1-14 Introduction and Overview VisualMotion 6.

1.5 CLC-D Overview

CLC-D02.3M hardware

Figure 1-9: CLC-D02.3M Hardware

CLC-D Serial Communication

Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity.

Serial Com Options Baud Rate Checksum Port Mode Protocol

Port A (X27) default 9600 enabled RS-232 Host Protocol
Port A (X27) valid settings 300, 1200, 2400, enabled or RS-232,422,485 Host Protocol
4800, 9600, disabled
19200, 38400
Port B (X28) default 9600 enabled RS-232 Host Protocol
Port B (X28) valid settings 300, 1200, 2400, enabled or RS-232,422,485 Off, Host Protocol,
4800, 9600 disabled BTC06

Table 1-1: CLC-D configurable communication settings

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VisualMotion 6.0 Introduction and Overview 1-15

CLC-D Jumper Configuration

Jumpers S1 and S2 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-10: CLC-D jumper configuration

CLC-D SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-D.

Figure 1-11: Fiber optic ring structure

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1-16 Introduction and Overview VisualMotion 6.0

On-Board Battery
This battery provides backup power for the CLC onboard SRAM when control
voltage is not applied. The battery's power level is checked every time the
CLC is powered up or during initialization from parameter mode to provide
advanced warning of impending failure. A diagnostic message is displayed
(E206 Battery is low: replace it soon) when the level falls below 10% of
remaining capacity. Based on the lifespan table below, this could translate
into less then a month before failure at 45 °C (113 °F.) It is vital for action to
be taken when a Battery is low warning is issued.

Recommended actions: • Secure a complete archive of the VisualMotion system data

• Order a new 3-volt Lithium button-style battery, CR2477N (MnO2/Li).
• Indramat material number: 254284
• Replace battery as soon as possible.

To prevent undue losses, a Preventive Maintenance Program should be

put into place that does not rely on the batteries power level check to
determine replacement period. The following lifespan table contains some
general guidelines that can be used to devise an appropriate schedule.

Battery lifespan
Ambient 3-shift 2-shift 1-shift Storage
temperature operations operations operation
25 °C (77 °F) 4 years 4 years 4 years 3 years
35 °C (95 °F) 4 years 3 years 2 years 1.5 years
45 °C (113 °F) 3 years 2 years 1.2 years 9 months

Table 1-2: Battery lifespan

Loss of VisualMotion System

Failure to replace can result in lost parameters.
⇒ The following is a list of items that will be lost if the battery
fails and is not replaced.
Warning
• CLC System parameters C-0-xxxx
• Axis parameters A-0-xxxx
• Task parameters
• CLC Cam tables, PLS and PID data
• Events, I/O Mapper, FieldBus Mapper
• Points tables, Variables, Zones
• Downloaded VisualMotion programs

Note: The battery is generally drained after this period and must be
replaced.

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VisualMotion 6.0 Introduction and Overview 1-17

Replacing the battery Once the battery is removed, any parameters stored in SRAM memory are
retained for only one minute. Replace the battery within this minute.
Procedure:
1. Remove the battery from its packaging and have it close at hand for
installation
2. Before replacing the battery, archive the system using VisualMotion
Toolkit. Refer to Chapter 2, The File Menu - Archive.
3. Switch power off to the system containing the CLC card
4. Remove CLC card from the system

Electro-static discharge
Sensitive electronic device
⇒ The CLC card is a sensitive electronic device, use caution
when handling this board. Do not expose to Electro-static
Caution discharge or place the board directly on a conductive
surface. Only handle the board by its face-plate or card
edges.
5. Remove old battery by sliding it out of it's holder
6. Insert the new battery into holder (no more than one minute later)
7. Write the month and year on the battery's end cap for future reference.
(This information should also be written on a label and place in close
proximity to the CLC for easier observation)

CLC-D02.3 Front Panel Diagnostic Display

7-Segment display
The CLC-D has a 7-Segment LED display (H4). It displays the current
operating and error conditions of the card.

7-Segment
H4 Display
CLC
Watchdog

Figure 1-12: 7-segment display on the CLC-D

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1-18 Introduction and Overview VisualMotion 6.0

Normal operations In normal operating conditions, a static display shows the current mode of the
CLC.

