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Motorcortex Hardware

Motorcortex Hardware

Motorcortex has to run on a separate operating system. Vectioneer has multiple options availavle to get started using Motorcortex quickly. More information on this can be found at www.vectioneer.com/products/. In docs.motorcortex the hardware manuals for these products are described.

If you want to try out Motorcortex from your own machine it is possible to do this using a Virtual Machine. The Virtual machine manual provides information on how to get your virtual machine going.

1 - Generic Control Case

Introduction

This document is the User Manual for the Generic Control Cabinet.

The Vectioneer Generic Control Case (GCC) is a complete Industrial Motion Control and Safety System in a small form-factor. It has everything you need to control any EtherCAT-based Machine or Robot safely. Out-of-the-box it is set-up with the MOTORCORTEX-Generic-App pre-installed. This allows you to control multiple EtherCAT servo axis and numerous EtherCAT IO straight from a connected web-browser. No software installation required.

System Overview

The Generic Control Case allows easy control of EtherCAT slaves. It also provides (limited) onboard power to supply externally connected EtherCAT devices. Two EtherCAT branches can be connected to the two EtherCAT sockets on the front panel.

An integrated FSoE (FailSafe over EtherCAT) master provides a complete safety system, that can be extended with extra FSoE slaves if needed. As a standard one two-channel Emergency Stop input and a 2 channel STO output are provided and configured.

The (typical) System Overview is shown in the figure below.

Optionally the Generic Control Case can be extended with an Application Case that will provide a robot or machine with power or servo amplifiers. Vectioneer has a standard Application 48v case for 48VDC robots.

what’s in the box

After Buying a GCC you the following components should be in the box:

  • 1x Generic Control Cabinet
  • 1x IEC C13 Power cable with Schuko (EU) plug
  • 1x Ethernet cable (1m)
  • 1x E-stop Button
  • 1x E-Stop Cable (5m)
  • 2x Spare Male M12 A-coded Connectors
  • 1x Spare Female M12 A-coded Connector

Connecting the Generic Control Case

To connect the Generic Control Case to your pc you will need to go trough te following steps.

  1. Connect the powercable to the power connector and a powerinlet
  2. Connect the E-stop using the E-stop Cable at the E-stop M12 connector.
  3. Connect the Yellow Ethernet Cable to the ENET port and your PC.
  4. Turn on your Generic Control case by pressing the Power Switch.
  5. The status light should light up white.

To continue setting up the connection to your Generic Control Case follow the steps at Generic Control Case Connect your PC.

Generic Control Case Connections

This chapter will provide more information on how to connect the hardware of the Generic Control Case. All of the connectors are located on the front panel of the Case. The figure below provides an overview of all connectors, which can be grouped as:

  • Power Connector
  • Supply Voltage Connectors
  • Safety Connectors
  • Networking Connectors
  • Media Connectors

Power In Connector

The Generic Control Case Receives power trough the Fused IEC C14 Power inlet. Voltage supplied should be between 85 and 264VAC.

Always make sure the correct fuse is placed in the fuse holder. Standard a 5x20mm 3.5A speed T fuse is placed inside the fuse holder.

24VDC Out Connectors

The 24V DC supply voltage connectors at the front of the case are two Female A-coded M12 connectors marked with 24V. These connectors provide a interface for Us “bus voltage” +24V DC and Up “auxiliary voltage” power to the user. The figure below shows the pin-out of these connectors.

Pin Description
1 +24 V DC Us (Σ 2A max for all Us)
2 +24 V DC Up (Σ 3 A max for all Up)
3 0 V DC
4 0 V DC
5 PE

The 24V DC output is protected from over current and over voltage protection values can be found in the table below.

Case Internal Protection
Over-current protection 3A Circuit Braker
Over-voltage Protection 27.60 to 33.60V Automatically resetting
Logic Out Protection (Us)
Over-current protection 2A Circuit Braker
Over-voltage Protection 27.60 to 33.60V Automatically resetting
Auxiliary Power Protection (Up)
Over-current protection 4.2A Circuit Braker
Over-voltage Protection 27.60 to 33.60V Automatically resetting

* Note that the over-voltage protection of the Internal Case and Logic Out is combined.

