Aerotech UNIDEX 600 Series User manual

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THE UNIDEX600 SERIES
USER’S GUIDE
P/N: EDU157 (V1.4)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotechinc.com

If you should have any questions about the UNIDEX 600 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.
UNIDEX 600 and UNIDEX 650 are products of Aerotech, Inc.
Windows, Windows 95, and Windows NT are registered trademarks of Microsoft.
Windows, Windows NT, and Visual Basic are products of Microsoft Corporation.
Visual Basic is a registered trademark of Microsoft.
The Aerdebug User’s Manual Revision History:
Rev 1.0 October 14, 1996
The UNIDEX 600 User’s Guide (previously the AerDebug User’s Manual) Revision History:
Rev 1.1 May 5, 1997
Rev 1.2 September, 1997
Rev 1.3 July 10, 2000
Rev 1.4 December 5, 2000

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION AND OVERVIEW........................................... 1-1
1.1. Introduction........................................................................................ 1-1
1.2. Installation.......................................................................................... 1-1
1.3. Programming...................................................................................... 1-2
1.4. Architecture Overview........................................................................ 1-3
1.4.1. Axis Processor...................................................................... 1-4
1.4.1.1. The Motion Controller Execution Unit..................1-4
1.4.1.2. Library Servicer..................................................... 1-5
1.4.1.3. CNC Engine........................................................... 1-5
1.4.2. The PC ................................................................................. 1-5
1.4.2.1. The PC Interrupt .................................................... 1-5
1.5. Motion................................................................................................ 1-6
1.5.1. The Servo Loop.................................................................... 1-6
1.5.2. Generating Motion ............................................................... 1-6
1.5.3. Monitoring Motion............................................................... 1-7
1.5.4. Multi-Axis Motion ............................................................... 1-7
1.5.5. Motion Resolution................................................................ 1-7
1.6. Faults.................................................................................................. 1-8
1.6.1. Axis Faults ........................................................................... 1-8
1.6.2. Task Faults........................................................................... 1-9
1.7. Option Ordering Information............................................................ 1-10
CHAPTER 2: GETTING STARTED...................................................................... 2-1
2.1. Introduction........................................................................................ 2-1
2.1.1. Minimum Requirements....................................................... 2-2
2.1.2. Fundamentals ....................................................................... 2-3
2.1.2.1. Parameters.............................................................. 2-3
2.1.2.2. Bit Masks............................................................... 2-4
2.1.2.3. Faults...................................................................... 2-4
2.2. Software Installation........................................................................... 2-5
2.2.1. UTIL600-NT Installation..................................................... 2-5
2.2.2. MMI Software Installation...................................................2-5
2.2.3. WinNT/Win95 Registration................................................. 2-5
2.2.4. Software Installation Testing................................................ 2-6
2.3. Axis Configuration ............................................................................. 2-7
2.3.1. Servo Loop Modes...............................................................2-7
2.3.2. Configuring Closed-Loop (Torque or Velocity)................... 2-8
2.3.2.1. Motor Types........................................................... 2-8
2.3.2.2. Feedback Devices .................................................. 2-8
2.3.2.3. Digital-to-Analog Conversion (Output to the
Amplifier) .............................................................. 2-9
2.3.3. Configuring a Spindle (Open-Loop Velocity Mode)............ 2-9
2.4. Motor Units (Resolution and Direction).......................................... 2-10
2.4.1. Linear vs. Rotary type ........................................................ 2-10
2.4.2. Motor Resolution ............................................................... 2-10
2.4.3. Motor Direction.................................................................. 2-10
2.5. Drive Signals.................................................................................... 2-11
2.6. Axis Faults........................................................................................ 2-11

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iv Aerotech, Inc. Version 1.4
2.6.1. FAULT...............................................................................2-12
2.6.1.1. Axis Faults and Programming..............................2-12
2.6.2. Fault Masks........................................................................2-14
2.6.2.1. FAULTMASK.....................................................2-15
2.6.2.2. DISABLEMASK .................................................2-15
2.6.2.3. HALTMASK .......................................................2-15
2.6.2.4. AUXMASK .........................................................2-15
2.6.2.5. ABORTMASK.....................................................2-16
2.6.2.6. INTMASK ...........................................................2-16
2.6.2.7. BRAKEMASK.....................................................2-16
2.6.2.8. Example ...............................................................2-16
2.7. Task Faults........................................................................................2-18
2.8. Emergency Stop (ESTOP)................................................................2-18
2.9. Axis Testing......................................................................................2-19
2.9.1. Axis Limits.........................................................................2-19
2.9.2. Axis Feedback....................................................................2-19
2.9.3. Axis Loop Closure..............................................................2-19
2.10. Accelerations....................................................................................2-20
2.11. Axis Tuning......................................................................................2-20
2.12. Jogging .............................................................................................2-20
2.13. Homing.............................................................................................2-21
2.14. Programmed Moves..........................................................................2-22
2.15. Digital I/O.........................................................................................2-22
2.15.1. Associating Virtual I/O with Physical I/O..........................2-22
2.16. Other Manuals ..................................................................................2-24
2.16.1. Hardware Manuals (UNIDEX 600)....................................2-24
2.16.2. Programming Manuals .......................................................2-24
2.16.3. MMI Interface....................................................................2-24
CHAPTER 3: PROGRAMMING............................................................................3-1
3.1. Introduction ........................................................................................3-1
3.1.1. Combination Programming ..................................................3-2
3.1.2. Multi-Tasking.......................................................................3-2
3.2. The Library Programming Interface...................................................3-3
3.2.1. Basic Elements of a Library Interface Program....................3-4
3.3. CNC G-code Programming.................................................................3-5
3.3.1. CNC Tasks and Programs ....................................................3-6
3.3.2. CNC Program Execution......................................................3-7
3.3.3. Motion from a CNC Program...............................................3-8
CHAPTER 4: AERDEBUG......................................................................................4-1
4.1. Introduction ........................................................................................4-1
4.2. The Screen..........................................................................................4-2
4.3. The Prompt.........................................................................................4-3
4.3.1. Entering Commands.............................................................4-3
4.3.2. Special Keys.........................................................................4-4
4.3.3. Help......................................................................................4-5
4.4. Axis and Faultmask Configurations....................................................4-6
4.4.1. Configuring an Axis .............................................................4-7
4.4.1.1. CONFIGRESOLVER - Resolver or Inductosyn
Feedback................................................................4-7

