700 series - motion solutions | dover motion
TRANSCRIPT
NEAT Servo Amplifier
700 SeriesHigh
Performance
Brush and
Brushless Servo
Motor Amplifier
New England Affiliated Technologies620 Essex Street, Lawrence, Massachusetts 01841
Tel: 1-800-227-1066 Fax: 1-800-523-8201
Tel: 508-685-4900 Fax: 508-688-8027
WWW page: http://www.neat.com/users/neat
E-Mail: [email protected]
700 Series
Users Manual
A MESSAGE FROM NEAT'S PRESIDENT
Thank you for selecting New England Affiliated Technologies as your positioning equipment supplier. We
understand that you can choose from a number of competitive suppliers and are pleased that you have selected
NEAT. As you unpack and begin to use our product, we would like your conclusions as to our products'
appearance, quality, precision, and suitability to your ultimate application. By providing us with feedback in
these and other areas, you can become an active participant in our on-going program of continuous improve-
ment. At the rear of this booklet, you will find a detachable, postage-paid response card for your reactions to
our product which allows you to include additional comments. I encourage you to fill out and mail in the
response card. I am also providing several additional paths if more immediate communications are desired.
Our Customer Service department can be reached at 1-800-227-1066 extension 30. If you would like to
address your comments to me directly, I can assure you of an immediate response by calling our toll-free num-
ber and asking for extension 211. Thank you again for choosing NEAT and we look forward to serving you in
the future.
Sincerely,
Kevin J. McCarthy
President
New England Affiliated Technologies
New England Affiliated Technologies620 Essex Street, Lawrence, Ma 01841
Phone 1.800.227.1066 Fax 1.800.523.8201
508.685.4900 508.688.8027
Table of ContentsRelease 1.0/0795 Part Number: 1030008
Preface...........................................................................................................................4
Chapter 1 Overview
Overview.........................................................................................................................5
Section 1-1 System Descriptions..................................................................................................5
Section 1-1.1 Single-Axis System......................................................................................5
Section 1-1.2 Two-Axis System..........................................................................................7
Section 1-2 700-Series Classifications..........................................................................................8
Section 1-2.1 Motor Drive Modes.......................................................................................9
Section 1-3 700-Series Chassis Types.........................................................................................10
Section 1-3.1 Single and Multi-Axis Systems..................................................................10
Section 1-4 System Cabling........................................................................................................11
The Breakout Box........................................................................................................................11
Chapter 2 Unpacking
Unpacking.....................................................................................................................12
Section 2-1 700 Unit and Related Items......................................................................................13
Section 2-1.1 Line Voltage Selection................................................................................13
Section 2-2 Other System Components.......................................................................................13
Section 2-2.1 The Motor(s)...............................................................................................13
Section 2-2.2 The Cable Set..............................................................................................14
Section 2-2.3 Controller Card and Related Items..............................................................14
Chapter 3 Initial Power Checks
Initial Power Checks....................................................................................................................16
1
Chapter 4 Installing the Controller Card
Installing the Controller Card......................................................................................................17
Section 4-1 Setting the Base Address..........................................................................................17
Section 4-1.1 Setting the Default Base Address................................................................18
Section 4-1.2 Setting a Non-Standard Base Address........................................................19
Section 4-2 Installing the Card....................................................................................................20
Section 4-3 Installing the Controller Card Software...................................................................21
Section 4-3.1 Installing the COMM Software..................................................................21
Section 4-3.2 Installing the SDK Software.......................................................................22
Chapter 5 Putting Your System Together
Putting Your System Together......................................................................................................23
Section 5-1 System Cabling........................................................................................................23
Section 5-2 System Assembly Procedure....................................................................................24
Chapter 6 Tuning the Servos
Tuning the Servos........................................................................................................................26
Section 6-1 Theory......................................................................................................................26
Section 6-2 Tuning Procedure.....................................................................................................27
Section 6-3 System Operation.....................................................................................................27
Chapter 7 Connector Pinouts
Connector Pinouts........................................................................................................................28
Chapter 8 Customer Service
Section 8-1 Return Instructions...................................................................................................30
Section 8-2 Shipping Procedures................................................................................................31
2
List of Figures
Figure 1-1 Single-Axis System.....................................................................................................5
Figure 1-2 Two-Axis System........................................................................................................7
Figure 1-3 700-Series Classifications...........................................................................................9
Figure 1-4 Front and Rear Panels of Multi-Axis Unit.................................................................11
Figure 2-1 "Roadmap" for the Various Unpacking Options........................................................12
Figure 2-2 A Typical 2-Axis Positioning Table...........................................................................14
Figure 2-3 The NEAT-1000 Controller Card (partial chip complement).....................................14
Figure 2-4 Breakout Box Used with NEAT-1000 Controller Card..............................................15
Figure 4-1 The NEAT-100 Controller Card.................................................................................17
Figure 4-2 Setting the Default Base Address...............................................................................18
Figure 4-3 Example of a Non-Standard Base Address................................................................19
Figure 4-4 Controller Card and the Auxiliary Connector Adapter...............................................20
Figure 5-1 System Cabling..........................................................................................................23
3
PrefaceThis manual describes the NEAT 700-Series Servo Amplifier Units. The 700-Series is really an entire class of
units which differ one from the other both in regard to the number of axes, and also the mode of motor drive.
