Parker Hannifin ACR-MotionMax User Manual

ACR-MotionMax

Installation Guide

Version 1.0, April 2004

ACR-MOTIONMAX Installation Guide

User Information



ACR Series products are used to control electrical and mechanical
components of motion control systems. You should test your motion system
for safety under all potential conditions. Failure to do so can result in damage
to equipment and/or serious injury to personnel.

ACR series products and the information in this guide are the proprietary property of Parker Hannifin
Corporation or its licensers, and may not be copied, disclosed, or used for any purpose not expressly
authorized by the owner thereof.

2

Since Parker Hannifin constantly strives to improve all of its products, we reserve the right to change this
guide, and software and hardware mentioned therein, at any time without notice.

In no event will the provider of the equipment be liable for any incidental, consequential, or special
damages of any kind or nature whatsoever, including but not limited to lost profits arising from or in any
way connected with the use of the equipment or this guide.

© 2004 Parker Hannifin Corporation
All Rights Reserved

Technical Assistance

Contact your local automation technology center (ATC) or distributor.

North America and Asia

Parker Hannifin
5500 Business Park Drive
Rohnert Park, CA 94928
Telephone: [phone] or [phone]
Fax: [phone]
Email:

[e-mail]

Internet: http://www.parkermotion.com

Europe (non-German speaking)

Parker Hannifin
21 Balena Close
Poole, Dorset
England BH17 7DX
Telephone: [phone]
Fax: [phone]
Email: [e-mail]

Germany, Austria, Switzerland

Parker Hannifin
Postfach: 77607-1720
Robert-Bosch-Str. 22
D-77656 Offenburg
Telephone: [phone]
Fax: [phone]

Email:

[e-mail]

Italy

Parker Hannifin
20092 Cinisello Balsamo
Milan, Italy via Gounod, 1
Telephone: [phone]
Fax: [phone]

Email: [e-mail]

Technical Support E-mail

[e-mail]

ACR-MOTIONMAX Installation Guide

3

ACR-MOTIONMAX Installation Guide

Table of Contents

Chapter 1Introduction and System Overview................................................................... 5

ACR-MOTIONMAX Control System Bit Signal Banks........................................................................ 5

M S & T Code Sequencing ..................................................................................................................... 5

Strobe & Done Signals Table: ................................................................................................................ 5

Jogging Functions................................................................................................................................... 5

Homing & HandWheel ........................................................................................................................... 6

System Overview Diagram..................................................................................................................... 6

ACR-MOTIONMAX to AcroBasic System Start up ............................................................................. 7

ACR-MOTIONMAX AcroBasic Project Template Files....................................................................... 8

Setting the Sys.8k file for Programs & Variable Memory Allocation.................................................... 8

Defining Bit Variables in AcroBasic...................................................................................................... 8

M Code Sequence Examples: ................................................................................................................. 9

M Code Sequence: M08 … Coolant On............................................................................................. 9

S Code Sequence: S2000 .................................................................................................................... 9

T Code Sequence: M6 T2 ................................................................................................................... 9

Chapter 2Setting up Installing ACR-MOTIONMAX....................................................... 9

Reference Files ..................................................................................................................................... 10

ACR-MOTIONMAX Directory & File Structure: ............................................................................... 10

Parameter & Log files....................................................................................................................... 10

Sample Part files............................................................................................................................... 10

Manuals & Reference Documents .................................................................................................... 10

ACR-MOTIONMAX System Setup Diagram...................................................................................... 10

Step 1. Install the Parker-Acroloop SDK (Software Development Kit) ............................................... 12

Step 2. Install ACR-MOTIONMAX to your PC .................................................................................. 12

Step 3. Print Reference Files ............................................................................................................... 13

Step 3. Load ACR-MOTIONMAX AcroBasic Project Template Files .............................................. 13

Step 4. Download Project to Controller Flash. ..................................................................................... 13

Step 5. Test & Phase the Motor/Encoders ............................................................................................ 13

To Change Motor Direction using Parameters: ................................................................................ 13

Step 6. Tune Axis Gains ....................................................................................................................... 14

Step 7. Update ACR-MOTIONMAX Parameters with the Current PPU / Gains Settings ................... 15

Step 8. Configure Homing Functions ................................................................................................... 16

