Aerotech UNIDEX 511 User manual

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THE UNIDEX511 MOTION
CONTROLLER
USER’S MANUAL
P/N: EDU162 (V1.1)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotechinc.com
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If you should have any questions about the UNIDEX 511 Motion Controller or comments regarding the
documentation, please refer to Aerotech online at:
http://www.aerotechinc.com.
For your convenience, a product registration form is available at our web site.
Our web site is continually updated with new product information, free downloadable software and special pricing on
selected products.
The UNIDEX 511 Motion Controller is a product of Aerotech, Inc.
Borland C is a product of Borland International, Inc.
IBM PC/AT bus is a registered trademark of International Business Machines, Inc.
Inductosyn is a registered trademark of Ruhle Companies, Inc.
iSBX is a registered trademark of Intel Corporation.
MS-DOS and Windows are products of Microsoft Corporation.
Opto 22 is a product and trademark of Opto 22.
The UNIDEX 511 Motion Controller
User’s Manual Revision History:
Preliminary October 2, 1997
Rev 1.0 May 7, 1998
Rev 1.0a July 27,1998
Rev 1.1 June 26, 2000
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U511 User’s Manual Table of Contents
Version 1.1 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION............................................................................ 1-1
1.1. Overview of the UNIDEX 511 System............................................... 1-1
1.2. Ordering Information.......................................................................... 1-3
1.3. Options and Accessories..................................................................... 1-4
1.4. Safety Procedures and Warnings........................................................ 1-5
CHAPTER 2: GETTING STARTED...................................................................... 2-1
2.1. Introduction........................................................................................ 2-1
2.2. Unpacking the UNIDEX 511 Unit ..................................................... 2-1
2.3. UNIDEX 511 Setup Flowchart........................................................... 2-2
2.4. Installing Cables and Wiring.............................................................. 2-3
2.5. Software Configuration Considerations.............................................. 2-4
2.6. Special Startup Considerations........................................................... 2-4
2.6.1. Feedback Verification.......................................................... 2-4
2.6.2. Limit Verification................................................................. 2-5
2.6.3. Preliminary Servo Loop Setup ............................................. 2-6
2.7. Enabling and Moving an Axis............................................................ 2-7
2.8. Internal System Wiring....................................................................... 2-7
CHAPTER 3: THE USER INTERFACE................................................................ 3-1
3.1. Introduction........................................................................................ 3-1
3.2. Control Panel...................................................................................... 3-1
3.3. Power-up Screen................................................................................. 3-3
3.4. Program Menu.................................................................................... 3-5
3.4.1. Program Menu: the Run Submenu ....................................... 3-5
3.4.2. Program Menu: the Edit Submenu.......................................3-7
3.4.3. The ASCII Utility............................................................... 3-11
3.4.4. Program Menu: the File Submenu...................................... 3-12
3.4.5. Program Menu: The Digitize Submenu.............................. 3-12
3.5. Setup Menu: Parameters................................................................... 3-17
3.5.1. Setup Menu: The Fault Masks Page................................... 3-19
3.6. Diagnostics Menu............................................................................. 3-20
3.6.1. Diagnostics Menu: Hardware Status Page.......................... 3-20
3.6.2. Diagnostics Menu: Primary I/O Page................................. 3-21
3.6.3. Diagnostics Menu: System Status Page.............................. 3-22
3.6.4. Diagnostics Menu: Position Page....................................... 3-23
3.6.5. Diagnostics Menu: Active Limits Page.............................. 3-24
3.6.6. Diagnostics Menu: Servo Faults Page................................ 3-25
3.6.7. Diagnostics Menu: Secondary I/O Page............................. 3-26
3.6.8. Diagnostics Menu: Terminal Page ..................................... 3-26
3.7. Tune Menu ....................................................................................... 3-28
3.7.1. Troubleshooting Autotuning .............................................. 3-30
3.8. MDI Menu........................................................................................ 3-31
