ORION Motion Controllers

ORMEC's Model 30, 50 & 70 motion controllers are the heart of the ORION® family of products.

Each motion controller features a PC/AT backplane and user expansion slots for a variety of system configurations. The Models 30/50/70 feature three, five and seven expansion slots respectively.

ORION® Controllers
The ORION® motion controllers feature high performance computing capability. Using the industry standard family of X86 & Pentium 32-bit processors with five speed options provides cost-effective compute power for multi-axis applications. Intensive math calculations performed in MotionBASIC® take advantage of the processor’s high-speed integral floating point hardware.

Memory access speed adds to the performance of the controller. The X86 ORION® has a memory bus that is 32 bits wide featuring four megabytes of main memory and 256K byte cache memory and the Pentium models feature a 64 bit wide bus, eight megabytes of main memory and 512K byte cache memory to enhance access speed between processor and memory.

Open PC Bus Standard
Use of the 16-bit ISA PC bus standard provides an effective platform for building multi-axis motion control systems. PC/AT ISA bus expansion slots interface to ServoWire Axis Module(s) plus adapters for factory network connectivity.

An industry standard PC BIOS is installed for booting the operating system to RAM from PC-card flash memory and performing power-on system testing for the motherboard backplane.

Battery-backed time and date hardware is used to log application events during system operation and for dating DOS file directory updates.

Integral Industrial Power Supply
Providing clean and consistent voltage while isolating the motion controller from industrial power sources is achieved by the integral power supply design. ORION® motion controllers include industrial grade multi-voltage power supplies, EMI line filters, transient protection and fuses. Input voltage selection is automatic, allowing the user to simply attach either 115 or 230 VAC, 50/60 Hz power to the removable terminal block connector.

ORION® System Module
The System Module integrates a number of important features for industrial control into ORION®.

• A dual slot PC Card (PCMCIA) interface provides access to mass memory that is nonvolatile, removable, compact and reliable. A Type II slot is provided for the MotionBASIC® System Card (6-136 Mbytes of Flash RAM) which normally includes all operating system and user software. A Type III slot provides the ability to add a second memory card or hard drive.
• 32K bytes of battery-backed memory can be used for nonvolatile MotionBASIC® variables, which are kept intact while power is off and available when the system is back on-line.
• A removable terminal block provides access to the fail-safe, optically-isolated "Emergency Stop" input and the "No Alarm" output, which is a normally-open, held-closed dry relay contact. Overall system integrity and safety are preserved by the fact that the No Alarm relay contact is held closed only if there is current in the input circuitry of the Emergency Stop input and the main processor continues to strobe the on-board Watchdog Timer circuit.
       System integrity is further insured by individual watchdog timers on each ServoWire Axis Module, open-wire detection from each motor’s position feedback, and fail-safe, opto-isolated "No Alarm" signal to each servodrive.
• Ten status LEDs and a single-character, alphanumeric display provide maintenance personnel with clear diagnostic indication of alarms, faults and operating status.
• A Reset pushbutton clears faults and automatically reloads the interrupted program from Flash memory.
• A program override pushbutton (PB1) allows the user to control program loading from the front panel, simplifying software distribution and/or machine diagnostics.
• An RS-232 serial Development Port is used to communicate with an IBM-compatible PC running ORMEC’s MotionDesk software.
• Two RS-422/485 serial communication ports can be used to interface the ORION® controller to a touchscreen or compact industrial terminal and/or provide connectivity to a Modbus factory network or Allen-Bradley SLC-500 PLCs.
• Four status LEDs for each serial port simplify troubleshooting.
• A CAN interface, including removable terminal blocks and status LEDs, is optionally provided for future connectivity. Call ORMEC for details.

Machine I/O
Machine I/O connectivity and flexibility is accomplished through the Discrete I/O board located behind the ORION® front cover. The Discrete I/O board conveniently integrates machine application inputs, interrupts and output configurations into the MotionBASIC® language structure. Machine I/O is optically isolated and can accept AC or DC input modules. Additional I/O can be added using the Extended I/O interface.

User Expansion Slots
The Models 30/50/70 feature three, five and seven 16-bit ISA expansion slots designed to accommodate ServoWire Axis Modules and/or PC compatible adapters such as factory network communications boards.

ORION® Motion Controller Specifications

• Model 30/50/70 controllers provide servo control, operator interface, machine I/O & communications
• Unique multi-processor architecture features Intel x86 and Pentium family main processors, and the Texas Instruments S320C52 digital signal processors for motion control.
• 256K & 512K bytes of cache memory between program memory and main processor
• Non-volatile memory for setup and user defined program variables
• Shared memory interface to DSPs provide fast access.

