Product Manual - SSt-1500 v3.5
Product Manual - SSt-1500 v3.5
TEKNIC, INC
TABLE OF CONTENTS
OVERVIEW...................................................................1
Benefits:.......................................................................................... 1
ELECTRICAL INSTALLATION ........................................5
Electrical Isolation & Grounding .................................................. 6
The Golden Rules of SSt Electrical Installation.............................7
Connecting your controller to the SSt-1500 ................................10
Connecting a Motor to the SSt-1500............................................14
Controller signalling details ......................................................... 15
Power Supply............................................................................... 24
MECHANICAL INSTALLATION.....................................31
Motor Outline Drawings: ............................................................ 32
ENCODER FEEDBACK IN YOUR APPLICATION ..........43
SST-QUICKSET CONFIGURATION AND
INTEGRATION SOFTWARE ........................................49
Required Hardware..................................................................... 49
SSt-QuickSet Installation ........................................................ 49
Using SSt-QuickSet.................................................................. 50
OPTIMIZING SYSTEM PERFORMANCE (TUNING) ......53
Servo Glossary ..............................................................................53
The SSt servo drive Compensator (Control Algorithms)........... 54
SSt servo drive Built-In Instrumentation ....................................55
Tuning for Performance.............................................................. 58
Tailoring the Response to Your Application............................... 66
TROUBLESHOOTING YOUR MACHINE.......................71
Problem Table of Contents...........................................................72
DRIVE SHUTS DOWN (GREEN LED BLINKS SLOWLY)73
Tracking Error Shutdowns Occur ................................................73
RMS limit shutdowns occur and/or Motor Runs Hot.................75
I/V shutdowns occur ....................................................................81
LACK (OR PARTIAL LACK) OF MOVEMENT ................84
Motor Will Not Move .................................................................. 84
MOVEMENT NOT SMOOTH ........................................88
Axis Jerks at End of Move........................................................... 88
Axis jerks at beginning of moves .................................................91
Motion erratic (jerky) while moving at constant velocity ....... 92
Large velocity/torque ripple or cogging is evident.................. 93
MOVE LENGTH INCORRECT/UNREPEATABLE ..........94
Motor shaft moves wrong, but repeatable, distance .................. 94
Motor shaft moves an unrepeatable distance............................. 95
Load moves an incorrect, unrepeatable distance ....................... 98
Motor walks when no step pulsesare given ............................. 99
TORQUE SEEMS LOW .............................................100
Motor moves but does not have full torque.............................. 100
Motor loses torque (or performance degrades) after running ..102
MISCELLANEOUS (LOW PROBABILITY PROBLEMS) 104
Axis sings or whines .............................................................104
Limit switches don't work ..........................................................106
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OVERVIEW
Congratulations on your investment in SSt servo drive: today's way to get
the easy digital control and low cost of a stepper motor system, but with
state-of-the-art DSP driven, sinewave-commutated brushless servo
performance.
Unlike most servo drives that control only torque or velocity, SSt
servo drive also controls position by using digital "step and direction"
pulses as input. And it's the only high-performance servo on the market
that can compete on a price basis with open-loop stepper motor systems.
So where's the catch? How can a servo offer state-of-the-art features
and performance, yet cost so little? Well, it's the combination of several
factors working together to increase performance, while simultaneously
lowering product cost, that explains this apparent contradiction:
1. To increase performance, SSt servo drive leverages the
extraordinary processing power of Digital Signal Processors
(DSPs). With the number crunching ability of DSPs, Teknic has
implemented advanced control algorithms that have been
previously impractical. For example, SSt servo drive uses PIV
control with dual feedforward terms, instead of the more
common, but inferior, PID algorithms. We have also
implemented several innovative and proprietary algorithms using
fuzzy logic, among other techniques, to achieve superior
performance.
2. To reduce cost, we have replaced expensive hardware, wherever
possible, with DSP firmware. For example, even the SSt servo
drives current loops are fully digital; in this case, not just
reducing cost, but also enhancing performance and improving
reliability at the same time.
3. Teknic designed SSt servo drive exclusively for OEM users,
allowing us maximize product value specifically for them. And
because we don't sell to end-users, we don't need distributors,
thus eliminating the cost of middlemen who add at least thirty
percent to your cost. Our sales engineers are all factory-direct
specialists, assuring you the top-notch technical support and
applications advice for which Teknic has earned respect.
So now that you know how a brushless, positioning servo drive with
state-of-the-art features can cost as little as an open-loop microstepper,
how about some specifics? How do these features benefit you, and how
does the SSt servo drives performance compare with other servo
solutions?
BENEFITS:
EXPANDED TORQUE-SPEED LEADS TO HIGHER THROUGHPUT
The throughput of your machine is directly related to the power your
drive motors can produce. The efficiency and dynamic performance of
SSt servo drives closed-loop vector torque control gives you higher
torque and speed for measurably greater power than most servos twice
its price, and typically four to eight times as much power as a stepper
motor of equivalent cost or size. This, coupled with the SSt servo drives
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fast settling performance, can more than double the throughput of your
machine in typical applications.
Best of all, if you now use steppers, you can, for the first time, get this
increased throughput with no increase in cost, and without rewriting
your software or retooling your mechanics.
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Moreover, the SSt servo drives DSP constantly calculates the proper
current-voltage phasing to maintain this optimal magnetic angle
regardless of motor speed or load. SSt servo drive also continually autocalibrates its current sensors to minimize inaccuracy and drift.
Combined, these techniques generate accurate and consistent torque
under all conditions, producing fluidly smooth motion. We have
customers with high-resolution imaging applications who have upgraded
to SSt servo drive just for this benefit alone.
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fewer parts than in other comparable servo systems. This low parts
count, coupled with conservative thermal design and robotic assembly
techniques, makes SSt servo drive very reliable (as well as low-cost).
In addition, SSt servo drive has a host of self-protection features
including protection against the following: shorting the motor cable
(phase-to-phase or phase-to-ground), thermal overloads, exceeding
motor RMS capability, motor jams and others. And to back up all this
reliability talk, Teknic offers a standard three year warranty on all drive
electronics.
Because SSt servo drive systems are consistent, reliable and smooth,
they enhance the operational reliability of your machine. SSt servo drivepowered axes never lose steps, so jams, misfeeds and lost
synchronization are things of the past. In addition, your mechanisms are
not subjected to high frequency vibrations that can shake things apart.
All of this means that you can more confidently stand behind the
machines you build.
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ELECTRICAL INSTALLATION
The electrical interface of the SSt-1500 servo drive has been designed to
minimize installation hassles, however, you will find it quite useful to
read through this section of the manual before beginning.
SSt-MC-X
Motor/Encoder
11 Motor-R
12 Motor-S
SSt-1500
13 Motor-T
1 Motor Shield
15 +5V Output
2 Comm-R
Encoder
3 Comm-S
4 Comm-T
Motor
14 N.O. Thermostat
5 GND
6 GND
19 A
9 A~
18 B
8 B~
17
I
I~
16 +5V Output
20 EncTTL~
10 GND
Load
SSt-LC
Limits
3 GND
2 -Limit
1 +5V Out
6 GND
Connections
shown in grey are
not required.
Internally connected
5 +Limit
4 +5V Out
Controller
10 +Limit
1 -Limit
Indexer or
Controller
4 I~
SSt-CC or eq.
13 I
3 B~
12 B
2 A~
11 A
8 Enable~
14 +5V Output
5 GND
15 Mode
17 Ready~
16 Analog+
7 MoveDone[Analog-]
6 GND
18 Step
9 Dir
3 GND
2 Tx
Power
1 Rx
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Every effort has been made in the design of the SSt servo drive to reduce
the complexity of the required harness. In most cases a single cable
connects to the motor, another connects the limit switches, and a third
connects to the indexer/controller without any need for tees or other
"spaghetti" wiring. Even the main DC power can be daisy chained..
Installing an SSt servo drive System is straightforward- Every effort has
been made to reduce your harnessing requirements (only the connections
shown with solid wiring are absolutely required)
Indexer/
Controller
Motor
Power
Amplification
DC
Chassis
Motor
Isolation
Limit
Switches
DC-DC
Converter
Feedback
Sensors
Isolation Diagram
All of the control signals used by the indexer/controller are electrically
isolated from the SSt-1500's DC power input and motor output circuits as
well as from the SSt-1500's chassis (Case Ground). This feature insures
that currents will not be induced into your control wiring by motor
and/or power supply currents. You can even daisy chain the power
wiring to multiple SSt-1500s while using an indexer/controller without
isolated control signals. Not only does this make your wiring simple, it
reduces your cost while increasing your system's operational reliability.
To fully take advantage of the isolation you need to be careful to
maintain separation between the isolated control ground and power
ground. This can be accomplished easily as outlined in the Golden
Rules section below.
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POWER
1.
WIRE GAUGE
FUSE/BREAKER
POWER CHAIN
REQUIRED
REQUIRED
1-3
18 AWG
4-5
16 AWG
5-6
12 AWG
5. The quiescent output voltage of the supply (when all of the SSt servo
drives are connected and disabled) should be no more than 81.0
VDC. If the output is higher than this, change the input (or output)
taps on the power supplys transformer to lower the voltage. (The
SSt servo drives perform a safety I/V shutdown at a minimum of 86
VDC.)
