LVD Service mail

Counting Principle on PPEB machines

(SSI-principle)
The meaning of this document is to give a clear view in the use of the counting principle (SSI-principle) on a
PPEB machine.
The document should give more information which signals must be measured and where those signals must
be measured. The document has also the intention to give some solutions when there is a problem with the
counting on the machine.

In an annex you will find a schematic overview of the SSI wiring on a PPEB machine.

The document has not the intention of explaining how the signals must be measured. That
description has already been given in the se rv i ce_rna i 1 W 46/0 0 .

Introduction
SSI stands for Synchrony Serial Interface. The electrical design meets the RS422 standard.

With the SSI-protocol is it possible (in the LVD application 500 KHz) to have a fast data transfer with 4 wires.
The SSI protocol is used on the PPEB machine to transfer the different encoder values to the controller

General principle
In the drawing below you will see the general principle.
The controller (Cadman-CNC) generates a number of sync pulses.

We have here two channels namely sync7+ en sync7- (see annexed drawing).
Both channels have been transformed in the receiving hardware (SSI-interface card or servo-drive) in
a one channel trigger signal Takt(+).

There are 24 sync pulses generated in our LVD application. That pulse rain (train of 24 pulses) is repeated
every 5 msec (period between two actual position readings).

On the receiver side, a "Sload" signal is generated on the first falling edge. With that "Sload" signal the
encoder value that must be send out is latched.
On every rising edge a new bit is shifted out and is than transferred by the data line to the controller
The data is now transferred via two data channels (data+ en data-) and is in the controller transformed into a
one-line data signal.
The bit read by the controller is the status of the data line after the rising edge of the sync signal.

LVD Compaq/ SSI Interface eng W42/02 1/8

LVD application
The axis board in the Cadman-CNC controller generates the sync+ en sync- lines. These lines are the
outputs 4 and 12 on XT1/J9.
Both signals are connected with the connector bloc A10 via connector XT1. That connector bloc distributes
the signals to all the receivers.
On that bloc there are three connectors. One must measure the same signal on each pin of that connector.
The outputs sync7+ and sync?- are now connected with the inputs 29 (sync7+) en 30 (sync?-) of the
multiplexer card.

The purpose of the multiplexer card is to become 8 different buffered sync channels (channel* and
channel-) starting with one synchronization signal from the controller.

You can see on the electrical drawing that the outputs 1 and 2 of the multiplexer card are used as sync signal
for both Y-axes. Both outputs are now connected with the terminals 1 and 9 of the connector bloc A10 and
than connected with both Y-axes.
Both sync signals are via the Y1 SSI-interface card connected with the Y2 interface card. On the end
terminal of that Y2 interface a connector must be placed with a terminal resistor (see drawing).

The data channels of both Y-axes are via the connector bloc A10 connected with the Cadman-CNC by the
terminals 5 (data7+) and 13 (data?-) for the Y2-axis and the terminals 2 (data6+) en 10 (dataG-) for the Y1-
axis.

You see on the electrical drawing that there are 6 extra sync lines (SDO-SD5) available on the multiplexer
board. Those outputs are used as sync signals for the motor driven axes. The sync signals are now
connected with the servo-drives.
On that drawing you see that the connection is always made via the terminals 3 (sync+) and 4(sync-). This
is the connection when you have a Mavilor drive. When Baldor drives are used the connection is made on
the terminal 3 (sync+) and 8 (sync-).

The position of the motor is now transferred to the controller by the data lines. The connection is made via the
terminals 11 (data*) and 10 (data-) when using Mavilor drives (see-attached drawing). When there are
Baldor drives used, the connection is made on the terminals 3 (data+) and 8 (data-).

On the machine drawing you will find which axis is connected to the respectively sync and data lines.

Remarks

The rules below must be followed to have an exact counting on the axes.

You can only make the connection according to the attached drawing.

Both channels must be correctly connected between the controller and the different receivers.

- That means that one must always check that on all connection points always both sync lines are
properly connected and that the sync+ and sync- lines are always connected with the + or - terminal.
- That means that one must always check that on all connection points always both data lines are
properly connected and that the data* and data- lines are always connected with the + or- terminal.

It's important to know that if one terminal connection is not properly made we can still have a
good counting on that axis for some time. In that case it's however possible that there is more
influence from disturbance so that we have sometimes a wrong counting.