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. v
4.4.1.2. CONFIGENCODER - Encoder Feedback............. 4-8
4.4.1.3. CONFIGHENCODER - Encoder and Hall
Effect Sensor Feedback.......................................... 4-8
4.4.1.4. CONFIGHRESOLVER - Resolver and Hall
effect sensor feedback............................................ 4-9
4.4.1.5. ConfigD2A - Configure a DAC (D/A) Channel
for Use by This Axis.............................................. 4-9
4.4.1.6. ConfigRead - Read an Axis Configuration From
a File .................................................................... 4-10
4.4.1.7. ConfigWrite - Write an Axis Configuration to a
File....................................................................... 4-10
4.4.2. Faults, Errors, and Faultmasks ........................................... 4-11
4.4.2.1. Acknowledging (and Clearing) Faults.................. 4-11
4.5. Programming Errors ......................................................................... 4-12
4.5.1. Running CNC Programs..................................................... 4-12
4.6. Programming Commands ................................................................. 4-15
4.6.1. ? or (command) ? ............................................................... 4-18
4.6.2. ! (memory_command)........................................................ 4-18
4.6.3. ! TI ..................................................................................... 4-18
4.6.4. AX (axis_number).............................................................. 4-18
4.6.5. CMDERR (axis_number)................................................... 4-19
4.6.6. CMDLAST (axis_number)................................................. 4-19
4.6.7. CONFIGD2A (D2A_channel_number).............................. 4-19
4.6.8. CONFIGENCODER (encoder_ch)
(lines_per_revolution) (bounded)...................................... 4-20
4.6.9. CONFIGHENCODER (encoder_ch) (lines_per_rev)
(hall_lines) (com_offset) (comm_ch) (bounded)............... 4-21
4.6.10. CONFIGHRESOLVER (resolver_ch) (resolution)
(hall_lines) (com_offset) (comm_ch)(bounded)................. 4-22
4.6.11. CONFIGREAD (filespec).................................................. 4-23
4.6.12. CONFIGRESOLVER (resolver_ch) (resolution)
(poles) (com_offset)(bounded).......................................... 4-23
4.6.13. CONFIGWRITE (filespec) ................................................ 4-24
4.6.14. DB (address) ...................................................................... 4-24
4.6.15. DCAX ................................................................................ 4-24
4.6.16. DIR..................................................................................... 4-24
4.6.17. DOWNLOAD .................................................................... 4-24
4.6.18. DRVINFO.......................................................................... 4-25
4.6.19. DUMPTABLE (table number)........................................... 4-25
4.6.20. DUMPERROR (table number) .......................................... 4-25
4.6.21. DW (address) ..................................................................... 4-25
4.6.22. DL (address)....................................................................... 4-25
4.6.23. ENABLEPENDANT (channel) (mode 1).......................... 4-25
4.6.24. EXELINE (“command string”) .......................................... 4-26
4.6.25. EXEPRG (filespec)............................................................ 4-26
4.6.26. EXIT .................................................................................. 4-26
4.6.27. GETPROG......................................................................... 4-26
4.6.28. INFO .................................................................................. 4-26
4.6.29. IOGET (type) (point_number) ........................................... 4-27
4.6.30. IOMON (type) (point_number).......................................... 4-27
4.6.31. IOSET (type) (point_number) (value)................................ 4-28

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vi Aerotech, Inc. Version 1.4
4.6.32. MABORT...........................................................................4-28
4.6.33. MABSOLUTE (position) (speed) ......................................4-29
4.6.34. MALTHOME (direction) (speed) ......................................4-29
4.6.35. MFREERUN (direction) (speed)........................................4-30
4.6.36. MHALT..............................................................................4-30
4.6.37. MHOLD.............................................................................4-30
4.6.38. MHOME (direction) (speed)..............................................4-31
4.6.39. MINCREMENTAL (distance) (speed) ..............................4-31
4.6.40. MINFEEDSLAVE (distance) (speed)...............................4-32
4.6.41. MNOLIMITHOME (direction) (speed).............................4-32
4.6.42. MOSCILLATE (distance) (speed).....................................4-32
4.6.43. MQABSOLUTE (position) (velocity)................................4-33
4.6.44. MQFLUSH.........................................................................4-33
4.6.45. MQHOLD ..........................................................................4-33
4.6.46. MQINCREMENTAL (distance) (speed)............................4-33
4.6.47. MQUICKHOME (direction) (speed) .................................4-34
4.6.48. MQRELEASE....................................................................4-34
4.6.49. MRELEASE.......................................................................4-34
4.6.50. MB (address)......................................................................4-34
4.6.51. MEM..................................................................................4-34
4.6.52. ML (address)......................................................................4-35
4.6.53. MW (address).....................................................................4-35
4.6.54. OUTON (filespec)..............................................................4-35
4.6.55. OUTOFF [Z]......................................................................4-35
4.6.56. OUTPAUSE.......................................................................4-35
4.6.57. PARMGET (type) (parameter_name) ................................4-36
4.6.58. PARMMON (type) (parameter_name)...............................4-36
4.6.59. PARMSET (type) (parameter_name) (value).....................4-36
4.6.60. PLAY (filespec) [S] [P]......................................................4-36
4.6.61. PLYREWIND ....................................................................4-37
4.6.62. PRG1 (“command string”) .................................................4-37
4.6.63. PRGCMPL (filespec) (option) ...........................................4-37
4.6.64. PRGDUMP (filespec) ........................................................4-38
4.6.65. PRGERRS (filespec)..........................................................4-38
4.6.66. PRGINFO (filespec)...........................................................4-38
4.6.67. PRGLOAD (filespec) [num_lines] [userline_offset]..........4-38
4.6.68. PRGRUN (filespec) [line_number]....................................4-39
4.6.69. PRGSTATS (filespec)........................................................4-39
4.6.70. PRGTYPE (filespec)..........................................................4-39
4.6.71. PRGUNLOAD (filespec) ...................................................4-39
4.6.72. PSODOWNLOAD.............................................................4-39
4.6.73. QUIT..................................................................................4-39
4.6.74. RB (address).......................................................................4-40
4.6.75. RDO ...................................................................................4-40
4.6.76. RESET ...............................................................................4-40
4.6.77. RGINFO [device_id] [card_num] ......................................4-40
4.6.78. RL (address).......................................................................4-40
4.6.79. RW (address)......................................................................4-40
4.6.80. SPENDANTTEXT (channel) (line #) (text).......................4-41
4.6.81. TK (task_number) ..............................................................4-41
4.6.82. TSKASSOC (filespec) .......................................................4-41