A 700-Series Servo Amplifier (hereafter 700-Series or just 700) is a component in a closed-loop position-con-
trol system. The system is controlled by a user-program in a PC-based controller card. The 700-Series is the
link between the Controller card and the servomotors in that, for each axis, it accepts a position-error voltage
from the controller, amplifies it, and derives suitable driving waveforms for the servomotors.
The Overview in Chapter 1 briefly describes how a NEAT position-control system works and the role that a
700-Series unit plays in that system. Subsequent chapters tell you how to set up, cable together, and operate
your system.
The systems described in this manual have a great many variants:
they may be 1-axis, 2-axis, 3-axis, or 4-axis systems
the motors may be brush motors or brushless motors
the mode of motor drive may be either Linear or Pulse Width Modulation (PWM)
This manual addresses all of these needs and, at the same time, enables the user to quickly "zero-in" on his/her
particular configuration.
The body of the manual consists of chapters followed by appendices. All of the information that you will need
is contained in the chapters. We urge you to read the manual from beginning to end. The appendices contain
technical information needed by NEAT engineers and technicians for maintenance purposes.
4
OverviewThe 700-Series Servo Amplifier (hereafter 700-Series, or just 700) is a component in a NEAT closed-loop
position-control system. The system is driven by a user-program in a PC-based controller card. The 700-
Series is the link between the Controller card and the servomotors in that, for each axis, it accepts a position-
error voltage from the controller, amplifies it, and forms suitable waveforms for the servomotors.
This manual describes the various NEAT systems that are available. For a first-time buyer however, the obvi-
ous question is: which system will best fit my needs? First-time buyers should discuss their requirements with
a NEAT applications engineer before purchasing any equipment.
Section 1-1 � System Descriptions
This section will illustrate the role played by the 700-Series for both a single-axis and a 2-axis system.
Section 1-1.1 � Single-Axis System
Figure 1-1, Single Axis System, shows the principal components of a single-axis NEAT position-control system.
Figure 1-1 Single-Axis System
5
The components and their functions are as follows:
Controller Card (mounted in an IBM-PC slot)
The Controller card mounts into an IBM-PC card slot. It processes the instructions in the user's pro-
gram and, from that, continually generates a position command output. This is compared with the position
feedback from the motor's position encoder. The result (following PID - proportional, integral, derivative
processing) is a position error signal to the 700-Series Servo Amplifier. This error signal input is a + 10V,
single-ended signal.
NOTE: Sinusoidal commutation, an available option, is not discussed in this manual. For
sinusoidal commutation, the error signal is a + 5V balanced pair.
We note that there are two servo loops:
� a loop entirely inside of the amplifier unit that forces the motor current waveforms to be
proportional to the position-error input
� the overall position-control loop (this loop is closed inside the Controller card)
As noted above, the Controller card is a PID (proportional, integral, derivative) processor. Processing a deriva-
tive term makes the system more responsive to sudden changes. Processing an integral term assures that any
position will, in time, be brought to zero. Without integral-term processing, this may not always be possible.
700-Series Servo Amplifier Unit
The 700 Unit, as shown, consists of both an amplifier subassembly and a Power Supply Unit (PSU) for each
axis, ensuring freedom from cross talk between amplifier axes.
The Servo Amplifier unit accepts a position-error signal from the Controller card and generates a set of drive
currents to the motor that are proportional to this error signal. These drive currents can be selected to drive
either single coil brush type motors, or three phase brushless motors.
In the event that brushless motors are selected, the motor returns position-encoding signals obtained from Hall-
effect sensors.
NOTE: Do not confuse Hall-sensor feedback with the feedback from the position encoder.
They have quite different purposes. The following section, Motor(s) and Positioning Table,
explains this.
These feedback signals are fed to waveform-logic circuits in the amplifier. The result, when applied to the
motor windings, is a net magnetic field that is constantly "pulling" the motor in the desired direction. Brush
motors incorporate their own electro-mechanical commutation and require no Hall sensors.
Inputs from the controller card enter the 700 unit at the 25-pin REMOTE connector. Signals passing
between the 700-Series unit and the motor are brought out on both a 9-pin and a 15-pin connector.
