Maxcue 600 Series Operator's Manual: Motionbase

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Motionbase
Maxcue 600 series operator's manual

Serial numbers MB 00001429 onward : Document 00058604.doc
Copyright Motionbase (Holdings) Ltd 1999.

All rights reserved
This document is copyrighted and all rights are reserved. This document may not, in whole or in part,
be copied or reproduced in any form without the prior written consent of Motionbase (Holdings) Ltd.
Motionbase (Holdings) Ltd makes no representations or warranties with respect to the contents hereof
and specifically disclaims any implied warranties of fitness for any particular purpose. The information
in this document is subject to change without notice. Motionbase (Holdings) Ltd assumes no
responsibility for any errors that may appear in this document.
Motionbase (Holdings) Ltd
52 Ashton Vale Road
Bristol
BS3 2HQ
England
Telephone:
Facsimile:
Technical Support
Document 00058604.doc
+44 117 907 7690

+44 117 987 3112
support@motionbase.com
Page 2 of 31
Table of contents
Table of contents ............................................................................. 3
1 Glossary of terms ....................................................................... 5
2 Essential information .................................................................. 6
2.1
Electrical testing.................................................................................................................. 6
3 Overview..................................................................................... 7
3.1
Motion base ........................................................................................................................ 7
3.2
MDU .................................................................................................................................. 7
3.3
MCC................................................................................................................................... 8
3.4
ICB..................................................................................................................................... 8
3.5
Software ............................................................................................................................. 8
4 System Installation ..................................................................... 9

4.1
Unpacking / Shipping.......................................................................................................... 9
4.1.1
Equipment / tools required. .......................................................................................... 9
4.1.2
MCC, ICB and cables .................................................................................................. 9
4.1.3
Lifting the motion base ................................................................................................ 9
4.1.4
Packing ..................................................................................................................... 10
4.2
Installation ........................................................................................................................ 10
4.2.1
Floor structural requirements ..................................................................................... 10
4.2.2
Equipment Required .................................................................................................. 10
4.2.3
Orientation of the motion base ................................................................................... 11
4.2.4
Securing the motion base ........................................................................................... 11
4.2.5
Removing and siting the MDU................................................................................... 12
4.2.6
Installing the motion control card............................................................................... 12
4.3
Connecting the MDU ........................................................................................................ 14
4.3.1
Motor power and signal cables................................................................................... 14
4.3.2
Motion control card ................................................................................................... 14
4.3.3
Interlock control box.................................................................................................. 14
4.3.4
Mains power supply................................................................................................... 14
4.3.5
Operation with an uninterruptible power supply (UPS) ............................................... 17
4.3.6
Customer digital I/O .................................................................................................. 17
4.3.7
Customer analogue I/O .............................................................................................. 18
5 Service and maintenance......................................................... 19

5.1
Motion base ...................................................................................................................... 19
5.1.1
5.2
Maintenance .............................................................................................................. 19
MDU ................................................................................................................................ 20
5.2.1
Maintenance .............................................................................................................. 20
Page 3 of 31
6 Health and Safety..................................................................... 21

6.1
Avoidance of moving parts................................................................................................ 21
6.2
Start button ....................................................................................................................... 21
6.3
Interlock circuit and emergency-stop action ....................................................................... 21
6.4
Action in the event of failure of the mains power supply .................................................... 22
Page 4 of 31
1 Glossary of terms
Operator
Person or body who owns and/or operates a Maxcue 600 series motion base.
Attendant
Person who is given responsibility by the operator for ensuring the safe use of a Maxcue 600 series
motion base on a day-to-day basis.
ICB
Interlock control box.
MCC
Motion control card.
MCP
Motion control program.
MDU
Motor drive unit.
Page 5 of 31
2 Essential information
This manual is written for the operator of Maxcue 600 series motion bases, product codes:
610-300-16-10
610-300-16-12
610-450-16-12
It provides information about safety, installation, maintenance, and operation of these bases.
The operator is responsible for ensuring that guards and barriers are provided to prevent access to
moving parts of the motion base. The operator must ensure that access to the motion base is possible
only when the motion base is in a safe state. To this end, it is strongly recommended that use is made of
the interlock system provided by Motionbase plc. Health and Safety issues, including advice on
guarding and interlocks, are considered further in section 6.
The operator is responsible for ensuring that barriers, guards, steps and walkways that control access to
the motion base comply with local safety regulations.
The operator is responsible for ensuring that attendants are trained in the safe operation of the motion
base.
Motionbase plc accepts no responsibility for death, injury or damage occurring due to inadequate
protection of moving parts, or installation not according to these instructions.
Pay particular attention to the warnings throughout the manual. Warnings draw attention to situations
that could result in personal injury or death. They are identified as follows:
WARNING This document also contains cautions. Cautions draw attention to situations that could result in damage
to equipment or property. They are identified as follows:
CAUTION Disassembly, maintenance, or repair other than in accordance with the instructions herein, or other
written instructions from Motionbase plc, will invalidate Motionbase plcs obligations under its
warranty.
If in doubt about the information presented in this document, consult Motionbase plc for clarification.
2.1
Electrical testing
Each Maxcue motion base is fully tested before despatch.