Step 9. Configure I/0 Labels for ACR-MOTIONMAX Diagnostics.................................................... 17

Step 10. Edit the Control Initialization Subroutine............................................................................... 18

Step 11. Edit the M Code Functions..................................................................................................... 19

Step 12. Editing the S Code Function................................................................................................... 20

Step 13. Edit the T Code Function........................................................................................................ 22

Step 14. Edit the Emergency Stop Function ......................................................................................... 23

Step 15. Configure the AcroBasic to ACR-MOTIONMAX User Error Msg. System ......................... 24

Step 16. Configure Valid Mcodes List for ACR-MOTIONMAX ........................................................ 25

Step 17. Configure Key ACR-MOTIONMAX Parameters .................................................................. 26

Step 17a) Configure the Overrides ....................................................................................................... 28

Step 18. Starting ACR-MOTIONMAX for the First Time.................................................................. 29

Running ACR-MOTIONMAX for the First Time................................................................................ 29

4

Appendix A. ACR-MOTIONMAX Parameters............................................................. 30

ACR-MOTIONMAX Installation Guide

Chapter 1 Introduction and System Overview

ACR-MOTIONMAX interfaces to the Parker-Acroloop Motion Card with 32bit Signal Banks provided on

the Motion Card. The Control system communicates with AcroBasic through the Matrix of 5 signal Banks
as shown in the following Chart. The Key bank of signals is the “Control Signals” (Bits 128 to 255) these
Signals are the Main interface between ACR-MOTIONMAX and the users AcroBasic programs.
The Strategy of the ACR-MOTIONMAX Software System is, “ACR-MOTIONMAX is a Core System
that’s designed to stay the same…you simply edit the AcroBasic programs and ACR-MOTIONMAX’s

Parameters to accommodate your particular application.

ACR-MOTIONMAX Control System Bit Signal Banks

Table 1:

Signal Bank Name Acroloop Bit Address’s Description

ControlSignals 128 to 255 Bit Addresses Reserved by ACR-MOTIONMAX
MCode Bits 1920 to 2047 MCodes … M00 to M127 Respectively
Master flags 512 to 544 Servo Motion State Flags
Inputs 0 to 31 …256 to 287 [Default … Ext. I/O Bank 1]
Outputs 32 to 63 … 288 to 319 [Default … Ext. I/O Bank 1]

M S & T Code Sequencing

ACR-MOTIONMAX Executes M S or T Codes by setting an M/S or T Code bit (1920-2047… M00-

M127) and an associated M/S or T Strobe Signal Bit. These bits are picked up by a looping P

and serviced.

rogram 1

5

All M S and T Codes Sent by ACR-MOTIONMAX are accompanied with a following M S or T
Strobe Signal.
The AcroBasic Program1 Intercepts M, S, T Codes and acts on them if its Strobe Signal is =1.
When the AcroBasic MS or T Code Function completes it must! set the associated Done Bit signaling
ACR-MOTIONMAX to continue.

Strobe & Done Signals Table:

Signal Name Address Function

M Done 147 Set by AcroBasic when the M-Code is Completed
S Done 148 Set by AcroBasic when the S-Code is Completed
T Done 149 Set by AcroBasic when the T-Code is Completed
M Strobe 150 Set By ACR-MOTIONMAX along with MCode Bit Pointer of subroutine

to Execute

S Strobe 151 Set by ACR-MOTIONMAX along with the new Dac value in

DAC5(P6480)

T Strobe 152 Set by ACR-MOTIONMAX along with the new Tool code in

Counter5(P6775)

Jogging Functions

ACR-MOTIONMAX Handles all Jogging internally and uses parameters in the Parameters.Cfg file for
Normal and Fast Jog speed settings as shown below.

[JogSpeeds]

Acceleration=1
Deceleration=1
Velocity=100
Stp=1

[FastJogSpeeds]

Acceleration=1
Deceleration=1
Velocity=200
Stp=1

ACR-MOTIONMAX Installation Guide

Homing & HandWheel

ACR-MOTIONMAX accomplishes two special machine functions Homing / HandWheel Step Mode
Functions by calling Subroutines in Prog0.8k Directly at assigned addresses, as shown in Diagram. 1.1
The user simply edits the AcroBasic code of the subroutines to accommodate their application. These
Functions are provided to facilitate the many types of homing a user may require. ACR-MOTIONMAX
simply calls the subroutines at dedicated address of prog0 to execute.