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. vii
4.6.83. TSKDEASSOC.................................................................. 4-41
4.6.84. TSKINFO........................................................................... 4-41
4.6.85. TSKPRG (mode) (execution_type or line_number)........... 4-42
4.6.86. TSKRESET........................................................................ 4-42
4.6.87. VAGET (type) (number).................................................... 4-42
4.6.88. VCGET .............................................................................. 4-42
4.6.89. VDGET (type) (number).................................................... 4-43
4.6.90. VDMON (type) (number) .................................................. 4-43
4.6.91. VDSET (type) (number) (value) ........................................4-44
4.6.92. VSGET (type) (number)..................................................... 4-44
4.6.93. VSMON (type) (number)................................................... 4-44
4.6.94. VSSET (type) (number) (“string”)..................................... 4-45
4.6.95. WAIT ([!] condition).......................................................... 4-45
4.6.96. WB (address) (value) ......................................................... 4-46
4.6.97. WRITESERIAL (channel) (text)........................................ 4-46
4.6.98. WW (address) (value)........................................................ 4-46
4.6.99. WL (address) (value).......................................................... 4-46
4.6.105. ZMONITOR....................................................................... 4-47
4.6.106. ZONGOSUB...................................................................... 4-47
4.7. Command to Library Cross Reference.............................................. 4-48
CHAPTER 5: AERTUNE ........................................................................................ 5-1
5.1. Introduction........................................................................................ 5-1
5.2. The Main Window of the AerTune Program...................................... 5-2
5.2.1. The Help Menu .................................................................... 5-2
5.2.2. The File Menu...................................................................... 5-2
5.2.3. The Plot Menu...................................................................... 5-3
5.2.4. The Collect Menu................................................................. 5-3
5.2.5. The Graph Options Menu..................................................... 5-3
5.2.6. The Trigger Menu................................................................ 5-3
5.2.7. The Axis Menu..................................................................... 5-4
5.2.8. The Tools Menu................................................................... 5-4
5.3. Using AerTune ................................................................................... 5-4
5.3.1. Step Move Parameters.......................................................... 5-5
5.3.2. FFT Analysis........................................................................ 5-6
5.3.2.1. The FFT Analysis Window Menu Description...... 5-6
5.3.3. Determining the Maximum Acceleration of an Axis............ 5-7
5.3.4. Identifying an Instability within the Servo Loop.................. 5-8
5.3.5. Minimizing Position Error due to Torque Ripple or
Amplifier Offsets.................................................................. 5-8
5.3.6. AC Brushless Motor Tuning Tip.......................................... 5-9
5.3.7. Computing Torque (Closed-Loop Torque Mode).............. 5-10
5.4. Servo Loop Auto Tuning.................................................................. 5-11
5.4.1. Setting up AutoTune Parameters........................................ 5-12
5.4.2. Excitation Parameters......................................................... 5-13
5.4.2.1. Amplitude of Excitation in AutoTune.................. 5-13
5.4.2.2. Excitation Amplitude will exceed Velocity Trap
Limit..................................................................... 5-13
5.4.2.3. Units: Inches/Degrees or Counts.......................... 5-13
5.4.2.4. Starting Frequency for Excitation in AutoTune... 5-13
5.4.2.5. Ending Frequency for Excitation in AutoTune.... 5-13

Table of Contents U600 User’s Guide
viii Aerotech, Inc. Version 1.4
5.4.2.6. # Points to Collect in AutoTune...........................5-14
5.4.3. Tuning Parameters..............................................................5-14
5.4.3.1. Velocity Bandwidth .............................................5-14
5.4.3.2. Damping...............................................................5-14
5.4.3.3. Use VFF...............................................................5-15
5.4.3.4. Calculate AFFGAIN ............................................5-15
5.5. Manual Servo Loop Tuning..............................................................5-16
5.5.1. Kp - Proportional Gain.......................................................5-18
5.5.2. Ki - Integral Gain ...............................................................5-18
5.5.3. PGain - Position Gain.........................................................5-18
5.5.4. Vff - Velocity Feedforward Gain .......................................5-18
5.5.5. AffGain - Acceleration Feedforward Gain.........................5-19
5.5.6. Alpha - AffGain Filter........................................................5-19
5.5.7. VGain - Constant Velocity Gain.........................................5-19
5.6. Tuning Procedure for Torque (Current) Mode Servo Loops............5-20
5.7. Tuning With Tachometer Feedback..................................................5-30
5.7.1. Vff - Velocity Feed Forward ..............................................5-30
5.7.2. VGain - Constant Velocity Gain.........................................5-30
5.7.3. Servo Parameter Setup for Tachometer Feedback..............5-30
5.7.4. The Servo Loop Parameters for Tachometer-Based
Systems...............................................................................5-31
5.7.4.1. PGain - Position Gain ..........................................5-31
5.7.4.2. Vff - Velocity Feedforward Gain.........................5-31
5.7.4.3. Kp - Proportional Gain.........................................5-31
5.7.4.4. Ki - Integral Gain.................................................5-31
5.7.4.5. AffGain - Acceleration Feedforward Gain...........5-31
5.7.4.6. VGain - Constant Velocity Gain ..........................5-31
5.8. Tuning Tachometer Loops................................................................5-32
CHAPTER 6: AERPLOT.........................................................................................6-1
6.1. Introduction ........................................................................................6-1
6.2. File Menu............................................................................................6-2
6.3. Plot Menu ........................................................................................... 6-2
6.4. Trigger Menu......................................................................................6-3
6.5. Collect Menu ...................................................................................... 6-3
6.6. Axis Menu ..........................................................................................6-3
6.7. Graph Options Menu .......................................................................... 6-3
6.8. Tools Menu.........................................................................................6-4
6.8.1. The FFT Analysis Window Menu Description.....................6-5
6.9. Help Menu..........................................................................................6-5
CHAPTER 7: AERSTAT.........................................................................................7-1
7.1. Introduction ........................................................................................7-1
7.2. Overview ............................................................................................7-2
CHAPTER 8: AERREG...........................................................................................8-1
8.1. Introduction ........................................................................................8-1
8.2. Editing Registry Entries......................................................................8-1
8.2.1. Finding and/or Creating a “Card 1” Entry............................8-1
8.2.2. Modifying the “Card 1” Entry..............................................8-2

