Reliability Electric PSC7000 Control Card Troubleshooting and Maintenance



Reliability Electric PSC7000 Control Card Troubleshooting and Maintenance

The Reliance Electric PSC7000 control card is responsible for core tasks such as program execution, feedback input, and analog output in servo control systems. It adopts a mother frame and modular structure, with three CompactPCI slots at the bottom of the mother frame: the DSP module must be installed on the rightmost side of slot 3, and the PG module and SERCOS module can be installed in slot 1 or slot 2. When replacing or troubleshooting on site, the first thing is not to replace the card, but to confirm whether the slot position, module type, and wiring are consistent with the configuration task. The DSP module has built-in Flash, and the user program will not be lost even if it is powered off or removed from the backplane after downloading; The battery on the DSP module is only used to store non-volatile variables such as NVMEMDEF and NVLOCAL, as well as real-time rewritable values. Therefore, 'program still alive, parameters lost' usually refers to battery or CF card recovery, rather than the DSP program itself.

Installation and disassembly: power off first, unlock first, and then plug and unplug in a straight line

The PSC7000 control card and module are sensitive to static electricity and mechanical stress. Before plugging or unplugging control cards, modules, or connecting cables, the machine power should be turned off to avoid accidental actions; Operators should follow ESD protection and avoid touching the connection pins on the back of the control card. Before inserting the module, the red lock on the handle must be pressed to release the plug-in handle; Align the edge of the module with the slot and push it horizontally into the card guide rail. After pushing it into place, lock the handle and tighten the fixing screws on the upper part of the module and below the handle. It is strictly prohibited to directly push the module panel, otherwise it may damage the card or bend the connector pins. When disassembling, first loosen the upper and lower screws, press the red button to unlock the handle, disconnect the module from the female rack connector, and then pull it out horizontally in a straight line; Do not pull diagonally to avoid damaging adjacent modules or the edges of the mother frame. The module supports disassembly and assembly after power failure, but it is not recommended to plug and unplug the module with power on or connect cables. The working temperature of the control card is 0 to 55 ℃, and the storage temperature is -20 to 85 ℃. It should avoid direct sunlight, proximity to the heater, high humidity, and the entry of metal foreign objects.

The mother machine rack provides three CompactPCI slots, with a 5V power supply capacity calculated as 5V/4A based on the conditions of one DSPM-1A, two MCIM-1, 20 × 7 dot matrix full brightness, 10V output for all analog channels, and maximum current of CF card slot. When adding modules or replacing them with DSPM-2A on site, the power margin should be rechecked to avoid "CPU OK light flashing or system restart after installing the new card". The size of the mother frame is approximately W65 × H220 × D222mm, with a depth of about 250mm after module installation and a weight of about 1718g. Cable and heat dissipation space should be left during installation.

BAT-OK light off: battery must be replaced while powered on

DSPM-1A uses BR-AGC2P (Panasonic 3.0V 2200mAh, Reliance part number 370861), with a standard memory retention time of approximately 13.6 years and a minimum of approximately 6.8 years; DSPM-2A uses CR2032 (FDK or Maxell, 3.0V 210mAh) and maintains the standard for about 8 years. The manufacturer recommends replacing it every 5 years, even if the voltage drop is not significant. BAT-OK green light will turn on when the battery voltage is higher than 2.7V; The BATTERY @ variable is true when the voltage exceeds 2.7V, while BTYWAR @ gives a warning when the voltage approaches 2.7V but falls below 2.9V. If the BAT-OK light goes out, first confirm whether the battery connector is plugged in properly, and then measure or replace the battery; If it still doesn't light up after replacement, handle it as a hardware abnormality and replace the control card.

Key safety point: Battery replacement must be carried out while the PSC7000 control card is in battery state. If the power is cut off and replaced, the backup power supply will be temporarily cut off, and the contents of non-volatile variables may be lost. When replacing DSPM-1A, remove the upper and lower screws of the battery box, pull out the two pole connectors, replace the battery with a new one, insert the connector into the panel hole until it is stuck, then reinstall the battery box and fix it. DSPM-2A: Remove the screws above the battery box, take out the old battery, insert it into CR2032 according to the positive and negative pole markings, and then fix the battery cover. Before replacement, it should be confirmed that the user program has been backed up to the CF card or PSC terminal to avoid parameter loss due to operational errors.