3.8.1. MDI Menu: Joystick Submenu........................................... 3-32
3.8.2. MDI Menu: Jog Submenu.................................................. 3-32
3.8.3. MDI Menu: Commands Submenu...................................... 3-33
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Table of Contents U511 User’s Manual
iv Aerotech, Inc. Version 1.1
CHAPTER 4: PARAMETERS................................................................................4-1
4.1. Introduction ........................................................................................4-1
4.2. Page 1: System Configuration.............................................................4-7
4.2.1. “Auto enable axes”...............................................................4-7
4.2.2. “Auto run program”..............................................................4-7
4.2.3. “Axis calibration file”...........................................................4-7
4.2.4. “Parameter file”....................................................................4-7
4.2.5. “Firmware file”.....................................................................4-7
4.2.6. “M-code file”........................................................................4-7
4.2.7. “Global subroutine file” .......................................................4-8
4.2.8. “PSO-PC firmware file”.......................................................4-8
4.2.9. “PSO-PC DPRAM address” (hex address 0xnnnn)..............4-8
4.2.10. “PSO-PC I/O address” (hex address 0xnnn) ........................4-9
4.2.11. “Safe zone output bit 0,1-8”.................................................4-9
4.2.12. “Option board setup code”...................................................4-9
4.2.13. “User interrupt setup code”................................................4-10
4.2.14. “A/D channel n joystick deadband” Parameters ................4-10
4.2.15. “A/D channel n center” Position Parameters......................4-11
4.2.16. “Enable speaker”................................................................4-11
4.2.17. “Password”.........................................................................4-12
4.2.18. “Abort on input high 0, 1-16”.............................................4-12
4.3. Pages 2 and 3: Serial Port #n Setup..................................................4-13
4.3.1. “Baud rate” (bits per second) .............................................4-13
4.3.2. “Data bits” (7-8).................................................................4-13
4.3.3. “Stop bits” (1-2).................................................................4-13
4.3.4. “Parity” (N, O, E)...............................................................4-13
4.3.5. “End of string character”....................................................4-13
4.3.6. “Fast output?” (y/n)............................................................4-13
4.3.7. “Command ACK character”...............................................4-14
4.3.8. “Command NAK character”...............................................4-14
4.3.9. “Default configuration”......................................................4-14
4.4. Page 4: GPIB/IEEE-488 Setup.........................................................4-15
4.4.1. “GPIB address” (0-30).......................................................4-15
4.4.2. “EOS character”.................................................................4-15
4.4.3. “Parallel Pol Response bit” (0-NONE or 1-8)....................4-15
4.4.4. “Time out” (seconds)..........................................................4-15
4.4.5. “Default configuration”......................................................4-15
4.5. Page 5: Axis Configuration...............................................................4-16
4.5.1. “Metric (x00) and English (x01) conversion factors”.........4-16
4.5.2. “Max accel/decel” (machine steps/ms/ms).........................4-19
4.5.3. “Positive (+) move is CW” (y/n)........................................4-19
4.5.4. “Positive (+) jog same as + move” (y/n) ............................4-20
4.5.5. “Enable pause in freerun” (y/n)..........................................4-20
4.5.6. “Enable MFO in freerun” (y/n)...........................................4-21
4.5.7. “Enable axis calibration” (y/n)...........................................4-21
4.5.8. “In position deadband” (machine steps).............................4-25
4.5.9. “Backlash correction amount” (machine steps)..................4-26
4.5.10. “Joystick high speed” (machine steps/sec) .........................4-27
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U511 User’s Manual Table of Contents
Version 1.1 Aerotech, Inc. v
4.5.11. “Joystick low speed” (machine steps/sec).......................... 4-27
4.5.12. “Joystick absolute scale” (machine steps).......................... 4-28
4.5.13. “Enable orthogonality table” (y/n) ..................................... 4-29
4.5.14. “Enable 2-D error mapping” (y/n)...................................... 4-29
4.5.15. “Modulo rollover” (machine steps) for axes 1-4................ 4-29
4.5.16. “Filter time constant” (ms)................................................. 4-31