* Note that the circuit brakers can be manually reset by the user.

Safety connectors

The GCC has two safety connectors, that can be easily identified by their yellow insert. These connectors allow the user to easily hook-up safety devices.

  • An Emergency Stop button can be connected to the female A-coded M12 connector.
  • A Safe output is available on the male A-coded M12 connector and can be used for e.g.for STO “Safe Torque Off” on Motor drives or a Safety Relay.

The figure below shows the pin-out of these connectors.

Emergency Stop

The GCC is outfitted with a M12 yellow e-stop connector for connecting the E-stop that comes in the box.

Pin Description
1 Pulse Output 1
2 Safe Input 1
3 Pulse Output 2
4 Safe Input 2
5 N.C.

STO-out

The STO-OUT Connector on the GCC is desitined for components using a safe torque off (STO) function. Using a Application Cabinet 48V the STO-OUT should be connected to STO-IN.

Pin Description
1 +24 V DC Us (Σ 2A max for all Us)
2 STO channel 1 (24v DC, 0.5A max)
3 0 V DC
4 STO channel 2 (24v DC, 0.5A max)
5 Feedback STO (non-safe)

The image below will provide an example of wiring STO output to drives with STO-input:

Example of STO-out connection to drives with STO-input

Altenatively, the STO can also be used with some types of Safety Relays if STO is not available on the drives. An example is given below:

Example of STO-out connection to a Safety Relay

Make sure that the Safety Relay is dimensioned for the load of the drives and motors.

Networking Connectors

On the top left of the front panel there are three RJ45 Cat6E ports. The table below provides an overview of the network ports

Port Description
ENET Gigabit Ethernet port (Used to connect to Motion PC), do not connect EtherCAT to this port
ECAT1 EtherCAT (Used to connect EtherCAT device), do not connect Ethernet to this port
ECAT2 EtherCAT (Used to connect EtherCAT device), do not connect Ethernet to this port

Note: That the ECAT2 port is always the last EtherCAT chain in the bus.

Media Connectors

On the bottom left of the front panel there are several media connectors. The table below provides detailed information:

Port Description
HDMI 1.4 4K @ 30 Hz
USB Blue: USB 3.0 White: USB 2.0
USB Blue: USB 3.0 White: USB 2.0

Auxiliary ports

On the front panel there are also two auxiliary ports marked with AUX. These ports are not connected and optional for the user to add extra port(s) via an connector that has an XLR form factor.

Operation of the Generic Control Case

This chapter provide more detail of operating the Generic Control Case. this chapter will go trough

  • switching on
  • switching off
  • connecting to Generic control cabinet

Switching the Case on

The Generic Control Case can be turned on by pressing the latching power button. When pressed the button should light up White, indicating that the case is powered with 24V DC. If the case does not power up its possible that one of the circuit breakers has been tripped. Resetting the internal circuit breaker manually has to be done by the following steps:

Make sure that the power cable is removed from the case before opening the case.

  1. Remove the side cover by removing the rubber strips with 4 Phillips screws as shown in the figure below.

\

  1. Reset the circuit breaker by pressing the button on top of the circuit breaker. The Location of the circuit breaker is shown in the figure below.

\

  1. When finished mount the right cover back on to the case. Make sure all that all panels line out correctly before fastening the Phillips screws.

If the case is powered the Motion PC will automatically start-up and the Status light will light up white if the system is “OK”

The Status Lamp is an RGB LED that is connected to 3 digital outputs (one for each channel). The Color of the lamp can be changed by changing the outputs accordingly from the Control Application. In the default installed Generic Application the Status Lamp pis configured as follows:

Status lamp color meaning
White System Okay
Yellow A Warning is active
Red An Error is active (Forced Disengage or Emergency Stop)

Note: More detail of these errors can be found in the GUI of the generic-app also it is possible to reset the errors in this GUI. More information about this can be found in Accessing the User Interface from your Controller

Switching the Case off

The Generic Control Case can be Turned Off by pressing the Power button such that it pops up to its off position. The power will be removed from the case.

2 - Application Case 48V

Introduction

This document is the User Manual for the Vectioneer Application Case 48V and a addition to the Generic Contol Case. This case provides 48v and a Interface for more demanding applications for example Robots.