6
Motor(s) and Positioning Table
The motor(s) will most likely be driving a positioning table. Motor travel will be sensed either by:
� a rotary encoder mounted onto the motor shaft, or
� a linear encoder mounted onto the positioning table
In either case, the encoder signals are fed back to the Controller card to enable it to close the servo positioning
loop.
Why both the Hall-sensor feedback and the encoder feedback?
� the Hall-sensor feedback allows the amplifier to generate the proper current waveforms for
brushless motors
� the encoder feedback tells the Controller card what the motor's current position is.
Section 1-1.2 � Two-Axis System
Figure 1-2 shows a block diagram of a two-axis system.
7
Figure 1-2 Two-Axis SystemWe see that there are two, independent servo loops; one for the X-axis, and the other for the Y-axis.
Controller Card
The controller card is now processing two axes simultaneously; sending out an error signal for each, and
receiving position feedback for each.
There are several types of Controller cards to choose from. A commonly-used card (and the one upon which
this manual is principally based) is the NEAT-1000 family. The members of this family are:
� NEAT-1010 for single-axis systems
� NEAT-1020 for 2-axis systems
� NEAT-1030 for 3-axis systems
� NEAT-1040 for 4-axis systems
700-Series Servo Amplifier
The 700-Series contains an amplifier unit for each axis and a 9-pin and 15-pin connector for each motor.
The nine pin connector is adequate for motor currents up to 3 amp continuous, 5 amp peak. The 15-pin
connector devotes three pins, in parallel, to each motor lead. The 15-pin connector is recommended when
motor currents exceed the above values. All input signals from the Controller card pass through the single 25-
pin connector at the left.
Motors
In this case, two motors are driving a 2-axis positioning table.
Now that we have examined a 2-axis system, it should be clear what the block diagram of a 3 and 4-axis sys-
tem would look like.
Section 1-2 � 700-Series Classifications
The NEAT 700-Series units are, in fact, a whole class of units. They are classified in two ways:
� according to the number of axes (1, 2, 3, or 4)
� according to the type of motor drive (either Linear or Pulse Width Modulation)
In general, a 700-Series unit will have the designation 7XY where:
� X indicates the type of motor drive (either Linear or PWM)
� Y indicates the number of axes (1, 2, 3, or 4)
Figure 1-3 shows these classifications.
8
Figure 1-3 700-Series Classifications
For example, a "703" would indicate that the unit is a 3-axis system and that it has a medium-power, PWM
motor drive.
Section 1-2.1 � Motor Drive Modes
There are two modes of motor drive: Linear and Pulse Width Modulation (PWM). In LINEAR drive, power to
the motor(s) is varied by controlling the amplitude of the driving waveforms. In PWM drive, power to the
motor(s) is varied by controlling the duty cycle of a high-frequency (* 30 kHz) square wave.
The advantages and disadvantages of each are described in Table 1-1.
Table 1-1 Comparison of LINEAR and PWM Motor Drive
You will notice a sort of symmetry: the advantage of one is the disadvantage of the other.
As Figure 1-3 shows, there are two variants to the PWM mode: medium-power and high-power.
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ADVANTAGE
Free of the noise that results from
the PWM high-frequency wave
Very little power dissipation in the
driving transistors
DISADVANTAGE
Heat problem. Must dissipate
power in the driving transistors
Noise resulting from the PWM
action
LINEAR
PWM
Section 1-3 � 700-Series Chassis Types
Section 1-3.1 � Single and Multi-Axis Systems
The chassis for the multi-axis system is 19" long by 5" high. Figure 1-3, Front and Rear Panels of Multi-
Axis Systems shows the front and rear panels.
Front Panel
There is only one control on the front panel:
* the Emergency Stop switch
Rear Panel
Note the connectors on the rear panel:
* The 25-pin connector is cabled to the Breakout box and is located on the right-hand side of the
amplifier unit.
* The 9-pin connector is cabled to the motor (one for a single-axis, two for a 2-axis, etc.). The 9-pin
connector is adequate for motor currents up to 3 amp continuous, 5 amp peak.
* The 15-pin connector is located to the left of the 9-pin connector and devotes three pins, in parallel,
to each motor lead. The 15-pin connector is recommended when motor currents exceed the above values.
Also on the rear panel are the power switch, AC receptacle, the motor and AC fuses, the voltage selection
switch, and the fan.
10
Figure 1-4 Front and Rear Panels of Multi-Axis Systems
Section 1-4 � System CablingThe Breakout Box
One component not shown up to this point is the Breakout Box. This is a convenience for making connections
between the Controller card, Servo Amplifier, and Motor(s). Use of the Breakout Box is described in Chapter 5.
11
2
Unpacking
This chapter provides a "checklist" so that you can be certain every, necessary component has been shipped to
you.