The MDU contains surge protection devices which are voltage dependent and preclude insulation tests
or high voltage tests being carried out.
Should electrical testing be deemed necessary for any reason Motionbase plc must be consulted before
proceeding.
WARNING The cables connecting the MDU to the actuators provide electrical safety
earthing. If the cables are likely to suffer mechanical damage e.g. from footwear or heavier
equipment they must be provided with adequate protection. Should mechanical damage be
suspected, earth bonding to each actuator must be tested before further operation.
Page 6 of 31
3 Overview
The key elements of a Maxcue 600 series motion platform are:
A high efficiency six degree of freedom electric motion base.
A motor drive unit (MDU).
A PC ISA bus motion control card (MCC).
An interlock control box (ICB).
Operating software.
3.1
Motion base
The motion base is a six-degree of freedom motion platform based upon the Stewart platform principle.
It consists of a bottom frame and top frame (flying frame) that are connected by six electromechanical
actuators.
The bottom frame has 5 mounting holes at each of its three corners. All 15 mounting holes must be
used to secure the motion base for operation.
The flying frame has 6 holes that must all be used to mount the payload.
The actuators comprise a precision ballscrew directly driven by an in-line brushless servomotor. Each
actuator has sub-micron position resolution. The motion base is factory wired to the motor drive unit
(MDU).
WARNING The motion base presents a crushing hazard. No person must be allowed to
approach the motion base when the MOTION BASE ENERGISED warning is active. The motion base
may begin to move at any time.
3.2
MDU
The motor drive unit (MDU) is the power stage for the motion base. It contains the following items:
Six servo amplifiers, one for each actuator of the motion base.
High-voltage DC power supply.
Control circuitry, including emergency-stop circuitry.
Shunt regulator.
Interface to the motion control card (MCC).
WARNING - The MDU contains hazardous voltages, even after the mains supplies have been
removed. Remove both the unconditioned and the conditioned (UPS) mains supplies, and wait
10s, before removing the cover. The MDU must only be serviced by qualified service personnel.
WARNING The MDU still contains hazardous voltages even when the motion base itself is
not energised. If the MOTION BASE ENERGISED output is inactive, this does not indicate that the
MDU is safe to work on.
WARNING The MDU contains components that become hot during operation.
CAUTION On no account must the motion base be operated while the MDU is mounted on its
shipping rails. Damage to the MDU and motion base may result.
Page 7 of 31
3.3
MCC
The MCC is an intelligent ISA based servo control card. It occupies two full-length, full height ISA
slots and backplates within a host PC. It has 1k words of dual port RAM (DPR) that allows rapid and
easy transfer of data to and from a host PC.
The MCC is connected to the MDU via two 2m cables.
The MCC executes a motion control program (MCP) that allows the motion base to be operated and
assists in fault diagnosis. Motionbase provide an API and support software that allows high level
communication with this program via DPR.
The MCP is a program that is downloaded to the MCC by the host PC. The program runs on the MCC
and is responsible for:
Servo loop closure.
Profile generation.
Kinematic transformations.
Actuator state limiting.
Washout filtering.
Implementation of a state machine.
Safety system checks.
3.4
ICB
The interlock control box (ICB) is a small enclosure that is connected to the MDU via a 3m cable. The
enclosure contains:
Start button - a momentary pushbutton switch to start the motion base. This is combined with a
green indicator which is illuminated when the interlock circuit is completed (INTERLOCK
HEALTHY).
Emergency-stop button - a latching push button switch that is included in the interlock circuit.
MOTION BASE ENERGISED
3.5
indicator (red), which when illuminated indicates that the motion base is
energised and there is a potential hazard to anyone in the vicinity.
Interlock extension socket - a 1/4" jack plug may be inserted to connect the customers safety
circuits. A shorting plug is fitted in this socket when the unit is delivered.
Software
The Maxcue is shipped with software that allows a motion base to be controlled in a variety of ways. A
full description of this software, its installation and operation may be found in a separate manual
shipped with the motion base.
Page 8 of 31
4 System Installation
4.1
Unpacking / Shipping
4.1.1
Equipment / tools required.
Power screwdriver.
Number 2 Pozi-drive bit.
2 x 19mm A/F spanners.
3 x 25mm U-clevis rated at 500kg SWL.
3 x 1m sling rated at 500kg SWL.
1 x U-clevis rated at 1000kg SWL.
Crane or fork-lift truck with lifting hook having 1000kg SWL at a reach of 1.2m and a minimum
height of 3.5m.
A custom 3-piece sling (part number 000144) is available from Motionbase.