Application Case 48V connections

This chapter will explain how to connect the hardware of the Application Case 48V. All of the connectors are located on the front panel of the Case.

Front vieuw of AC 48 Case

Power Connector

The Application Case 48V Receives power trough the IEC C14 Power inlet. Voltage supplied should be between 100 and 250VAC. Inside the Case there is a 10A Circuit breaker to protect the power Inlet.

The Circuit breaker is designed for protection on CE regulation. This will result in reduced power of the 48V power supply when using +/- 100V. It is possible to place a 15A Circuit breaker according to UL regulation.

STO IN connector

A Male A-coded M12 connector provides Safe output for STO (Safe Torque Off) from the Generic Control Case to the Robot Connector. The figure below shows the pin-out of this connector.

Pin Description
1 +24 V DC Us (Σ 2A max for all Us from GCC)
2 STO channel 1 (24v DC, 0.5A max)
3 0 V DC
4 STO channel 2 (24v DC, 0.5A max)
5 Feedback STO (non-safe)

The image below will provide an example of wiring STO output to drives with STO-input:

Example of STO-out connection to drives with STO-input

Altenatively, the STO can also be used with some types of Safety Relays if STO is not available on the drives. An example is given below:

Example of STO-out connection to a Safety Relay

Make sure that the Safety Relay is dimensioned for the load of the drives and motors.

EtherCAT IN Connector

On the front panel there is one RJ45 Cat6E port. It is possible to use this port to connect a EtherCAT port from the Generic Control Case to the Robot Connector.

Auxiliary ports

On the front panel there are also two auxiliary ports marked with AUX. These ports are not connected and optional for the user to reconfigure.

Robot Connector

The Application Case 48V has one Robot Connector for the user to connect a robot to. And still make it possible to connect separately without connector. In the robot connector there are three connectors:

  • 48V DC power connectors
  • Robot EtherCAT Connector
  • Robot STO Connector

48V DC power OUT Connector

On the Application Case 48V has an internal voltage of 48V DC. On the front Panel in the Robot connector position A there is a 2 Pole connector for the user. Protection values can be found in the table below:

Case Protection
Over-current protection 32A Self resetting Circuit breaker
Over-voltage Protection 57.00 to 67.20 Automatically resetting

Pin Description
1 +48 V DC Us (32A max)
2 0 v DC

EtherCAT OUT Connector

In the Robot Connector Position B There is a RJ45 Interface to connect to EtherCAT.

STO OUT connector

In the Robot Connector Position C there is a 5 pole connector for STO.

Pin Description
1 +24 V DC Us (2A max)
2 STO channel 1 (24v DC, 0.5A max)
3 0 V DC
4 STO channel 2 (24v DC, 0.5A max)
5 PE

Switching the Case on

The 48V Application Case can be turned on by rotating the main disconnector. When set to “1” the Status LED should light up White, indicating that the Case is provided with 48V DC.

If this it not the case it might be possible that the circuit breaker is tripped. Resetting the Circuit breaker can be done by the following steps

Make sure that the Power Cable is removed from the case before opening the case.

  1. Remove the side cover by removing 4 Phillips screws as shown in the figure below

  1. Reset the circuit breaker by flicking the the switch on top of the circuit breaker. Location of the circuit breakers is shown in the figure below.

  1. When finished mount the right cover back on to the case. Make sure all that all panels line out correctly before fastening the Phillips screws.

After any Fault the User shall check the cause of the Fault and make sure the problem is solved.

Switching the Case off

The 48V Application Case can be Turned Off by rotating the main disconnector. When set to “0” the Status LED will fade out, indicating that the Case is no longer provided with 48V DC.

Keep in mind that the Disconnector will turn off the 48 VDC. All other instances like STO and EtherCAT will stay connected.

3 - Motorcortex Fitlet2

Fitlet2 - Manual

Motorcortex Fitlet2 - Manual

The Motorcortex Fitlet2 is a ideal Industrial Embedded Computer to try out MOTORCORTEX. This Fitlet2 comes pre-installed with Vectioneer Linux and MOTORCORTEX-Core libraries. Is also has the Vectioneer Generic-App installed that allows you to control a number of EtherCAT servo drives out of the box. Or use it as a platform to build your own custom MOTORCORTEX-based control systems in C++ and use the tools on motorcortex.io to configure hardware devices, deploy web-interfaces to your controller and analyze your system’s realtime data.