There are different checklists depending on what you have purchased. You may have purchased a 700 unit
only, or a complete system which includes, among other things, the controller card and the items associated
with it (a controller card manual, Breakout box, and software drivers). The most commonly used controller
card belongs to the NEAT-1000 family. Although other controllers are available, this manual lists the associated
items for cards of the NEAT-1000 family only.
Figure 2-1 provides a "roadmap" in the form of a flow diagram. It will help to guide you through the chapter.
Figure 2-1 "Roadmap" for the Various Unpacking OptionsSection 2-1, 700 Unit and Related Items, lists the 700 unit and all of its related items. Everyone should use
this "checklist".
12
Section 2-1 � 700 Unit and Related Items
The following items have been shipped to you:
� 700 Unit Servo Amplifier
- see Figure 1-4
� A power cord for the 700 unit
� A 700-Series Servo Amplifier manual
Now that you have checked your shipment against this list, if you have purchased a 700 unit only, proceed to
the next chapter. If you have purchased an entire system, proceed to Section 2-2, System Components.
Section 2-1.1 � Line Voltage Selection
To change the AC line input voltage, pop open the hinged cover on the AC line receptacle module. This can
be done by simply slipping a screwdriver into the slot on the far right and opening the cover. This reveals the
red, plastic fuse holder assembly which can be removed by prying gently on either its top or bottom. To
inspect or replace fuses, simply remove the assembly. To change the line voltage setting, rotate the assembly
180 degrees before reinstalling. Close the cover, confirming both the line voltage setting and that the AC
power switch is set to zero (off) before installing the AC cord.
Section 2-2 � Other System Components
Refer back to Figure 2-1. Please check that your shipment includes the following:
� The motor(s) (these may be mounted to a positioning table)
� The cable set
� The Controller card and its related items as follows:
- a controller card manual
- the Breakout Box
- the supporting software driver diskettes
Section 2-2.1 � The Motor(s)
If you have ordered a one, two, three, or four-axis system, it is likely that the motors will be mounted to a
positioning table with motor mounts that include 9-pin or 15-pin connectors for cabling connections. Please
refer to Figure 2-2, A Typical 2-Axis Positioning Table.
13
Figure 2-2 A Typical 2-Axis Positioning Table
Section 2-2.2� The Cable Set
Along with your cable set will come a cabling diagram that will instruct you on the placement for each cable
in your set. Each cable is numbered and the diagram refers to each cable by its number.
You are urged to make certain that every cable referenced in the diagram has been shipped.
Section 2-2.3 � Controller Card and Related Items
If you are using a controller card that does not belong to the NEAT-1000 family, please familiarize yourself
with the manual supplied by the controller card's manufacturer.
Figure 2-3 shows a card from the NEAT-1000 family.
Figure 2-3 The NEAT-1000 Controller Card (partial chip complement)
The NEAT-1000 card is approximately 13" long. Figure 2-3 shows only those components referenced in this
manual.
14
There are three items associated with the Controller card:
1. A manual for the NEAT-1000 Controller card entitled: DMC-1000 Technical Reference Guide
2. The Breakout Box
Figure 2-4 shows the Breakout Box used with the NEAT-1000 Controller card.
Figure 2-4 Breakout Box Used with NEAT-1000 Controller Card
As stated previously, the Breakout Box is used for convenient cable connections between the Controller card,
the Amplifier unit, and the Motor(s).
3. Software drivers for the Controller card. The Software Drivers for the Controller card are on two,
floppy disks (either 3.5" or 5.25"). These two disks are labeled: SDK and COMM.
This completes the checklist. Please proceed to Chapter 3, Initial Power Checks.
15
3
Initial Power Checks
Certain steps must be taken before power is applied to your 700 unit. Perform each of these steps in the order
given. Make sure that the AC power cord is removed from the rear panel AC receptacle before proceeding.
1. Inspect for obvious, physical damage. If you find that your unit has been damaged in shipping,
please proceed to Chapter 8, Customer Service.
2. Remove each of the motor fuses and examine them to make certain they are in working order. For
the locations of the fuses, see Figure 1-4.
3. Check that your unit is configured for the correct line voltage for your area (either 110V AC or
220V AC). To do this, simply examine the voltage label visible through a window on the right side of
the rear panel AC line receptacle. This will display either 115V or 230V depending upon the voltage
setting.
4. To change the AC line input voltage, pop open the hinged cover on the AC line receptacle module.
This can be done by simply slipping a screwdrive into the slot on the far right and opening the cover.
This reveals the red, plastic fuse holder assembly which can be removed by prying gently on either its
top or bottom. To inspect or replace fuses, simply remove the assembly. To change the line voltage
setting, rotate the assembly 180 degrees before reinstalling. Close the cover, confirming both the line
voltage setting and that the AC power switch is set to zero (off) before installing the AC cord.
5. To apply AC power to the unit, simply press the top of the ON-OFF switch (marked 1). The AC
power switch is located in the rear panel AC line receptacle.