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Use shielded cable for all control signal connections: limit switches,
the motors encoder & commutation signals and the controller cable.
The shield should be connected to the SSt servo drives isolated
control ground (pins 5 and 6 on the controller connector, pins 3 and
6 on the limit switch connector and pins 5 and 6 on the motor
connector). The encoder and controller cables should have low
capacitance insulation. Low capacitance cable conductors are
typically made from polyethylene, foamed polyethylene, Teflon,
FEP, etc. The recommend cable stock shown in the table below has
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MFGR./PN
CABLE DESCRIPTION
Belden/9935
10 conductor 24AWG
foamed polyethylene
conductors, foil + braid
shield. PVC jacket.
Belden/9935
10 conductor 24AWG
foamed polyethylene
conductors, foil + braid
shield, PVC jacket.
Belden/8108
Belden/8108
Belden/9533
3 conductor 24AWG SR
PVC, foil shield, PVC
jacket.
Belden/8618
3 conductor 16AWG
polyethylene, foil shield,
PVC jacket
or
Belden/8770
3 conductor 18AWG
polyethylene, foil shield,
PVC jacket
MOTOR CABLES
10. Use heavy gauge shielded cable for the motor phase wiring.
Connect the shield to pin 1 on the SSt servo drives motor connector
(case ground). Cable with 18AWG conductors can be used up to 12
foot cable lengths. Longer cables should use cable with 16AWG
conductors. Cables in excess of 25 feet will begin to affect the torque
speed curve of the motors and should be avoided, if possible.
11. When constructing the motor cable, ensure that the shield from the
motor phase cable and the shield from the encoder & commutation
sensor cable do not touch.
CONTROLLER/INDEXER INTERFACING
12. Use pull-up resistors on the Ready and MoveDone output signals
from the SSt servo drive. These pull-up resistors can be connected to
a supply voltage of up to 24V.
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13. Be sure the step and direction outputs on the controller can sink
12mA or more (to pull-down a 470 ohm resistor connected to 5V)
14. If encoder feedback is desired at the controller set up the controllers
encoder input to be consistent with the encoder type used on the
motor. The SSt servo drive simply passes the motors encoder
signals through to the controller connector, it does not buffer them.
So, for example, if the motor has a TTL single ended encoder your
controller must be configured to accept this (the A~, B~ and I~
signals will not be active).
STATIC PRECAUTIONS
15. When installing an SSt servo drive you should observe the same
static sensitive procedures as you would for any piece of sensitive
electronic equipment. Although the SSt-1500 inputs are protected
from small amounts of electrostatic discharge (ESD), SSt servo drives
should not be considered immune to ESD. The use of wrist straps is
recommended during installation. Note that both the isolated
control ground and the case ground should be used for grounding the
unit for ESD protection purposes during installation.
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Controller/
Indexer
14
13
12
AC
filter
isolated control
ground to
frame except
at controller
Don't hook
Controller conn.
the SSt-1500
drive's chassis
to machine
frame
Do connect
Limit conn.
Motor conn.
return to
machine frame,
but only at
supply!
Do ground DC
Recommended;
Unregulated
DC Supply
gauge wire to
power drive(s)
Do use heavy
10
limit switch
signals to the
machine frame
chain power to
other SSt servo
drives in
machine
O.K! Daisy
isolated control
ground to
frame except
at controller
Don't hook
power return
through
machine frame
Don't run
Don't ground
11
10
SST SYSTEM MANUAL V3.3
Its easy to connect your control system to the SSt-1500. One connector
provides your system with all of the necessary control inputs and outputs
including: Digital command (step & direction), Analog command (+/10V), Limit switch signals, Encoder signals, [drive] Ready~, MoveDone,
and [control] Mode. All of these signals can be connected to your control
11
470
BRN
Direction
filter
18 17 16 15 14 13 12 11 10
470
WHT
BLK
BLU
18
6
Step
Isolated
Control
Ground
15
17
2K
GRN
Belden 9935
(recommended)
GRY
RED
7
5
10
1
14
11
2
12
3
13
4
filter
+5V ISO
filter
Ready~
(In-Range)
Isolated
Control i
Ground
+5V ISO
MoveDone
VIO
Isolation Barrier
YEL
Mode
Enable~
+5V ISO
digital
filter
filter
2K
ORN
+5V ISO
POWER IN
POWER OUT
(optional)
i
2K
+Limit~
2K
+Limit~
Pass through
from limit
switch
connector
(not shown)
digital
filter
I~
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OR
OR
Input
Ground
Output
Ground
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GND: BLU/RED
READY~: GRY/WHT
CW LIMIT: RED/GRN
ENABLE~: RED/BLU
DIR(CCW/CW): BRN/WHT
GND: WHT/BRN
GND: WHT/GRN
STEP( ): GRN/WHT
MODE: WHT/GRY
ENCODER A: ORN/RED
ENCODER A~: RED/ORN
ENCODER B: BRN/RED
ENCODER B~: RED/BRN
ENCODER I: WHT/ORN
ENCODER I~: ORN/WHT
-ANALOG/MoveDone: BLU/WHT
+ANALOG: WHT/BLU
5V-24V logic
5V logic
Your Indexer/Controller
twisted pairs
SSt-CC cable
Controller
Connector
15
11
2
12
3
13
4
7
16
17
10
18
2K
Isolated Control
Ground
470
2K
2K
Machine Frame
470
+5VDC
SSt-1500
Servo Drive
Motor
Connector
Power
Connector
Limit Switch
Connector
DONT
Machine Frame
Machine Frame
CW Limit Switch
13
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14
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15
Drive End
Motor-R
Motor End
11
Red
Motor-S 12
Wht
Motor-T 13
Motor Shield
GND
+5V Output 15
Wht
Comm-S
2
3
Comm-T
Brn
GND
Blk
Comm-R
Grn
Orn(Pnk)
Encoder-A 19
Yel
Encoder-B 18
Vlt(Red/Blk)
Encoder-I 17
Gry(Blu/Blk)
+5V Output 16
Blu
Thermostat 14
Encoder-A~
9 n/c
Encoder-B~
8 n/c
Encoder-I~
7 n/c
GND 10
EncTTL~
Motor-R
10
Motor-S
11
Motor-T
Motor Shield
Signal Shield
+5V
Comm-R
Comm-S
Comm-T
GND
15
Encoder-A
14
Encoder-B
13
Encoder-I
12
+5V
Thermostat
16
Thermostat Return
20
Phone Numbers
Belden: (765) 983-5200
Olflex Cable: (800) 225-1336
Molex: (708) 969-4550
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Indexer/Controller
+5
5V
Logic
470
-or1
Step
Twisted Pair
Open
Collector
+5
5V
Logic
470
-or-
Isolated
Control
Ground
Twisted Pair
(optional for direction)
Open
Collector
Direction
twl
Step
twh
tsd
th
Direction
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SSt-1500 Logic
+5
5V Logic
Output:
74HC
74LS
2K
74HC14
-or10K
Logic Input Pins
Enable~: 8
Mode: 15
Open
CollectorTransistor
Indexer/Controller
-orSwitch
or
Relay
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disabling the drive at times, and the switch can also be used as a "kill"
switch, if necessary. Toggling the switch will also clear any drive
protection shutdowns that might occur. (De-asserting the Enable~ line
clears the Ready condition. SSt servo drive will then be fully operational
when the Enable~ line is re-asserted. )
MODE (PIN 15)
The Mode signal toggles the drive between two operating modes.
On the SSt-1500-AXX (advanced positioning) setting the Mode line
low will put the drive into a torque/force limit mode that will limit
torque/force in the positive direction, negative direction or both. The
fold-back torque/force limit and direction is set using SSt-QuickSets
Inputs and Limits window. This mode is useful for clamping objects or
allowing the axis to become compliant.
On the SSt 1500-PXX (programmable analog) the Mode line switches
the drive between velocity control mode and torque control mode. When
this signal is grounded, SSt 1500-PXX will be in torque control mode;
when driven to a high level, or left open, the drive will be in velocity
mode. The state of the Mode signal can be changed at any time and the
SSt-1500-PXX will respond by changing the control mode within 120S.
If you want to switch between velocity and torque modes "on the fly" you
should hook it to an I/O line from your indexer/controller and run it
under program control. Otherwise this input should be left disconnected
for velocity control or connected directly to ground for torque control.
LIMIT- AND LIMIT+ (PINS 1, 10)
Limit switch inputs are provided to safely shutdown of the motor in case
preset travel restrictions are exceeded. Inputs are provided to operate
with normally-closed switches only. Normally-closed switches are used
so the motor will not function if the limit switch connector is
inadvertently removed or the circuit is interrupted elsewhere in the
machine.
The limit switch inputs can operate in two distinct modes. The first
will limit torque in the direction of the limit switch. This is the
traditional torque limit switch mode used on most servo systems. The
second, more popular mode, is position limit switch mode that will use
the available power of the SSt-1500 to stop the axis at the limit switch
position. This mode can also be used for precise axis homing when used
with an optical switch.