4.1.2
MCC, ICB and cables
The MCC, ICB, cables and other lightweight items are contained within a single package secured to the
motion base pallet. This should be removed before the motion base is lifted from its pallet.
4.1.3
Lifting the motion base
The motion base (approx. 550kg) must be lifted from its pallet and moved to its operating position.
Three 30 lifting points are provided as shown in Figure 1.
Figure 1 - Motion base lifting points

When using three separate slings, one sling should be attached to each lifting point and the free ends
joined to give a single lifting point. The slings should be routed through the inside of the top frame
taking care to protect the MDU-to-actuator cables.
Page 9 of 31

4.1.4
Packing
The motion base and associated components should be packed and secured as received should they
need to be shipped to another location.
4.2
Installation
This section describes the equipment required and procedures that must be followed to safely install the
motion base and its ancillary equipment.
4.2.1
Floor structural requirements
The floor requirements are as follows:

Each of the three groups of five floor fixings must be able to withstand 50kN tensile force. This
equates to 10kN for each fixing. A suitable factor of safety should be applied to this figure.
The floor must be able to withstand a downward force of 50kN spread over an area of 20,000mm2.
This equates to a downward pressure of 2.5N/mm2.
4.2.2
Equipment Required
Installation equipment required

Lifting gear as described in section 4.1.1.
Fixings to suit the floor material. The motion base has fifteen holes in the base frame which must
all be used. Refer to Figure 2 for the hole layout.
To secure the motion base to a steel or similar surface, M16 high-tensile bolts must be used
(minimum grade 8.8).
To secure to a concrete surface, epoxy acrylate resin anchors are recommended. The size of
fixing depends on the strength of the concrete. Where the concrete has a strength greater than
28N/mm2 bolting should be M16 with 125mm insertion; where the concrete has a strength less
than 28N/mm2, bolting should be M20 with 170mm insertion. Time must be allowed for the
chemical anchor to cure prior to installation in accordance with the manufactures instructions.
Figure 2 Motion base mounting holes
Page 10 of 31

4.2.3
Orientation of the motion base
The top frame has three axes of symmetry so there are six principle orientations in which the motion
base can be positioned. Figure 3 shows the control system X-axis related to the actuator joints on the
bottom frame. The X-axis is normally aligned with the payload forward / backward direction.
Figure 3 Motion base actuator and axes orientation

4.2.4
Securing the motion base
Floor fixings must use spreader plates, full washers, spring washers and high-tensile nuts (refer to
Figure 4). High-tensile self-locking nuts may be used in place of the plain nuts and spring washers. The
spreader plate is available from Motionbase; part number 000146.
The location of floor bolts should be determined by positioning the motion base in its proposed
location and marking through the 15 mounting holes in the bottom frame.
The motion base should be removed to a clean area whilst the floor is prepared.
CAUTION - Take care to protect the motion base and in particular, protect the actuator
cylinders, top seals and pivot bearings from dust and dirt.
For concrete floor.

With careful reference to the manufacturers instructions, drill and prepare the fifteen holes
and install all the epoxy-resin anchor studs.
Allow the epoxy resin to cure completely.
Position the motion base over the mounting holes. Check for correct orientation.
Fit the spreader plates, washers and nuts as described above.
Page 11 of 31
For other surfaces.

Prepare holes for the fifteen bolts.
Position the motion base over the mounting holes. Check for correct orientation.
Fit the spreader plates, washers, nuts and bolts as described above.
Torque the fixings to 40Nm.
Use paint or similar substance such as varnish to mark the position of the fully-tightened nuts
relative to the exposed thread of the screws for future maintenance and safety checking.
Figure 4 - Spreader plate details