16
4
Installing the Controller Card
This chapter explains how to install your NEAT-1000 controller card and its supporting software. If you have
purchased a different controller card, please call NEAT's Service Department at 1-800-227-1066 for assistance.
Section 4-1 � Setting the Base Address
Before the card can be installed into your machine, the correct base address must be set. This address is set
using the 7 position DIP switches, A2-A8, shown in Figure 4-1.
17
Figure 4-1 The NEAT-100 Controller Card
Please note the locations of these components:
� the front connector, J2
� the top-edge connectors, J3 and J5
� the 7 position DIP switch into which we will set the base address
All other components are shown strictly for orientation.
Before installing the card, you must set the correct base address using the DIP switches. The default base
address is 1000 (dec).
Section 4-1.1 � Setting the Default Base Address
The default base address of 1000 (dec) is 3e8H (hex). Figure 4-2 shows an expanded view of how the default
number is set using the DIP switches.
Figure 4-2 Setting the Default Base Address
For each switch element, UP is a 0; DOWN is a 1. The complete hex number is made up of 12 bits. It
includes two understood, fixed 0's at the lower-order end, and a fixed 001 at the high-order end.
18
Section 4-1.2 � Setting a Non-Standard Base Address
If another device has pre-empted address 1000, then you will have to choose a different number for the NEAT
controller card. The permissible choices are (in decimal numbers) 512, 516, 520, ... 1020, etc. in steps of four.
In hex numbers this translates to 200, 204, 208, 20C, ... 3FC.
If you choose the address as a decimal number, you must convert it to hex first to set the DIP switches.
For example, suppose we want our address to be 700 (dec). We need to convert this to the hex number
H2H1H0.
1. Begin with the number to be converted and divide it by 256. The result is a quotient and a
remainder. The quotient in this case is 2 and becomes H2.
2. Take the remainder (in this case 188) and divide it by 16. This results in yet another quotient and
another remainder. The new quotient in this case is 11 (or B) and becomes H1. The new remainder in
this case is 12 (or C) and becomes H0.
Thus, 700 (dec) is 2BC (hex).
Figure 4-3 shows this base address set using the DIP switches.
Figure 4-3 Example of a Non-Standard Base Address
19
Section 4-2 � Installing the Card
Turn the power off!
� If you do not intend to install an Auxiliary Connector Adapter then you may install the controller
card in any, unused slot.
� If you do intend to install an Auxiliary Connector Adapter then you must find a pair of adjacent,
unused slots. Place the Controller card so that, when the card is inserted, connectors J3 and J5 face the
other slot. The Auxiliary Connector Adapter will screw into the adjacent, card cage panel (it does not
plug into the slot connectors).
� Connect the two ribbon cables to J3 and J5 as shown in Figure 4-4.
20
Figure 4-4 Controller Card and the Auxiliary Connector Adapter
Section 4-3 � Installing the Controller Card Software
Accompanying your controller card are two disks of supporting software (either 3.5" or 5.25"):
* a COMM disk which contains the software that enables communication between your keyboard
and the controller card
* a SDK disk which contains the software used for tuning the card's servo characteristics
Section 4-3.1 � Installing the COMM Software
1. Start at the C >: prompt.
2. Insert the COMM disk into Drive A. Type A: and press ENTER. Type INSTALL. You should see this
window:
21
CommDisk Installation Procedure
-*-
CommDisk by Galil Motion Control
575 Maude Court
Sunnyvale, CA 94086
(408) 746-2300
Installation Program by HPI
P.O. Box 16078
Huntsville, AL 35082
Press a key to continue...
SELECT A DRIVE FOR INSTALLATION
Press the letter for the drive of your choice or use the arrow keys, then press <Enter>.
3. Press any key to continue. Your screen should display this window:
A: a removable drive
B: a removable drive
C: a local fixed drive
D: a local fixed drive
4. Select the C: drive for installation. Type ENTER. Your screen will display this window:
22
Install Install Programs and Source Code
Install Install Programs only
Install Install Source Code only
Exit now
>Transcript<
This program provides interactive
communication between the computer
and the DMC controller. Characters
typed from the keyboard are sent to the
controller. Responses from the controller
are seen in the Transcript window. Note
that the DMC is expecting to receive
capital letters for legal commands. You
may want to set Caps Lock on.
TALK2BUS version 1.16
PC/XT/AT 27-APR-93
Interactive communication tool for Galil
DMC PC-Bus Based Controllers. Galil
Motion Control (400) 746-2300. Address:
1000 decimal
>Commands<
F1 - help
F2 - perform upload
F3 - perform download
F4 - perform file send
F5 - configure screen
F6 - configure address
F7 - test communication
F8 - exit
5. Choose Install Programs and Source Code (the default selection).
6. When you are prompted for Windows 3.x loaded, choose YES.
7. Choose the offered default for an installation directory.
8. Revision notes will appear on your screen. Type ESC to return to the C >: prompt.
9. You are now in the COMMDISK directory.
10. Type TALK2BUS. Your screen will display this window:
11. Type ENTER. A colon (:) prompt will appear on your screen. The COMM software is ready to accept a
command.