CF card: the last line of defense for program recovery

CF card is not a standard accessory for PSC7000 control card and needs to be provided by the user. The original CFI-512MDG or CFI-256MDG should be used, and the format must be FAT (FAT16), otherwise the control card cannot recognize it. The CF card can store user data (library, configuration tasks, application tasks, NVMEMDEF and NVLOCAL variable values) as well as the OS of the PSC7000. The DSP module has a backup battery, and normal power outages will not lose user data, but in the event of accidental loss, the CF card is a means of recovery. Therefore, after program modifications, the latest user data and OS should be regularly saved to the CF card.

When inserting the CF card, the front of the card should face the LED side and be inserted directly into the end of the slot. When the recognition is successful, the Access LED will light up for about 1 second; If inserted silently or not in place, the control card may not recognize it. CF cards can be inserted with or without power, but before unplugging, it is necessary to confirm that the Access LED is not lit, that is, it is not in the process of saving or downloading. When saving to a CF card, the PSC7000 will delete all data in the card and write new data instead of writing or deleting some areas; If all tasks are stopped, power is turned off, or the card is unplugged during the card writing process, subsequent operations cannot be guaranteed.

When downloading from a CF card, first insert the CF card that has saved user data and/or OS, and hold down the system switch for at least 3 seconds; After pressing the switch for 3 seconds, the CPU OK light will turn off. Release the button at this time. If the CF card data is correct and the status indicator (dot matrix LED) displays "LdTK", download begins; If "Fxxx" is displayed, it indicates that the CF card data is incorrect and should be checked according to the error code. After the download is completed, the control card will automatically reset and restart, and the status indicator will display "PSC7" before the task starts automatically. Attention: When downloading the OS from the CF card, the libraries and all application tasks in the PSC7000 will be deleted. It is necessary to confirm that the CF card contains the complete applications before executing them.

PG module wiring: 5-channel feedback and analog output

The PG module provides 5 channels of A, B, and Z-phase pulse inputs and 5 channels of analog outputs. Each PG module can independently control 5 axes, with a maximum of 10 axes for two PG modules. PG input supports four types of signals: 5V differential, 12V emitter follower, 12V totem pole, and 12V collector open circuit; 5V differential and other 12V signals have their own input terminals. The 5V emitter follower, 5V collector open circuit, and 5V totem pole cannot be directly input and require an external signal converter. A. B phase is a rectangular pulse with a difference of 90 degrees, used to determine direction and velocity; The Z pulse appears once per revolution at a specific angle. MARK and ORG inputs are 12 to 24V signals, used for marking and origin detection, respectively. Analog output can output ± 8V or ± 10V full-scale, used for servo amplifier reference voltage.

The PG module is connected to the terminal block through a dedicated cable. The terminal block has 100 terminals (two sets of 50 positions), M3 screws, rated DC24V/0.5A, recommended wire of 1.25mm ², and terminal screw torque of 0.5 to 0.75N · m. After installing the connector, tighten the screw lock to avoid poor contact caused by on-site vibration. PG signal input, MARK/ORG input, and analog output all have optoelectronic isolation and interface circuits; Shielded cables should be used on site, and the shielding layer should be treated according to the grounding specifications inside the cabinet to avoid parallel connection with AC power lines. If the encoder has a negative logic output, the input logic can be reversed by using CHn_Z-POL @, CHn_ORG_POL @, and CHn_MARK_POL @; When the input logic variable is False, use it according to the original logic, and when it is True, use it in reverse.

System variables: count, latch, and multiplier

The system variables corresponding to the PG module can be directly used in configuration tasks and control block tasks without the need for additional definition. CHn_COUNTER! As a counter variable, the range is from 0 to 65535. If it exceeds 65535, it will return to zero, and if it falls below 0, it will return to 65535. The counter will not automatically reset to zero; Can be read using PULSE-READ block. CHn_MULT! Set the multiplier, write 2 as the 2nd multiplier (counted by the upper and lower edges of phase B), and write 4 as the 4th multiplier (counted by the upper and lower edges of phases A and B); MCIM-2 also supports 1x mode. CHn_Z_LATCH! Lock the counter value on the upper or lower edge of the Z pulse, and both forward and reverse rotation can detect the origin with an error of about ± 1 pulse. CHn_REF_LATCH! Reference latch used for marking signals, origin signals, or other channel marking signals; CHn_ORG_LATCH! Used for origin detection, as the counter cannot be reset, the position reference can be established by locking the counter value when the origin is reached.