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. ix
CHAPTER 9: AERPLOT3D.................................................................................... 9-1
9.1. Introduction........................................................................................ 9-1
9.1.1. File Menu............................................................................. 9-1
9.1.1.1. Writing a Plot Data File......................................... 9-2
9.1.1.2. Reading and Displaying a Plot Data File............... 9-2
9.1.2. Plot Type Menu.................................................................... 9-2
9.1.3. Setup Menu .......................................................................... 9-2
9.1.4. Colors Menu......................................................................... 9-3
9.1.5. Grid Lines Menu .................................................................. 9-3
9.1.6. Units Menu........................................................................... 9-3
9.1.7. Start Menu............................................................................ 9-3
9.1.8. Stop Menu............................................................................ 9-4
9.1.9. Resume Menu....................................................................... 9-4
9.1.10. Suspend Menu...................................................................... 9-4
9.1.11. Help Menu............................................................................ 9-4
9.2. Auto Scaling the Display in AerPlot3D.............................................. 9-4
CHAPTER 10: AERPLOTIO.................................................................................. 10-1
10.1. Introduction...................................................................................... 10-1
CHAPTER 11: FILTER........................................................................................... 11-1
11.1. Introduction...................................................................................... 11-1
CHAPTER 12: SETUP WIZ.................................................................................... 12-1
12.1. Introduction...................................................................................... 12-1
12.2. Axis Names and Number.................................................................. 12-2
12.2.1. Axis Names........................................................................ 12-2
12.3. Configuring Axis Type..................................................................... 12-3
12.4. Axis Configuration ........................................................................... 12-4
12.4.1. Axis Configuration Wizard ................................................ 12-5
12.4.2. Axis & Parameter Names and Task Number
Configuration ..................................................................... 12-6
12.4.3. Configuring Axis Type....................................................... 12-7
12.4.3.1.Predefined Axis Types......................................... 12-8
12.4.4. Configuring the Primary Feedback Device ........................ 12-8
12.4.5. Configuring a DAC Channel.............................................. 12-9
12.4.6. Configuring the Secondary Feedback Device ..................12-10
12.4.6.1.Encoder Configuration....................................... 12-11
12.4.6.2.EncoderHall Configuration................................ 12-11
12.4.6.3.EncoderHall (Pole Pairs) Configuration ............ 12-13
12.4.6.4.Resolver Configuration (or Inductosyn)............. 12-15
12.4.6.5.ResolverHall Configuration ............................... 12-16
12.4.6.6.Stepper Motor Configuration............................. 12-17
12.4.6.7.Null (Virtual) Configuration.............................. 12-18
12.4.6.8.Configuring Dual Loop Axes............................. 12-18
12.4.7. Configuring Axis Calibration Data................................... 12-19
12.4.8. Saving an Axis Configuration .......................................... 12-20
12.5. Scaling and Feedrates..................................................................... 12-21
12.6. Home Cycle Configuration............................................................. 12-22
12.7. Asynchronous and G0 Accel/Decel Parameters ............................. 12-24

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xAerotech, Inc. Version 1.4
12.8. Position Limits and Velocity Trap..................................................12-24
12.9. Configure the Drive Interface States...............................................12-25
12.10. Configure the FAULTMASK.........................................................12-26
12.11. Configure the DISABLEMASK.....................................................12-27
12.12. Configure the HALTMASK...........................................................12-28
12.13. Configure the AUXMASK.............................................................12-29
12.14. Configure the ABORTMASK ........................................................12-30
12.15. Configure the INTMASK...............................................................12-31
12.16. Configure the BRAKEMASK ........................................................12-32
12.17. Configure the Current Limits..........................................................12-33
12.18. Axis Configuration Complete.........................................................12-34
12.19. Accel/Decel and Task Initialization................................................12-35
12.20. Configure the ESTOP, Feedhold, and MFO...................................12-36
12.21. Configure Synchronous Accel/Decel..............................................12-37
12.22. Setup Wizard – Configuration Complete........................................12-38
CHAPTER 13: PRMSETUP....................................................................................13-1
13.1. Introduction ......................................................................................13-1
APPENDIX A: GLOSSARY OF TERMS................................................................ A-1
A.1. Introduction ....................................................................................... A-1
APPENDIX B: TROUBLESHOOTING.................................................................. B-1
APPENDIX C: PARAMETERS................................................................................C-1
C.1. Description .........................................................................................C-1
C.1.1. Name ....................................................................................C-2
C.1.2. Type (of Parameter) .............................................................C-2
C.1.3. Access ..................................................................................C-2
C.1.4. Minimum, Maximum............................................................C-2
C.1.5. Default..................................................................................C-2
C.2. Axis Parameters..................................................................................C-3
C.2.1. Modifying an Axis’ Parameter within a CNC Program........C-5
C.2.2. ABORTMASK.....................................................................C-5
C.2.3. ACCEL.................................................................................C-6
C.2.4. ACCELMODE.....................................................................C-6
C.2.5. ACCELRATE ......................................................................C-7
C.2.6. AFFGAIN.............................................................................C-7
C.2.7. ALPHA.................................................................................C-7
C.2.8. ALT_STATUS.....................................................................C-7
C.2.9. AUX (Mode) Output............................................................C-8
C.2.10. AUXDELAY........................................................................C-9
C.2.11. AUXMASK..........................................................................C-9
C.2.12. AUXOFFSET.......................................................................C-9
C.2.13. AUXVELCMD ....................................................................C-9
C.2.14. AVGVEL ...........................................................................C-10
C.2.15. AVGVELTIME..................................................................C-10
C.2.16. B0/B1/B2/A1/A2................................................................C-10
C.2.16.1. A Typical Low-Pass Filter............................C-11
C.2.17. BASE_SPEED ...................................................................C-12
C.2.18. BRAKEMASK...................................................................C-12