System Overview Diagram

6

ACR-MOTIONMAX Installation Guide

7

Direct
Called

Functions

Control Signals

Bank 1

Bits 128 - 255

"User" AcroBasic Program Template Layout

(1-30)Initialazation

(40) Setup Gearing

Configuration

End of Prog

Bank 2

Bits 1920 to 2047

M Codes

No

Bits 512 to 544

Master Flags

Progam 1Program 0

Control

Ready

Bit 143

= 1 ?

MotionMax

Bank 3

Bits 0 to 31

Inputs Bank0

Bits 256 to 287

Inputs Bank 1

Line 5Line 4

Initialized

Yes

( Line 6 )

Bank 4

Control

Bit 145

=1 ?

Bank 5

Bits 32 to 63

Outputs Bank 0

Bits 288 to 319

Outputs Bank 1

NoYes

Parker

Acroloop

Controler

( 30000 )

Do Control Initialazation

MotionMax Internal

Functions

Operator Interface
GCode File Editor
G Code Processor

Graphics Engine

Overrides

ACR-MC Core Dll

ACR-MC

Parameters

Tool/Work Offsets

Diagnostics

MDI Functions

Jog/Homing

functions

No

(50) X1 Gearing

(60) X10 Gearing

(70) X100 Gearing

(100) X Homing

(200) Y Homing

(300) Z Homing

(400) 4 Homing

(1500) Move Z to

Tool Change Pos.

(1600) Spindle Orient

Program 1 Calls these

2 Functions

fot ToolChanges

ACR-MOTIONMAX to AcroBasic System Start up

MStrobe = 1

STrobe = 0

(Line 7)

No

SStrobe = 1

(Line 8)

No

TStrobe = 1

(Line 9)

No

( 10000 )

General Handler

(11 to 150 )

Yes

Yes

Yes

EStop Reset PB F-Hold PB

Parse

M-Code

( 8000-8999 )

Process
S-Code

( 9000 to 9999 )

Process

T-Code

(1000 to 7999 )

Do MCode

Functions

S Code

Process

Done ?

T Code

Process

Done ?

Over
Travels

M Code
Process

Done

?

Yes

Yes

Yes

No

Set S Done

No

Set T
Done

Error Msg. System

( 40500 )

Set M Done

Clear All M

Codes



Control Ready Bit (143) … This bit will Be Set =1 when ACR-MOTIONMAX initializes and is up

and running. This signal tells the AcroBasic program to start Looping as shown in figure 1.2.

ACR-MOTIONMAX Installation Guide



Control Initialized bit (145)… Tells ACR-MOTIONMAX that the machine is initialized (Drives

Ready) and ready to Run. Insert your Drive Ready and any other initialization code in this function
(30000) to inform ACR-MOTIONMAX that initialization is complete and the machine is ready to run.
Program1 is the Main AcroBasic Program, all MS & T Codes are sent from ACR-MOTIONMAX and
processed in Program1 as shown.

ACR-MOTIONMAX AcroBasic Project Template Files

When ACR-MOTIONMAX is installed it will install an AcroBasic Template Project so the end user can
insert AcroBasic code into ACR-MOTIONMAX’s Predefined Structure of programs and subroutines to
form a repeatable control system. This Project is located in…
“C:\Program files\Parker\ACR-MOTIONMAX\AcroBasicFiles”
…and contains 5 files. Copy these files to your Acroview Default Project Folder.

AcroBasic Template Files list:

Prog0.8k: Sets Axis and Variable Definitions and Axis Homing and Spindle Orient Subroutines.
Prog1.8k: Contains the M S T Code Processing Code, and all other General Machine Functions.
PLC0.8k: Contains a Sample Lube System Code Ladder Program.
Sys.8k Defines System Memory Allocations on the Acroloop Card
Gains.8k Defines All initial Axis Gains.

8

Note: The Gains are overwritten when ACR-MOTIONMAX loads as ACR-MOTIONMAX uses the Gain

Settings

Defined in the Parameters.Cfg file so be sure to duplicate them in the Parameters.Cfg file.

