 6 of 34 PUB-0001-06
About the PMAC The PMAC is a high-performance motion controller that is capable of managing up to 8 drives. The PMAC resides in a VME rack along with the Allen-Bradley V30B PLC processor. The Allen-Bradley reads and writes blocks of data to and from the PMAC, and to and from the SoftPLC in the control cabinet. This ongoing transfer of data allows high-speed control and adjustment of various parameters that can be changed via the HMI. The PMAC runs control software/code much like a PLC. Along with this program code, the PMAC also has memory definitions, drive specific parameters, setup variables, etc., which are similar in structure to a PLC. 2.1 Required Tools To complete the procedures in this section, you will need the following: A UMAC controller A Windows-compatible PC The PEWin32Pro or PEWin32Pro2 software If you purchased this software through AMS, it is located on the Delta Tau documentation CD shipped with your system. Alternatively, you can download a free trial version from Delta Tau s Web site (www.deltatau.com). A serial or Ethernet cable to connect your PC to the controller Note: If you are performing this procedure on a spare controller, you must install it in a rack with an identical hardware setup as is used in your system. 2.1.1 Cautions Do not attempt this operation while any motors in the system are running. When bringing a spare UMAC into service for the first time, verify all the jumpers are set correctly to ensure that the hardware is properly configured to your specific drive system (see drawing set shipped with your system for jumper details). When in doubt, compare the new card to the old one. Failure to comply with this instruction may cause severe damage to the UMAC card as well as any and all connected electronics and equipment. UMAC Guide Page 7 of 34 PUB-0001-06 34
2.2 Summary of Uploading and Saving a Configuration Following is an abbreviated version of the process of uploading and saving a configuration to a backup file. For a detailed version of this process, see Uploading and Saving a Configuration on page 16. 1. Establish communications. Use PEWin32Pro/Pro2 to establish either serial or Ethernet communications with the UMAC. The software may take several seconds to find your UMAC. 2. Stop all programs. From the terminal window, type I5=0 and then Enter to stop all programs. 3. Kill the axes. Type CTRL+K to kill all running axes. 4. Select Backup Upload Configuration from the PEWin32Pro/Pro2 toolbar. 5. Configure the backup options as shown in Figure 9 on page 16. 6. Save a global configuration. Choose the location and filename for the configuration file (ex: Name_Shop#_YYMMDD.CFG where YYMMDD is the file creation date, e.g., 070622 denotes the 22nd of June, 2007). Select SAVE and wait for the upload operation to complete. 7. Close the Backup Configuration window by selecting DONE. 8. Re-enable the programs. In the terminal window, type I5=3 [Enter] to re-enable PLC and PLCC programs. 2.3 Summary of Downloading and Restoring a Configuration Following is an abbreviated version of the process of downloading and restoring a configuration to a UMAC CPU. For a detailed version of this process, see Downloading and Restoring a Configuration on page 18. 1. Establish communications. Use PEWin32Pro/Pro2 to establish either serial or Ethernet communications with the UMAC. The software may take several seconds to find your UMAC. 2. Stop programs. From the terminal window, type I5=0 and then Enter to stop all programs. 3. Kill the axes. Type CTRL+K to kill all running axes. 4. Clear the UMAC memory. Type $$$*** [Enter] to clear the UMAC memory. 5. Set the I46 value. Check the value of I46 in the backup (.cfg) file and set it in the UMAC. UMAC Guide Page 8 of 34 PUB-0001-06
6. Save the I46 value. Type SAVE [Enter] to save the I46 value. 7. Activate the I46 value. Reset the system. Type $$$ [Enter] to enable the new I46 setting. 8. Select File Download File from the PEWin32Pro/Pro2 toolbar. 9. Download the compiled code. Choose the UMAC compiled code file to download (ex: Name_Shop#_PLCC_YYMMDD.PMC). Check for errors and warnings. 10. Select Backup Restore Configuration from the PEWin32Pro menu. 11. Download the configuration. Choose the UMAC configuration file to restore (ex: Name_Shop#_YYMMDD.CFG). Check for errors and warnings. 12. Enable the programs. In the terminal window, type I5=3 [Enter] to enable the PLC and PLCC programs. 13. Save the programs. Type SAVE [Enter] to save the program to flash memory. 14. Reset the system. Type $$$ [Enter] to reset the system. 2.4 Establishing Communications If your computer has been previously set up to communicate with the UMAC, those settings are automatically saved. When you subsequently restart the PEWin32Pro or PEWin32Pro2 software, it should begin communicating with the UMAC as it had before. This section is intended for users who have just installed the software or encounter difficulties in getting online with the controller. Depending on your specific system and the UMAC CPU used, you may have the option of communicating via serial and/or Ethernet protocols. Ethernet is faster and should be used if it is an option. These instructions detail setting up both the serial and Ethernet communication methods; disregard comments if they do not apply to the connection type you will be using. Install the PEWin32Pro or PEWin32Pro2 software on your computer. For additional details see the Required Tools on page 7 section of this guide. UMAC Guide Page 9 of 34 PUB-0001-06 34