4.2.5
Removing and siting the MDU
Tools required: Two 13mm A/F spanners

Remove any protective material from the motion base.
Remove the four sets of M8 nuts, bolts and washers that secure the MDU to its transport rails on
the motion base.
Remove any cable ties or other strapping securing the actuator cables to the motion base, but leave
intact any cable ties that bind the pairs of actuator cables together.
Slide the MDU out of the motion base being careful not to stress the actuator cables.
The transport rails may be removed or left in place as preferred.
Retain all fixings for future shipping requirements.
The MDU-to-actuator cables are 7m long and the MDU-to-MCC cables are 2m long. The MDU must
be installed in free air with a minimum space of 250mm around it to ensure adequate ventilation and
access for servicing.
The MDU weighs 76kg and may be mounted horizontally or vertically and if vertical, the MDU must
be orientated so that the cables exit downwards. All cables should have a straight run away from the
MDU for at least 200mm before any bend and the minimum bend radius for all cables is 200mm.
4.2.6
Installing the motion control card
CAUTION - The Motion Control Card is a static sensitive device. Observe normal precautions
for handling such devices.
The motion control card (MCC) is a standard, full length, full height, PC-AT ISA card fitted with a
half-length daughterboard. It occupies two full-length ISA slots and backplates.
Page 12 of 31

4.2.6.1
Selection Of MCC Address
The MCC uses four consecutive I/O address locations that allow access to its Dual Port RAM. The base
address of the card may be set using a combination of DIP switches and jumper links. The card is
factory configured to reside at a base I/O address of hexadecimal 300. If the card is likely to conflict
with other hardware within the PC the address may be changed using the table below.
S1.1
S1.2
S1.3
S1.4
On
On
On
On
On
On
On
On
Off
On
On
Off
MCC Address (hex)
On
300
Off
On
Off
On
On
Off
On
On
Off
Off
On
Off
Off
On
308
Off
On
On
On
Off
On
On
Off
On
Off
Off
On
Off
On
Off
On
Off
Off
On
Off
Off
Off
Off
Off
Off
31C
320
Off
Off
314
318
On
Off
30C
310
Off
Off
304
On
324
328
Off
On
32C
330
Off
On
334
338
Off
33C
If jumper link H is fitted, subtract $100 from the address values.

4.2.6.2
Fitting the MCC
Note - Consult the PC manuals for general advice about fitting PC cards.
Configure the MCC address as required.

Turn off the PC and carefully insert the MCC into a spare full-length slot.
Note - Take care that the card does not touch any tall components on the PC motherboard.
Screw the main card bracket and ribbon-mounted daughterboard bracket to the PC chassis.
Before replacing the PC cover, connect the 2m 37-way daughterboard cable to the daughterboard
rear connector.
Note - The daughterboard bracket must be supported from the rear as the cable is inserted to
prevent distortion of the bracket.
Connect the 2m 100-way cable to the main board rear connector.

Note - Ensure that the connector is fully engaged and that the screwlocks are properly tightened.
Page 13 of 31
4.3
Connecting the MDU
Figure 5 shows the front panel layout of the MDU and identifies its connectors (should information be
required for an MDU of an earlier serial number, please contact Motionbase plc for the appropriate
manual). Figure 8 (towards the end of the document) shows the wiring of MDU connectors P9, P10 and
P11.
Figure 5 - Motor drive unit front panel serial numbers MB 00001429 onward
4.3.1
Motor power and signal cables
The MDU is factory wired to the motion base. Motor power cables are terminated within the MDU and
pass through glands G0 to G5. Motor signal cables are connected via MDU connectors P0 to P5.
Should it become necessary to disconnect the MDU from the motion base, for example to change an
actuator, consult Motionbase before proceeding.
4.3.2
Motion control card
Connect the MDU to the MCC via connectors P7 and P8 using the cables provided.
When an (optional) UPS is in use, as described in section 4.3.5, it is essential that the conditioned
mains output from the UPS is also used as the power supply to the host computer since the MCC
controls the parking operation after failure of the mains supply. Modern UPS units have multiple
outlets so that both the MDU (via P12) and the host computer can be directly connected to the UPS.
4.3.3
Interlock control box
Connect the ICB to the MDU via connector P9.

4.3.4
Mains power supply
Mains power for the motion base must be applied to the MDU via connector P15, see Figure 5. The
mating half (S15) of this BS4343 connector is supplied with the MDU and wiring connections are
detailed in Table 1. A link cable is also supplied for connection of the IEC 320 outlet P13 to P12,
which is necessary in the absence of a UPS see section 4.3.5.
The MDU is factory configured to one of the following voltages - the mains supply must match this
configuration:
220 VAC, single-phase, 50/60Hz.
240 VAC, single-phase, 50/60Hz.
The MDU configuration may be determined by reference to its rating plate located adjacent to
connector P15 (see Figure 5).
Page 14 of 31