H4 Display Status
Initial display
Initialization Mode, SERCOS phases 1-4
Parameter mode
No user tasks are running (Halt)
Task A is running
Task B is running
Task C is running
Task D is running

Table 1-3: Normal operating conditions

Error codes When an error exists, the CLC-D displays an "E", indicating error, followed by
a three digit diagnostic code. To the viewer, the display appears to be
blinking. The following figure illustrates the chronological sequence for
emergency stop condition, E400.

1000ms 500ms 500ms 500ms

Figure 1-13: Example of an E400, Emergency Stop, error code

Code Error Type

E200 - E399 Warning
E400 - E999 Shutdown Error

Refer to Chapter 3, Monitoring and Diagnostics, for a complete listing of the

available three digit Warning and Shutdown error codes.

System Watchdog
The decimal point on the display is connected to a hardware watchdog circuit
that is refreshed by the CLC every 100ms. If the microprocessor fails or if the
CLC drops into the pROBE monitor, the display is blanked and the decimal
point turns on. While the CLC is running, the decimal point is off.

7-Segment Display
H4 (OFF)
CLC Watchdog
(On)

Figure 1-14: Watchdog message on the CLC

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VisualMotion 6.0 Introduction and Overview 1-19

1.6 CLC-P01.1 Overview

CLC-P01.1 hardware

Figure 1-15: CLC-P01.1 Hardware

CLC-P Serial Communication

Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity
For configurable communication settings, refer to Table 1-1 on page 1-14

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CLC-P01.1 Jumper Configuration

Jumpers S1 and S2 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-16: CLC-P01.1 jumper location

Jumpers S5 through S7 set the PC interrupt. Only IRQ2 (default) can be

used.

PC Interrupt S5 S6 S7
IRQ2 (IRQ9) In Out Out
IRQ3 Out In Out
IRQ5 Out Out In

Table 1-4: CLC-P01.1 IRQ settings

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VisualMotion 6.0 Introduction and Overview 1-21

Jumpers S8 through S11 set the base address of a 16K memory segment in
the Host’s RAM. This memory space is used to exchange information
between the CLC and the Host.

Card Number Base S11 S10 S9 S8

Address
0 C000 In In In In
1 C400 In In In Out
2 C800 In In Out In
3 CC00 In In Out Out
4 D000 In Out In In
5 D400 In Out In Out
6 D800 In Out Out In
7 DC00 In Out Out Out
8 E000 Out In In In
9 E400 Out In In Out
10 E800 Out In Out In
11 EC00 Out In Out Out
12 F000 Out Out In In
13 F400 Out Out In Out
14 F800 Out Out Out In
15 FC00 Out Out Out Out

Table 1-5: CLC-P base address jumper settings

On-Board Battery
This battery provides backup power for the CLC onboard SRAM when control
voltage is not applied. The battery's power level is checked every time the
CLC is powered up or during initialization from parameter mode to provide
advanced warning of impending failure. A diagnostic message is displayed
(206 Battery is low: replace it soon) when the level falls below 10% of
remaining capacity. Based on the lifespan table on page 1-16, this could
translate into less then a month before failure at 45 °C (113 °F.) It is vital for
action to be taken when a Battery is low warning is issued.

Recommended actions: • Secure a complete archive of the VisualMotion system data

• Order a new 3-volt Lithium button-style battery, CR2477N (MnO2/Li).
• Indramat material number: 254284
• Replace battery as soon as possible.

For complete details on battery lifespan and replacement, refer to On-Board

Battery on page 1-16.

CLC-P SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to

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1-22 Introduction and Overview VisualMotion 6.0

the SERCOS input, Rx, of the CLC-P. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

Viewing Error codes using VisualMotion's CLC DDE Server

Physically viewing diagnostic messages on the CLC-P hardware is not
possible. Unlike the CLC-D card, which has a visible 7-Segment display (H4)
for viewing error codes, the CLC-P does not have a visible display. The
design of the CLC-P does not require for it to have a visible means of viewing
errors. This card is generally installed in a personal computer and for this
reason is normally not visible.
The monitoring and communications of error codes are handle by means of
the CLC DDE Server. This Windows based Dynamic Data Exchange (DDE)
Server application is used to communicate with Indramat's CLC motion
control cards. Unlike the CLC-D which begins an error code with the letter
"E", the DDE Server represents an error code with it's respective three digit
number followed by the error's description. For example, an Emergency Stop
error on CLC-D would appears as a alternating blinking "E400", while on the
DDE Server it would simply appear as "400 EMERGENCY STOP."