The installation of the COMM software is complete. COMM software requires all-caps keyboard inputs so
you will need to set the CAPS LOCK key before issuing any commands.
As an example, try typing the command RP. This will give you the position on each axis.
Section 4-3.2 � Installing the SDK Software
The procedure for installing the SDK software is identical to that of the COMM software. Please refer to
Section 4-3.1 for instructions.
5Putting Your System Together
Section 5-1 � System Cabling
Figure 5-1 shows a fully-assembled system. However, please follow the assembly instructions in the order given.
Figure 5-1 System Cabling
Figure 5-1 illustrates connections using only one motor. In this case, there can be up to five (5) cables. These
cables are:
� No. 1: from the Controller Card to the Breakout Box
� No. 2: from the Auxiliary Connector Adapter (if present) to the Breakout Box
� No. 3: from the Breakout Box to the Amplifier
� No. 4: from the Amplifier XMOTOR connector to the DB9M (M = male) connector on the X-axis
motor mount. There will be two DB9 connectors on the motor mount; one will be male, the other
female. The relative positions of the two will vary depending on stage type. Always cable an amplifier
motor connector to the male DB9 connector on the motor mount.
� No. 5: from the Breakout Box to the DB9F (female) Limit/Encoder connector on the motor mount.
For each additional motor, there will be two, additional cables corresponding to No. 4 and No. 5.
23
Section 5-2 � System Assembly Procedure
Turn the power off!
1. Cable the amplifier unit to each motor:
1.1 Do not attach any of the encoder feedback cables at this time!
� cable the amplifier XMOTOR connector to the DB9M connector of the X-axis
motor mount
� cable the amplifier YMOTOR connector to the DB9M connector of the Y-axis
motor mount
1.2 Apply AC power to the amplifier unit. The motors should not move or vibrate.
1.3 Turn the power off.
2. Making sure that the power is off, cable your entire system together:
2.1 Apply power to the computer but not to the amplifier.
2.2 Disable the servo loop by typing in the command: MO.
2.3 Check that the limit stops are working. Do this by manually moving the stage up
against each limit stop and issuing a TS command.
2.4 Check that the encoders are working by manually moving the stage and successively
issuing TP commands to confirm that the encoder(s) are incrementing correctly.
2.5 Verify that each motor travels in the correct direction (positive or negative) as follows:
� for a rotary motor (coupled to its load via a leadscrew), the positive direction is
away from the motor
� for a linear motor, the positive direction is away from the connector
2.6 A motor should travel in its positive direction when subjected to a positive drive voltage.
When subjected to a negative drive voltage, the motor should travel in its negative
direction.
Checking each axis in succession, apply a very small, positive driving voltage and check
the direction of travel. This voltage should be just enough to overcome friction. Begin
with 0.25 volts and, if necessary, increase the voltage.
Thus, on the X-axis, issue the command: OF 0.25
24
You must verify not only that the motor is turning (and turning in the correct direction)
but is also turning smoothly. To do this, grasp the shaft (but do not attempt to stall the
motor) and check that the motion is smooth rather than jerky. If it is not smooth, it may
indicate a fault in the Hall-sensor feedback. Please contact NEAT's Service Department
at 1-800-227-1066.
You can stop the motion with: ST. Perform these same tests on the other axes. To
command motion on the Y-axis, type: OF ,0.25. On the Z-axis, type: OF ,,0.25.
2.7 Set a fairly low following error trip threshold with the error command FE1000. Enable
encoder feedback on all axes with the SH command and check for the following
characteristics on each axis. Perform these tests in the order given and do not go on to
the next test unless all preceding tests have been successful.
2.7.1 Making sure that no driving voltage is being applied, the motor should be
stationary.
2.7.2 Grasp the motor's shaft and attempt to turn it. The motor's holding torque should
firmly resist your effort.
2.7.3 Command a small movement with the PR command (it should be just enough to
produce 0.25" to 0.5" of travel).
WARNING! Before issuing this command, make certain that nothing is in
the path of any movable object!
The carriage will do one of two things:
� will come to rest where it should, indicating that the encoder feedback
is in the correct sense, or
� will accelerate towards either end of the stage, tripping the following
error limit and a motor off condition, indicating that the encoder feedback
is in the wrong sense. If this happens, correct the feedback sense by
swapping the A and B lines (and A and B , if present) and repeat the test.