The limit switch inputs are routed to the indexer/controller connector
so the limit information can be relayed to the indexer (controller), if
desired, without any need for a tee in the wiring harness.
For the purpose of testing, or if limit switches are not used it will be
necessary to fabricate a limit switch "cheater" plug as shown below to
defeat the limit inputs. Such a plug is provided with each SSt servo drive
evaluation kit (P/N: SSt-CP).
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19
+5V
2.0K
Optical Interruptor
5
6
+5V
Limit Switch
Connector
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20
40V
MAX
Lamp
Indicator
-or-
V+
MPSA06
Logic
Relay
Coil
40V
MAX
-orOptoisolator
500
Typical
Indexer/Controller
-or-
14
+5V Output
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21
complete. The state of the MoveDone line is calculated every servo cycle
and is set true when the axis has settled within a pre-programmed
window for a pre-programmed amount of time. Fuzzy logic is also
employed to prevent false triggering of the MoveDone signal if an axis is
ringing at the end of a move.
The InRange~ mode is popular for a path following applications (e.g.
CNC cutting). In the InRange~ mode this signal acts as a positive-true,
open collector output signal which is pulled low when the following error
(the instantaneous difference between the commanded position and the
actual position) of the SSt is outside a pre-programmed window. It is
typically used as a following-error flag to alert your controller/indexer to
reduce the feed-rate (or change the cutting tool) in contouring
applications.
Because it is de-asserted when true, InRange~ signals from several
SSt servo drives can be connected together to form a "wired-OR"
indication that one or more of the axis are not in range. If any SSt
drive is out of range, this wired-OR line will be asserted (pulled low).
This wired-OR signal can then be used as a global out of range input to
your controller (using only one input on your controller for to monitor all
the axis involved in the contouring application.) Note: This can only be
done if you have connected the isolated control ground (GND) on each of
the drives to a central ground point at your controller/indexer.
The operation of the MoveDone[InRange~] signal is configured using
SSt-QuickSets Inputs and Limits window.
Analog Output
Controller
MPSAO6
10K
GND
Analog Out
7
10K
16
6
+2.5V Ref
Isolated Control
Ground
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ENCODER INTERFACE
Incremental encoders are available with one of two types of output drive
circuits: Single-ended or differential. Single-ended outputs are usually
TTL driven lines or open collector outputs. Differential output circuits
have two driven balanced output lines for each signal.
SINGLE-ENDED ENCODERS
The SSt-1726, 2330, 2348, 3437 and 3450 motors incorporate a singleended encoder for position/velocity feedback. The particular encoders
used on these Teknic motors have rugged Mylar optical disks and faulttolerant read sensors for high reliability.
Encoders with single-ended outputs are the most common and least
expensive type of encoder. Properly terminated and shielded, this
signaling method provides excellent fidelity for cable runs up to 25 feet.
In some industrial circles, however, single-ended encoders have an
undeserved reputation as being noise susceptible. Yet they are no more
noise susceptible than any other TTL digital device. Most problems
occur with single-ended encoder signaling because of poor termination,
shielding or ground loops. If you follow the recommendations for cable
wiring shown in this manual, you will be very unlikely to encounter any
problems.
To configure the SSt servo drive for use with a single-ended encoder
connect pin 20 to GND (pin 10). (This has already been done in a Teknic
SSt-MC cable.) The circuit shown in the diagram below will then be used
to receive signals from the encoder. The diagram below also shows
typical encoder cabling. Take care to construct this cabling literally and
do not connect the cable shield or the encoder ground (isolated control
ground) to the motor or chassis, as this is likely to induce noise.
SSt-1500
+5V
1.0K
Motor Connector
+5V 16
11
19
12
18
13
17
Encoder
20
10
74HC14
Typical (X3)
Single-Ended Encoder Wiring. (Used on Teknic M1726, 2330, 2348, 3237 and 3450 motors.)
NOTE: Leave A~, B~ and I~ (pins 2, 3 and 4 on the SSt-1500s controller
connector disconnected when using a motor with a single-ended encoder!
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DIFFERENTIAL ENCODERS
SSt-3462, 3471, 497P and 497T motors have encoders with differentially
driven output signals.
Differential encoders have balanced (symmetrical, inverted) driven
outputs intended to drive terminated, twisted pair transmission lines.
This type of signaling method has high noise immunity and will function
well when high common-mode noise would otherwise be a problem.
They are also well suited to signals in excess of 200kHz and long cable
runs.
To configure SSt servo drive for use with a differential encoder leave
pin 20 open (disconnected) on the Motor connector. The circuit shown
in the diagram below will then be used to receive signals from the
encoder. The diagram below also shows typical encoder cabling. Take
care to construct this cabling literally and do not connect the cable shield
or the encoder ground (isolated control ground).
SSt-1500
Typical (x3)
26LS32
Motor
Connector
11
2
470
12
3
470
13
4
19
A~
18
B~
I
17
I~
Encoder
+5V 16
470
Isolated Control 6
Ground
20
Leave Disconnected
Indexer/Controller
Connector
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POWER SUPPLY
The SSt servo drive runs off unregulated DC voltages from 24 to 75 volts.
A bulk, linear supply (essentially a transformer, bridge rectifier and
capacitor) with a large output capacitance (for minimum droop at high
current draw) is best. Aside from being inexpensive, this kind of supply
can source large peak currents relative to its RMS rating. This is exactly
what you want for powering a high-performance servo system. Switching
power supplies have current limiting to protect themselves in case of an
overload. When high current is drawn from the supply, the voltage drops
until the current ceases. This also occurs when using a ferroresonant
supply beyond its rated current. This will cause reduced performance at
best, and, if the voltage drops below 24 volts, may cause SSt servo drive
to cycle off and on.
Each SSt-1500 has two identical bussed power connectors, and the
power circuitry is electrically isolated from both isolated control ground
(GND) and the chassis. This allows power to be daisy-chained from one
SSt-1500 to the next for a minimized wiring harness without fear of
creating ground loops in the system. The power connectors are rated at
15A RMS. If the RMS current for a group of the SSt servo drives is less
than 15A (see the next section on Power Supply Current Requirements),
they can safely be daisy-chained. Otherwise traditional "star" power
distribution is required. In typical incremental positioning applications,
at least five the SSt servo drives can be wired in a daisy-chained manner.
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Power
Supply
Daisy Chain
Power Distribution
Power
Supply
Star
Power Distribution
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current back into the supply. Most switchers are not built to accept this
and may cycle, shutdown or, in the worst case, fail.
27
general, be easily calculated. Worst case peak shaft power values have
been pre-calculated and verified for Teknic standard motors when
operated with a 75V supply and you should use these in figures your
calculations. If you are using a custom motor or a different supply
voltage, contact Teknic for an estimate of the peak shaft power that will
be produced using an SSt-1500 drive.
PEAK CURRENT WHEN USING LESS THAN FULL
OUTPUT
If you are planning on using the motor at a peak speed below the speed at
which maximum power is produced and/or if you plan to limit the torque
to some value (Tp) less than the peak rated torque1 (Tr), then calculate
Spmax and Ip as follows for use in the Ismax formula above:
Spmax = TpVmax/1352, and
Ip = 23Tp/Tr
where Vmax is the maximum speed in RPM.
tdc
3 2 3 2
S p max + I p Rt I p Rt
2
4
4
I RMS =
3Vs2 S p max
tdc
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torque on time
torque on time + torque off time
This can be accomplished explicitly by setting a torque limit parameter within the SSt1500 using SSt-QuickSet or by reducing the acceleration demand so less torque is
required.
CNC cutting type applications usually are a hybrid of both incremental positioning and
constant velocity applications so the higher of the two calculated RMS current figures
should be used to determine the worst case maximum RMS current.
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Torque on time should not be confused with the running time of the
motor. It is the time that torque is being used to accelerate or decelerate
the motor and can be a small portion of the running time when
trapezoidal velocity move profiles are used. (It is equivalent to the motor
running time when only triangular velocity type move profiles are used.)
tdc can be a maximum of 0.15 for an SSt-1500 that uses full output
torque to accelerate and decelerate the load (at this duty cycle the output
current is 9A RMS which is the rated limit of the Motor connector). You
should attempt to estimate tdc for your application if possible, otherwise
use 0.15 as a conservative estimate if you plan to use the full output
torque capability for acceleration (although this will probably cause you
to over-specify your supply requirements).
1A. INCREMENTAL POSITIONING WITH REDUCED
OUTPUT
If you are planing on using the motor at a peak speed below the speed at
which maximum power is produced and/or if you plan to limit the torque
to some value (Tp) less than the peak rated torque (Tr), then calculate
Spmax, Ip and tdcmax as follows:
Spmax = TpVmax/1352,
Ip = 23Tp/Tr , and
tdcmax
9T 2
= min 1, r
23T p
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DIAGNOSTIC CONNECTOR:
REAL-TIME MONITOR PORT AND THE
SST-QUICKSET CONFIGURATION
REAL-TIME MONITOR PORT
The SSt servo drive includes an Real-time Monitor port (analog monitor
output) for viewing system variables on an oscilloscope or for use with a
data logger. This Real-time port is typically viewed with a standard
oscilloscope and provides a wealth of analytical information on SSt servo
drive and the mechanics to which it is connected.