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. xi
C.2.19. CAMADVANCE ...............................................................C-13
C.2.20. CAMOFFSET....................................................................C-13
C.2.21. CAMPOINT.......................................................................C-14
C.2.22. CAMPOSITION ................................................................C-14
C.2.23. CCWEOT...........................................................................C-14
C.2.24. CLOCK..............................................................................C-15
C.2.25. CWEOT .............................................................................C-15
C.2.26. DACOFFSET.....................................................................C-16
C.2.27. DECEL...............................................................................C-16
C.2.28. DECELMODE...................................................................C-16
C.2.29. DECELRATE ....................................................................C-17
C.2.30. DISABLEMASK ...............................................................C-17
C.2.31. DRIVE ...............................................................................C-17
C.2.31.1. Enabling Drives................................................C-17
C.2.32. ECHO.................................................................................C-18
C.2.33. EXTR2DSCL.....................................................................C-18
C.2.34. FAULT...............................................................................C-18
C.2.35. FAULTMASK ...................................................................C-20
C.2.36. FBWINDOW.....................................................................C-21
C.2.37. FEEDRATEMODE............................................................C-21
C.2.38. GANTRYMODE ...............................................................C-21
C.2.38.1. Configuring GANTRYMODE......................C-21
C.2.39. GANTRYOFFSET.............................................................C-21
C.2.40. GEARMASTER.................................................................C-22
C.2.41. GEARSLAVE....................................................................C-22
C.2.42. GEARMODE.....................................................................C-22
C.2.43. HALTMASK......................................................................C-23
C.2.44. HOMEOFFSET .................................................................C-23
C.2.45. HOMESWITCHPOS .........................................................C-23
C.2.46. HOMESWITCHTOL.........................................................C-24
C.2.47. HOMEVELMULT.............................................................C-24
C.2.48. IAVG..................................................................................C-24
C.2.49. IAVGLIMIT.......................................................................C-24
C.2.50. IAVGTIME........................................................................C-25
C.2.51. ICMD.................................................................................C-25
C.2.52. ICMDPOLARITY..............................................................C-25
C.2.53. IMAX.................................................................................C-26
C.2.53.1. Computing Torque (Closed-Loop Torque
Mode) ...........................................................C-26
C.2.54. INPOSLIMIT.....................................................................C-27
C.2.55. INTMASK .........................................................................C-27
C.2.56. IOLEVEL...........................................................................C-27
C.2.57. IVEL ..................................................................................C-28
C.2.58. KI .......................................................................................C-28
C.2.59. KP ......................................................................................C-28
C.2.60. MASTERLEN....................................................................C-29
C.2.61. MASTERPOS....................................................................C-29
C.2.61.1. Master Axis Selection...................................C-30
C.2.62. MASTERRES....................................................................C-30
C.2.63. MAX_PHASE....................................................................C-30
C.2.64. MAXCAMACCEL ............................................................C-30

Table of Contents U600 User’s Guide
xii Aerotech, Inc. Version 1.4
C.2.65. MOTIONSTATUS.............................................................C-31
C.2.65.1. Profiling Bit in the MOTIONSTATUS
Axis Parameter..............................................C-32
C.2.65.2. Moving Bit in the MOTIONSTATUS Axis
Parameter......................................................C-32
C.2.66. MOVEQDEPTH ................................................................C-32
C.2.67. MOVEQSIZE.....................................................................C-32
C.2.68. PGAIN................................................................................C-32
C.2.69. PHASE_SPEED.................................................................C-32
C.2.70. PHASEAOFFSET..............................................................C-32
C.2.71. PHASEBOFFSET..............................................................C-33
C.2.72. POS ....................................................................................C-33
C.2.73. POSCMD ...........................................................................C-33
C.2.74. POSERR.............................................................................C-33
C.2.75. POSERRLIMIT..................................................................C-34
C.2.76. POSTARGET.....................................................................C-34
C.2.77. POSTOGO .........................................................................C-34
C.2.78. POSTOGOIRQ ..................................................................C-34
C.2.79. POSTOLERANCE.............................................................C-35
C.2.80. POSTOLTIME...................................................................C-35
C.2.81. PROFILETIME..................................................................C-35
C.2.82. PROFQDEPTH..................................................................C-35
C.2.83. PROFQSIZE.......................................................................C-35
C.2.84. RAWPOS...........................................................................C-35
C.2.85. RESOLVER .......................................................................C-35
C.2.86. REVERSALMODE............................................................C-35
C.2.87. REVERSALVALUE..........................................................C-36
C.2.88. SAFEZONECCW ..............................................................C-37
C.2.89. SAFEZONECW.................................................................C-37
C.2.90. SAFEZONEMODE............................................................C-37
C.2.91. SCALEPGAIN...................................................................C-37
C.2.92. SERVOSTATUS................................................................C-39
C.2.93. SIMULATION...................................................................C-40
C.2.94. SOFTLIMITMODE...........................................................C-40
C.2.95. STATUS.............................................................................C-41
C.2.96. SYNCSPEED.....................................................................C-42
C.2.97. SYSTEMCLOCK...............................................................C-42
C.2.98. VELCMDTRAP.................................................................C-42
C.2.99. VELPOSITION..................................................................C-42
C.2.100.VELTIMECONST .............................................................C-43
C.2.101.VFF ....................................................................................C-44
C.2.102.VGAIN...............................................................................C-44
C.3. Machine Parameters..........................................................................C-45
C.3.1. Modifying a Machine Parameter within a CNC
Program..............................................................................C-46
C.3.2. AvgVelUnits.......................................................................C-46
C.3.3. AxisState ............................................................................C-46
C.3.4. CntsPerDeg.........................................................................C-46
C.3.5. CntsPerInch........................................................................C-47
C.3.6. ControllingTask..................................................................C-47
C.3.7. FixtureOffset ......................................................................C-48