4.5.17. “AUX output active high” (y/n) ......................................... 4-31
4.5.18. Reverse Joystick Direction................................................. 4-31
4.5.19. “Jog low speed” ( machine steps / ms ).............................. 4-31
4.5.20. “Jog high speed” ( machine steps / ms )............................. 4-31
4.5.21. “Jog distance” ( machine steps )......................................... 4-31
4.6. Page 6: Servo Loop .......................................................................... 4-32
4.6.1. “Kpos” (position loop gain, 0-8,388,607).......................... 4-32
4.6.2. “Ki” (velocity loop integrator, 0-8,388,607)...................... 4-32
4.6.3. “Kp” (velocity loop proportional gain, 0-8,388,607).........4-32
4.6.4. “Vff” (velocity feed forward, 0-8,388,607)........................ 4-33
4.6.5. “Aff” (acceleration feed forward, 0-8,388,607)................. 4-33
4.6.6. “Loop update rate (* 0.25 ms)”.......................................... 4-34
4.6.7. “Enable Notch Filter?” (y/n) .............................................. 4-34
4.6.8. “Notch filter N0, N1, N2, D1, and D2”.............................. 4-35
4.6.8.1. The Notch Filter............................................ 4-35
4.6.8.2. Notch Filter Example.................................... 4-36
4.6.8.3. The Second Order, Low Pass Filter.............. 4-38
4.6.9. “Servo loop type”............................................................... 4-39
4.7. Page 7: Homing and Limits.............................................................. 4-41
4.7.1. The Home Cycle................................................................. 4-41
4.7.2. “Home direction CCW” (y/n)............................................. 4-42
4.7.3. “Home switch normally open” (y/n)................................... 4-43
4.7.4. “Home feedrate” (machine steps/ms)................................. 4-44
4.7.5. “Home offset” (machine steps)........................................... 4-44
4.7.6. “Limit switch normally open” (y/n).................................... 4-45
4.7.7. “Limit to mechanical stop” (machine steps)....................... 4-45
4.7.8. “CCW software limit” (machine steps) .............................. 4-46
4.7.9. “CW software limit” (machine steps)................................. 4-46
4.7.10. “Use home limit during home” (y/n).................................. 4-47
4.7.11. “Safe zone limits” (machine steps)..................................... 4-47
4.7.12. “Limit debounce distance” (machine steps) ....................... 4-48
4.8. Page 8: Motors and Feedback...........................................................4-49
4.8.1. Introduction to Motor and Feedback Configurations ......... 4-50
4.8.2. “Position channel”.............................................................. 4-56
4.8.3. “Velocity channel”............................................................. 4-57
4.8.4. “Position setup code” ......................................................... 4-58
4.8.5. “Velocity setup code”......................................................... 4-59
4.8.6. “Amplifier type” (0-DC Brush, 1-AC Brushless, 2-Step, 3-
Recirc)................................................................................ 4-60
4.8.7. “Commutation cycles/rev” (AC brushless motors only)..... 4-61
4.8.8. “Feedback steps/rev” (AC brushless motors only)............. 4-62
4.8.9. “Commutation phase offset” (0-359 degrees) ....................4-62
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Table of Contents U511 User’s Manual
vi Aerotech, Inc. Version 1.1
4.8.10. “Stepper high current %” (0-100%) (stepper drives only)......... 4-62
4.8.11. “Stepper low current %” (0-100%) (stepper drives only).......... 4-63
4.8.12. “Microstepping resolution” (machine steps) (stepper drives
only) .......................................................................................... 4-63
4.8.13. “Stepper correction” (y/n) (stepper drives only)........................ 4-63
4.8.14. “Stepper correction speed” (microsteps/ms) .............................4-64
4.8.15. “Base speed” (machine steps/ms) (AC brushless only)............. 4-64
4.8.16. “Base speed advance” (0-359 degrees) (AC brushless only)..... 4-65
4.8.17. “Phase speed” (machine steps/ms) (AC brushless only)............ 4-65
4.8.18. “Phase speed advance” (0-359 degrees) (AC brushless only)... 4-65
4.8.19. “DAC offset parameters” (mV)................................................. 4-65
4.8.20. “Encoder factor”........................................................................ 4-66
4.9. Page 9: Fault Masks................................................................................. 4-67
4.9.1. Introduction to Fault Masks....................................................... 4-67
4.9.2. “Global fault mask”................................................................... 4-69
4.9.3. “Disable”................................................................................... 4-69
4.9.4. “Interrupt” ................................................................................. 4-69
