Yaskawa
eLearning
Welcome to the MP3200iec Hardware Overview
eLearning Module
Hi, my name is Matt Pelletier
and I'm a Product Training Engineer for
Yaskawa Motion Control and Servo Products.
I'll be your instructor for this eLearning Module.
In this training module,
We'll overview the basic features of the MP3200iec.
Then we'll go through the Front Panel,
discuss MECHATROLINK III network,
Ethernet communication,
Programming,
and finish with a few Frequently Asked Questions.
The MP3200iec is designed for
extreme performance in the most
demanding applications such as printing,
converting, packaging or any application
that requires a high number of axes
along with fast network and PLC scan times.
It is currently the performance leader
in Yaskawa America's offering of MPiec Controllers.
By measurable performance metrics,
it is four times faster than the MP2300iec Controllers
and eight times faster than the single axis MP2600iec.
This performance advantage exists
thanks to a 1 GHz, 64-bit processor,
up to eight slots of I/O and the ultra-fast
MECHATROLINK III Motion and I/O Network.
You can see from the table below that the MP3200iec
can easily handle up to four servo axes at .25 milliseconds.
Even at the maximum of 62 axes,
the network still updates at four milliseconds.
A typical system configuration is as follows:
The MECHATROLINK III Motion and I/O Network
connects Sigma-5 servos and
MECHATROLINK III Network I/O.
Switches, sensors, relays, indicators, external encoders
are all connected through the local I/O modules.
All other connections are made through Ethernet.
HMI, third-party I/O and PLC
are connected using the communication protocols
EtherNet IP and/or Modbus TCP.
Connections to a PC are made with OPC server
or the web server and the MPiec Controllers
support all these connections at the
same time over the same ports.
The MP3200iec consists of three basic units:
The power supply and the CPU together
comprise an operable system,
add the option base and the user installed I/O
in each slot to make a system complete
with inputs and outputs.
These pieces connect and lock together to make one
customized machine controller.
Now let's take a look at the Front Panel
and connections for each of these units
starting with the power supply.
There are two different power supply units,
the AC 110/220 volt and a 24-volt DC unit.
The input voltage is printed next to the connector.
Power on is indicated by the green LED.
Medium and high output load level
is indicated by the yellow and red LED.
And in the middle, is the Relay Out connection.
This connection is closed when the CPU
is in Ready status, as indicated by the Ready status LED.
This way the controller's Ready status
can be directly wired to external control circuitry.
Now let's look at the CPU unit.
At the top is a simple 7 segment display
which can show the controller IP address
when powered on with the testp DIP switch on.
To the right of the display, you see status LEDs.
These operate the same as the other MPiec Controllers
with indicators for ready, run, alarm, error,
low battery and MECHATROLINK alarm.
The rotary switches set the last
bite of the IP address override.
This address is selected when the controller
is powered on with both E-INIT
and E-PM0 DIP switches set on.
The MP3200iec has a few more DIP switches
compared to the other MPiec controllers.
Details on the DIP switch function
can be found in the manual.
The OP Port is for factory use only
and for this reason has a clear
protective cover in order to prevent user connection.
Two ports are available for
Ethernet connection to the controller.
Unlike the single axis MP2600iec,
these ports are connected internally as a hub
the controller has just one IP address.
Finally, at the bottom left we have two connections for
the MECHATROLINK III Motion and I/O Network.
The included memory backup battery is located inside
the bottom of the CPU unit.
This battery is required to store variable data,
alarm history and calendar when power is off.
The battery is good for about one year of
cumulative power off time and when the
voltage of the battery is low the BAT LED
will turn on and it's time to replace the battery.
The empty Option Base can be selected with
3, 5 or 8 slots according to the required I/O capacity.
I/O cards such as the LIO-01
are selected and individually installed
creating a machine controller customized
for the application. Cards can be removed
using this small tool built into the
front of the option base.
The MP3200iec supports the same option cards
as the MP2300iec Controllers.
The LIO-01 and the LIO-02 provide 16 digital
inputs and outputs along with an external encoder
input with high-speed latch. For higher
on board I/O count without the external
encoder input consider using the LIO-04
or LIO-05 with 32 digital inputs and outputs.
For a solid mix of I/O capabilities, the LIO-06
offers eight digital inputs and outputs,
analog input and output
and encoder input with high-speed latch.
Also available are dedicated
analog input and analog output,
64-point digital output is available on the DO-01
and Ethernet communication can
be expanded using the 218IF-Y1.
This card also provides serial communication.
Wiring to the I/O cards is accomplished
through breakout cables with terminal blocks.
Terminal block conversion kits are available for the
LIO-01, 02, 04, 05, 06 as well as for the
servo amplifier I/O connector.
MECHATROLINK is the network of choice for
Yaskawa MPiec Controllers.
It's an open, high-speed, deterministic motion and
I/O network optimized for electrically noisy
factory environments.
The MP3200iec is optimized for the high-speed
communication of MECHATROLINK III.
Operating over the Ethernet physical layer,
it provides network communication
cycles as low as .25 milliseconds.
The feature that sets MECHATROLINK apart
from other motion and I/O networks is the
capability for data retry within the
same network communications cycle.
You can see here in MotionWorks IEC,
MECHATROLINK III configuration,
the Max Retries setting.
Here's how it works:
If, for example, the response message from
slave node 1 were corrupted due to
electrical noise, there is within the
same communication cycle a second chance
for the data to be received.
Data retry greatly reduces the possibility of data
loss in electrically noisy environments
such as the plant floor, thereby, ensuring
consistent and reliable performance of
MECHATROLINK servos and I/O.