The MDU is protected by a type C MCB rated at 40A. It is the customers responsibility to provide
over-current protection for the wiring to connector S15/P15.
The motion base draws a current of between 3A and 32A rms, depending on the payload and the
motion being performed. The mains supply and wiring must be rated accordingly. Consult Motionbase
plc if in doubt about the appropriate rating of the supply.
It should be noted that the MDU current demand is very variable, depending on operating conditions,
with brief (a few milli-seconds) demands of greater than 100A. For this reason, the wiring of the supply
for the MDU needs to be of low impedance and of greater copper cross-section than might be installed
on the basis of the nominal rating. Normally an electrician may install either 2.5mm2 or 4mm2 wiring to
a 32A outlet. However, it is strongly recommended that the wiring to the 32A outlet for the motion
platform is of 6mm2 minimum conductors for runs up to 35m in length from the distribution board, and
10mm2 for runs from 35m to 60m. Although the rms current drawn by the MDU will be below 32A,
the current waveform is such that unacceptable voltage drops may develop if smaller conductors are
used. Such voltage drops will have a direct effect on the maximum available speed of the actuators.
Of course, if statutory regulations require larger conductors than those recommended above (a local
qualified electrician will advise) then those larger sizes should be used.
WARNING - On no account should a three-phase supply be connected to the MDU, unless the
internal wiring changes detailed in section 4.3.4.3 have been carried out. Note that these
modifications make the MDU suitable for use with three-phase supplies up to 240 volts phaseto-phase. Higher voltages such as the 415 or 380 volt three-phase supplies commonly available
in Europe must not be connected directly to the MDU as severe damage will be caused, possibly
causing violent ejection of particulate material.
4.3.4.1
Single-phase operation of the MDU (European voltages)
Figure 9 shows a partial schematic wiring diagram for the MDU, including the external wiring
connections, for operation without a UPS whilst Figure 10 shows the corresponding diagram with an
(optional) UPS, see section 4.3.5.
CAUTION It is good practice, to avoid problems associated with grounding potentials, to
ensure that the unconditioned mains supply to the PC indicated in Figure 9 is of the same phase
as that connected to the MDU.
4.3.4.2
Two/three-phase operation of the MDU (USA voltages)
In the USA the usual way to operate higher power equipment is to connect two hot phases as the
supply. This is possible without any wiring changes within the MDU as shown in Table 1. Figure 11
gives a partial schematic wiring diagram for the MDU, including the external wiring connections, for
two-phase operation without a UPS.
CAUTION It is good practice, to avoid problems associated with grounding potentials, to
ensure that the unconditioned mains supply to the PC indicated in Figure 11 is of the same phase
as that connected to the MDU.
BS4343 Pin
Europe
USA
Earth
Protective earth
Protective earth
220/240 VAC neutral
208 VAC hot 1
L1
NC
NC
L2
NC
NC
L3
220/240 VAC live
208 VAC hot 2
Table 1 Single-phase (European) and two-phase wiring (USA) of the S15 (BS4343) connector.
Page 15 of 31

For USA operation with a UPS (see section 4.3.5), it is recommended that all three phases are used,
since the neutral has to be connected anyway. This requires a few changes to the internal wiring of the
MDU, detailed below, as it is normally supplied for single or two-phase operation. Consult Motionbase
plc if in any doubt regarding the wiring changes needed.
WARNING The wiring changes below should only be carried out by a qualified electrician.
Figure 6 gives a layout of the DIN connector assembly in the MDU and should be used in conjunction
with Figure 12 to carry out the wiring modifications listed below for conversion to three-phase,
120/208 volt operation: remove the IEC 320 link cable between P12 and P13 and discard
remove and discard the wire connecting DT9b to CN1A/1 on the main contactor
connect a 6 mm2 red wire between DT6b and CN1A/3
check that the original connections to SUPP1 and SUPP2 are still secure after these changes.
Figure 6 Partial view of MDU interior showing DIN connector assembly

4.3.4.3
Three-phase operation of the MDU (European voltages)
Operation of the actuators of the platform at the highest speeds can place considerable demand on the
power supply. For the best performance at high speeds it is recommended that the MDU be operated
using three-phase power with 240 volts between phases. For this purpose an auto-transformer (supplied
by the customer) is required and is connected as shown in Figure 13 (without UPS) or Figure 14 when
a UPS is used. A few changes to the MDU internal wiring need to be made for three-phase operation
(the MDU is normally supplied for single-phase operation) which are detailed below. Consult
Motionbase plc if in any doubt about the transformer rating or the wiring changes needed.
Page 16 of 31

