Operation Instructions for Reliance Electric PSC7000 Control Card

Operation Instructions for Reliance Electric PSC7000 Control Card

Product Overview

Hardware architecture: Mother Chassis comes with 3 CompactPCI slots, and the DSP module must be installed on the rightmost slot 3; Optional PG encoder module and SERCOS fiber optic communication module.

Performance indicators: DSP main frequency of 75MHz, floating point computing capability of 150MFLOPS; The minimum scanning period is 50 μ s/62.5 μ s; DSP board with 8MB Flash storage for user programs, no loss of programs in case of power failure; Lithium batteries only store non-volatile variables NVMEMDEF and NVLOCAL.

Axis capability: A single PG module (MCIM-1/MCIM-2) supports 5 axes; Up to 2 PG modules can be installed, with a maximum of 10 axes.

Two feedback options:

PG module: Pulse encoder input+± 8V/± 10V analog output, driving analog servo driver;

SERCOS-1 module: fiber optic SERCOS bus, digital servo driver.

Storage medium: CF card (FAT16 format, original factory 256MB/512MB), backup OS, applications, non-volatile variables; You can download programs directly from the CF card without leaving the PC to restore the entire machine.

External debugging interface: USB 2.0 high-speed, DCS programming serial port.

Working environment: Operating temperature range of 0-55 ℃, storage range of -20~85 ℃.

Whole machine panel components

Component Function

Dot matrix LED display screen displays operating status, version number, fault error code Fxxx

System Switch AutoRun enable/disable, press and hold for 3 seconds to reset the entire machine, triggering CF card download program

UP/DOWN button to browse historical fault records

If the CPU OK green light DSP watchdog is normal, it will be constantly on

BAT-OK green light backup battery voltage ≥ 2.7V lights up

Access red light illuminates when accessing CF storage card

Insert a CompactFlash card into the CF card slot

Terminal interface USB debugging port

Module hardware specifications

1. DSP module (DSPM-1A/DSPM-2A, mandatory)

DSPM-1A: Battery Model BR-AGC2P; It is recommended to replace it every 5 years, with a nominal data retention of ≥ 6.8 years.

DSPM-2A: Upgraded version; Button battery CR2032 (FDK/Maxell), it is recommended to replace it every 5 years and store data for at least 8 years.

Memory: 2MB main memory, 1MB backup memory, 8MB Flash.

Power consumption: 3.3V 700mA.

Key points for battery replacement operation: The controller must remain powered on, and replacing the battery with a power off will result in the loss of non-volatile variables; Only replacing the battery will not lose the user program in Flash.

2. PG module MCIM-1/MCIM-2 (pulse encoder interface module)

Each 5-axis channel contains:

PG encoder input: A/B/Z phase; Supports 5V differential, 12V emitter follower, 12V totem pole, and 12V collector open circuit; Single channel up to 300kHz, 1.2MPPS after 4th harmonic generation;

Mark signal and Origin signal input: 12-24V digital input;

Analog output: ± 8V, ± 10V dual output, 13 bit resolution;

MCIM-2 enhanced features: encoder disconnection detection function in differential mode; MCIM-1 has no disconnection detection.

Supporting peripherals: PG terminal block PS7XW-10080, connecting cable MB-D5021.

3. SERCOS-1 (SRCS-1) digital bus module

Transmission medium: fiber optic ring network; Speed of 4Mbps;

Maximum of 16 nodes; The maximum distance between optical fibers between nodes is 20m; the communication interval is 62.5 μ s~10ms.

Module disassembly process (CompactPCI handle mechanism)

Installation: Press the red unlock button on the handle → Break the handle down → Align the module with the slot and push it horizontally → Pull back the handle to lock it → Tighten the upper and lower fixing screws of the module. Do not push the panel directly, as it will bend the connector pins.

Disassembly: Loosen the upper and lower fixing screws → Press the red button to pull down the handle, and the module will be ejected by mechanical force → Pull out the module horizontally to prevent scratching adjacent boards.

All disassembly and assembly operations must be powered off.

CF memory card operation

Format mandatory requirement: FAT16, must use the original factory specified models CFI-256MDG/CFI-512MDG, third-party cards are not covered by warranty.

Read and write conditions: Access light is off before insertion and removal is allowed; Supports hot swapping, but it is strictly prohibited to remove the card during the card writing process.

Save program: PC PSC Terminal software is required to write the entire OS, task program, and non-volatile variables to the CF card; When writing, all contents of the CF card will be cleared, and local file modifications cannot be made.

To restore the controller from a CF card: Insert the CF card and press and hold the System Switch button for ≥ 3 seconds to release it; The screen shows that LdTK has started downloading; The controller automatically restarts after the download is completed.

Error: The appearance of Fxxx on the screen indicates that the CF card data is damaged or the version is incompatible.