Setting the Sys.8k file for Programs & Variable Memory Allocation

ACR-MOTIONMAX must be configured with enough memory in the SYS. 8k file, for the type of card
used.
PCI buss type cards use DPCB (Dual Port Cache Buffer), ISA buss type cards use FIFO (First in First Out)
Edit the 2 parameters of the SYS.8k file depending on the type of card your using (PCI is Default).

If using PCI Card If using ISA Type Card

Clear DPCB Clear FIFO
Dim DPCB (4096) Dim FIFO (4096)

Sys.8k File listing for PCI Type Controller

REM-----Clear out old allocations----­SYS
HALT ALL
NEW ALL
CLEAR
DETACH ALL

REM-----Allocate system memory----­DIM PROG0 (35000)
DIM PROG1 (35000)
DIM PROG2 (5000)
DIM PLC0 (5000)
DIM P (24)
DIM DEF (300) : REM Allocate Bit Variable Space for 300 Variables
CLEAR DPCB : REM Clear PCI Buss Type Cache Buffer
DIM DPCB (4096) : Rem Allocate for PCI Type Cache Buffer
REM - USER DEFINED AREA

:

Defining Bit Variables in AcroBasic

ACR-MOTIONMAX Installation Guide

9

The Dim DEF (300) parameter in the
progo.8k to allow all bits to called with a Variable Name. No Punctuation is allowed in the variable name
and must be proceeded with #Define statement as shown. See Prog0.8k header.

Example & Format:

REM Input Bit Definitions
#DEFINE INPResetButton BIT0
#DEFINE INPFeedHoldButton BIT1

Sys.8k

should not be changed and is used in the AcroBasic file

M Code Sequence Examples:

ACR-MOTIONMAX MCodes (Bits 1920 to 2047) = M00 to M127

ACR-MOTIONMAX uses these bits to tell the AcroBasic Program which MCode Subroutine to Call.
Do not use any of these bits in your AcroBasic Programs they are reserved for ACR-MOTIONMAX
MCodes.
MCodes are triggered by Setting a MCode Bit (Bits 1920 to 2047) and an M Strobe Bit (150) signal bit.
Then the AcroBasic Program Prog1 will parse and call the appropriate MCode subroutine for execution and
return setting the MDone (Bit 147) Signal. ACR-MOTIONMAX will not execute another MCode or Gcode
if MDone = 0. See Prog1.8k line 6

M Code Sequence: M08 … Coolant On

[ACR-MOTIONMAX Sequence] [AcroBasic Action]

1) Sets bit 1928 M08 does nothing

2) Sets Bit 150 M Strobe 3) Parses the MCode bit and Calls Subroutine to be serviced

4) Returns with Mdone=1 and the Mstrobe=0 and Bit 1928=0

5) Continues

S Code Sequence: S2000

[ACR-MOTIONMAX Sequence] [AcroBasic S Code Handler Action]

1) Writes Dac5 Val to P6480 does nothing

2) Sets the Gear Range Bits

3) Sets the S Strobe Bit 151 4) Processes gear change if required

5) Enables Axis if was running previously with new Dac Value

6) Waits for Spindle to get up to Speed

7) Returns with S Done=1 and the S Strobe=0

T Code Sequence: M6 T2

[ACR-MOTIONMAX Sequence] [AcroBasic T Code Handler Action]

1) If new T Code is different Does nothing
From the Current tool then

Set 159 (ToolChangeRequest)

2) Set 1926 (M6 bit)

3) Set new Target into P6775

4) Set M Strobe ( Bit 150)

5) Set T Strobe (Bit 152) 7) Service M6 Code if ToolChangeRequest = 1

8) Clear ToolChangeRequest and M/T Strobe =0

9) Return with M/T Done Bits = 0.

Chapter 2 Setting up Installing ACR-MOTIONMAX

Install ACR-MOTIONMAX with the Install Program. (Install_ACR-MOTIONMAX.exe)

ACR-MOTIONMAX Installation Guide

Print the following 2 Files for Reference after ACR-MOTIONMAX has been installed:

10

Reference Files

Print the following 2 files for reference:

“C:\Program Files\Parker\ACR-MOTIONMAX\Docs\Default Bit Definitions.xls.”