2.4.1 Before You Begin 1. Connect your computer to the UMAC using any of the following cables: Ethernet Use an Ethernet cable with RJ-45 connectors (AMS part number CAT5E-S, supplied with your system). You can plug directly into the front of the UMAC or through an Ethernet switch if it was provided with your system. Serial Use a 10-pin DB-9 adapter cable (AMS part number CBL-0005), which may already be attached, with a straight-through serial cable (AMS part number CV-20106, supplied with your system). 2. Ensure your computer port settings are correct. Ethernet To communicate with the UMAC over Ethernet, you must ensure your PC IP address and subnet mask are set appropriately. It is always a good idea to open a command window and ping the address of the UMAC to ensure cabling and address issues are correct. Serial Ensure that RSLinx is not active. RSLinx is often set to use one of your computer s RS-232 COM ports and will tie it up, preventing the PEWin32Pro/Pro2 software from accessing the port and getting online with the UMAC. 2.4.2 Select and Test the Desired PMAC Device 1. Open the PEWin32Pro/Pro2 software. Go to Setup General Setup and Options as shown in the following figure. UMAC Guide Page 10 of 34 PUB-0001-06
Figure 1 PEWin32Pro Setup Menu 2. Under the Default Device tab, click the Select button as shown in Figure 2. This opens the UMAC Devices window as shown in Figure 3. Figure 2 PEWin32Pro General Setup and Options Dialog Box UMAC Guide Page 11 of 34 PUB-0001-06 34
Figure 3 PEWin32Pro Device Select Dialog Box 3. If the desired serial or Ethernet device is listed, select it and skip to Test the Device (step 6). Otherwise, if this is your first time running the program, there will not be any devices listed in the list box (as there are in Figure 3); you have not yet added any to your operating system so you will need to insert them. In the PMAC Devices list box, highlight any unassigned NA device numbers and then click Insert. 4. In the Available PMAC Devices list box, select the one you want to add and click OK. Figure 4 PEWin32Pro Available Devices Dialog Box Note: Ethernet devices require a special configuration program to be run before they show up as available devices in PEWin32Pro/Pro2. Please consult AMS to verify you have the latest copy of the Ethernet configuration software and instructions for setting up Ethernet devices. Note: If you are using PEWin32Pro (versus PEWin32Pro2) for the first time and need to insert a serial device, there is a driver installation procedure that must be completed before the serial device will become available to insert. Refer to the PEWin32Pro help documentation or consult AMS for details with installing the serial driver. 5. If using a serial device, you need to set its baud rate to match the baud rate of the UMAC CPU. Highlight the serial PMAC device and click the Properties button. On the Configure UMAC Serial Port dialog box that appears, UMAC Guide Page 12 of 34 PUB-0001-06
select the appropriate baud rate (38400 is most common, followed by 19200) and then click OK. Figure 5 PEWin32Pro Device Properties Dialog Box 6. After you have inserted and highlighted the desired PMAC device, click the Test button to poll communications. The program will pause momentarily while loading the driver. Figure 6 Poll Communications Test Window UMAC Guide Page 13 of 34 PUB-0001-06 34
If communication is successfully established, a dialog box informs you: The UMAC device was successfully detected. If communication is not established, a dialog box informs you: Unable to establish communications. If this occurs, ensure that you have the correct cable connected to the system and that your communications settings match. You may also need to ensure that there are no other serial drivers such as RSLinx interfering with the use of your RS-232 port. If you are unable to resolve this problem, contact AMS for technical support. 7. Click OK until all open configuration windows are closed. 8. If any terminal or position windows were previously open, you need to force them to use the communications device you just set up and tested. Go to Setup Force All Windows to Device Number to bring up the PMAC devices dialog box again. Figure 7 Forcing All Windows to Device Number 9. Select the device you wish all open windows to use and click OK. Your computer is now configured to communicate with the UMAC and initial communications have been established. To continue using the PEWin32Pro/Pro2 software for online functions with the UMAC, see PEWin32Pro/Pro2 Functions on page 15. UMAC Guide Page 14 of 34 PUB-0001-06