WARNING The wiring changes below should only be carried out by a qualified electrician.
Figure 6 gives a layout of the DIN connector assembly in the MDU and should be used in conjunction
with Figure 13 or Figure 14 to carry out the wiring modifications listed below to operate the MDU with
three-phase AC (up to 240 volts between phases): remove the IEC 320 link cable between P12 and P13 if a UPS is not in use; otherwise remove the
IEC 320 connector from P13 and provide a separate supply direct to the UPS
extract the wire ends from DT4b and DT10b and insulate the ferrules (thus isolating P13)
remove and discard the wire connecting DT9b to CN1A/1 on the main contactor
check that the original connections to SUPP1 and SUPP2 are still secure after these changes.
4.3.4.4
Three-phase operation of the MDU (Norwegian IT system)
The MDU can be supplied wired for this system with 240 volts between phases. The corresponding
partial schematics are Figure 15 without UPS or Figure 16 with UPS.
4.3.5
Operation with an uninterruptible power supply (UPS)
If desired, the user can provide an uninterruptible power supply (UPS). A UPS allows the motion base
to return automatically to its parked position if the mains power supply should fail (see section 4.3.4).
The UPS will itself require a mains power supply. It is the customers responsibility to ensure that an
appropriately rated fuse protects the output of the UPS. The external connections to the MDU when
used in conjunction with a UPS are given in Figure 10 for single-phase operation and Figure 12 or
Figure 14 for three-phase operation. Note that the IEC-320 cable supplied with the MDU to link
connectors P12 and P13 when a UPS is not used should be removed and discarded in either case.
In the single-phase application, a supply is routed from P15 to connector P13, which may be used to
supply mains to the UPS as shown in Figure 10. Similarly, the supply from P13 is available for the
UPS when a three-phase USA supply is in use as in Figure 12. The voltage and frequency of the UPS
must always match the voltage and frequency of the supply to P15.
In the case of the three-phase (European voltages) application a supply must be provided for the UPS
from one of the phase feeds to the auto-transformer, as shown in Figure 14.
The conditioned mains output from the UPS must be connected to connector P12 in all cases.
4.3.6
Customer digital I/O
User configurable digital I/O may be connected via the 25-way D-type socket, P11.
4.3.6.1
Outputs
There is one 24VDC digital output available. This is an NPN Darlington driver that may be used to
switch loads up to 50mA. One side of the load should be connected to the 24VDC supply available
from P11.5. The other side of the load (load return) should be connected to the output on P11.4.
When the output is switched on, the load return is connected to the 0V side of the 24VDC supply.
4.3.6.2
Inputs
There are eight NPN digital inputs available. The inputs are internally pulled up to the 24VDC supply
available from P11.5 via 10K resistors. The input device should be connected between the input and
one of the input returns. All of the input returns are connected to the 0V side of the 24VDC supply. An
input is on when the input device connects the input to the input return.
Page 17 of 31
P11 Pin #
4.3.7
Function
Output 6
24VDC
Input 21
Input 17
10
Input 18
11
Input 16
15
Input 19
16
Input return
18
Input 22
19
Input return
21
Input 23
22
Input return
24
Input 20
25
Input return
Customer analogue I/O
User analogue inputs may be connected via the 25-way D-type socket, P10.
The +/-12VDC supplies available from P10.1 and P10.2 may be used to power potentiometers. The
potentiometer wiper should be connected to the analogue input. If an external supply is used to power
the input device, its 0V side should be connected to the analogue input reference.
P10 Pin #
Function
+12VDC (80mA max.)
-12 VDC (80mA max.)
Analogue input 5 (-10V/+10V)
Analogue input 5 reference
10
11
13
0V
15
16
18
19
21
22
24
25
Page 18 of 31
5 Service and maintenance

5.1
Motion base
WARNING - There are no operator-serviceable parts. Tampering with nuts, bolts, etc that have
been factory set may result in failure of the actuator.
5.1.1
Maintenance
The following sections list the maintenance tasks that must be carried out at daily, weekly and monthly
intervals. Details of how to carry out the tasks are provided in later sections.
The attendant will become used to the normal operating sounds of the motion base. Any deviation from
normal should be reported to Motionbase.
Figure 7 - Critical fastenings

5.1.1.1
Daily maintenance
Visual inspection of the following:

Check the actuators for oil leaks. If any oil is visible the actuator may have to be replaced. Contact
Motionbase for advice.
All critical fastenings (see Figure 7) have a paint or coloured varnish stripe marking the fully
tightened position. If loosening has occurred, the motion base should be taken out of service and
Motionbase should be contacted immediately. The critical fastenings are:
Upper and lower mount lock rings.
Upper and lower main pivot lock nuts.
Upper and lower pivot pin nuts.
Lower-attachment-plate screws.
Outer-tube-plate screws.
Outer tube top.
Top spigot.
Tie-rod nuts.
Check the actuator cables for splits, chafing and general condition. Contact Motionbase if damage
to the outer insulation material is apparent.
Check the complete system for abnormal noises during operation. Report any queries to
Motionbase.
Page 19 of 31