A great benefit of the ports real-time nature is that you can use your
oscilloscope to look at SSt servo variables while viewing other non-servo
signals in your machine to verify controller timing and find software
bugs.
Actual velocity, commanded velocity, velocity error, tracking error,
commanded torque as well as other variables can be displayed with ease.
The Monitor output is configured using SSt-QuickSet as described in
the SSt-QuickSet on-line Help.
The monitor output is a 0.5-4.5 volt signal centered around a 2.5 volt
"zero" reference. A 2.5 volt DC reference signal is also provided at the
diagnostic connector (pin 5) for use with instruments that have
differential inputs.
RS-232 CONFIGURATION PORT
An RS-232 interface is provided for configuring SSt servo drive using
SSt-QuickSet software. There is no need to install this interface
permanently.
RS-232 handshaking signals are not provided or used by the SSt1500. The Rx and Tx signals are fully RS-232 compatible. The
communication format is 8 bit, asynchronous, half duplex with a single
start bit, a single stop bit and no parity. It is recommended that the DCE
CD, RI, DSR, and CTS input signals be connected to the DCE DTR signal
to prevent noise from affecting the operation of the host computer.
Molex
50-57-9405
DB9
Female
4
6
7
8
9
BNC plug to
oscilloscope
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MECHANICAL INSTALLATION
Mechanical drawings for the SSt-1500 (with and without the case
option), and for Teknic motors are shown on the following pages.
Mechanical mounting data are provided within each drawing.
Any of the following outline drawings can be downloaded from Teknics
web site in native AutoCad .DWG format. Simply look for a download
link on the motor specification page for the particular model you are
interested in.
Mounting Options:
(4) #8-32 UNF-2B
2 on back (preferred mounting surface)
2 on bottom
CAUTION:
#8 mounting screws must not penetrate
more than 0.30" (7.5mm) into case
Preferred Mounting:
Power connectors this end
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Mounting Options:
(4) #8-32 UNF-2B
2 on back (preferred mounting surface)
2 on bottom
CAUTION:
#8 mounting screws must not penetrate
more than 0.30" (7.5mm) into case
Preferred Mounting:
Power connectors this end
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Life(in years ) =
week year
day
12000
10000
8000
6000
4000
2000
0
1
10
15
20
5 lb axial load
10 lb axial load
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Winding insulation breakdown can become an important factor if the motor is run at a
winding temperature of over 155C for any period of time. As long as the winding
temperature is kept under this value, insulation breakdown will not normally be a
problem. This winding temperature corresponds to a steady-state case temperature of
about 75C under most thermal transfer conditions.
Non-corrosive atmosphere at 0-90% relative humidity (non-condensing) with moderate
levels of airborne contaminants.
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70000
60000
50000
40000
30000
20000
10000
0
1
10
15
20 25 30 35 40 45
50
55
60 65
70
5 lb axial load
10 lb axial load
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ENCODER FEEDBACK
IN YOUR APPLICATION
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If your application does require on-the-fly synchronization to the exact encoder count
you will need an encoder feedback card for use with this soft controller or a
commercially available indexer card with encoder feedback but only for the one or two
axes in your machine that require this.
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adds between 20mS to 50mS of latency for every move in your machine
(decreasing your throughput).
The SSt servo drive can greatly offload your control code by doing this
processing for you. The MoveDone signal is a high level TTL signal that
actuates when the position error at the end of the move has been within a
desired accuracy for a qualification period of time. Both the accuracy and
the qualification period are configurable and are usually set to a few
counts and a few milliseconds. The MoveDone signal is calculated every
100uS to eliminate latency and it also has fuzzy logic false triggering
suppression (which suppresses the signal if it looks like the position
will move out of the accuracy window).
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Lets say that you have an axis that is 100,000 counts long. You
simply make a moderate speed move toward a limit switch of 100,100
counts. At some point during the move the axis will contact the limit
switch, at that point the SSt will automatically ignore further pulses in
that direction. Any pulses in the other direction (away from the limit
switch) will be responded to as usual. So after the completion of the
100,100 count move you simply command the axis to move away from
the limit switch by a fixed amount to a precision home position.
Hard Stop Homing will provide the same function for you without any
switch! Hard Stop homing allows you to home an axis with excellent
precision by simply driving the axis into a hard mechanical stop at a
moderate speed. At some point during the move the axis will contact the
mechanical stop, the SSt servo drive will automatically sense the hard
stop, fold back the torque/force to a low level, ignore further pulses in
that direction and assert the MoveDone signal. You can choose to
monitor MoveDone to speed up homing or simply overdrive the axis
into the stop (as in the 100,100 count example above). Any subsequent
pulses in the other direction (away from the mechanical stop) will be
responded to as usual. So after the completion of the Hard Stop Homing
move you simply command the axis to move away from the mechanical
stop by a fixed amount to a precision home position (usually repeatable
to within one encoder count if the axis is relatively stiff).
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flag
from
controller
slotted
optical
switch
driving the axis to an end stop of the axis and depend on the
tolerance of the mechanics for alignment,
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you might be able to remove the manual alignment altogether making the
procedure more repeatable.
b. Figure out how to drive the machine state, in the most optimum
way, avoiding potential obstacles, to the desired state to continue
operating without damaging product?
Upon some careful discussion/analysis of all the possible
permutations that can occur during an interruption, this often turns out
to be a massive undertaking that it not worth the effort and/or has fault
opportunities of its own.
In most machines its overwhelmingly likely that there exists a simple rehoming sequence that will resume operations without damaging product
(if it has not been damaged already) after a fault, e-stop, etc. Sometimes
there are a few of these sequences depending on which axis, or group of
axes, faulted, but very rarely, if ever, do they need to (or should they) rely
on the secondary encoder data for proper operation. The most robust
error recovery strategy is to find these simple re-homing sequences and
use them without relying on potentially corrupt secondary encoder data.
You may lose a few seconds on average in the event of a fault by not using
secondary encoder data in these sequences, but you will gain enhanced
system reliability and typically, faster time to market with your machine.
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REQUIRED HARDWARE
SSt-QuickSet runs on IBM PC compatible computers with a
486/Pentium CPU, a minimum of 16MB of RAM, a CD-ROM, 10MB of
free disk space and a free serial port. (The serial port cannot be shared
with other active serial devices such as a mouse).
Required software is Microsoft Windows 95, 98 or NT4.0 SP3 or
better.
SST-QUICKSET INSTALLATION
Insert the SSt-QuickSet installation CD-ROM into your drive on a
Windows 95, 98 or NT4.0 computer. If AutoRun is enabled, the installer
will start shortly after inserting the disk. If it does not start, open a
window to the CD-ROM drive and run the application program
SETUP.EXE.
An installation screen will appear and ask you to select a destination
on your hard drive, etc. The installation process will take a couple of
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USING SST-QUICKSET
Most often SSt drive configuration is accomplished using two windows
within SSt-QuickSet: The main window and the Inputs & Limits window.
These are shown below with call-outs explaining major functions.
Drive State Indicator
[Double click to
clear shutdowns.]
RMS Meter
displays load in real time
[Peak hold function
allows you to easily test
for worst case loading.]
PIV compensator is
easy to tune.
[much easier than PID]
Feedforward Gains
Position/Velocity
readout can be set-up
to display in
user units:
M/sec, inches, etc.
Shutdown messages
help you quickly
troubleshoot
problems in
your machine.
Real-time LEDs show you
the status of the SSt servo drive.
[Even sub-millisecond events are "stretched" for display.]
Exclusive, IMT:
Adaptive
compensation
to quell overshoot
even with large
inertial and
varying loads.
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Input Resolution
programmable
over a wide range
MoveDone torque
Foldback allows the
use of inexpensive
mechanics
MoveDone verification
is fully programmable
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Check any extension cables for open wires on the RS-232 control
signals. If these lines float they may be interrupting your machine
with unnecessary work. The SSt-DC cable is wired to make COM
port see an on-line modem whenever the PC is powered up. If
you have a break-out box, loop the PC's DTR to DSR, DCD, RI
and CTS at the PC end of the cable. See the section on the Realtime Monitor port for more details.
For older machines make sure serial port based on the 16450 chip
(the 16550A chip is even better).
Check for interrupt and I/O address conflicts on the serial port.
Try removing any LAN drivers or the connection from the LAN to
your machine.
Get a faster machine. A slow machine and display card may cause
some of the time-outs.
53
SERVO GLOSSARY
SSt servo drive works by continuously adjusting the amount of torque
being applied to the motor shaft in response to a commanded signal
(torque, velocity or position), and feedback from an encoder mounted on
the back of the motor. The sophisticated software algorithms that
calculate and adjust the instantaneous torque output need some
information about the mechanical system and the performance objectives
of the system in order to work effectively. This information is entered by
the system designer in the form of various numerical gains. When we
talk about optimizing system performance, we are referring to the
process of adjusting these gains appropriately.