2.5 PEWin32Pro/Pro2 Functions After you have successfully connected your computer and established communications with the controller, you can do the following using the PEWin32Pro/Pro2 software: Type any valid UMAC online command or query by going to View Terminal. View the positions of each of the axes by going to View Position. Continuously monitor any variables by going to View Watch Window. Download and restore a configuration to a UMAC CPU (see Downloading and Restoring a Configuration on page 18). Upload and save a configuration to a backup file (see Uploading and Saving a Configuration on page 16). The following figure shows the Terminal window open. If the Terminal Window or any other window is maximized, you will not be able to see the other windows easily. If this occurs, click on the Window Restore button at the top right corner of the screen; do not confuse this button with the Application restore button, which is top-most in the upper right-hand corner. Figure 8 PEWin32Pro with the Terminal Window Open UMAC Guide Page 15 of 34 PUB-0001-06 34
2.6 Uploading and Saving a Configuration Uploading and saving a UMAC configuration to a backup file ensures that a UMAC can be restored to a proper running state at any time in the future. To save the UMAC s configuration to a backup file: 1. From the PEWin32Pro/Pro2 toolbar, select View Terminal. 2. In the terminal window, type I5=0 and then Enter. This disables the code running on the UMAC. 3. Type CTRL+K to kill all running axes. 4. From the toolbar, select Backup Upload Configuration. This brings up a dialog box with an assortment of check boxes used to determine what will be added to the configuration file. Set up the check boxes as follows, then click OK. Figure 9 PEWin32Pro/Pro2 Backup Configuration Options Dialog Box UMAC Guide Page 16 of 34 PUB-0001-06
5. After clicking OK, you are prompted for a filename. Select (or create) the folder and filename on the hard drive and click Save. The file type for the backup must be.cfg. This is the default setting, so you do not need to enter the CFG file extension in the Save as type box. Figure 10 PEWin32Pro Save Configuration Filename Select Dialog Box 6. If you are using a serial connection, you are asked if you want to use check sum communications. Select Yes. The software then begins to upload the configuration file from the UMAC. A progress bar appears at the bottom of the window. The upload may take a few minutes. 7. After the upload is complete, in the Backup Configuration window, click Done. 8. When the software indicates the upload is complete, you need to set I5 equal to three in order to start the PLCs running again. In the terminal window, type I5=3 and then Enter. Note: This procedure does not save the compiled programs (PLCC). The PLCC programs should only be downloaded from PEWin32Pro/Pro2 and not saved in a backup file. This is because the compiled code is firmware-dependent and can only be loaded into a UMAC with the same firmware as it was backed up with. Uploading all code except the PLCC offers the most flexibility in restoration if a new UMAC processor has different firmware than the processor it is replacing. The downloadable PLCC source code supplied by the AMS engineer at startup should be kept in a safe place. UMAC Guide Page 17 of 34 PUB-0001-06 34
2.7 Downloading and Restoring a Configuration Downloading and restoring a software configuration to a UMAC CPU board is a four-part process: 1. Prepare the processor (see page 18). 2. Download the compiled code (see page 22). 3. Download and restore the configuration file (including uncompiled code) (see page 24). 4. Verify the downloads (see page 28). Each of these steps is explained in detail in the following sections. 2.7.1 Prepare the Processor To prepare the processor, you must first clear the CPU memory and restore the card to factory defaults. This ensures that any previously running code is cleared and begins the restore process from a consistent starting point. Following the memory reset, you need to set any UMAC configurations that only take affect at power-up. Here we address only the location for storing P & Q variables. Each type or both can be stored in either battery-backed or RAM memory. The value of parameter I46 defines how they are stored. This value needs to be set and saved in the processor before loading configuration files. To set and save the I46 value: UMAC Guide Page 18 of 34 PUB-0001-06
1. Open the backup configuration file with a text editor and note the value assigned to parameter I46, then close the file. (The value for parameter I46 should be a 0, 1, 2, or 3). Figure 11 Backup File Opened in a Text Editor 2. Establish communications with the UMAC. (For instructions, see PEWin32Pro/Pro2 Functions on page 15). 3. From the PEWin32Pro/Pro2 toolbar, select View Terminal. 4. In the terminal window, type I5=0 and then Enter. This disables the code running in the UMAC. 5. In the terminal window, type CTRL+K. This kills any currently executing motion programs. UMAC Guide Page 19 of 34 PUB-0001-06 34