5.1.1.2
Weekly maintenance

Inspect the paint markings on the fifteen base-frame mounting bolts. If these markings indicate that
loosening has occurred, check the tightening torque. Refer to the motion base installation details in
section 4.2.4 for the tightening torque for these bolts. If frequent loosening occurs, contact
Motionbase for advice.
5.1.1.3
Monthly maintenance

Check all welds and framework for signs of fatigue, deformation and damage. None is acceptable.
Contact Motionbase immediately if any failure or damage is suspected.
5.2
MDU
There are no operator-serviceable parts inside the MDU case. The cover should not be removed.
5.2.1
5.2.1.1
Maintenance
Monthly maintenance
The only parts that need maintenance are the filters for the two air-circulation fans on the front panel.
The two filters are mounted in housings on the outside surface of the MDU. They may be replaced
without removing the MDU cover.
Remove the plastic filter cover by pulling first one edge, then the complete cover, away from its
housing.
Remove the foam filter element and inspect for damage. If it is in an unserviceable condition,
replace it with the correct part (Motionbase part number 000155).
If the element is serviceable, clean it by washing in warm, soapy water then dry.
Replace the element into the filter housing and fit the filter cover by pushing it over the housing
until its snaps into place.
5.2.1.2
Half-yearly maintenance
Remove and clean the two filters for the air-circulation exhaust air on the rear panel. They may be
replaced without removing the MDU cover.
Remove the plastic filter cover by pulling first one edge, then the complete cover, away from its
housing.
Remove the foam filter element and inspect for damage. If it is in an unserviceable condition,
replace it with the correct part (Motionbase part number 000155).
If the element is serviceable, clean it by washing in warm, soapy water then dry.
Replace the element into the filter housing and fit the filter cover by pushing it over the housing
until its snaps into place.
Page 20 of 31
6 Health and Safety

The following sections describe health and safety matters pertaining to the Maxcue. It should be noted
that the cables connecting the MDU to the actuators of the motion base have integral electrical screens.
The integrity of these screens is important to the correct operation of the motion base and adequate
precautions should be taken to avoid mechanical damage to the cables.
WARNING The cables connecting the MDU to the actuators provide electrical safety
earthing. If the cables are likely to suffer mechanical damage e.g. from footwear or heavier
equipment they must be provided with adequate protection. Should mechanical damage be
suspected, earth bonding to each actuator must be tested before further operation.
6.1
Avoidance of moving parts
Barriers that conform to the local regulations governing the guarding of machinery must guard the
moving parts of the motion base. It is the responsibility of the operator to provide such barriers. The
barriers must be sited so that there is no risk of injury to persons reaching over or through the barriers,
taking account of the full range of motion of the motion base. The barriers must be positioned so that
body parts cannot be crushed between the barriers and any parts of the motion base.
A gate or similar device must control access to the motion base. This device must control an approved
interlock switch that is connected to the interlock circuit of the Maxcue.
Wherever steps or elevated walkways are used to gain access to the motion base, these should conform
to local safety regulations. For example, suitable handrails, barriers and non-slip surfaces should be
provided.
The interlock control box is equipped with a red warning light, called the
MOTION BASE ENERGISED
light. When illuminated, this light indicates that the motion base is energised. The motion base must
not be approached if this light is illuminated, even if the motion base is stationary; motion could occur
at any time. This light must be checked for correct operation every day.
6.2
Start button
The interlock control box is equipped with a start button. This button is the only means of starting the
motion base; the design of the motion base ensures that it cannot start of its own accord. This means
that an attendant must take responsibility for ensuring that it is safe for the motion base to move. This
requirement for human intervention in the start-up process is a key aspect of the design of the motion
base.
6.3
Interlock circuit and emergency-stop action
The motion base is equipped with a safety interlock circuit. The interlock circuit functions as a stop
category 1 as detailed in EN418, 1992. This circuit is a simple series circuit consisting of contacts that
are operated by emergency stop buttons and other interlock devices. The motion base will not start if
this circuit is not complete. As supplied, the following devices form part of the interlock circuit:
Emergency-stop button in the interlock control box.
jack plug in the interlock control box.
The operator can and should add devices to this circuit as required. Advice should be sought from
Motionbase plc before doing so.
If the motion base is operating when the interlock circuit is broken (because, for example, someone
opens an interlocked barrier), the motion base will rapidly return to its parked position and power to the
motion base will be automatically removed. After this happens, the motion base must not be
approached until the red MOTION BASE ENERGISED light goes out.
The Start button on the interlock control box is combined with a green light, called the INTERLOCK
HEALTHY light. This indicates the state of the interlock circuit, being illuminated if the interlock circuit
is complete.
Page 21 of 31
6.4
Action in the event of failure of the mains power supply
If the mains power is removed without warning, the motion base will settle in an attitude determined by
the motion being performed at the time and the payload mounted to the top frame. During this settling
the MDU provides regenerative (or dynamic) braking, where energy is dissipated as heat in a power
resistor. This braking retards the actuators as they move under the weight of the payload.
The motion base may settle in an attitude where one or more actuators are extended.
WARNING Any subsequent changes in the distribution of the payload may result in further
settling motion. There is therefore a potential hazard to anyone in the vicinity of the motion base
until power is restored and the base can be returned to its normal parked position. For this
reason it is strongly recommended that an uninterruptible power supply (UPS) be used, so that
the motion base can be automatically returned to its parked position.
When a UPS is used, the motion control program will wait for the motion base to settle, and will
then use the UPS to bring the motion base to its parked position. This action may take 30-40s.
The MOTION BASE ENERGISED light will briefly go out when the mains fails, and will then come
on again when UPS power is being used to park the motion base. The attendant must be made
aware that backup power will be applied after failure of the mains power supply.
Page 22 of 31
Figure 8 Pin designations for MDU con ectors P9, P10, P11 and wiring of Interlock control box (ICB)
Page 23 of 31
Figure 9 Partial schematic wiring diagram for the MDU showing external power connections: Singlephase without UPS, European supply (220/240 volts)
Page 24 of 31
Figure 10 - Partial schematic wiring diagram for the MDU showing external power connections: Singlephase supply with UPS, European voltage (220/240 volts)
Page 25 of 31
Figure 11 Partial schematic wiring diagram for the MDU showing external power connections: Twophase supply without UPS, USA voltage (120/208 volts)
Page 26 of 31
Figure 12 Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, USA voltage (120/208 volts)
Page 27 of 31
Figure 13 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply without UPS, European voltages
Page 28 of 31
Figure 14 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, European voltages
Page 29 of 31
Figure 15 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply without UPS, Norwegian IT supply
Page 30 of 31
Figure 16 - Partial schematic wiring diagram for the MDU showing external power connections: Threephase supply with UPS, Norwegian IT supply
Page 31 of 31