LVD Company -SSI Tnterface_eng W42/02 2/8

Error analysis
When there is a problem with the counting on an axis you must always measure the different signals with an
oscilloscope.

Control 1
We first have to measure the sync signal (both sync signals) that is coming from the controller.
Those signals must be controlled on their:
Form
Amplitude
Repetition (pulse train must be found every 5 msec.).

The form of those signals and the method to measure those signals is explained in the service mail W46/00.

Remark
When we diagnose a failure in the sync signals one must start to disconnect the connector on the
Cadman-CNC. The sync signal can already be measured on the Cadman-CNC terminals without any
terminal connected. One must have a clear signal at this point.
When the measured signal is OK you connect the controller output to the input of the multiplexer board
(make sure there are no outputs connected on the multiplexer board). Afterwards you can connect the first
output again.
By making all the different connections one by one you can find out which element is causing the fault on
the signal.
If the signal that comes out of the controller is faulty you can try to select another output on the controller
board. On the electrical drawing you see that we have the outputs 1 (sync6+) and 9 (sync-) also
available. If those signals are OK you can use those signals as the sync source. If those signals are also
faulty one must control the starting up of the axis board or measure the tensions inside the
controller to find out the problem.
A description to control the starting up of the axis board is given in the service mail "Process-control on
the axis board of the Cadman-CNC" (mail W38/01). You can already measure the signals from the
moment the axis board is put under tension. It's not necessary to start-up the Cadman-Cnc application.

Control 2
When the signals from the Cadman-CNC are OK one must measure the output signals on the multiplexer
board. As already mentioned there are 8 different sync output channels available on that board. When the
input signals to the board are OK you must find the same signals on all 8 outputs.
If one of the output signals is wrong (no connections made on the outputs) the problems must be caused
internally in the multiplexer board or on the power supply (+15 Volt) of that board. One should check that
voltage with an oscilloscope (checking on spikes, amplitude and shape). One must always check the 5-Volt
generated on the multiplexer board. That tension can be measured on terminal 26 (see attached drawing).

Remark
On the drawing you can see that there are 8 identical outputs on the multiplexer board. On most machines
there are mostly some outputs still available. If one output is not functioning OK you can always try with
another output (a free one or interchange two outputs to see if the problem is changing from axis).

Control 3
When all the outputs on the multiplexer board are Ok you can start to measure the signals on the SSI-
interface card and at the inputs of the different servo-drives. You must always check if both channels are OK.
The best way is to connect one terminal at the time and then check both channels at that terminal.

Control 4
If you are sure that all the sync signals are OK (measured at the receiver side) you must start to check the
data lines for the different axes. In case there are problems with the counting you can start to disconnect all
the connections of the data lines at the SSI-interface cards or at the servo-drives and start to measure the
signals who are coming out of those cards.

Those signals must be controlled on their

Form
Amplitude
Repetition (pulse train must be found every 5 msec.).

LVD Company - SSI Interface_cng W42/02 3/8

The form of those signals and the method to measure those signals is explained in the ser ce —tal /\Mg'00.

You must measure both data signals on each measuring point in the line

Remark
There are 24 sync pulses generated. There are however only 12 data pulses received (the received
encoder data has only 12 bit)
\A/hen you control the data you will find the 12 bit starting at bit 1 for the servo axes and starting at bit 5 for
the Y-axes.

When none of the axes is moving you must always measure the same data value. This can be a random
pattern. When the axis is moved (you can move it by hand) you must see that this pattern is constantly
changing.

Checking the axis readout

You can easily check the value read by the controller. That value must be the same as the pattern that can
be found when measuring with the scope.
When the controller is started up (start of the application Cadman -CMC) you can check data when going into
the restart mode. After selecting the Restart mode on the controller you can check the readout for all the
axes.
Below you find an example of the picture you have in restart mode where you can control the value for all the
different axes. You find the readout value for the different axes below the item Position.

nn
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When you start to move the axis (by hand) the readout value must change. The value must count up when
turning in one direction and count down when turning m the other direction.

Note
You can only do this control the first time after the application is started up. Once a restart is done and you
return to that window again you will see the actual IST-position on the screen.

LVD Company - SSI Interface e\° W42/02

 Remarks

Servo-axes
The readout for the different servo axes is 12-bit absolute pro rotation of the motor. This means that in
the same position for each rotation the readout value must be the same.
Since we have a readout of 12 bit pro rotation we must see a value on the screen between "0" and "4095".
When you start to turn the motor (in the + direction) the value must start to count up. At a certain point the
value will reach "4095" and start than again with "0" to end at the start value when you turned the motor
one rotation.