CHn_REF_SEL! Select the standard latch input edge, which can be the MARK/ORG upper or lower edge of this channel or other channels; When selecting across channels, the input logic is determined by the channel in which the signal enters. CHn_ORG_SEL! Provide 0 to 8 types of origin latch combinations, including the upper edge of the origin signal during reverse rotation, the upper edge of the origin signal during forward rotation, both forward and reverse rotation latch, the upper edge of the origin when the Z pulse is true, the lower/upper edge of the Z pulse when the origin signal is true, and the "OR" combination of 6 and 7. CHn_ANALOG_OUT! For real valued variables, the range is -8192 to+8192, and if it exceeds the range, it will be limited to the maximum/minimum amplitude; The ± 8V terminal outputs 976.5625 μ V/word, and the ± 10V terminal outputs 1.220703125mV/word. If there is an offset voltage, it can be added to the variable or adjusted on the servo amplifier side. AUTORUN @ reflects the status of the system switch ENABLE/ISABLE; BATTERY @ and BTYWAR @ are used for battery monitoring; Sync1_LOCKED @ and Sync1_MILLISECONDS are used for synchronizing the status and interval settings of Sync-1 in the same rack.

MCIM-2 wire breakage detection: differential mode is only effective

MCIM-2 has added disconnection detection compared to MCIM-1. The default single ended mode is the same as MCIM-1 and cannot use wire breakage detection; The differential mode uses a balanced circuit to detect A, B, and Z phase disconnections and make the counting points more uniform during constant speed rotation. To enable differential mode, CHn_DIF-PODE @ needs to be defined in the configuration task, with addresses of BUS=1, SLOT=s, REGIST=45, and BIT of 03, 09, 15, 21, and 27 (channels 1 to 5), respectively. Write 1 to enable and default 0 to disable. When the wire is disconnected, CHn_PG_SRR @ becomes 1, and after recovery, it becomes 0. The address is REGIST=46, and the corresponding BIT is the same as above. If there is a situation where the encoder cable is crushed but the low speed is normal and the high speed is losing pulses on site, priority should be given to checking whether the differential mode is turned on, shielded, and the terminals are tightened, and then checking the PG-ERR @ status.

Error codes and fault trees

The status indicator displays "Init...", "vX.XX", "PSC7" in sequence when powered on, with vX.XX being the OS version. When the system switch is turned to the middle position, the task automatically runs; Pressing and holding for more than 3 seconds will restart and initialize, and user tasks can be downloaded from the CF card when inserted. The UP/DOWN button is used to view the error history. The CPU OK light indicates that the DSP module watchdog is functioning properly; Before turning off the lights, check if the power supply and control card are properly plugged in, and if the backplane power supply is still not restored, replace the control card. BAT-OK lights should be turned off in the order of battery connection, battery voltage, battery replacement, and card replacement.

In terms of error codes: F001 bus error, accessing undefined address, checking for control card, slot, installation errors, and replacing cards block by block if necessary; F002 watchdog error, check configuration tasks, control card and slot definitions, application task I/O usage; F004 overload error, adjust task priority, control block task execution interval, and other application tasks; ERR! If the OS file is damaged or NdOS is displayed, use a CF card to download the OS again. BASIC execution errors F140 to F154 include GOSUB/RETURN mismatch, jump address error, FOR/NEXT usage error, SQRT negative number, bus error, channel not opened, GOSUB nesting exceeding 32 layers, and no DATA in the STORE line. They should be checked item by item in conjunction with the programming manual. CF card error F901 read failure, F902 write failure, F903 creation failure, F904 version incompatibility, F905 CRC error, F940 communication error, F941 CF timeout. The handling principle is to retry read and write after restarting, save user data to CF card again, replace CF card, and if it still fails, replace the control card.