More detailed information on the Fitlet2 Industrial PC can be found on the FITPC WIKI

Connecting the Fitlet2

This chapter will explain how to connect the hardware of the Motorcortex Fitlet2. all interfaces are located in the front and the back the figure below provides an overvieuw of all interfaces:

  • 2x USB 2.0 (White)
  • 1x HDMI
  • 1x mini display port
  • 1x 12v Power connector
  • 1x COM port
  • 2x RJ45 ports Eth1|2
  • 1x powerbutton
  • 2x USB 3.0 (Blue)
  • 1x micro SD slot

Front view fitlet 2

Communication from and to the Motorcortex Fitlet2 will go trough the RJ45 connectors. it is also possible to connect directly to the Motorcortex Fitlet2 with a screen and USB keyboard.

RJ45 Connectors

Communication from and to the Motorcortex Fitlet2 will go trough the RJ45 connectors. Eth1 is configured for Ethercat and Eth2 is configuered for ethernet connection.

4 - Virtual machine

This chapter will explain how to install a Virtual Machine on your PC. Please select the operating system you are u using:

Linux Linux Windows Windows Windows MacOS

A vitrual machine can be used to try out Motorcortex. Using a virtual machine you will need a .img file or a .vdi file. and VirtualBox installed on your machine. this chapter will show how to install VirtualBox and get your virtual machine up and going.

Installing VirtualBox (Linux)

To get VirtualBox you wil have to download it from the https://www.virtualbox.org/wiki/Downloads website. choose the operating system you are using. and download the .deb file.

  1. Double click the .deb file.

  2. Click install in the pop-up. VirtualBox will now be installed.

Converting image

to use virtual box you will need a .vdi file. If you have a .img or compressed .img.xz you will need to convert these files using the following commands.

to uncompress a .img.xz file run the following command in the folder the file is located.

    unxz -k -v yourfile.xz

the compressed image will now be uncompressed. after this you can convert the .img file to a .vdi file. make sure you are in the correct folder where the file is located.

    VBoxManage convertfromraw yourfile.img yourfile.vdi		

Setting up the virtal machine

Setting up the virtual machine has to be done using the folowing steps:

  1. Open VirtualBox and click on New.

  1. In the Create Virtual Machine pop-up the following settings have to be selected.
  • Name: desired name
  • Machine Folder: desired folder
  • Type: Linux
  • Version: Linux 2.6/3.x/4.x(64-bit)

  1. Click Next.

  2. Set the memory size to 8000 MB and click Next.

  1. select the Use an existing virtual hard disk file and click on the folder icon.

  1. Click the Add icon and browse to the desired .vdi file.

  1. Click Choose.

  1. Click Create.

A virtual machine is created. Now the Network has to be configured.

  1. Click File and go to Host Network Manager.

  1. In the Host Network Manager fill in the settings as following:
  • Disable the DHCP Server by unchecking the box
  • IPv4 Address: 192.168.2.1
  • Network Mask: 255.255.255.0

  1. Close the Host Network Manager.

The network manager is now configured. Now the system settings have to be checked.

  1. click on settings.

  1. In System under the Motherboard tab make sure the Enable EFI box is checked.

  1. In System under the Motherboard tab make sure that Processor(s) is set to 4 CPU’s.

  1. In Network under the Adapter1 tab set Attached to to Host-only Adapter.

  1. Click OK

The virtual machine has now been set up.

Using virtual machine

Starting your virtual machine has to be done using the folowing steps:

  1. In virtual box select the desired virtual machine and press Start.

  1. The virtual machine will boot now this can take up to 5 seconds or longer.

  1. Log in to the controller.
  • Login: Admin
  • Password: vectioneer

the command line should change like this.

    mcx-intel:~$

If no hardware is connected to the virtual machine make sure the simulation mode is activated. how to activate simulation mode is described in Sumulation Mode

5 -

Bios Settings Fitlet2

Introduction

This chapter tells the bios settings of the Fitlet2 Motorcortex Controller.