Maxcue 600 Series Operator's Manual: Motionbase

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Maxcue 600 series operator's manual

Maxcue 600 series operator's manual

Copyright Motionbase (Holdings) Ltd 1999.

+44 117 907 7690

Maxcue 600 series operator's manual

Motion base ........................................................................................................................ 7

4 System Installation ..................................................................... 9

Equipment / tools required. .......................................................................................... 9

MCC, ICB and cables .................................................................................................. 9

Lifting the motion base ................................................................................................ 9

Floor structural requirements ..................................................................................... 10

Equipment Required .................................................................................................. 10

Orientation of the motion base ................................................................................... 11

Securing the motion base ........................................................................................... 11

Removing and siting the MDU................................................................................... 12

Installing the motion control card............................................................................... 12

Connecting the MDU ........................................................................................................ 14

Motor power and signal cables................................................................................... 14

Motion control card ................................................................................................... 14

Interlock control box.................................................................................................. 14

Mains power supply................................................................................................... 14

Operation with an uninterruptible power supply (UPS) ............................................... 17

Customer digital I/O .................................................................................................. 17

Customer analogue I/O .............................................................................................. 18

5 Service and maintenance......................................................... 19

Motion base ...................................................................................................................... 19

Maxcue 600 series operator's manual

6 Health and Safety..................................................................... 21

Avoidance of moving parts................................................................................................ 21

Start button ....................................................................................................................... 21

Interlock circuit and emergency-stop action ....................................................................... 21

Action in the event of failure of the mains power supply .................................................... 22

Maxcue 600 series operator's manual

Maxcue 600 series operator's manual

Each Maxcue motion base is fully tested before despatch.

Maxcue 600 series operator's manual

A high efficiency six degree of freedom electric motion base.

A motor drive unit (MDU).

A PC ISA bus motion control card (MCC).

An interlock control box (ICB).

Maxcue 600 series operator's manual

Servo loop closure.

Actuator state limiting.

Implementation of a state machine.

Safety system checks.

MOTION BASE ENERGISED

Maxcue 600 series operator's manual

Equipment / tools required.

A custom 3-piece sling (part number 000144) is available from Motionbase.

MCC, ICB and cables

Lifting the motion base

Figure 1 - Motion base lifting points

Maxcue 600 series operator's manual

Floor structural requirements

The floor requirements are as follows:

Installation equipment required

Figure 2 Motion base mounting holes

Maxcue 600 series operator's manual

Orientation of the motion base

Figure 3 Motion base actuator and axes orientation

Securing the motion base

For concrete floor.