Figure 1-17: CLC DDE Server

In order to view diagnostic messages on the DDE Server, the "CLC Status
Display" must be set to SERIAL_0. This is accomplished by selecting
Settings ⇒ Server Configuration from the CLC DDE Server's main menu.
Refer to Chapter 4, CLC DDE Server for more information.

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VisualMotion 6.0 Introduction and Overview 1-23

Figure 1-18: Setting SERIAL_0 for CLC Status Display - DDE Server

Viewing Error codes using VisualMotion Toolkit

To view error codes using VisualMotion, simply select the following menu
selection:
Status ⇒ System from VisualMotion's main menu and the following screen
appears.

Figure 1-19: Viewing error codes using VisualMotion

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1-24 Introduction and Overview VisualMotion 6.0

1.7 CLC-P02 Overview

The CLC-P02 is a motion control on the PC/104 platform. The VisualMotion
firmware on this platform includes all of the features of the CLC-P01, with
improvements in the configuration and memory capacity.

CLC-P02.2 hardware

Figure 1-20: CLC-P02.2 Hardware

CLC-P02 Serial Communication

Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. Both ports always operate with:
• 8 bits per character
• 1 stop bit
• no parity

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VisualMotion 6.0 Introduction and Overview 1-25

Serial Com Options Baud Rate Checksum Port Mode Protocol

Port A (X27) default 9600 enabled RS-232 Host Protocol
Port A (X27) valid settings 300, 1200, 2400, enabled or RS-232,422,485 Host Protocol
4800, 9600, disabled
19200, 38400
Port B (X28) default 9600 enabled RS-232 Host Protocol
Port B (X28) valid settings 300, 1200, 2400, enabled or RS-232,422,485 Off, Host Protocol,
4800, 9600 disabled BTC06

Table 1-6: CLC-P02 configurable communication settings

CLC-P02 Jumper Configuration

Jumpers I5 and I6 set the default configuration for serial ports X27 and X28
respectively. If the jumper is installed, the port is configured for the default
settings of RS-232 and 9600 baud.

Figure 1-21: CLC-P02 jumper configuration

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1-26 Introduction and Overview VisualMotion 6.0

PC/104 Memory Address Switches 1 through 4 set the base address of a 1MB memory segment in the
Selection Host's RAM. This memory space is used to exchange information between
the CLC and the Host.

Card Base 1 2 3 4
Number Address
0 D000:0000 OFF ON ON ON
1 D000:2000 OFF ON ON OFF
2 D000:4000 OFF ON OFF ON
3 D000:6000 OFF ON OFF OFF
4 D000:8000 OFF OFF ON ON
5 D000:A000 OFF OFF ON OFF
6 D000:C000 OFF OFF OFF ON
7 D000:E000 OFF OFF OFF OFF
8 E000:0000 ON ON ON ON
9 E000:2000 ON ON ON OFF
10 E000:4000 ON ON OFF ON
11 E000:6000 ON ON OFF OFF
12 E000:8000 ON OFF ON ON
13 E000:A000 ON OFF ON OFF
14 E000:C000 ON OFF OFF ON
15 E000:E000 ON OFF OFF OFF
Table 1-7: CLC-P02 base address switch settings

PC/104 Interrupt Selection Switches 5 through 8 on the S1 DIP switch, selects the interrupt line for the
CLC to PC interrupt.

Note: Only one of these switches can be on at a time, or there will be an

interrupt conflict.