• All-digital servo control algorithms featuring velocity and acceleration feedforward eliminating following error
• Servo loop update rates up to 5 kHz
• High speed sensor inputs routed directly to DSP axis processor
• High speed position capture hardware (<1 microsecond response)
• Drive fault protection circuits, watchdog timers, and integrated diagnostics for fail-safe operation

MotionDATA Electronic Gearing

• Electronic gearing---linear or cascade
• Contour motion---electronic cams and time-based multi-speed profiles
• 625 kHz DSP-to-DSP broadcast network for precise multi-axis synchronization and control

• Multi-tasking, multiprocessor operating system with DOS compatibility
• MotionBASIC® programming language with concurrent mode operation
• Powerful and easy-to-use motion statement language.
• Predefined motion and I/O variables
• Exact user units conversion with rational numbers
• Program and data memory area of 512 kilobytes with 32K bytes of non-volatile memory for variables
• 32-bit integers and hardware double precision floating point math is standard

• RS-232 serial port for software development system (Port D) with TCP/IP stack and modem support.
• Two RS-422/485 serial ports for operator interfaces and controller networking

• Compact industrial terminal
• Standard color or mono multi-drop industrial LCD terminals with touchscreens or with keypad & display
• Supports IBM-PC/AT compatible keyboard input connector.

• Interface adapters for PLC Networks including TCP/IP Ethernet.
• Supports serial communications adapter providing two auxiliary serial ports, RS-232/422, user configured
• Multi-drop support for serial devices

• 16 standard Opto-22 compatible Generation 4 discrete I/O points
• 24 additional digital I/O points via optional expansion connector, or
• 512 remote analog or discrete I/O using Pamux which is an open, industry-standard parallel multiplexed I/O system.

• 14 system diagnostic LEDs
• 5x7 dot matrix alphanumeric LED
• 12 Serial port status LEDs

• Model 30: 315 watts maximum
• Model 50: 340 watts maximum
• Model 70: 415 watts maximum

• Input voltage: 90-127 or 190-253 VAC, 47-63 Hz single phase
• 10/15/20A circuit breaker provides switched drive control power
• Operating Temperature: 0 to 50C
• Storage Temperature: -20 to 85C
• Humidity: 90% (non-condensing)

• Model 30: 17.2 lbs (7.8 kg)
• Model 50: 18.2 lbs (8.3 kg)
• Model 70: 19.9 lbs (9.0 kg)
• Axis Module: 1.2 lbs (0.54 kg)

Anatomy of an ORION® Motion Controller

Controller Motherboard

• Intel architecture microprocessor (Pentium MMX 233 MHz, Pentium/133, 80586/133, 80486-DX2/66 or DX4/100)
• PC-AT bus with up to seven expansion slots
• 4 Mbytes DRAM
• 256K external cache
• Keyboard connector

ORION® System Module

• Slot 1: MotionBASIC® System Card & additional user memory for most motion control programs
• Slot 2: Additional memory card, communications card or hard drive

• RS-232 development ports
• Two RS-422/485 serial ports
• Supports standard Ethernet hardware using TCP/IP and Windows 95/NT dial-up networking

• Reset and user pushbuttons
• System Status LED, Watchdog Timers
• Monitoring & Diagnostic LEDs
• No-Fault Relay Output
• Non-volatile memory for machine configuration parameters

Discrete I/O Board

• 16 Opto-22 G4 discrete I/O
• Expansion connector to 16 or 24-slot I/O rack or Opto-22’s Pamux standard for up to 512 analog and/or digital I/O

MotionBASIC® System Card

• 6 to 136 Mbytes Flash RAM
• DOS Operating System extended for real-time, multi-tasking
• MotionBASIC® Programming Language
• MotionBASIC® Extensions (MBX) which provide additional software---primarily support for a variety of factory network communications (A-B Ethernet, Modbus TCP, Profibus DP Slave, Modbus, S908, Data Highway/Plus GE Genius and connectivity to Allen Bradley SLC-500 series PLCs).

ServoWire Axis Module

• Interfaces up to eight servos using ServoWire® drive network. Servo loop update rates selectable based on application requirements (2kHz for 8 servos; 4 kHz for 4 servos).
• Digital signal processor operating at 80 MHz provides real-time servicing of servo systems
• Dual port RAM shared memory interface to main Intel microprocessor
• MotionDATA DSP-to-DSP communications for highly coordinated, multi-axis motion performance

• Analog inputs (4 or eight channels of 12-bit analog inputs) available as option
• High-speed drive I/O (programmable limit switches, high-speed sensors) communicated to Axis Module via ServoWire® interface at loop update rate.

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