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. xiii
C.3.8. FixtureOffset2 ....................................................................C-48
C.3.9. FixtureOffset3 ....................................................................C-48
C.3.10. FixtureOffset4 ....................................................................C-48
C.3.11. FixtureOffset5 ....................................................................C-48
C.3.12. FixtureOffset6 ....................................................................C-48
C.3.13. HomeDirection...................................................................C-48
C.3.14. HomeFeedRateIPM............................................................C-48
C.3.15. HomeFeedRateRPM...........................................................C-48
C.3.16. HomeOffsetDeg .................................................................C-49
C.3.17. HomeOffsetInch.................................................................C-49
C.3.18. HomeType..........................................................................C-49
C.3.18.1. TYPE 0 - Home to Limit AND Reference
Pulse .............................................................C-50
C.3.18.2. TYPE 1 - Home into Limit & Reverse to
Reference Pulse, (Aerotech Std.)..................C-50
C.3.18.3. TYPE 2 - Home to Marker ...........................C-51
C.3.18.4. TYPE 3 - Quick Home to Limit Switch........C-52
C.3.18.5. Type 4 - Home Position at Current Position.C-52
C.3.19. JogDistanceDeg..................................................................C-52
C.3.20. JogDistanceInch.................................................................C-52
C.3.21. JogVelocityIPM .................................................................C-52
C.3.22. JogVelocityRPM................................................................C-52
C.3.23. MaxFeedRateIPM ..............................................................C-53
C.3.24. MaxFeedRateRPM.............................................................C-53
C.3.25. NumDecimalsEnglish.........................................................C-53
C.3.26. NumDecimalsMetric ..........................................................C-53
C.3.27. PositionCmdUnits ..............................................................C-54
C.3.28. PositionUnits......................................................................C-54
C.3.29. PresetCmdUnits..................................................................C-54
C.3.30. RapidFeedRateIPM............................................................C-54
C.3.31. RapidFeedRateRPM...........................................................C-54
C.3.32. ReverseSlewDir..................................................................C-54
C.3.33. ScaleFactor.........................................................................C-55
C.3.33.1. Scaling Limitations.......................................C-55
C.3.34. Type ...................................................................................C-55
C.3.35. Unused Axis.......................................................................C-56
C.4. Task Parameters ...............................................................................C-57
C.4.1. Modifying the Task Parameters of another Task................C-60
C.4.2. AccelRate...........................................................................C-60
C.4.3. AccelRateDPS2..................................................................C-61
C.4.4. AccelRateIPS2 ...................................................................C-61
C.4.5. AccelTimeSec ....................................................................C-61
C.4.6. AnalogMFOInput...............................................................C-62
C.4.7. AnalogMSOInput...............................................................C-62
C.4.8. BlendMaxAccelLinearIPS2................................................C-62
C.4.8.1. Force Deceleration to Zero (G9), if
Maximum Acceleration is Exceeded.............C-63
C.4.8.2. Limit Acceleration without Full
Deceleration..................................................C-63
C.4.8.3. Blending Limitations of
BlendMaxAccelLinearIPS2 and

Table of Contents U600 User’s Guide
xiv Aerotech, Inc. Version 1.4
BlendMaxAccelRotaryDPS2 Task
Parameters.....................................................C-64
C.4.8.4. Calculating the value for the
BlendMaxAccelLinearIPS2 and
BlendMaxAccelRotaryDPS2 Task
Parameters.....................................................C-64
C.4.9. BlendMaxAccelRotaryDPS2..............................................C-65
C.4.9.1. Force Rotary Axes Deceleration to Zero
(G9), if Maximum Acceleration is
exceeded .......................................................C-65
C.4.9.2. Limit Rotary Acceleration without Full
Deceleration..................................................C-65
C.4.10. BlendMaxAccelCircleIPS2 ................................................C-65
C.4.10.1. Calculating the value of the
BlendMaxAccelCircleIPS2 Task Parameter.C-66
C.4.11. CannedFunctionID .............................................................C-66
C.4.12. ChordicalSlowdownMsec...................................................C-66
C.4.13. ChordicalToleranceInch.....................................................C-67
C.4.14. CommandVelocityVariance ...............................................C-67
C.4.15. Coord1Plane.......................................................................C-67
C.4.15.1. Clockwise Circular Axes Plane.....................C-68
C.4.16. Coord1I ..............................................................................C-68
C.4.17. Coord1J..............................................................................C-69
C.4.18. Coord1K.............................................................................C-69
C.4.19. Coord2Plane.......................................................................C-69
C.4.19.1. Clockwise Circular Axes Plane.....................C-70
C.4.20. Coord2I ..............................................................................C-70
C.4.21. Coord2J..............................................................................C-71
C.4.22. Coord2K.............................................................................C-71
C.4.23. CutterRadiusInch................................................................C-71
C.4.24. CutterToleranceDeg ...........................................................C-72
C.4.25. Link Move..........................................................................C-73
C.4.26. Offset Move........................................................................C-73
C.4.27. Link Method.......................................................................C-73
C.4.28. Offset Method ....................................................................C-73
C.4.29. CutterX...............................................................................C-73
C.4.30. CutterY...............................................................................C-73
C.4.31. CutterY...............................................................................C-73
C.4.32. DecelOnProgramAbortMask..............................................C-74
C.4.33. DecelRate...........................................................................C-74
C.4.34. DecelRateDPS2..................................................................C-74
C.4.35. DecelRateIPS2 ...................................................................C-74
C.4.36. DecelTimeSec ....................................................................C-75
C.4.37. DryRunLinearFeedRateIPM...............................................C-75
C.4.38. DryRunRotaryFeedRateRPM.............................................C-75
C.4.39. ErrCode..............................................................................C-75
C.4.40. EStopInput..........................................................................C-75
C.4.41. ExecuteNumLines ..............................................................C-75
C.4.42. ExecuteNumMonitors.........................................................C-77
C.4.43. ExecuteNumSpindles .........................................................C-77
C.4.44. FeedHold............................................................................C-77