PC Interrupt 5 6 7 8
IRQ10 OFF OFF OFF ON
IRQ11 OFF OFF ON OFF
IRQ12 OFF ON OFF OFF
IRQ15 ON OFF OFF OFF
None OFF OFF OFF OFF
Table 1-8: CLC-P02 IRQ settings

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VisualMotion 6.0 Introduction and Overview 1-27

CLC-P02 On-Board Backup Power (Accumulator)

The backup power device on the CLC-P02 is not a battery, but an
accumulator which provides power to the onboard SRAM when control
voltage is not applied.

Note: A defective accumulator cannot be replaced by the customer.

Since the accumulator is soldered to the board, the card must be
returned to INDRAMAT for maintenance repair.

A fully charged accumulator will provide approximately 6 months of SRAM

buffering at an ambient temperature of 25 °C (77 °F) if the card is not in
operation.
At 45 °C (113 °F), the accumulator backup power will last approximately 3
months.
If the accumulator is completely discharged, it will require approximately 50
hours of online power to fully charge.

Note: Charge time:

1 hour of recharging will provide about 100 hours of buffering at 25
°C (77 °F.)
Lifetime Expectancy:
The lifetime expectancy of the accumulator on a CLC-P02 card
that is powered for 8 hours and off for 16 hours is at least 7 - 10
years.

A diagnostic message is displayed (206 Battery is low: replace it soon)

when the level falls below 10% of the remaining capacity. Diagnostic
messages can be viewed by selecting Status ⇒ System from VisualMotion
Toolkits' main menu. The diagnostic message field within the System
Parameters window is read from CLC card parameter C-0-0122.

Note: A "206 Battery is low: replace it soon" error does not

necessarily mean that the accumulator is defective. Unlike
batteries, accumulators can be re-charged by applying and
maintaining power for a few days. If the error returns after the
re-charging period, and power is still applied to the system, send
the card in to INDRAMAT for repairs.

Recommended actions: • Secure a complete archive of the VisualMotion system data

• Re-charge the accumulator by powering the card for a few days
• If error persist, return the card to INDRAMAT for repairs

CLC-P SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-P. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

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1-28 Introduction and Overview VisualMotion 6.0

1.8 CLC-V Overview

CLC-V02.3 hardware

Figure 1-22: CLC-V02.3 Hardware

CLC-V Serial Communication

Port A (X27) is configured to respond to the VisualMotion ASCII Host
Protocol. Port B (X28) can be configured to respond to Host Protocol, BTC06
or another interface. The serial interface is compatible with EIA RS-232C and
supports signals for both AT and XT type Host PCs. Both ports always
operate with:
• 9600 baud
• 8 bits per character
• 1 stop bit
• no parity.

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VisualMotion 6.0 Introduction and Overview 1-29

For configurable communication settings, refer to Table 1-1 on page 1-14

CLC-V SERCOS
The SERCOS port is used for loop-through, daisy-chained installation into a
SERCOS fiber-optic ring. The output port, Tx, is connected to the SERCOS
input port, Rx, of the next SERCOS device in the ring. Each SERCOS device
is interconnected, output to input, with the output of the last device returned to
the SERCOS input, Rx, of the CLC-V. See Figure 1-11: Fiber optic ring
structure on page 1-15 for an illustration.

CLC-V Configuration Switches

Slide Switch SW5 (Default)

OFF ON

1
2
SW5 3
+ 4
5
A B
Math Coprocessor / Flash Mezzanine 6
EPROM

7
8

SERCOS MODULE
Opto Isolated I/O

J1
Drivers

SERCOS
ASIC

J2
Slide Switch SW6 (Default)

SW6

OFF ON
1

Figure 1-23: CLC-V Configuration Switches

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1-30 Introduction and Overview VisualMotion 6.0

Configuration Switch - SW5

SW5 Position Default Function

1 ON ON - Programming of the local Flash EPROM
enabled
OFF - Local Flash EPROM write protected
2 OFF ON - CLC-V Drives VME SYSRESET
OFF - SYSRESET not driven
3 OFF ON - CLC-V Accepts SYSRESET from VME
OFF - SYSRESET not received
4 ON ON - Power-fail reset voltage set to 4.8V
OFF - Power-fail reset voltage set to 4.2V
5 ON ON - Programming of Flash EPROM enabled
OFF - Flash EPROM write protected
6 & 7 Select the CLC's VME Bus request level:
BR0 BR1 BR2 BR3
6 ON OFF OFF ON ON
7 ON OFF ON OFF ON
8 ON ON - VME Slot 1 functions enabled
OFF - VME Slot 1 functions disabled

Table 1-9: Configuration switch - SW5

Configuration Switch - SW6

Both switches SW6-1 and SW6-2 are functionally used as one switch. Both
must have the same setting, ON or OFF.