Important: Flashing the OS version from the CF card will clear all internal libraries and application tasks of the controller.

PC debugging connection method

PSC Terminal (MH-5009, CD-ROM software) is the only programming and maintenance software, with two types of connections:

USB cable (priority, high-speed): B-Type USB connected to PSC7000 panel terminal port; Connect the other end to PC USB; Do not plug or unplug cables when downloading programs.

DCS programming cable M-82170:25pin connected to power card Port-B, 9-pin connected to PC serial port; The speed is relatively low.

Communication cables can be hot swappable, but insertion and removal are prohibited during program upload and download processes.

PG module external wiring

The PG module is connected to the cable through an 80 pin Hirose connector and then connected to an external terminal block. Each channel signal:

PG encoder: A,/A; B、/B； Z. /Z (5V differential and 12V input are two independent terminals that cannot be mixed);

Mark (CHxMK) input, Origin (CHxOG) input;

Analog output: CHx REF8 (± 8V), CHx REF10 (± 10V);

CN-CHK terminal: Cable connection detection, internal short circuit when the cable is normal; FG shielding grounding terminal.

Counting and locking function (system variable)

The PG module provides a large number of system variables that can be directly called by programming without the need for variable definitions.

CHn_COUNTER! Counter variable: encoder pulse count value; Support 1x, 2x, and 4x frequency counting; The counter will not automatically reset to zero.

Latch variable (LATCH)

CHn_Z_LATCH! Z-pulse latch, capturing the count value of the arrival time of the Z-pulse; Both forward and reverse rotation can accurately capture;

CHn_REF_LATCH! Reference latch, capture Mark/Origin signal edge; Support cross channel capture of signals from other axes;

CHn_ORG_LATCH! Origin latch, used for returning to zero; Configurable combination conditions: origin signal edge, Z-pulse, motor rotation direction (forward/reverse), a total of 9 capture modes.

CHn_MULT! Pulse doubling setting: 2x/4x (MCIM-2 supports 1x doubling).

Input polarity variable CHn_xxx-POL @: Z pulse Mark、 The origin signal can be software flipped input logic (normally open/normally closed adaptation).

CHn_xxx_SEL! Select variables: configure the edge and signal source triggered by the latch.

CHn_ANALOG_OUT! Analog output variables: numerical values -8192~+8192, corresponding to full-scale ± 8V or ± 10V output.

MCIM-2 exclusive: differential mode can detect A/B/Z phase disconnection when turned on; The disconnection corresponds to CHx_PG.ERR @ set to 1.

Variable suffix description:! Readable and writable; @Status read-only variable.

Programming support

Three programming languages can be mixed and run:

PSC BASIC；

PC Ladder ladder diagram;

Control Block language, suitable for servo high-speed closed-loop operation.

System variables do not need to be defined in the task and can be directly referenced; The appendix of the manual provides a complete table of all system variables for axes 1-10.

Error codes and troubleshooting

The dot matrix LED panel displays Fxxxxx fault codes, which are divided into three categories:

Firmware hardware failure (F0xx)

F001 bus error; F002 watchdog timeout; F004DSP task overload;

BASIC program execution error (F140-F154): nested subroutines FOR‑NEXT、 Jump, negative square root, file channel error, etc;

CF memory card error (F901-F941): read/write failure, version mismatch, CRC check error, timeout.

Typical investigation

CPU OK light off: Check if the backplane power supply and board are securely plugged in; If the hardware is damaged, replace the control card.

BAT-OK light off: battery voltage below 2.7V; replace the corresponding model battery when powered on; Still replacing the DSP module abnormally.

Troubleshooting: After troubleshooting the hardware issue, use PSC Terminal software to clear the fault code.

Complete PSC7000 series accessory list

The entire system consists of a backplane, power card, PSC7000 main control card, and various optional boards. Optional cards: DIO digital IO, AIO analog IO, PNET network card, Sync-1 synchronization card, SAEI absolute encoder card, ControlNet, CC Link, PRIO remote IO card. Backboard specification: 4-slot FSBP-1; 5 slots FSBP-2; 6-slot SSBP-2. Limitation: The maximum number of AIO-1 analog IO cards in the entire machine is 3.

Key precautions

Hot plugging: Modules are strictly prohibited from hot plugging; CF cards can be hot swappable, but are not allowed to be unplugged during the writing process; The USB/serial debugging cable can be hot swappable, but it is prohibited to unplug the downloaded program.

Battery replacement must be carried out with the entire machine powered on. Power off battery replacement will result in the loss of non-volatile variables, and the internal user program of Flash is not affected by the battery.

MCIM-1 does not support encoder disconnection detection, only MCIM-2 differential mode supports disconnection.

CF cards can only be used for overall backup and recovery, and cannot be read or written as regular file systems. They will be completely erased when saved.

Flashing the OS version from the CF card will clear all user programs, so be sure to backup to the PC in advance.