6. In the terminal window type $$$*** [Enter]. This clears the UMAC memory of all programs and definitions, and sets the processor back to factory defaults. The following figure shows the terminal window after clearing the UMAC memory. Figure 12 Terminal Window after Clearing the UMAC Memory 7. In the terminal window, type I46 [Enter] to check the current value of I46. If the value of I46 is different than you noted in Step 1, then set the value to the one from Step 1 by typing I46=n [Enter], where n is the value you noted in Step 1. 8. In the terminal window, type SAVE [Enter] to save the updated values to flash memory. UMAC Guide Page 20 of 34 PUB-0001-06
9. In the terminal window, type $$$ [Enter]. This resets the UMAC and enables the new settings. The following figure shows the terminal window after setting up I46. Figure 13 Terminal Window after Setting Up I46 10. To continue, proceed to the next step in Download and Restore the Configuration File. UMAC Guide Page 21 of 34 PUB-0001-06 34
2.7.2 Download the Compiled Code After you have prepared the processor, you must download the compiled code. To do so: 1. In the PEWin32Pro/Pro2 software, go to File Download File as shown in the following figure. Figure 14 PEWin32Pro File Menu UMAC Guide Page 22 of 34 PUB-0001-06
2. In the Download File dialog box, select the necessary compiled code file (e.g., Name_Shop#_PLCC_YYMMDD.PMC) as shown in the following figure and click Open. If you are using a serial connection, you are asked if you want to use check sum communications. Select Yes. The software begins downloading the file to the UMAC card. A progress bar appears at the bottom of the window. The download may take a few minutes. Figure 15 Download File Dialog Box 3. When the software indicates the download is complete, check the status of the download in the status Results window at the bottom of PEWin32Pro/Pro2. It should read 0 warnings, 0 errors. Note: If the results show anything but 0 warnings and 0 errors, contact technical support at Applied Motion Systems at (360) 253-4810. Figure 16 Results Window UMAC Guide Page 23 of 34 PUB-0001-06 34
4. The compiled code is now downloaded. To continue, proceed to the Download and Restore the Configuration File section. 2.7.3 Download and Restore the Configuration File After you have downloaded the compiled code, you must restore the configuration file. The UMAC Executive Program s Restore Configuration function manages this task. Make sure you copy the backup file to be used to your hard drive before using the Restore Configuration function. 1. In the terminal window, type I5=0 and then Enter. This disables the code running on the UMAC. 2. From the toolbar, select Backup Restore Configuration. This causes the software to open a window where you can select the required *.cfg backup file of your machine s setup parameters and software. This file contains all the information required to run the drive system and should be located on the hard drive, not a floppy drive. UMAC Guide Page 24 of 34 PUB-0001-06
Figure 17 PEWin32Pro Backup Menu UMAC Guide Page 25 of 34 PUB-0001-06 34
3. In the Download File box, select the file that you wish to use to restore the card (if your system does not have a mouse, use the Tab and arrow keys to select the file). The file you select should be the last backup file created from a known working system. If any changes to the operating software have been made since this backup was created, you must reload the changes after you have completed the restore process. Figure 18 Select Restore File Dialog Box (Download File) 4. After you have highlighted the appropriate backup file, press Enter. If you are using a serial connection, you are asked if you want to use check sum communications. Select Yes. The software begins restoring the file to the UMAC card. The downloading process may take several minutes. 5. When the software indicates the download is complete, check the status of the download in the status Results window at the bottom of PEWin32Pro/Pro2. It should read 0 warnings, 0 errors. Note: If the results show anything but 0 warnings and 0 errors, contact technical support at Applied Motion Systems at (360) 253-4810. UMAC Guide Page 26 of 34 PUB-0001-06
Figure 19 Results Window 6. Type I5=3 and then Enter in the terminal window. This starts the PLCs running again. 7. In the terminal window, type SAVE [Enter]. This saves the new configuration to the flash memory in the UMAC and indicates when the operation is finished. 8. Restart the software by resetting the card. In the terminal window, type $$$ [Enter], or cycle power on the system. This ensures that the proper initialization sequence occurs. 9. Now that you have installed both of the required files to restore the UMAC, and the card has been saved and reset, ensure that the downloaded code is running properly. To continue, proceed to the final step of Downloading and Restoring a Configuration on page 18. UMAC Guide Page 27 of 34 PUB-0001-06 34
