Aerotech BA-Intellidrive BAI 10 User manual

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BA-INTELLIDRIVE
USER’S MANUAL
P/N: EDU163 (V1.4)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotech.com
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If you should have any questions about the BA-Intellidrive or comments regarding the documentation, please refer to
Aerotech online at:
http://www.aerotech.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 BAI amplifier and BAI software are products of Aerotech, Inc.
Windows 95/NT are products of Microsoft Corporation.
The BA-Intellidrive User’s Manual Revision History:
Preliminary December 12,1997
Version 1.0 February 10, 1998
Version 1.1 November 12, 1998
Version 1.2 March 31, 2000
Version 1.3 November 15, 2000
Version 1.4 February 14, 2001
© Aerotech, Inc., 2001
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BA Intellidrive User’s Manual Table of Contents
Version 1.4 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION............................................................................ 1-1
1.1. Product Overview............................................................................... 1-1
1.2. Indexer................................................................................................ 1-2
1.2.1. Teach Mode .........................................................................1-4
1.2.2. Clock and Direction .............................................................1-6
1.3. BAI DOS Software............................................................................. 1-6
1.4. Hardware Overview and Function...................................................... 1-7
1.4.1. Motor and AC Power Connections.......................................1-8
1.4.1.1. BAI 10/20/30.........................................................1-8
1.4.1.2. BAI 50/75/100.......................................................1-9
1.4.2. Fusing and Inrush Limiting ................................................1-10
1.4.2.1. BAI 10/20/30.......................................................1-10
1.4.2.2. BAI 50/75/100.....................................................1-11
1.4.3. 20 - 80 Volt Option – BAI 10/20/30..................................1-12
1.4.4. COM Port...........................................................................1-13
1.4.5. RS232 Daisy Chain Configuration.....................................1-13
1.4.6. LED Status Indicators ........................................................1-14
1.4.7. The I/O Port (P1) ...............................................................1-14
1.4.8. Encoder/Limits/Hall Effects Port (P3) ...............................1-15
1.5. Safety Procedures and Warnings...................................................... 1-17
CHAPTER 2: GETTING STARTED...................................................................... 2-1
2.1. Introduction........................................................................................ 2-1
2.2. Unpacking the BA-Intellidrive ........................................................... 2-2
2.3. Minimum Hardware Requirements and Recommended System
Configurations.................................................................................... 2-2
2.4. Inspection of the BAI ......................................................................... 2-3
2.5. Physical Setup of the Motion Controller ............................................ 2-3
2.5.1. BAI Cable Connections........................................................2-4
2.5.2. Local Mode..........................................................................2-4
2.5.3. Standard Installation of the Software ...................................2-5
2.5.3.1. Writing a Short BAI Program................................2-7
2.5.3.2. BAI Windows Software Interface........................2-11
2.5.3.3. BAI MMI Windows Software Installation...........2-13
2.6. Parameters Screen - BAI MMI......................................................... 2-17
2.7. Axis Scope Tuning Window............................................................. 2-19
2.7.1. Tuning Procedure for Servo Loops....................................2-21
2.8. Autotuning........................................................................................ 2-29
2.9. Tuning Tips ...................................................................................... 2-33
CHAPTER 3: COMMUNICATION AND COMMANDS .................................... 3-1
3.1. Introduction........................................................................................ 3-1
3.2. BAI Communications Modes ............................................................. 3-1
3.2.1. Local Mode..........................................................................3-1
3.2.2. Remote Mode.......................................................................3-2
3.2.2.1. Enabling RS232 Remote Communications............3-2
3.2.2.2. Daisy Chain............................................................3-3
3.3. Menu Commands................................................................................ 3-4
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Table of Contents BA Intellidrive User’s Manual
iv Aerotech, Inc. Version 1.4
3.3.1. C-Change Parameter.............................................................3-4
3.3.2. D-Display Tracking Information..........................................3-6
3.3.3. O-Other Menus.....................................................................3-7
3.3.3.1. Running a Program ................................................3-7
3.3.3.2. Read Register.........................................................3-8
3.3.3.3. Read/Write Parameter............................................3-8
3.3.3.4. Display Error Message...........................................3-8
3.3.4. F-File Operations..................................................................3-9