4.9.5. “AUX output”............................................................................ 4-69
4.9.6. “Halt queue”.............................................................................. 4-70
4.9.7. “Abort motion”.......................................................................... 4-70
4.9.8. “Enable brake” .......................................................................... 4-70
4.10. Page 10: Traps......................................................................................... 4-71
4.10.1. “Top feedrate” (machine steps/ms) ........................................... 4-71
4.10.2. “Maximum velocity error” (0-8,388,607) ................................. 4-72
4.10.3. “Maximum position error” (0-8,388,607) ................................. 4-73
4.10.4. “Maximum integral error” (0-8,388,607).................................. 4-74
4.10.5. “RMS current trap” (0-100%)................................................... 4-75
4.10.6. “RMS current sample time” (1-16,383 ms)...............................4-77
4.10.7. “Clamp current output” (0-100%)............................................. 4-78
4.10.8. “AUX fault output bit” (0, 1-8)................................................. 4-79
4.10.9. “Amplifier fault active low” (y/n)..............................................4-80
4.11. Page 11: Planes and Mapping.................................................................. 4-81
4.11.1. Overview of Planes.................................................................... 4-81
4.11.2. “Number of contour planes” (1, 2, or 4).................................... 4-84
4.11.3. “Keep position after reset?” (y/n).............................................. 4-86
4.11.4. “MFO pot offset” (0-255).......................................................... 4-87
4.11.5. “Axis {1, 2, 3, 4} plane 1-4 as X, Y, Z, U”............................... 4-88
4.11.6. “Axis {1,2,3,4} gantry yes/none slave {1,2,3,4}”.....................4-90
4.11.7. “Segment time” (1-20 ms)......................................................... 4-93
4.11.8. “Ramp time” (1-32,000 ms) ...................................................... 4-94
4.11.9. “Default to metric” (yes/no)...................................................... 4-95
4.11.10. “Linear accel/decel” (y/n).......................................................... 4-96
4.11.11. “Contour feedrate” (program steps/ms)..................................... 4-97
4.11.12. “X, Y, Z, and U axes index feedrates” (program steps/ms)....... 4-97
4.11.13. “Clamp feedrate” (program steps/ms) ....................................... 4-98
4.11.14. “Corner rounding time” (1-32,000 ms) .....................................4-98
4.11.15. “Metric digits” (1-8)................................................................ 4-101
4.11.16. “English digits” (1-8) .............................................................. 4-102
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U511 User’s Manual Table of Contents
Version 1.1 Aerotech, Inc. vii
4.11.17. “Contouring mode” .......................................................... 4-103
CHAPTER 5: PROGRAMMING COMMANDS.................................................. 5-1
5.1. Introduction........................................................................................ 5-1
5.2. Mathematical Function Commands .................................................... 5-2
5.2.1. Direct Variables (V0 through V255).................................... 5-2
5.2.2. Indirect Variables (VV0 through VV255)............................ 5-2
5.2.3. Functions.............................................................................. 5-3
5.2.4. Operators and Evaluation Hierarchy.................................... 5-4
5.3. System Registers................................................................................. 5-5
5.3.1. Relative Position Registers................................................... 5-5
5.3.2. Absolute Position Registers.................................................. 5-6
5.3.3. Real Time Feedback Position Registers............................... 5-6
5.3.4. Real Time Command Position Registers.............................. 5-7
5.3.5. Understanding the Concept of Program Steps...................... 5-7
5.3.6. A/D Channel Registers......................................................... 5-8
5.4. System Inputs $INP and $IN0-$INF .................................................. 5-8
5.5. Programming Commands ................................................................. 5-10
5.5.1. ABORT.............................................................................. 5-13
5.5.2. ACCELERATION ............................................................. 5-13
5.5.3. AC PL (ACCEL PLANE).................................................. 5-14
5.5.4. AFCO (Auto Focus)........................................................... 5-15
5.5.5. AGAIN............................................................................... 5-18
5.5.6. AT (Autotune).................................................................... 5-19
5.5.7. BEEP.................................................................................. 5-20