While all versions of MECHATROLINK support
data retry, this table summarizes a few of the key
improvements in MECHATROLINK III
over MECHATROLINK II.
Most notable is the baud rate,
now ten times higher at 100 megabits per second.
The network cycle time can be as low as
31.25 microseconds, although for practical
purposes on a multi-axis system,
the MP3000iec Controller supports cycle times
starting at 250 microseconds.
The maximum number of nodes is now 62 with a longer
max distance between stations now of 100
meters and no minimum limit.
Running on Ethernet CAT5 cable, several connection
topologies are supported by MECHATROLINK III
which will be illustrated next.
Network topology defines how the devices can be
physically connected together.
The devices are commonly referred to as the
network master and slave nodes.
In our case, the master is the MPiec Controller
and the slaves are the Sigma-5 servo amplifiers.
Your normal Cascade Topology simply connects the
devices one to another.
Since each device retransmits to the
next device, Star Topology offers the
fastest network response but requires
another device called a hub, a central
point that connects the nodes together,
transmitting simultaneously.
These typologies can be combined as required
for more complex topologies, network times
can be modeled using the MECHATROLINK III
utility software available for free from
www.mechatrolink.org
The MPiec Controllers support a wide range of
Ethernet communication options.
Through PC communication, we can use
MotionWorks IEC programming software,
access the internal web server
or set up an OPC server to access variable tags.
Third-party devices can interface using
Modbus/TCP and Ethernet IP protocols and
any other type of data transfer can be
accomplished using custom protocol.
All MPiec controllers have a web server,
an interface which is built into the controller itself.
Connect the PC to the controller, enter the controller
IP address in your browser and the web
server gives you access to many of the
critical functions of the controller.
No software on your PC other than
Internet Explorer and Java 6 is required to
access the controller's internal web server.
Lots of troubleshooting and maintenance
can be accomplished directly through the web interface,
even on a computer that doesn't have
MotionWorks IEC installed.
You can troubleshoot and clear alarms.
View alarm history,
monitor and graph motion and I/O,
even test servo motion,
set and restore servo paramaters
and backup or restore the project.
You can do with a web server pretty much
everything except to edit and monitor
the code itself. Passwords can be
configured to control access to the
various functions of the web server.
If necessary, the controller firmware
can be upgraded in the field.
For more details on how to use the web server,
documentation is available within
MotionWorks IEC and also online.
OPC, OLE for process control, is yet another
communications option over Ethernet.
OPC is a widely used standard communication
interface for factory automation.
Once you have Yaskawa's OPC server software
running on a PC in the network,
you've opened the Gateway to real-time
communication between the machine
process and the factory network.
For an overview and demonstration of OPC server,
check out the eLearning video.
From the single axis MP2600iec to the MP3200iec
with 62 axes, all the MPiec Controllers
program and operate on one common platform.
That means one common programming software,
MotionWorks IEC.
Just one set of PLC open motion instructions
or motion libraries.
The same libraries of Application Toolbox Code
from Yaskawa works with every controller
and if you can reuse our code,
you can reuse your own code from one
application to another and from one
controller to another.
Whatever application knowledge and code
you've written in one MPiec controller
can be scaled up to the MP3200iec
and code developed for the MP3200iec can
be scaled down for use in the others.
This means that machine designers can
create code libraries and scale the
control systems to meet the level of
automation the customer is able to invest in.
It's one control platform and one software
environment for single or multi-axis.
Now for a few Frequently Asked Questions...
Some have asked if the MP3200iec
can be used with MECHATROLINK II servos.
While some of the features such
as data retry exist on both MECHATROLINK II AND III,
the networks are quite different and not interoperable.
The high performance characteristics of the MP3200iec
are optimized for use with the high-speed
communication of MECHATROLINK III only.
What about the USB port?
The USB port and corresponding STOP/SAVE button
will allow a project to be loaded
or the firmware to be updated without a computer.
Perfect for easy maintenance and program upgrades.
This feature will be supported in a future firmware release.
What version of MotionWorks IEC do you
need for use with the MP3200iec?
You do need version 2.4 or higher.
You can download the latest version from
yaskawa.com
Are there any new features related
specifically to the MP3200iec?
While programming is identical between
MPiec Controllers, the differences and hard work
can be seen in the configuration.
First, you'll notice that the node number
and logical access numbers begin at
three rather than that one.
This is simply characteristic of MECHATROLINK III.
More importantly, however, each MECHATROLINK III
node has the configured response time setting,
which can be set to default, measured or maximum.
These settings comprise the communication cycle
usage as displayed graphically.
Find Quick Start videos on these and many other
How-To topics on the product homepage.
Another important feature is the ability
to simultaneously capture two positions
from the same servo axis at high speed.
For the programmer, this means that
two MC_TouchProbes blocks can be executed
at the same time, on the same axis.
Thanks to MECHATROLINK III,
one or two input sensors can be used to
latch positions and maintain
synchronization in web handling applications.
For example, a sensor can be
used to detect a product as it moves by,
and the length of the product can be
accurately measured using the positions
captured at the rising and falling edge of the sensor.
Another feature in the hardware configuration is
the ability to copy axis parameters from one servo
to another, making it simple to configure
axes that are the same.
It's also easy to set specific parameters
simultaneously on multiple axes in order to
configure the hardware quickly and accurately.
This feature is also available for the
other multi-axis MPiec Controllers.
This concludes the eLearning module.
Thanks for watching and please feel free to contact the
Technical Training Services Group of
Yaskawa America with any and all comments and questions.
Thank you and have a great day!