These settings make it easier to back-up the system and use other storage devices to boot from.

Setting Fitlet2 Bios settings

  1. Make sure the controller is switched off.
  2. Attach a keyboard to one of the USB-ports.
  3. Start tapping the delete key.
  4. Switch the controller on.
  5. Stop tapping the delete key when the bios menu appears.
  6. In the Main screen Load Optimized Defaults by pressing the F3 key. Select Yes.

  1. Use the arow keys to navigate trough the BIOS. Go to OS Selection hit enter and select Linux.

  1. Go to the Boot screen using the arow keys and go to Boot Options hit enter and set the correct boot options as below:

    1. Go to Boot Option #1 and select USB Key.
    2. Go to Boot Option #2 and select USB HDD.
    3. Go to Boot Option #3 and select USB CD/DVD.
    4. Go to Boot Option #4 and select SD.
    5. Go to Boot Option #5 and select HDD:....

  1. go to the Save & Exit screen.
  2. Press F4 or go to Save Changes and Exit. Select Yes.

6 -

This chapter will explain how to install a Virtual Machine on your PC. Please select the operating system you are u using:

Linux Linux Windows Windows Windows MacOS

A vitrual machine can be used to try out Motorcortex. Using a virtual machine you will need a .img file or a .vdi file. and VirtualBox installed on your machine. this chapter will show how to install VirtualBox and get your virtual machine up and going.

Installing VirtualBox (Windows)

To get VirtualBox you wil have to download it from the https://www.virtualbox.org/wiki/Downloads website. choose the operating system you are using. and download the .exe file.

  1. Double click the .exe file.

  2. The setup wizard will pop-up click next.

  1. Click Next unless you want to change the location for the VirtualBox.

  1. Click ‘Next’ unless you want to change some of the install options.

  1. A warning will tell you that network connections will be disconected temporarily. Click Yes.

  1. Click Install.

  1. The instalation will start. During the instalation a security warning will pop-up click Install.

  1. click Finish to complete the instalation.

Converting image

to use virtual box a .vdi file is needed. .img files or compressed .img.xz files have to be converted.

to uncompress a .img.xz file run the following command in the folder the file is located.

    unxz -k -v yourfile.xz

the compressed image will now be uncompressed. after this you can convert the .img file to a .vdi file. make sure you are in the correct folder where the file is located.

    VBoxManage convertfromraw yourfile.img yourfile.vdi		

Setting up virtal machine

Setting up the virtual machine has to be done using the folowing steps:

  1. Open VirtualBox and click on New.

  1. In the Create Virtual Machine pop-up the following settings have to be selected.
  • Name: desired name
  • Machine Folder: desired folder
  • Type: Linux
  • Version: Linux 2.6/3.x/4.x(64-bit)

  1. Click Next.

  2. Set the memory size to 8000 MB and click Next.

  1. select the Use an existing virtual hard disk file and click on the folder icon.

  1. Click the Add icon and browse to the desired .vdi file.

  1. Click Choose.

  1. Click Create.

A virtual machine is created. Now the Network has to be configured.

  1. Click File and go to Host Network Manager.

  1. In the Host Network Manager fill in the settings as following:
  • Disable the DHCP Server by unchecking the box
  • IPv4 Address: 192.168.2.1
  • Network Mask: 255.255.255.0

  1. Close the Host Network Manager.

The network manager is now configured. Now the system settings have to be checked.

  1. click on settings.

  1. In System under the Motherboard tab make sure the Enable EFI box is checked.

  1. In System under the Motherboard tab make sure that Processor(s) is set to 4 CPU’s.

  1. In Network under the Adapter1 tab set Attached to to Host-only Adapter.

  1. Click OK

The virtual machine has now been set up.

Using virtual machine

Starting your virtual machine has to be done using the folowing steps:

  1. In virtual box select the desired virtual machine and press Start.

  1. The virtual machine will boot now this can take up to 5 seconds or longer.

  1. Log in to the controller.
  • Login: Admin
  • Password: vectioneer

the command line should change like this.

    mcx-intel:~$

If no hardware is connected to the virtual machine make sure the simulation mode is activated. how to activate simulation mode is described in Sumulation Mode