With SSt servo drive, the optimization process is easier than ever. It
no longer has to be done by feel by an expert. Built-in stimulus/response
instrumentation makes the process systematic and straightforward. If
you are an experienced servo veteran, you'll be excited at how much more
effectively you can use your knowledge and expertise with the SSt servo
drives measurement capabilities. For servo neophytes, it will be easier to
understand the optimization procedures that follow, if we begin by
defining some terminology:
Compensator: The algorithm that calculates the amount of torque to
apply to the motor, based upon the feedback from the encoder sensor.
Feedforward Gain: Extra torque applied based on the current value of
the specified type. These gains compensate for the delays caused by
actions of the Compensator. The velocity feedforward applies a fraction
of maximum torque based on the current velocity command.
Acceleration feedforward similarly applies torque based on the current
acceleration demands.
Following Error: Another name for Tracking Error (see below).
Gains: Parameters within the SSt servo drives compensator that
multiply the various errors and command values. The results of these
multiplications are summed at various points to calculate the
compensator output.
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Loops: Control feedback paths within the compensator. The SSt servo
drive has a position loop, a velocity loop and a vector torque controller (a
sophisticated current loop).
Position Integrator: A device that sums the history of the tracking
error over time. The use of this device within the SSt servo drives
compensator assures that the tracking error will be forced to zero over a
short period of time when the integrator gain Ki is used.
Overshoot: A possible response property of a servo system- It is
defined as: the maximum amount that a response goes beyond or "overshoots" a target before being forced back toward the target value.
Position Error: Another name for Tracking Error (see below).
Ringing: A response property- when the response cycles around the
target value after a change in target or in response to an external
disturbance.
Settling Time: There are various definitions for this response property,
but the one used is this document is- The amount of time that is required
for the response to reach its target value from the last change in that
target (position or velocity). The response is considered to have reached
its target value when it is within some pre-defined window: e.g. 2% of
the move length, .001", 1 RPS, etc.
Stiffness: The amount of force (torque) applied divided by the position
error distance (angle). Typically measured when the system is at rest.
Tracking Error: By definition, all systems that respond to a command
signal exhibit some finite error with respect to the command. The
instantaneous position error that occurs during SSt servo drive
movement is referred to as "tracking" error; it refers to how well the SSt
servo drive tracks the incoming steps. The SSt servo drives high
bandwidth means that this error will be small compared to other systems
for any given command signal. (Note: Contrary to some manufacturer's
claims, stepper motors also have continual tracking error. Their error,
however, is either less than 3.6 degrees (two full steps) or essentially
infinite, because beyond two steps of tracking error, the stepper motor
will stall.)
Velocity Error: By definition, all systems that respond to a command
signal exhibit some finite error with respect to the command. The
difference between the commanded velocity and the measured velocity is
the velocity error. Inside SSt servo drive, the commanded velocity is
calculated by counting the number of input step pulses that have
occurred over a period of time, and the measured velocity is calculated by
counting the number of encoder counts have occurred over a period of
time.
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contains velocity and acceleration feedforward terms that are not shown
below.
digital
command
(steps in)
v*
RAS
d/dt
integrator
Kfv
torque
filter torque
command
Ki
p*
Kp
Kv
imbedded
velocity loop
velocity
estimator
measured
torque
Kfa
Adaptive
Inertia Matching
Technology (IMT)
Knv
Knp
measured
position
main gains
feed-forward gains
adaptive gains
PIV Compensator
Analog Equivalent (feed-forward terms not
shown)
First the innermost vector torque controller is tuned and then each
successive "layer" is tuned until the position integrator is finally adjusted.
After the loops are tuned in this manner you may wish to experiment
with each of the gains to "tweak" the performance for your application,
but this is usually unnecessary.
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Period
Adjust
Amplitude
Adjust
Velocity
Cmd.
Position
Cmd.
Measured
Position
Torque
Cmd.
Measured
Velocity
Calculated
Torque
Don't use it in torque mode with an amplitude above 25% unless the
total time the Tuning Stimulus will run is less than a few seconds.
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500mV
10ms
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and your indexer. This will allow for a fast and easy way to disable
SSt servo drive, without the intervention of software. The tuning
process requires disabling the drive at times, and the switch can also
be used as a "kill" switch, if necessary. Toggling the switch will also
clear any drive protection shutdowns that might occur.
E. Open the User Units setup window and depress the Default button.
(This step is not necessary but it does assure that the units shown on
your screen are the same as the ones in this manual.)
F. Connect an oscilloscope to the Real-time Monitor port and adjust the
controls as described above.
G. It will be helpful to you if you first read through this entire section
before actually beginning the tuning process.
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500mV
10ms
overshoot "spike"
Kv adjusted well
Kv too low
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This usually indicates that there is a mechanical resonance in your system which will
ultimately limit performance. Although you can "tune around" this resonance, your
61
500mV
10ms
system performance will be enhanced if it is removed from the system. There may be
several simple solutions to this problem, contact Teknic for details.
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500mV
10ms
Disable SSt servo drive and move the axis to its mechanical center (if
it moved off during the previous procedure).
8. Click on the 2-Kp Tune button. This will zero out the Kp and Ki
gains, set up the Real-time Monitor port and Tuning Stimulus.
[The Real-time Monitor port will be set to Tracking Error with a
range of 40 degrees (10 degrees/division) and the Tuning
Stimulus will be set to inject a 30 degree command signal into the
position loop with a period if 500ms.]
9. Enable SSt servo drive.
10. Start the Tuning Stimulus by clicking on the On/Off button.
The indicator above the On/Off button should come on and
stay on. If it does not stay on, the drive is not enabled; enable the
drive and try again. Your oscilloscope should display a 3 division
high square wave edge.
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Because the position gain, Kp, is set to zero, the motor will not
yet respond to the position moves commanded by the Tuning
Stimulus.
11. Begin to increase Kp: the motor should start to move.
Keep increasing Kp until you notice overshoot on your
oscilloscope as shown in the figure below. Adjust Kp for
approximately 5% overshoot.
Values for Kp usually fall between 1,000 and 25,000. (In 80
percent of systems, Kp falls between 7,000 and 16,000.) You should
start around 1000 and increase in increments of 2000 (i.e.: 1000
3,000, 5,000, etc.) until you bracket the correct response. Then go
back and iterate in smaller steps until the desired response is
achieved.
AS YOU INCREASE Kp, THE AXIS MAY REACT QUITE VIOLENTLY.
IF YOU THINK THAT YOUR MECHANISM MAY BE DAMAGED,
REDUCE THE EXCITATION AMPLITUDE (i.e.: REDUCE THE TUNING
STIMULUS AMPLITUDE FROM 30 DEGREES TO, SAY, 15 DEGREES).
500mV
10mS
Kp Gain Increases
No Kp Gain
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This can also be done by double-clicking on the word "Ready" where it appears in the
main menu bar, or by using the Reset Shutdowns command found under the Setup
menu.
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12. Stop the test by clicking on the On/Off button in the Tuning
Stimulus section of the main window. (Alternately, if you have
followed the tuning procedure from the start, and plan on
continuing, you can leave the Tuning Stimulus running and
proceed immediately to step 15.)
ANTI-HUNT
During the above tuning procedures you may have noticed that the motor
began to "buzz" or "grind". What is occurring is a low level limit cycle as
the motor hunts between encoder ticks. This usually is not a problem,
but it may be perceived as one by your customers (users) and should be
avoided. For this reason, Teknic developed the Anti-Hunt feature.
When in use, SSt servo drive uses a non-linear, fuzzy technique that helps
quell the buzzing motion that can occur at zero speed with other servo
controlled systems. In general, this allows the use of higher gains for
stiffer and faster response without annoying buzzing.
To enable Anti-Hunt, open the main window of SSt-QuickSet and
turn the Anti-Hunt button to On.
If, after Anti-Hunt is invoked, the buzzing is still unacceptable, you
may wish to reduce the gains of your loops. Reducing the Kv gain while
increasing Kp and holding the product of Kp and Kv constant may stop
the grinding without reducing performance.
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Velocity
+max
-max
Time
17. Trigger your oscilloscope such that you can view the response during
the entire move. The easiest way to do this is to use the Real-time
monitor ports Sync pulse pull-down menu setting it to plus.
Adjust the HORIZONTAL TIMEBASE so it corresponds to the length
of the move as shown above. To be sure you have the scope set up
right set the Real-time Monitor port to Commanded Velocity with a
range equaling twice the maximum speed your indexer is
commanding. Your oscilloscope should display a picture like above.
18. Set the Real-time Monitor port to Commanded Torque with the
range set to the maximum number of ounce-inches that your SSt
servo drive can produce.
19. Start the axis moving. (The SSt servo drive gains Kv, Kp, Kfv and Ki
should be set using the previous steps of the tuning procedure as
described above.)
20. View the Commanded Torque during the moves to ensure that the
output stage of SSt servo drive is not saturating (i.e.: attempting to
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use more than the maximum available torque). The torque output
should not exceed 3 divisions at any time during the move. If more
than this torque is being used, reduce the acceleration of the move.
21. Switch the Real-time Monitor port to view Tracking Error and set
the range to one tenth of the maximum velocity commanded by the
indexer during the move.
22. Set Ki to zero.
23. Increase Kfa while viewing Tracking Error for the entire move. At
some value of Kfa, the Tracking Error will be minimized.