5.5.8. BOARD.............................................................................. 5-20
5.5.9. BRAKE.............................................................................. 5-21
5.5.10. CAL (Load Calibration File).............................................. 5-22
5.5.11. CLOCKWISE and COUNTERCLOCKWISE CIRCULAR
INTERPOLATION............................................................ 5-22
5.5.12. CLRSCR (Clear Screen) .................................................... 5-26
5.5.13. CI (Command Interrupt)..................................................... 5-26
5.5.14. CM (Contouring Mode) ..................................................... 5-27
5.5.15. COMREC (Strings In Port)................................................ 5-28
5.5.16. COMVAR (String to Variable).......................................... 5-29
5.5.17. CS (Command Scope)........................................................ 5-30
5.5.18. Cutter Compensation Commands....................................... 5-31
5.5.19. CVI (Convert to Integer).................................................... 5-34
5.5.20. CYCLE............................................................................... 5-34
5.5.21. DAC (D/A Output)............................................................. 5-35
5.5.22. DISABLE........................................................................... 5-36
5.5.23. DS (Display Servo Loop Data) ..........................................5-37
5.5.24. DWELL.............................................................................. 5-38
5.5.25. DY (Dynamic Gain)........................................................... 5-38
5.5.26. ENABLE............................................................................ 5-39
5.5.27. ERROR .............................................................................. 5-40
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Table of Contents U511 User’s Manual
viii Aerotech, Inc. Version 1.1
5.5.28. EXIT...................................................................................5-41
5.5.29. FAULT ACKNOWLEDGE...............................................5-42
5.5.30. FL (Filter Time Constant) ..................................................5-42
5.5.31. FREERUN..........................................................................5-43
5.5.32. GAIN..................................................................................5-44
5.5.33. GEAR.................................................................................5-45
5.5.34. GOTO.................................................................................5-46
5.5.35. HALT.................................................................................5-47
5.5.36. HOME................................................................................5-48
5.5.37. IF........................................................................................5-48
5.5.38. INDEX ...............................................................................5-50
5.5.39. INn (Read Inputs)...............................................................5-51
5.5.40. INTERRUPT......................................................................5-52
5.5.41. IO (Set/Read 8 X 3 I/O) .....................................................5-52
5.5.42. IOSET (Setup 8 X 3 I/O)....................................................5-53
5.5.43. JOG ....................................................................................5-54
5.5.44. Label Marker (:).................................................................5-54
5.5.45. LINEAR.............................................................................5-55
5.5.46. LOOP .................................................................................5-56
5.5.47. LVDT.................................................................................5-57
5.5.48. M0 (M Zero) ......................................................................5-58
5.5.49. MAP...................................................................................5-58
5.5.50. MCOMM (Motor Commutation) .......................................5-59
5.5.51. MESSAGE.........................................................................5-60
5.5.52. MR (Memory Read)...........................................................5-61
5.5.53. MSET (Motor Setup) .........................................................5-62
5.5.54. MW (Memory Write).........................................................5-64
5.5.55. NEXT.................................................................................5-65
5.5.56. OEn (Extended Output)......................................................5-65
5.5.57. OUTPUT............................................................................5-66
5.5.58. PARALLEL........................................................................5-67
5.5.59. PRM (PARAMETER READ)...........................................5-67
5.5.60. PAUSE...............................................................................5-68
5.5.61. PLANE...............................................................................5-69
5.5.62. PROGRAM........................................................................5-70