Note
If you have a value "0" or "4095" when you check the readout a problem on the counting can be expected.

Y-axes
The readout of the Y-axes is also 12bit. In the same restart screen you dont see the total 12bit value.
The value on the screen must be between 1024 and 1279 (normally at the first start up you will find a
value of 1279). When moving the linear encoder the value must change between both limits (1024 and
1279). To have a change over that full range the linear encoder must be moved over 20.48 mm.
If you don't have a value between previous limits (will be "0" or "4095") there is a problem with the
counting.

General directives
General
You first have to find out if the counting problem is on all the machine axes or only on some axes. You must
also find out if the problem is only on the Y-axes or also on the servo axes.
If a problem exists on all the machine axes than you must look in the direction of the sync pulses and more
into detail in the rack and the multiplexer board.
In other cases there must be made a difference if the problem occurs on the servo axes or on the Y axes.

Servo-axes problems
De displacement of an axis is calculated of the difference between two data readouts (SSI-data value read
every 5 msec.) The rule is that there may never be a difference more than % rotation of the motor between
those 2 readouts. This rule limits the max number of rotation the motor may make and limits also the max
speed of the axis).

You can determine an error on the servo axes on two different manners.

1. We first have the situation that due to some data readout errors the difference between two
successive readouts is more than a 1/2 rotation. In this case the difference between the actual
measured position on the machine axis and the actual value displayed on the screen will always
be exactly the displacement of one motor rotation or a multiple of this displacement.

2. Because we have an absolute readout pro rotation the system can compensate a wrong readout.
If the error is less than 1/2 motor rotation the next readout will compensate the previous error. In
that case there will be no difference between the actual position of the axis and the position on
the screen. That error can however be detected when controlling the speed diagram in the
diagnostic view. When we have such an error we will always have two successive spikes (one
positive and one negative) on the speed. In some case you will also notice this on the actual
running of the axis. When we have frequently those errors during the displacement of an axis we
will notice vibrations during the displacement.

If we only notice an error on one axis then we must examine the wiring (between rack and servo-drive) on
that axis, control the servo-drive (interchange the drive), control the wiring between the drive and the motor
(wiring of the resolver) or the motor itself.
When the error is on all the drives the error will be in most cases caused by the 24 V power supply
(especially with Baldor drives). The 24 Volt must than be examined (see sen/ice ma*! week 48/30).

LVD Company - SSI interfacing W4 2/02 5/8

 Remark
When a problem is noticed on the 24 V (especially with Baldor drives) you must control if one drive does
not cause the disturbances. The best way to find out is unplug the drives one by one and check
afterwards the 24 Volt.

Y-axes problems
1 o control a problem with Y-axes you must always control the position of the ram with dial indicator. When
always the same Y-value is programmed the ram must always stop at the same point.

We can distinguish here also two different cases:

Error 1
The calculation of the actual position of the Y-axes follows the same principle as for the servo-axes.
When we have a readout error this can cause a difference in the actual position and the position on
the screen of 20.48 mm. When such an error only occurs on one of the Y-axes, it will cause a tilting of
the ram and the motor will be switched off.

Error 2
When an irregular positioning of the Y-axes is noticed the problem must by found in the linear
encoder, the SSI-interface, the assembling of the encoder or the wiring between the encoder and the
SSI-interface card.

Remark
On the SSI-data from the Y-axes there is a possibility to check the received data. Like already explained
the actual axis data starts at bits of the readout value. In the first three bits there is now a code "010" filled
in by the SSI-interface card. The controller checks that bit pattern. When that pattern is not found in the
data the controller will give an error "Wrong counting Y-axis" (axis error 19).
When that error occurs, you must look for the problem in the wiring between the SSI-interface and the
controller, the SSI-interface itself or on the controller (axis board). You must also check the power supply
to the SSI-interface board. When that voltage is missing the interface will not work and the bit patterns will
not be set.

Note
You have to notice that even when there is no error "wrong counting" it's still possible to have problems
with the counting on the Y-axes.

LVT> Company - SSI Interfacing W42/°: 6/8

 POWER SUPPLY

CONNECTOR
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LVD Company - SSI Interface_eng W42/02 7/8

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LVD Company - SSI Interface_eng W42/02 8/8