2.7.4 Verify the Downloads This procedure includes checking the status of the PLC and PLCC program files to verify they were downloaded correctly and are active. 1. In the PEWin32Pro/Pro2 software, go to View Program/PLC Status (and Upload) to check the status of the uncompiled code. There should be a number of PLC and motion programs listed. In most cases, all will be active except PLC1. (We recommend making a list of the active ones on your project when the system is running correctly. That way you can compare them to the current code after a restore procedure). Figure 20 Upload Programs (Motion and PLC) Dialog Box UMAC Guide Page 28 of 34 PUB-0001-06
2. To check the status of your compiled code, go to View PLCC Status. This brings up a window that shows the status of each of the compiled code modules. All of the PLCCs should be listed as active (not necessarily the numbers shown in the following figure). Figure 21 PLCC Program Status Dialog Box 3. There are a number of parameters associated with machine operation that may have changed since the backup was made (e.g., production rates). In the HMI, verify machine setup before putting the machine back into production. The UMAC processor is now set up correctly for proper system operation. 3 Controller Operation and Programming Details For detailed information about the PEWin32Pro software and the controller hardware, refer to the Delta Tau documentation CD included with your system. UMAC Guide Page 29 of 34 PUB-0001-06 34
4 Configuring a Spare ControlNet UMAC Board Many AMS control systems implement the UMAC motion controller coupled with a PLC via a ControlNet network. The UMAC manages all the lower level motor control and precise synchronization operations, while the PLC handles the supervisory functions of start and stop signals, interfacing with the HMI, and general digital I/O manipulations. The ControlNet link is a vital interface between the UMAC and PLC controllers and is required for certain systems to operate. The UMAC interfaces to the ControlNet network via an ACC-72E ControlNet slave accessory board in the UMAC rack. This card relays information back and forth between the PLC on the ControlNet network and the UMAC CPU board across the UMAC backplane. In order for the data transfer to occur, the ACC-72E must have its own ControlNet configuration downloaded to it. This setup only needs to be downloaded once and is done at system commissioning by the AMS startup engineer. However, if the ACC-72E board were to fail and you replaced it with a spare, the new board would need to be configured before the system could become operational. To set up a new ACC-72E board: 1. Install the SyCon configuration setup/download program if it is not already on your computer. This software is provided with the AMS system documentation on the ACC-72E CD from Delta Tau. 2. Run the SyCon software and go to File Open to open the ControlNet configuration file for the ACC-72E. This file was provided with the system backup code at commissioning and has a.cn file extension (e.g., Sycon UMAC GW Config 215.cn ). UMAC Guide Page 30 of 34 PUB-0001-06
Figure 22 Opening the ControlNet File from SyCon 3. Double-click on the ControlNet icon on the left side of the screen to bring up the ControlNet Device Configuration window as shown in Figure 23. UMAC Guide Page 31 of 34 PUB-0001-06 34
Figure 23 ControlNet Device Configuration Window 4. Make sure all the settings match the settings shown in Figure 23. The MAC ID is the node of the card on the ControlNet. Input and Output lengths should be left at 215 words each, the maximum possible for the ACC-72E. 5. Attach a 9-pin straight-through serial cable between your laptop serial port and the front of the ACC-72E card. Your specific UMAC rack may or may not contain the other cards shown in Figure 24. UMAC Guide Page 32 of 34 PUB-0001-06
Figure 24 Serial Port on the ACC-72E Card 6. Now download the configuration file to the ACC-72E by selecting Online Download. Choose the CIF Serial Driver when prompted, then click OK. Figure 25 Driver Select Window Note: Make sure that RSLinx is not running in the background. It often uses the same PC COM port and will prevent the SyCon software from using the port to download the configuration. 7. When the Device Assignment CIF Serial Driver window opens, select the Connect COM button to the COM port that the serial cable is connected to (typically COM 1). UMAC Guide Page 33 of 34 PUB-0001-06 34
Check the associated box on the left and press OK. This should open communications with the ACC-72E and begin the configuration file download. If the communications don t start and you get a -51 error, you may have a cross-over or null modem serial cable attached. Figure 26 Device Assignment CIF Serial Driver Window 8. A Download window will appear with a progress bar. Wait for the complete configuration to be transferred, then close SyCon and remove the serial cable. This completes the setup of the ACC-72E. Figure 27 Download Progress Bar UMAC Guide Page 34 of 34 PUB-0001-06