5.5.63. QUEUE..............................................................................5-72
5.5.64. RAMP ................................................................................5-74
5.5.65. REFERENCE.....................................................................5-75
5.5.66. RETURN............................................................................5-75
5.5.67. ROTATE (Part Rotation)...................................................5-75
5.5.68. ROUNDING.......................................................................5-76
5.5.69. SCF (Overriding Scale Factor)...........................................5-77
5.5.70. SEGMENT.........................................................................5-79
5.5.71. SKEY (Soft Keys)..............................................................5-80
5.5.72. SLEW.................................................................................5-81
5.5.73. SOFTWARE ......................................................................5-83
5.5.74. SPLINE..............................................................................5-84
5.5.75. START...............................................................................5-85
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U511 User’s Manual Table of Contents
Version 1.1 Aerotech, Inc. ix
5.5.76. SUBROUTINE .................................................................. 5-86
5.5.77. SYNC................................................................................. 5-87
5.5.78. Target Tracking Commands (TE, TD, TP) ........................ 5-87
5.5.79. TRAJECTORY.................................................................. 5-88
5.5.80. TRIGGER .......................................................................... 5-89
5.5.81. UMFO (Manual Feed Override)......................................... 5-90
5.5.82. VAR (Read/Write Variables)............................................. 5-91
5.5.83. VELOCITY........................................................................ 5-92
5.5.83.1. Correct Usage and Limitations of the Velocity
Profiling Algorithm....................................... 5-93
5.5.83.2. CM1 Contouring Mode................................. 5-96
5.5.84. WAIT............................................................................... 5-100
5.5.85. WHILE/ENDWHILE....................................................... 5-101
CHAPTER 6: REMOTE MODE OPERATIONS.................................................. 6-1
6.1. Introduction........................................................................................ 6-1
6.1.1. GPIB IEEE-488 Interface ....................................................6-1
6.1.2. RS-232 (COM1 and COM2) Interface................................. 6-1
6.2. Troubleshooting Remote Communications......................................... 6-2
6.3. Command Handshake Mode (RS-232 Only)...................................... 6-2
6.4. Remote Commands............................................................................. 6-2
6.4.1. ##: Enable RS-232 Remote Communications...................... 6-2
6.4.2. Program Execution............................................................... 6-3
6.4.3. PA: Program Abort .............................................................. 6-4
6.4.4. Service Request Mode (SRQ) .............................................. 6-5
6.4.5. Hold/Trigger/Cancel ............................................................ 6-7
6.4.6. PE: Print Error Message String............................................ 6-8
6.4.7. I: Execute Immediate Command.......................................... 6-9
6.4.8. FMn: Format of Returned Data.......................................... 6-10
6.4.9. PXn, PYn, PZn, PUn: Axis Positions................................. 6-11
6.4.10. Q: Serial Pol command ......................................................6-12
6.4.11. PSn: Print Status................................................................. 6-13
6.4.12. RRn/WRn,val: Read / Write Register................................ 6-16
6.4.13. Parameter Editing............................................................... 6-18
6.4.14. RE: Hardware Reset........................................................... 6-19
6.4.15. File Transfers ..................................................................... 6-20
6.4.16. PD: Print Directory ............................................................ 6-22
6.4.17. PPfile: Print Program “File” to Port................................... 6-23
6.4.18. RVn: Read Variable........................................................... 6-23
6.4.19. DFfilename: Delete File..................................................... 6-24
6.4.20. HE [cmd]: Help Menu........................................................ 6-24
6.4.21. GV: Software Version........................................................ 6-25
6.5. UNIDEX 511 Remote Timing.......................................................... 6-26
6.6. C Program Example.......................................................................... 6-27
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