24. If you cannot detect any positive benefit when using a non-zero Kfa
because the error was already so low you could not detect any
improvement- be pleased. This means that you have a very high
bandwidth, low error system. In order to set Kfa appropriately try
reducing Kv and Kp to half their original value and repeat step 24.
After you have completed this step restore Kv and Kp to their prior
values.
25. As before, switch the Real-time Monitor port to Commanded
Torque with the range set to the maximum number of ounce-inches
that your SSt servo drive can produce.
26. View the Commanded Torque during the move with Kfa set to ensure
that the output stage of the SSt servo drive is not saturating (The
torque output should not exceed 3 divisions at any time during the
move.) If more than this torque is being used reduce the acceleration
of the move and repeat step 8.
27. Restore Ki.
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noise in the system will not be abrupt or at all oscillatory. The tuning
procedure above will produce a slightly underdamped response
characteristics that is not necessarily optimum for applications where the
smoothest response is desired. (In a scanner, underdamped response
can produce qualitatively poor images.) Underdamped response should
generally be avoided wherever the human eye is used as the final
measure of quality.
We describe here three levels of tuning for a smooth response, named
level I, II and III. Level III is the smoothest. As you progress from level I
to level III, however, you will be lowering the speed of response to
disturbances (servo bandwidth) and the axis under control will feel
"softer" with each level to which you proceed. In general, if you have a
smooth, well-isolated and disturbance free mechanism you will want to
use level II or level III tuning. If however, your mechanism is
mechanically noisy or if the axis is likely to be disturbed by external
forces, standard tuning or level I tuning may actually give you overall
smoother response. Note: Level III should only be used if you have no
concern that the axis may have some finite tracking error (this would be
an application where you are concerned about velocity control only).
Level I:
Adjust Kv using the standard velocity loop tuning procedure except set
Kv for the fastest rise time response that exhibits no velocity overshoot;
Adjust Kp using the standard position loop tuning procedure except
adjust Kp for the fastest rise time response that exhibits no position
overshoot, then increase Ki until position overshoot is barely detectable.
Level II:
Adjust Kv using the standard velocity loop tuning procedure except set
Kv for the fastest rise time response that exhibits no velocity overshoot.
Then, do not follow the standard procedure for Kp, but instead adjust Kp
using the velocity loop tuning procedure, increasing Kp, as before, until
you observe the fastest rise time response that exhibits no velocity
overshoot. After you have adjusted Kv and Kp in this manner adjust Ki
using the Position loop tuning procedure for the fastest rise time
response that exhibits no position overshoot.
Level III.
Follow the Level II procedure to adjust Kv and Kp. Set Ki to zero.
The best way to evaluate which tuning level is right for you is to look
at the final result when operating your machine using the Real-time
Monitor port and an oscilloscope. Alternately, you may have a specified
velocity frequency spectrum envelope you must stay below. If this is the
case, then you can use the Real-time Monitor port in Velocity Error mode
as an input to an FFT analyzer with one caution: Ignore any response
spikes at or around frequencies that are the speed in RPS times the line
frequency (lines per revolution) or 4 times the line frequency of the
encoder. Also ignore any response spikes above 1000Hz.
ELIMINATING SERVO JITTER
In certain applications the typical low level perturbations of an optimally
tuned servo system can not be tolerated. These perturbations or "jitter"
are a result of the servo responding to sensor noise (primarily
quantization noise). Often this jitter, which typically sounds like a
Teknic, Inc
69
grinding, is the limiting factor as to how high the gains, and hence the
bandwidth, of the system can be adjusted. Most applications can tolerate
a small amount of jitter especially if the frequency is low. For
applications that are sensitive to jitter, a few things can be done to reduce
it:
1
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also be adjusted, but rarely has a positive effect unless your system has a
significant amount of viscous friction.)
NOTE: This procedure will not work properly if the acceleration or
maximum velocity demand from your indexer/controller are too
aggressive for the load. To check if this is the case, select Commanded
Torque from the Real-time Monitor port's pull down menu. Enter the
maximum rated torque for your SSt servo drive into the range field9 and
view the output during the same move sequence used above to tune Ki
and Kfa. The torque should stay below maximum (four oscilloscope
screen divisions) during the deceleration portion of the move.
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2.
3.
4.
5.
6.
COMPREHENSIVE ANALYSIS
1.
2.
3.
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behind. The loss of torque can occur for several reasons. For diagnostic
procedures and solutions see the Motor moves, but does not have full
torque. and Motor loses torque (or performance degrades) after
running sections.
4.
5.
6.
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2.
3.
4.
6.
7.
8.
9.
COMPREHENSIVE ANALYSIS
All motors have a maximum operating temperature. The maximum safe
temperature is usually determined by the maximum temperature of the
wire in the windings, but can also be limited by the magnetic material in
the rotor and/or the maximum operating temperature of any electronics
in the motor. Teknic standard motors, supplied as part of a SSt servo
drive system should not be operated such that the case temperature is
allowed to rise above 75C.
A motor can run hot for three principal reasons: (i) The application
requires more torque than the motor can deliver continuously and/or the
motor does not have a good thermal path to remove heat, (ii) The motor
is damaged, or (iii) The Vector Torque control (sinewave commutation)
is not aligned (i.e.: is out of phase) with the rotor (this causes some or all
of the current to heat the motor without producing torque). The last
reason is also the cause of reduced torque output so you should ask the
following question:
1.
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Is the R/O number set incorrectly (off by more than 20% of the
motors nameplate R/O value)?
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2.
3.
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display Commanded Torque and set the range to the motors full
capability (e.g.: 160 oz-in for a 160 oz-in motor). Hook up your
oscilloscope and set it up using SSt-QuickSets Calibrate button.
Have your indexer/controller make long back and forth moves at top
speed (or run at a constant speed, if applicable) while viewing the torque
on the oscilloscope. During the constant speed portions of the move, look
at the torque used. Is it what you expected? To find out if the friction is
primarily viscous or static, reduce the speed to half of top speed. If the
torque used during the constant speed portion of the moves has been
reduced significantly, then the friction has a significant viscous portion8.
Viscous friction is caused by fluid flow or plastic deformation (oil being
pumped in a gearbox, linear seal deformation, belt tooth deformation at
speed, etc.) while static friction is usually caused by sliding surfaces
(bearings, nut preload, sliding seals, etc.).
Solutions: (1) [PREFERRED] Remove the source of the friction, if
excessive. (2) Use a gearbox on the motor if you can tolerate the cost and
speed reduction. (3) Use a larger motor. (4) Increase the thermal
capability of the motor with one or more of the following methods:
blowing air over the motor (this has a dramatically beneficial effect);
using a more substantial mounting (heavier bracket, plate, etc.) to the
machine frame; using thermal heat sink grease to mount the motor and
the motor bracket to the frame. If you do this you will have to increase
the RMS limit within the SSt servo drive (and this may require different
mounting or even forced air cooling in some situations). Contact Teknic
for information on how to do this.
4.
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To calculate the viscous and static friction subtract the torque at half top speed from the
torque at top speed. Divide the result by the top speed and divide again by two. This
result is the viscous friction reflected at the motor shaft in (oz-in/speed) units. To
calculate the static friction multiply the viscous friction by the top speed and subtract
this from the commanded torque at top speed. The result is the static friction torque.
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5.
6.
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8.
9.
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If you are using a fan to cool the motor be sure to mount the thermostat on the side of
the motor with the least amount of airflow.
81
Are the vector torque control gains, Kii or Kip set too high?
2.
3.
4.
5.
6.
COMPREHENSIVE ANALYSIS
I/V protection shutdowns can occur for two reasons: (1) The supply
voltage exceeds a maximum limit of 90VDC nominal (86VDC minimum
trip point) or, (2) The instantaneous DC bus current exceeds 27A. If
either of these situations occur, the drive is disabled to prevent damage
to the output stage.
1.
Are the vector torque control gains, Kii or Kip set too high?
If you are using a standard motor supplied by Teknic, make sure that Kii
and Kip gains are the same as the ones in the original configuration file
for that motor. If you are using a custom motor contact Teknic to find the
proper Kip and Kii values.
Solution: Set Kip and Kii to their proper values. Note that the factory
settings assume the power supply voltage is 75VDC. If its not, first set
the supply voltage to 75V in the Inputs and Limits window. Then enter
the factory Kip and Kii values (in the Custom Motor Setup window) and
then set the power supply voltage to its correct value (SSt-QuickSet will
adjust the Kip and Kii values to the appropriate values for your power
supply.)
Hint: To view the Kii and Kip gains in a previous configuration file
without downloading it into a SSt servo drive, disconnect the SSt servo
drive diagnostic cable from your PC and load the file into SSt-QuickSet.
You can then view and/or print the configuration using Configuration
Report (accessed via the Setup menu). You cannot, however, edit the
file without the SSt servo drive on-lineit handles much of the error
checking for the system.
2.
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very quickly. If the voltage exceeds 86VDC at any time the SSt servo drive
will go into I/V protection shutdown.
Solution: Switch to a bulk linear type supply with a large output
capacitance.
3.
4.
5.
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6.
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2.
3.
4.
5.
6.
7.
Is power applied?
8.
9.