25
6
Tuning the Servos
Section 6-1 � Theory
The servo that controls the motion on each axis is a PID servo (proportional, integral, derivative). This means
that the control action is based on three different terms:
� the proportional term is based upon the error signal (which is the difference between the commanded
position and the actual position)
� the derivative term is based upon the time derivative of the error signal
� the integral term is based upon the time integral of the error signal
There is a separate gain for each term. These gains are KP, KD, and KI respectively.
Thus, the net controlling action is:
KP* (proportional term) + KD* (derivative term) + KI* (integral term)
� The proportional term is the basic response of the system. It may be likened to the spring constant in
a spring-mass oscillatory system. Thus, having a higher proportional gain, or KP, is like having a
"stiffer" spring.
� The derivative term affects both the response to sudden changes and the amount of damping.
Increasing the integral gain, or KI, tends to reduce the error to zero more quickly but, at the same time,
increases the risk of instability.
The simplest way to tune the servos is to use the SDK software which you installed in Chapter 4. Instructions
for using this software are given in the SDK SERVO DESIGN KIT USER GUIDE. Novice users may pre-
fer to follow the User's Guide while more experienced users may choose to follow the procedure given below.
26
Section 6-2 � Tuning Procedure
1. Start by increasing KD until you notice any instability. You will either see or hear this. Then
reduce KD by 30 %.
2. Start increasing KP until you notice any instability. Then reduce KP by 30 %.
3. Set IL (integrator limit) = 0.
4. Set KI = KP/20.
5. Check for long-term positioning error by grabbing the motor shaft, twisting it a few degrees, and
then releasing it. Wait a few seconds, then ascertain the error (if any) with a TE command.
5.1 If TE returns 0, then set KI = 0.
5.2 If TE returns a non-zero error, repeat the test and successively increase IL in increments of
0.25 until you have a zero following error. Once you have a zero following error, increase IL
by 30 %.
6. Increase KI until you observe signs of instability. Then reduce KI by 50 %. This completes the
tuning.
If any unexpected instability is encountered, begin the tests again but with reduced initial values. If you con-
tinue to have difficulties, call NEAT's Service Department at 1-800-227-1066.
Section 6-3 � System Operation
Your system is ready for operation. We urge you to study the DMC-1000 Technical Reference Guide in
order to master the controller card's programming language. As you do so, practice as many commands as you
can to become familiar with your system. When you feel you are ready, begin writing your operating program.
27
7
Connector PinoutsThis chapter gives the connector pinouts for the rear panel connectors:
� the 25-pin connector that links the amplifier to the Breakout Box (and thus to the controller card)
� each of the 9-pin or 15-pin connectors that link an amplifier unit to a motor
REMOTE CONNECTOR
DB-25-S
Mates with DB-25-P
28
PIN NUMBER
1
2
3
4
5
6
7
8
9
10
11
12
13
PIN NAME
XAI+
XAI-
XEN
XFLT
YAI+
YAI-
YEN
YFLT
NC
NC
NC
NC
GND
FUNCTION
X analog input
X analog return
X axis enable
X axis fault
Y analog input
Y analog return
Y axis enable
Y axis fault
No connection
No connection
No connection
No connection
Ground
PIN NUMBER
14
15
16
17
18
19
20
21
22
23
24
25
PIN NAME
ZAI+
ZAI-
ZEN
ZFLT
WAI+
WAI-
WEN
WFLT
NC
NC
GND
FUNCTION
Z analog input
Z analog return
Z axis enable
Z axis fault
W analog input
W analog return
W axis enable
W axis fault
No connection
No connection
Abort input
Ground
MOTOR CONNECTOR
DE-9-S
Mates with DE-9-P
MOTOR CONNECTOR
DA-15-S
Mates with DA-15-P
The 700-Series contains an amplifier unit for each axis and a 9-pin and 15-pin connector for each motor. The
9-pin connector is adequate for motor currents up to 3 amps continuous, 5 amps peak. The 15-pin connector
devotes three pins, in parallel, to each motor lead. The 15-pin connector is recommended when motor currents
exceed the above values.
29
PIN NUMBER
1
2
3
4
5
PIN NAME
MP1
MP2
GND
HI1
HI2
FUNCTION
Motor Phase 1
Motor Phase 2
Ground
Hall Input 1
Hall Input 2
PIN NUMBER
6
7
8
9
PIN NAME
MP3
V5
MFI
HI3
FUNCTION
Motor Phase 3
+ 5 Volts
M Fault Input
Hall Input 3
PIN NUMBER
1
2
3
4
5
6
7
8
PIN NAME
MP1
MP1
MP3
MP2
MP2
GND
HI1
HI2
FUNCTION
Motor Phase 1
Motor Phase 1
Motor Phase 3
Motor Phase 2
Motor Phase 2
Ground
Hall Input 1
Hall Input 2
PIN NUMBER
9
10
11
12
13
14
15
PIN NAME
MP1
MP3
MP3
MP2
V5
MFI
HI3
FUNCTION
Motor Phase 1
Motor Phase 3
Motor Phase 3
Motor Phase 2
+ 5 Volts
M Fault Input
Hall Input 3
8Customer ServiceThis chapter provides instructions for returning your equipment in the event that your system is damaged in
shipping.