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. xv
C.4.45. FeedHoldEdgeInput ...........................................................C-77
C.4.46. FeedHoldInput ...................................................................C-77
C.4.47. GlobalEstopDisabled..........................................................C-78
C.4.48. HaltTaskOnAxisFault.........................................................C-78
C.4.49. IgnoreAxesMask ................................................................C-78
C.4.50. InterruptMotion..................................................................C-78
C.4.51. InterruptMotionReturnType...............................................C-79
C.4.52. External Jog Key Example.................................................C-79
C.4.53. JogPair1Axis1MinusIn.......................................................C-80
C.4.54. JogPair1Axis1PlusIn..........................................................C-80
C.4.55. JogPair1Axis2MinusIn.......................................................C-80
C.4.56. JogPair1Axis2PlusIn..........................................................C-80
C.4.57. JogPair1EnableIn...............................................................C-80
C.4.58. JogPair1Axis1....................................................................C-80
C.4.59. JogPair1Axis2....................................................................C-80
C.4.59.1. JogPair1Axis Example..................................C-81
C.4.60. JogPair1Mode....................................................................C-81
C.4.61. JogPair2Axis1MinusIn.......................................................C-81
C.4.62. JogPair2Axis1PlusIn..........................................................C-82
C.4.63. JogPair2Axis2MinusIn.......................................................C-82
C.4.64. JogPair2Axis2PlusIn..........................................................C-82
C.4.65. JogPair2EnableIn...............................................................C-82
C.4.66. JogPair2Axis1....................................................................C-82
C.4.67. JogPair2Axis2....................................................................C-82
C.4.68. JogPair2Mode....................................................................C-82
C.4.69. JoyStickPort .......................................................................C-83
C.4.70. LinearFeedRate..................................................................C-83
C.4.71. LinearFeedRateActual........................................................C-84
C.4.72. LineNumberUser................................................................C-84
C.4.73. LineNumber960 .................................................................C-84
C.4.74. MaxCallStack.....................................................................C-84
C.4.75. MaxLookAheadMoves.......................................................C-84
C.4.76. MaxModeStack..................................................................C-85
C.4.77. MaxMonitorData................................................................C-85
C.4.78. MaxOnGosubData..............................................................C-85
C.4.79. MaxRadiusAdjust...............................................................C-85
C.4.80. MaxRadiusError.................................................................C-85
C.4.81. MFO...................................................................................C-86
C.4.82. Mode1................................................................................C-86
C.4.83. MSO...................................................................................C-88
C.4.84. NormalcyToleranceDeg .....................................................C-88
C.4.85. NormalcyAxis ....................................................................C-88
C.4.86. NormalcyX.........................................................................C-89
C.4.87. NormalcyY.........................................................................C-89
C.4.88. Number...............................................................................C-89
C.4.89. NumTaskAxisPts................................................................C-89
C.4.90. NumTaskDoubles...............................................................C-89
C.4.91. NumTaskStrings.................................................................C-89
C.4.92. ROReq1..............................................................................C-89
C.4.93. RIAction1...........................................................................C-90
C.4.94. RIActionAxis .....................................................................C-91

Table of Contents U600 User’s Guide
xvi Aerotech, Inc. Version 1.4
C.4.95. RIActionParm1...................................................................C-92
C.4.96. RIActionParm2...................................................................C-92
C.4.97. RIActionOpCode................................................................C-92
C.4.98. ROAction1 .........................................................................C-94
C.4.99. ROReq1Mask.....................................................................C-95
C.4.100.RotaryFeedRate..................................................................C-95
C.4.101.RotaryFeedRateActual .......................................................C-96
C.4.102.RotateAngleDeg.................................................................C-96
C.4.103.RotateX ..............................................................................C-97
C.4.104.RotateY ..............................................................................C-97
C.4.105.RThetaEnabled...................................................................C-97
C.4.106.RThetaR .............................................................................C-97
C.4.107.RThetaRadius.....................................................................C-98
C.4.108.RThetaRadiusInch..............................................................C-98
C.4.109.RThetaT .............................................................................C-98
C.4.110.RThetaX.............................................................................C-98
C.4.111.RThetaY.............................................................................C-98
C.4.112.S1_Index ............................................................................C-98
C.4.113.S1_RPM.............................................................................C-98
C.4.114.S1_SpindleRadius ..............................................................C-99
C.4.115.S2_AnalogMSOInput.........................................................C-99
C.4.116.S2_Index ............................................................................C-99
C.4.117.S2_MSO.............................................................................C-99
C.4.118.S2_RPM...........................................................................C-100
C.4.119.S2_SpindleRadius ............................................................C-100
C.4.120.S3_AnalogMSOInput.......................................................C-100
C.4.121.S3_Index ..........................................................................C-100
C.4.122.S3_MSO...........................................................................C-100
C.4.123.S3_RPM...........................................................................C-101
C.4.124.S3_SpindleRadius ............................................................C-101
C.4.125.S4_AnalogMSOInput.......................................................C-101
C.4.126.S4_Index ..........................................................................C-101
C.4.127.S4_MSO...........................................................................C-101
C.4.128.S4_RPM...........................................................................C-102
C.4.129.S4_SpindleRadius ............................................................C-102
C.4.130.SlewPair1 .........................................................................C-102
C.4.131.SlewPair2 .........................................................................C-102
C.4.132.SlewPair3 .........................................................................C-103
C.4.133.SlewPair4 .........................................................................C-103
C.4.134.SlewPair5 .........................................................................C-103
C.4.135.SlewPair6 .........................................................................C-103
C.4.136.SlewPair7 .........................................................................C-103
C.4.137.SlewPair8 .........................................................................C-104
C.4.138.SlewPair# Example ..........................................................C-104
C.4.139.Task Modes......................................................................C-104
C.4.140.Status1..............................................................................C-105
C.4.140.1. CNC Program Active..................................C-106
C.4.140.2. CNC Program Executing.............................C-106
C.4.140.3. CNC Program Aborted ...............................C-106
C.4.141.Status2..............................................................................C-106
C.4.141.1. Spindle FeedHold Active............................C-107