10. Is the SSt servo drive receiving the Step & Direction signals?
11. Was the proper configuration file loaded?
or Is SSt servo drive properly configured to the motor?
12. Are the Kv or Kp gains set to zero?
13. Are the torque loop gains Kii and/or Kip set to zero?
COMPREHENSIVE ANALYSIS
1.
2.
3.
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4.
5.
6.
7.
Is power applied?
Look at SSt servo drive; the green status LED should be lit (on solid) or
winking (blinking at a fast rate) and the red fuse indicator LED should be
off. If both green and red LEDs are off, then no power is applied to the
drive.
8.
9.
10
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This window is accessed by first clicking once on the word Online on the main menu
bar and then simultaneously pressing Control-Shift-M
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10. Is the SSt servo drive receiving the Step & Direction signals?
To check that the indexer/controller is outputting step and direction
signals, and that the wiring to SSt servo drive is intact, you can use the
Real-time Monitor Port to view the Commanded Velocity.
Hook up an oscilloscope and use the SSt servo drives Calibrate
button to set the vertical scaling and position. Trigger your oscilloscope
using NORMAL mode. Set up the SSt servo drives Monitor Port to view
Commanded Velocity. Set the Monitor Port range so its about 33%
greater than the maximum velocity that your indexer/controller is
programmed to deliver.
Set up your indexer/controller to repeat a typical move back and forth
with a pause in between cycles of a couple of seconds. Start the
indexer/controller. You should be able to view the incoming profile on
the oscilloscope. If not, the wiring and/or the indexer/controller is at
fault. (To get an idea of what a typical profile looks like, see the diagram
under Motor Jerks at the end of move section.)
11. Was the proper configuration file loaded?
or Is the SSt servo drive properly configured to the motor?
SSt servo drive drives normally come pre-configured to a motor bundled
together in the same package. If, however, motor and drive pairs become
confused and/or if someone has been using a SSt servo drive to
experiment with or learn SSt-QuickSet, then the configuration file may
no longer match the motor.
Solutions: (a) If you are using a SSt servo drive system with a Teknic
supplied motor and you are using it for the first time make sure you load
the proper factory supplied configuration file into the SSt servo drive. (b)
If you have previously set up a SSt servo drive with an identical motor
and mechanics and have a known-good configuration file (that has
worked properly in the past for this motor/mechanics) then load that file.
If you have started with a factory configuration file or other known-good
configuration file, and the motor stopped moving after changes were
made to the configuration, check that the R/O number and Encoder
Counts per Turn have not been changed. Also check that the Kv, Kp, Kip
and Kii gains are not zero. You can view and/or print the entire drive
configuration easily by using Configuration Report under the Setup
window.
Solutions: (a) Reload the proper factory file or other known-good
configuration file. (b) Adjust the R/O number, Encoder Counts per Turn,
Vector Reference, Kip and Kii to the proper values. (Note: To adjust the
number of steps per revolution, do not use the Encoder Counts per Turn
field in the Custom Motor Setup window. This is adjusted using the
Step Position Resolution field in the Inputs and Limits window.)
Tune the drive, if necessary, using the tuning procedure described in
the Optimizing Performance section of the user manual.
12. Are the Kv or Kp gains set to zero?
If the Kv gain is zero the motor will not move. If Kv is very low (less than
3,000) the motor may not move. If Kv is non-zero, but Kp is set to zero,
the motor may move, although not repeatable, and it will have no holding
torque. You can view and change these gains from SSt-QuickSets main
window.
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2.
3.
4.
COMPREHENSIVE ANALYSIS
The axis sounds as if it is slamming at the end of the move profile
and/or a large overshoot is detected either visually or by using the SSt
servo drives Real-time Monitor Port. This is caused by a large error
being present at the end of move (when the indexer/controller stops
sending pulses to the SSt servo drive).
1.
2.
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Examples of good
"smooth" profiles
Examples of poor
"discontinous" profiles
Bad
Bad
Bad
Bad
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2.
COMPREHENSIVE ANALYSIS
1.
2.
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SYMPTOM SUMMARY
1.
2.
COMPREHENSIVE ANALYSIS
1.
2.
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2.
3.
COMPREHENSIVE ANALYSIS
1.
2.
3.
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2.
COMPREHENSIVE ANALYSIS
1.
2.
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2.
3.
4.
5.
6.
Are the timing requirements for the Step and Direction signals
being met?
7.
8.
9.
COMPREHENSIVE ANALYSIS
To diagnose this problem, set up your indexer/controller to repeat a
typical move back and forth with a pause in between of a couple of
seconds. Using the User Units window, set the position display to show
quadrature counts. Enable your drive and zero the Current Position
display in the main window using the 0Pos button (or by doubleclicking on the value). Start your indexer moving back and forth.
1.
2.
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Solution: Set the Ki gain to some non-zero value using the tuning
procedure as defined in the Optimizing Performance section.
3.
4.
5.
6.
Are the timing requirements for the Step and Direction signals
being met?
Check the timing of the Step and Direction lines to insure they meet the
timing requirements shown in the installation section of the user manual.
The timing requirements are quite liberal and it is unlikely that they
would be violated by any commercial indexer unless the pulse rate
capability is extremely high (greater than 1MHz), but it is a possible
problem. Solutions: (a) Change your indexers internal hardware or
firmware, if applicable. (b) Change your indexer. (c) Send the Step and
Direction signals through pulse shaping circuits.
8.
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9.
11
12
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To obtain Fmax, the maximum count frequency of the encoder, multiply the line count
of the encoder times four and then multiply by the maximum motor speed for the
application in revolutions per second.
If you have a capacitance meter with poor resolution in the picofarad range, measure an
entire spool of the same cable and then divide the capacitance measured by the number
of cables you could make from that length spool.
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13
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Although the SSt is vastly superior to most servos with respect to jitter or hunting,
a system that is tuned with high gains to maximize dynamic performance, may still
jitter back and forth (by a few encoder counts) around its commanded position when
its supposed to be still. Turn on AntiHunt in Quick-Sets main window, and/or
reduce the gains to reduce or eliminate this problem.
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2.
3.
4.
COMPREHENSIVE ANALYSIS
1.
2.
3.
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Solutions: (a) If you are using a SSt servo drive system with a Teknicsupplied motor and you are using it for the first time, make sure you load
the proper Teknic-supplied configuration file into SSt servo drive. (b) If
you have previously set up a SSt servo drive with an identical motor and
mechanics and have a known-good configuration file that has worked
properly in the past for this motor and mechanics, then load in that file.
If you have started with a factory or known-good configuration file
and the motor stopped moving after changes were made to the
configuration check that the R/O number, Encoder Counts per Turn and
the Vector Reference have not been changed. Also check that the Kv, Kp,
Kip and Kii gains are not zero. You can easily check all these parameters
by using the Configuration Report (accessed via the Setup menu).
Hint: To view a previous configuration file from disk without
downloading it into a SSt servo drive, disconnect the SSt servo drive
diagnostic cable from your PC and load the file into SSt-QuickSet. You
can then view and/or print the configuration using Configuration
Report (accessed via the Setup menu). You cannot, however, edit the
file without SSt servo drive on-lineit handles much of the error
checking for the system.
Solutions: (a) Reload the proper factory or known good configuration
file. (b) Adjust the R/O number, Encoder Counts per Turn, Kip and Kii
to the proper values. (Note to adjust the number of steps per revolution
do not use the Encoder Counts per Turn field in the Custom Motor
Setup window. This is adjusted using the Steps/rev field in the Inputs
and Limits window.)
4.
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SYMPTOM SUMMARY
1.
2.
3.
4.
COMPREHENSIVE ANALYSIS
1.
2.
3.
14
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To obtain Fmax, the maximum count frequency of the encoder, multiply the line count
of the encoder times four and then multiply by the maximum motor speed for the
application in revolutions per second.
103
Disconnect your drive-motor extension cable from the drive and the
motor. Measure the capacitance of the cable between an encoder phase
lead and the shield, to see if it exceeds the limit stated above.15
Solutions: (a) Use a lower capacitance cable (with perhaps
polyethylene or Teflon insulated conductors). (b) Reduce the length of
the cable. (c) Use a balanced encoder.
4.
15
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If you have a capacitance meter with poor resolution in the picofarad range, measure an
entire spool of the same cable and then divide the capacitance measured by the number
of cables you could make from that length spool.
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2.
Have the mechanics been changed since SSt servo drive was
tuned?
3.
4.
5.
COMPREHENSIVE ANALYSIS
1.
2.
Have the mechanics been changed since SSt servo drive was
tuned?
If you have changed the mechanics, even slightly, you should re-tune the
system and verify performance. Although SSt servo drive has the ability
to accommodate widely varying loads with the same tuning, sometimes
what appears to be a subtle change in the mechanics can affect the load
seen by the motor significantly. Examples of changes that are often
overlooked:
Changing the brand or type of coupling,
Increasing or decreasing the weight of the load by using
different materials,
Changing the belt type or width,
Changing the materials of which pulleys are constructed,
Increasing the length of a drive shaft,
Changing the overall gearing,
Changing the gearing of various transmission stages,
thus reflecting more inertia back to the motor (even if
the overall gear ratio hasnt changed), and many others...