SW6 Position Setting Function

1 OFF Disables the CLC-V's on-board secondary
2 (default) battery. Backup battery is provided through
OFF the VME bus STDBY line.
(default)
1 ON Enables the CLC-V's on-board secondary
2 ON battery and disconnects the CLC-V from the
VME bus STDBY line. Both positions of
SW6 must be ON to enable the on-board
secondary battery and disconnect the CLC-V
from the VME bus STDBY line.
CAUTION: Leave both switch positions OFF, as set by the factory. The VME
card cage is the required source of battery back-up. Damage to the CLC-V's
on-board secondary battery may occur if a VME card cage supplies battery
backup and either position of SW6 is set ON.

Table 1-10: Configuration switch - SW6

On-Board Battery
This battery provides backup power for the CLC onboard SRAM and the real
time clock (RTC) when control voltage is not applied. The battery's power
level is checked every time the CLC is powered up or during initialization from
parameter mode to provide advanced warning of impending failure. A
diagnostic message is displayed (206 Battery is low: replace it soon) when
the level falls below 10% of remaining capacity. It is vital for action to be taken
when a Battery is low warning is issued.

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VisualMotion 6.0 Introduction and Overview 1-31

Recommended actions: • Secure a complete archive of the VisualMotion system data

• Order a new 3-volt Lithium button-style battery, CR2032 (MnO2/Li).
• Indramat material number: 600482
• Replace battery as soon as possible.

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VisualMotion 6.0 Using VisualMotion Toolkit for diagnosing 2-1

2 Using VisualMotion Toolkit for diagnosing

2.1 VisualMotion Toolkit 6

VisualMotion Toolkit 6 (VMT) is Indramat's Windows  based development
environment for programming the VisualMotion Controller (VMC) cards.
Along with VMT's programming capabilities, it can also be used to help
diagnose system, drive and card diagnostics.

Note: This chapter is intended to help trained operating and

maintenance personnel diagnose error codes using VisualMotion
Toolkit. For a complete description of VisualMotion Toolkit, please
refer to the following documentation.

• VisualMotion GPS 6.0, Start Up Guide

• DOK-VISMOT-VM*06VRS**-PRJ1-AE-P, Material No. 282762
• VisualMotion GPS 6.0, Reference Manual
• DOK-VISMOT-VM*06VRS**-FKB1-AE-P, Material No. 280585

2.2 VisualMotion to PC connection

To establish communications between the VisualMotion CLC-D cards and a
PC, use the IKS0061 standard RS-232 serial communication cable. For the
CLC-V, use the IKS0110 standard RS-232 serial communication cable.

.
Figure 2-1: VisualMotion to PC connection diagram

Once the hardware connections have been made, use the following
procedure to confirm communications.

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2-2 Using VisualMotion Toolkit for diagnosing VisualMotion 6.0

⇒ Connect communication cable between CLC port X28 and the PC's com
port.
⇒ Power-up VisualMotion System (drives, CLC cards, motors, etc.)
⇒ Open VisualMotion Toolkit windows program (Refer to the VisualMotion
Start-up Guide for installation instructions)
⇒ From the VisualMotion Toolkit main menu, select Status ⇒ System. If
the System Parameters screen loads with information, communications
have been established.
The user is now ready to use VisualMotion Toolkit.

2.3 The File menu

The file menu allows the user to perform standard windows file commands
such as new, open, save, etc. This menu also has functions for compiling
CLC programs, archiving user programs and variables and printing CLC
programs. For the purpose of this manual, only Program Management will be
covered in this section. For a complete description of all the File menu
selections, refer to the VisualMotion Reference manual.

Figure 2-2: VisualMotion File Menu screen

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