This file contains a Complete Bit Map of the ACR-MOTIONMAX System. This file is an Excel
spreadsheet for your reference and is your best resource to understanding how ACR-MOTIONMAX
communicates with the Parker-Acroloop Controller and AcroBasic.

“C:\Program Files\Parker\ACR-MOTIONMAX\Docs\Parameter_Definitionst.xls” in the ACR­MOTIONMAX/Docs Sub Folder. This file describes the functions of all Parameters in the Parameters.Cfg
file that ACR-MOTIONMAX uses at runtime

ACR-MOTIONMAX Directory & File Structure:

Default Location … C:\Program Files\Parker\ACR-MOTIONMAX

ACR-MOTIONMAX.exe GUI Interface Program (The Graphical Operator Interface)
Core.Dll API Driven Core of ACR-MOTIONMAX (low level functions DLL File)

Parameter & Log files

Default Location … C:\Program Files\Parker\ACR-MOTIONMAX\Parfiles

Parameters.mdb Contains Machine Parameters (Used by ACR-MOTIONMAX Only)
Parameters.Cfg Contains Machine Parameters
I/O.Cfg Contains Control I/O Map
UserDefined.Err Contains User Defined Error Strings
ToolTables.Mdb Contains Tool Tables Database (Used by ACR-MOTIONMAX Only)
Tool.tbl Contains Current Runtime Tool & Offset Information
ViewPorts.Cfg Used By DLL to Define Zooming and Viewport Options at runtime.
MoveLog.txt Text file listing of all moves and Mcodes that ACR-MOTIONMAX executes.
User.txt Text log file of all functions that the operator does.

Sample Part files

Default Location … C:\Program Files\Parker\ACR-MOTIONMAX\Partfiles

Looping.nc
NestedLooping.nc
NestedSubProgramming.nc
SubProgramming.nc
Mold.nc
Pocket.nc

Manuals & Reference Documents

Default Location … C:\Program Files\Parker\ACR-MOTIONMAX\Docs

ACR-MOTIONMAX_Install_Guide.pdf This Manual
Programmers Reference Manual.pdf G-Code Reference Manual
ControlSignalsDef.doc Control Signals Reference Manual
Default Bit Definitions.xls The ACR-MOTIONMAX I/O Map Reference
MasterVectorInstructions.txt Servo Firmware upgrade instructions
Parameter_Definitionst.XLS Listing of all ACR-MOTIONMAX User Parameters

ACR-MOTIONMAX System Setup Diagram

ACR-MOTIONMAX Installation Guide

Getting Started

Install AcroBasic SDK Software

Install MotionMax Software

Print Reference Manuals

Edit & Print Usert I/0 Map

Copy MotionMax AcroBasic Template Project to Acroview folder

Edit Acrobasic Program 0

Set Encoder Resolutions PPU
Set Encoder Multipliers MULT

Download to Servo Flash

Test & Phase Basic Servo Motion

Tune Servo Drives (Set Gains)

Configure Homing Functions

Configure I/0 Bit Variable Assignments

Save Setting to the Flash

Edit Acrobasic Program 1

Edit Initialzation Code

Edit MCode Functions M00 to M127

Edit S Code Function

Edit T Code Function

Edit Estop Function

Setup Error Msg System Strings

Test MCodes

Save Setting to the Flash

11

Edit MotiomMax Parameters.cfg

Configure #Encoder Resolutions

Configure #of Axis

Configure Gains

Configure Encoder Multipliers

Setup Speeds & Acceleration/
Deceleration

Setup Jog Speeds & Acceleration/
Deceleration

Configure ToolChanger

Configure Spindle Gear Ranges

Configure Inposition Bands

Configure Axis Backlash Values

Configure Axis Travel for Graphics
Display

Configure Overrides

Start Using MotionMax

ACR-MOTIONMAX Installation Guide

Step 1. Install the Parker-Acroloop SDK (Software Development Kit)

Install the Parker-Acroloop SDK to your PC with the CD shipped with your Controller Card.

Important! When installing the SDK be sure to select the Type of Controller you’re using.

Step 2. Install ACR-MOTIONMAX to your PC

12

Install ACR-MOTIONMAX with the Install Program. (

Important!

Do not attempt to run ACR-MOTIONMAX attached to your machine until you have

Install_ACR-MotionMax.exe

)

completed the following tests in AcroBasic!