U600 User’s Guide Table of Contents
Version 1.4 Aerotech, Inc. xvii
C.4.141.2. Asynchronous FeedHold Active.................C-107
C.4.142.Status3..............................................................................C-107
C.4.142.1. Motion FeedHold Active............................C-108
C.4.142.2. Motion Continuous Bit ...............................C-108
C.4.143.TaskFault..........................................................................C-108
C.4.143.1. TaskWarning...............................................C-109
C.4.143.2. Stopping the CNC program in Response to
a TaskFault .................................................C-109
C.4.143.3. Generating an Axis Fault in Response to a
TaskFault....................................................C-109
C.4.143.4. Generating a PC Interrupt in Response to a
TaskFault....................................................C-110
C.4.144.UpdateNumEntries...........................................................C-110
C.4.145.UpdateTimeSec................................................................C-110
C.4.145.1. Effects of Decreasing the UpdateTimeSec
Task Parameter ...........................................C-111
C.4.145.2. Effects of Increasing the UpdateTimeSec
Task Parameter ...........................................C-111
C.4.146.UserFeedRateMode..........................................................C-112
C.5. Global Parameters ..........................................................................C-113
C.5.1. AvgPollTimeSec ..............................................................C-113
C.5.2. BuildNumber....................................................................C-114
C.5.3. CallBackTimeoutSec........................................................C-115
C.5.4. CompatibilityMode ..........................................................C-115
C.5.4.1. Move Calculation Averaging......................C-115
C.5.4.2. Radius Error Bit 2.......................................C-115
C.5.4.3. Convert G43/G47/G65/G66 to User Units..C-115
C.5.4.4. Non Modal G2 / G3 Commands.................C-116
C.5.4.5. Old Style Contouring..................................C-116
C.5.5. Enable1KHzServo............................................................C-116
C.5.6. Enable2Dcalibration.........................................................C-117
C.5.7. EStopEnabled...................................................................C-117
C.5.8. Interrupt2TimeSec............................................................C-117
C.5.9. Measurement Mode..........................................................C-117
C.5.10. NumCannedFunctions......................................................C-117
C.5.11. NumDecimalsCompare ....................................................C-118
C.5.12. NumGlobalAxisPts...........................................................C-118
C.5.13. NumGlobalDoubles..........................................................C-118
C.5.14. NumGlobalStrings............................................................C-118
C.5.15. ThrowTaskWarningsAsFaults..........................................C-118
C.5.16. UserMode.........................................................................C-118
C.5.17. Version.............................................................................C-118
APPENDIX D: WARRANTY AND FIELD SERVICE POLICY ........................... D-1
INDEX
∇∇∇

Table of Contents U600 User’s Guide
xviii Aerotech, Inc. Version 1.4

U600 User’s Guide List of Figures
Version 1.4 Aerotech, Inc. xix
LIST OF FIGURES
Figure 1-1. Installation Process............................................................................. 1-2
Figure 1-2. System Architecture............................................................................ 1-3
Figure 2-1. Flowchart Overviewing the Installation/Configuration Process ......... 2-2
Figure 4-1. AerDebug Screen................................................................................ 4-2
Figure 4-2. Help Screen (AerDebug).................................................................... 4-5
Figure 5-1. AerTune Main Window...................................................................... 5-2
Figure 5-2. Plot Comment..................................................................................... 5-2
Figure 5-3. Step Move Parameters........................................................................ 5-5
Figure 5-4. FFT Analysis...................................................................................... 5-6
Figure 5-5. Torque Ripple Plot of an AC Brushless Motor................................... 5-9
Figure 5-6. Closed-Loop Torque Mode .............................................................. 5-10
Figure 5-7. AutoTune Screen.............................................................................. 5-12
Figure 5-8. Servo Loop Diagram (Torque Mode)............................................... 5-17
Figure 5-9. Servo Loop (Open-Loop Velocity Mode) ........................................ 5-17
Figure 5-10. Servo Loop (Velocity Mode, Closed Loop)..................................... 5-18
Figure 5-11. Flowchart of Overall Tuning Process............................................... 5-21
Figure 5-12. Unacceptable Velocity Error............................................................ 5-24
Figure 5-13. Acceptable Velocity Error (While Adjusting Kp)............................ 5-24
Figure 5-14. Unacceptable Position Error (While Adjusting Ki).......................... 5-25
Figure 5-15. Acceptable Position Error (While Adjusting Ki).............................. 5-25
Figure 5-16. Plot Showing an Appropriate Value for PGain................................. 5-26
Figure 5-17. Plot Showing Overall Effects when PGain is High........................... 5-26
Figure 5-18. Plot Showing Velocity Feedforward Enabled (Vff=1) ..................... 5-27
Figure 5-19. Plot Showing Optimal AffGain Adjustment..................................... 5-28
Figure 5-20. Plot Showing Final Performance of ATS3220140P X axis
table, with a BM130 motor and an AS32030 amplifier.................... 5-28
Figure 5-21. Flowchart of Overall Tachometer Tuning Process........................... 5-32
Figure 5-22. Cross-Section of the DS16020/16030 Amplifier.............................. 5-34
Figure 5-23. Amplifier Potentiometer Layout....................................................... 5-34
Figure 5-24. Oscilloscope Showing Current Feedback for One Move.................. 5-37
Figure 6-1. AerPlot Screen.................................................................................... 6-1
Figure 6-2. Plot Selection Window....................................................................... 6-2
Figure 6-3. FFT Analysis Window........................................................................ 6-4
Figure 7-1. AerStat Screen.................................................................................... 7-1
Figure 8-1. AerReg Screen.................................................................................... 8-1
Figure 8-2. AerReg Registry Editor Screen........................................................... 8-2
Figure 9-1. The Setup Screen of AerPlot3D ......................................................... 9-1
Figure 9-2. The Setup Screen of AerPlot3D ......................................................... 9-2
Figure 9-3. The Axis Min/Max Travel Screen of AerPlot3D................................ 9-3
Figure 10-1. AerPlotIO Screen .............................................................................10-1
Figure 10-2. AerPlotIO Screen .............................................................................10-3
Figure 11-1. The Filter Screen .............................................................................. 11-1
Figure 12-1. The Setup Wizard Start Screen......................................................... 12-1
Figure 12-2. The Axis Name/Number Configuration Screen................................ 12-2
Figure 12-3. The Axis “Type” Configuration Screen............................................ 12-3
Figure 12-4. The Axis Configuration “Correct or Reconfigure” Screen............... 12-4