Section 8-1 � Return Instructions1. PLEASE CALL (OR FAX) THE CUSTOMER SERVICE DEPARTMENT FIRST
NEAT provides over-the-phone technical assistance which can, in many cases, resolve the problem(s)
you may be having. We require that you contact our Customer Service Department before returning any equip
ment for repair. Our telephone and fax numbers are: Phone: 1-800-227-1066 Fax: (508) 685-0379
2. REQUEST A RETURN AUTHORIZATION (RA) NUMBER
If, after speaking with a Customer Service Technician, it is determined that you will need to return the
equipment for repair, request a Return Authorization (RA) number. NOTE: This number is mandatory
for all repairs.
3. REQUEST AND FILL OUT A CUSTOMER RETURN FORM. INCLUDE A PURCHASE
ORDER (PO) NUMBER AND A CONTACT NAME.
Before shipping any equipment to NEAT for repair, please fill out a Customer Return Form. Please
make sure that the mandatory Return Authorization and Purchase Order numbers are supplied as well
as a complete, detailed description of the problem(s) with the equipment. NEAT will provide an esti
mate before charging any dollar amount to the issued Purchase Order number. When the estimate
has been accepted by written confirmation, NEAT will proceed with the repair of the equipment.
NOTE: Please follow all return shipping procedures outlined in this section.
4. TURN-AROUND TIMES
For all repairs covered under Warranty, the typical turn-around time is 48 hours from receipt of the
equipment at NEAT's facility. For repairs that are not covered under warranty, a typical turn-around time of
two weeks can be expected (depending on the type of work that is required to repair the system and the
Customer Service Department's schedule). Please do not hesitate to call if you have any questions about the sta
tus of your in-house repair.
5. DOCUMENTATION
Once the repair has been completed, you will receive a Customer Repair Report complete with a description of
the parts and labor needed to repair the equipment. For repairs covered under Warranty, a no-charge invoice will
be included for your records. For repairs not covered under Warranty, an invoice, referencing the Purchase
Order number issued, will be forwarded to your Accounts Payable department. The equipment will then be
shipped to the address given on the Customer Return Form.30
Section 8-2 � Shipping Procedures
THIS EQUIPMENT HAS BEEN PACKAGED CAREFULLY. THE FOLLOWING PROCEDURES
MUST BE FOLLOWED WHEN RETURNING EQUIPMENT TO NEAT.
1. SHIPPING STOPS
If the product you have purchased is equipped with one or more shipping stops, they must be re-
installed before packaging to prevent damage to the bearings and nut assembly.
2. PLASTIC WRAPPING
Equipment must be wrapped and tape-sealed in a heavy, plastic bag to prevent packing materials from
entering encoders, bearings, leadscrew cavity, etc.
3. PACKAGING
Please do not re-use shipping container if it utilizes "Instapak" foam material. Degradation in the sup
port characteristics of this foam will occur if it is used more than once.
4. MULTIPLE SMALL ITEMS (ex. BALL SLIDES)
Ball slides must be individually wrapped in "Bubble Wrap", or a similar packing material, to prevent
them from coming into contact with each other.
31
NEATNESS REPORTThis manual has been reviewed for errors. However, mistakes can be overlooked. If you
should happen to find an error within this manual, please fill out this form and mail (or fax) it
back to us. We will make the correction(s) and send you a revised copy when it becomes
available. As always, we thank you for your business and for your help in making sure we
provide the finest equipment and documentation possible.
New England Affiliated TechnologiesAttn: Marketing Department
620 Essex Street, Lawrence, MA 01841
Phone: 1-800-227-1066 Fax: 1-800-523-8201
Company Name: ______________________________________________________________
Contact Name: ________________________________________________________________
Address: _____________________________________________________________________
City, State, Zip: _______________________________________________________________
Phone: ________________________________ Fax: _______________________________
Page Numbers and Errors Found: _________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Product: _____________________________________________________________________
FOR OFFICE USE ONLY:
MANUAL PART NUMBER:103008 Rev 1.1 DATE RECEIVED: REVISION(S) MADE: YES/NO
32
508-685-4900 508-688-8027
New England Affiliated Technologies
620 Essex Street, Lawrence, MA 01841
Tel: 1-800-227-1066 Fax: 1-800-523-8201
Tel: 508-685-4900 Fax: 508-688-8027
WWW page: http://www.neat.com
E-Mail: [email protected]
Rel 1.1
2/97
Part Number: 1030008