Disconnect all ServoMotors from any leadscrews or mechanism in case of axis runaway for the initial
setup phase.



Test Emergency Stop Circuitry & OverTravels



Emergency Stop Must Stop all Axis’s & (Spindle/Laser if equipped)



OverTravels Must Stop all Axis’s & (Spindle/Laser if equipped)



Set And Confirmed Encoder Resolutions and Multipliers



Phased the Motors Directionally



Set Axis Gains and can control Motors at the AcroView Command Line.



Duplicate the Encoder PPU / Gains Setting to the Parameters.Cfg file for ACR-MOTIONMAX

Important!

When handling OverTravels, most drives have 3 enables to aid in stopping an axis, Drive Enable,

Forward Enable and Reverse Enable.

Never simply cut main power to the drive in case of Emergency Stop or OverTravel.
Most Drives use Regenitive braking that is disabled if you cut power to the Drives.

If you simply cut the Power to the Drives they will just coast to zero speed and may destroy an Axis.
Instead of stopping the Machine in a Controlled Manner using the drives Internal Braking Power.
The idea here is “If your Amp can’t stop your Axis in a Controlled Manner, The Amp is to Small to
Control your Axis at Full Speed Accurately”.



Always Wire the OverTravels & Estop System into the Drive Enables as shown

Emergency Stop

Fwd. Over Travel Switch

Rev. Over Travel Switch

Servo Drive

Enable

Fwd. Enable

Rev. Enable

Signal Comm.

.

ACR-MOTIONMAX Installation Guide

Step 3. Print Reference Files

Print the following 2 files for reference:

“

C:\Program Files\Parker\ACR-MOTIONMAX\Docs\Default Bit Definitions.xls.”

This file is a Complete I/O Bit Map of the ACR-MOTIONMAX System Signal Banks. This file is an
Excel spreadsheet for your reference and is your best resource to understanding how ACR-MOTIONMAX
communicates with the Parker-Acroloop Controller and AcroBasic.

“

C:\Program Files\Parker\ACR-MOTIONMAX\Docs\Parameter_Definitionst.xls

Parker\ACR-MOTIONMAX\Docs Sub Folder. This file describes the functions of all Parameters in the

Parameters.Cfg file that ACR-MOTIONMAX uses at runtime

” in the

Step 4. Load ACR-MOTIONMAX AcroBasic Project Template Files



Copy the 5 AcroBasic Template files

folder to C:\Program files\Parker\Acroloop\Acroview\Projects\Default folder. If you already have
code in the AcroView default folder it will be overwritten so back it up in necessary.



Open AcroView and Edit Prog0

Don’t Download to Card when prompted by Acroview yet.
Edit Prog0 @ 6 and configure the Axis Encoder Resolutions and Multipliers
Set the PPU Values (Encoder Resolution) for your application… Units = XXXX Counts per 1” of
travel.
Example: PPU X4000 Y4000 Z4000

Mult X1 Y1 Z1

contained in the ACR-MOTIONMAX\AcroBasic sub

13

Step 5. Download Project to Controller Flash.



Download All AcroBasic Programs to the Servo Cards Flash and save it with (No Errors).

Note: to enable error checking … right click in the lower window and select “Logging”. Next

download the file to the card. AcroView writes a log file that resides in the AcroView folder.
Open this file with notepad or create a shortcut to it on your desktop, as you will probably look at
this file hundreds of time to check the program for errors.

When all Programs are Downloaded Error Free. Type the Following at the Command line.

Flash Save
ESave

Step 6. Test & Phase the Motor/Encoders

Phasing is correct when the Axis Readout Increments when moved in a positive direction on your machine.
Enable your Drives manually and type the following at the Command line:
While watching the Readouts on the Top Upper left of the AcroView Screen.

Repeat for All Attached Axes.

Prog0
X1

The X Axis Motor should move 1 inch positive, and in a direction you consider to be Forward on your
Machine. If it doesn’t the Motor is Out of Phase and the Mult Parameter/Encoder or DAC lines will need to
be changed.

To Change Motor Direction using Parameters:

Set the MULT Parameter to –1 for the Axis Axis0 MULT –1
Reverse the Dac Gain for the Axis Dac0 Gain -3276.8