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4.
5.
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SYMPTOM SUMMARY
1.
2.
3.
4.
5.
6.
COMPREHENSIVE ANALYSIS
1.
2.
16
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To obtain Fmax, the maximum count frequency of the encoder, multiply the line count
of the encoder times four (to get the quadrature counts per rev.) and then multiply by
the maximum motor speed for the application in revolutions per second.
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Disconnect your drive-motor extension cable from the drive and the
motor. Measure the capacitance of the cable between an encoder phase
lead and the shield, to see if it exceeds the limit stated above.17
Solutions: (a) Use a lower capacitance cable with perhaps polyethylene
or Teflon insulated conductors. Teknic has tested inexpensive Belden
9935 cable (foamed polyethylene insulation) for use with single-ended
encoders at lengths up to 50 feet and Fmax up to 670 KHz. (b) Reduce
the length of the cable. (c) Use a balanced encoder.
3.
4.
5.
RPM
Fem 60
Lc
where: Lc is the line count of the encoder in lines per turn (1/4 of the
quadrature counts per turn) and Fem is the lower of the
maximum operating frequency of the encoder or 500,000.
Solutions: (a) Set the speed limit on the SSt servo drive to limit the
maximum speed of the motor to a speed below the maximum count
frequency of the encoder (contact Teknic for details on how to do this).
(b) Change to a higher speed or lower resolution encoder.
6.
17
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If you have a capacitance meter with poor resolution in the picofarad range measure an
entire spool of the same cable and then divide the capacitance measured by the number
of cables you could make from that length spool.
109
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2.
3.
COMPREHENSIVE ANALYSIS
1.
2.
3.
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Output
Dimensions:
Weight:
Temperature:
Humidity:
Input Voltage:
Input Current:
PWM Frequency:
Current Capability:
Protection:
Encoder Input
Type:
Rate:
Courtsey Power:
Isolated Format:
Maximum rate:
Format:
Features:
Variables:
Vector Commutation
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Vector Error:
Type:
Calculation Rate:
Format:
Impedance:
Scale:
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APPENDIX B: CONNECTORS
Shown below are the connector pin-outs on the SSt-1500 drive, and not
those on the opposite end of Teknic cablesthey are not necessarily the
same. Your motor, controller and limit cables are likely to have different
mating pin-outs depending on the connector used on the end of the cable
away from the drive. For example, see page 14 for the motor-side
connector pin-out for a Teknic motor.
S
T
N.O. Thmstat.
Comm. +5V
Encoder +5V
Encoder I
Encoder B
Encoder A
Controller
+Limit
Enc. A Out
Enc. B Out
Enc. I Out
+5V Out
Mode
Analog+
Ready~
Step
Limits
18 17 16 15 14 13 12 11 10
Encoder TTL~
+5V Out
+Limit In
GND
9 8 7 6 5 4 3 2 1
Motor Shield
Comm. R
Comm. S
Comm. T
Comm. GND
Encoder GND
Encoder I~
Encoder B~
Encoder A~
GND
-Limit
Enc. A~ Out
Enc. B~ Out
Enc. I~ Out
GND
GND
MoveDone[Analog-]
Enable~
Direction
6 5 4
3 2 1
Motor/Encoder
20 19 18 17 16 15 14 13 12 11
10 9 8 7 6 5 4 3 2 1
Note: The figures below show the view looking into the SSt-1500s
connectors. (These diagrams can also be interpreted at the wire-end-view
of the mating connectors.)
+5V Out
-Limit In
GND
Power
AMP Universal Mate-N-Lock,
mates with 1-480-698-0
Real-time Monitor port &
QuickSet Configuration
port&
Molex .120" pocket header,
mates with 50-57-9405
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1
2
3
4
5
Data Rx
Data Tx
GND
Real-time Monitor
Reference (2.5V)
INDEX
Acceleration Feedforward Tuning, 66
All Windings Off, 17
Analog Input Wiring, 21
AntiHunt, 65
Application Note
Clamping or Inserting Objects, 45
Error Recovery, 47
Homing Axes, 44
Manual Calibrations, 46
Monitor Port, 58
Move Completion, 43
Optical Interrupter Limit Switches, 19
Secondary Encoder, 47
Torque Foldback, 45
Use with Servo Controller, 21
Watching Positioning Errors, 44
Axial Loading, 41
Axis sings, 105
Axis Jerks at Beginning of Moves, 92
Axis Jerks at End of Move, 89
Bearing Life, 41
Benefits, 1
Ease of Use, 3
Efficient, 3
Expanded Torque-speed, 1
High Bandwidth, 2
Low Jitter, 2
Reliable, 3
Smooth motion, 2
Built-In Instrumentation, 56
Cable
Controller, 8, 11
Diagnostic, 29
Encoder, 8
Flexible, 14
Limit Switch, 8
Motor, 8, 14
Power, 7
SSt-CC, 12
Compensator, 54, 56
Configuration Cable, 29
Configuration Port, 29
Connectors, 113
Controller, 10
Diagnostic, 29
Motor, 15
Power Input, 25
Control Algorithms, 55
Controller
Interfacing, 10
Controller Cable, 8
Controller Interface, 8
Custom Motors, 30
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114
Step & Direction, 15
Thermostat, 30
Typical Circuit, 17
Inputs & Limits Window, 52
Installation
Grounding, 7, 10
Power Supply Wiring, 7
Shielding, 7
Instrumentation, 56
Integrator
Tuning, 65, 69, 70
Interfacing
Controller, 8
Indexer, 8
Limit Switches, 8
Isolation
Electrical, 6
Kill, 18
Lack of Movement, 85
Large velocity/torque ripple, 94
Limit Cycle, 65
Limit Switch
Cable, 8
Limit Switch Cheater Plug, 19
Limit Switches, 8
Limit Switches Don't Work, 107
Logic Input Circuit, 17
Logic Outputs, 19
Loops, 55
Main Window, 51
Mechanical Installation, 31
Minimizing Settling Time, 70
Mode Input, 18
Monitor port, 29, 54, 56, 58
Monitor Port, 58
Motion erratic, 93
Motor
cable, 8
Interfacing, 14
Wiring, 14
Motor Walks with No Step Pulses, 100
Motor Outline
M-1726-FX, 32
M-2330-FH, 34
M-2330-FX, 33
M-2330-XH, 34
M-2330-XX, 33
M-2348-FH, 36
M-2348-FX, 35
M-2348-XH, 36
M-2348-XX, 35
M-3437-FX, 37
M-3437-XX, 37
M-3450-XX, 38
M-3462-FH, 39
M-3471-FH, 40
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M-497P-FI, 40
M-497T-FI, 40
Motor Phase Cable, 8
Mounting
SSt-1500-C, 31
Move Length Incorrect, 95
Movement Not Smooth, 89
Offline, 52
Optical Interrupter Limits, 19
Oscilloscope Setup, 58
Outputs
MoveDone, 20
Ready, 20
Shutdown, 20
Typical Circuit, 20
Overshoot, 55
Over-Travel Limit Inputs, 18
Performance Degrades, 103
PIV, 55
PIV Compensator, 56
Position Error, 55
Position Integrator, 55
Position Loop Tuning, 63
Power Supply, 24
Current Requirements, 26
Daisy Chain, 6, 7
Peak Currents, 26
Quick Sizing, 26
RMS Current Calculation, 27
Rules, 7
Radial Loading, 41
Real-Time Monitor port, 29, 58
Reversing Step & Direction Sense, 17
Ringing, 55
RMS Current Calculation, 27
Continuous Velocity, 28
Incremental Positioning, 27
Incremental Positioning / Reduced Output,
28
RMS Limit Shutdowns, 76
RS-232 Port, 29
Servo Controller Usage, 21
Servo Glossary, 54
Servo Jitter, 69
Setting up your Oscilloscope, 58
Settling Time, 55
Setup
Monitor Port, 58
Oscilloscope, 58
Shaft Loading Specifications, 41
Shielding, 7
Shutdown
Clearing Existing, 18
Encoder, 108
I/V, 82, 84
Output Line, 20
115
Over-Current/Voltage, 7
Position Tracking, 44
RMS, 61, 64, 76, 79
Thermal, 111
Tracking Error, 74
Single Ended Encoder, 22
Smooth Response, 68
Specification
Shaft Loading, 41
Specifications, 112
SSt-CC, 13
SSt-DC, 29
SSt-MC, 15
SSt-QuickSet, 50
Inputs & Limits Window, 52
Main Window, 51
Static Precautions, 9
Step & Direction
Polarity, 17
Reversing Direction, 17
Signals, 15
Timing, 16
Wiring, 16
Stiffness, 55
Stimulus Generator, 57
Termination
Encoder Inputs, 23
Thermal Protection Shutdowns, 111
Thermostat, 30
Torque Foldback, 46
Torque Saturation, 74, 91
Torque Seems Low, 101
Tracking Error, 55
Troubleshooting, 72
Axis sings, 105
Axis Jerks at Beginning of Moves, 92
Axis Jerks at End of Move, 89
Drive resets When Motor Attempts to Move,
110
Drive Shuts Down, 74
Teknic, Inc
Fax (585)784-7460
Voice (585)784-7454