3.3.5. F1- Abort Entry/Up One Menu Level...................................3-9
3.3.6. F2/F3 - Previous/Next Menu................................................3-9
3.3.7. F5 – Aborts Motion and Programs.....................................3-10
3.3.8. I – Enter Motion Command................................................3-10
3.3.9. S – Save Parameters to Flash..............................................3-10
3.3.10. T-Teach Mode....................................................................3-11
3.3.11. Space Bar ...........................................................................3-12
3.4. BAI System Commands....................................................................3-13
3.4.1. Program/Motion Abort.......................................................3-14
3.4.2. Program Execution.............................................................3-14
3.4.3. DF Delete File....................................................................3-14
3.4.4. File Transfers – Download File to PC................................3-14
3.4.5. Format................................................................................3-15
3.4.6. Get Message Command......................................................3-15
3.4.7. HOLD/TRIGGER/CANCEL..............................................3-15
3.4.8. Execute Immediate Command............................................3-16
3.4.9. Print Directory....................................................................3-16
3.4.10. Return Error Message String..............................................3-16
3.4.11. Print Program “file” to Port................................................3-17
3.4.12. Print Status .........................................................................3-17
3.4.13. Return Axis Position...........................................................3-18
3.4.14. Serial Poll command ..........................................................3-18
3.4.15. Hardware Reset ..................................................................3-19
3.4.16. Parameter Editing...............................................................3-19
3.4.17. Read/Write Register...........................................................3-20
3.4.18. Save Program/Parameters to Flash Memory.......................3-20
3.4.19. Service Request Mode (SRQ) ............................................3-20
3.4.20. File Transfers – Upload File to BAI...................................3-21
3.4.21. ; Comment..........................................................................3-22
3.5. BAI Motion and Program Commands..............................................3-23
3.5.1. Acceleration Command......................................................3-24
3.5.2. Clear Limit .........................................................................3-24
3.5.3. Conditional Gosub..............................................................3-24
3.5.4. Conditional Goto................................................................3-24
3.5.5. Disable Amplifier...............................................................3-25
3.5.6. Dwell Command.................................................................3-25
3.5.7. Enable Amplifier................................................................3-25
3.5.8. Fault Acknowledge.............................................................3-25
3.5.9. Freerun ...............................................................................3-26
3.5.10. Gain Command...................................................................3-26
3.5.11. Gosub Command................................................................3-27
3.5.12. Goto Command ..................................................................3-27
3.5.13. Home Command.................................................................3-27
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BA Intellidrive User’s Manual Table of Contents
Version 1.4 Aerotech, Inc. v
3.5.14. Index Command.................................................................3-28
3.5.15. IT Command ......................................................................3-29
3.5.16. Label – Define a Label.......................................................3-29
3.5.17. Load Position Register.......................................................3-29
3.5.18. Loop Start and Loop End...................................................3-30
3.5.19. Motor Commutate..............................................................3-30
3.5.20. Change opto-isolated outputs.............................................3-30
3.5.21. Print Message.....................................................................3-30
3.5.22. Position Mode – Absolute or Incremental..........................3-31
3.5.23. Program Stop......................................................................3-31
3.5.24. Ramp Time.........................................................................3-31
3.5.25. Register Functions..............................................................3-32
3.5.26. Run the teach program.......................................................3-32
3.5.27. Return from subroutine ......................................................3-32
3.5.28. WM/WA – Wait Move.......................................................3-32
3.6. Teach Mode...................................................................................... 3-33
3.6.1. Using the Teach Program...................................................3-33
3.6.1.1. +/- Increment/Decrement Current Position.........3-34
3.6.1.2. F2/F3 Next/Previous Index.................................3-34
3.6.1.3. 1,2,3 Learn the Current
Position/Feedrate/Bit Pattern ...............................3-34
3.6.1.4. I-Change the Index...............................................3-35
3.6.1.5. Z-Zero the Teach Program...................................3-35
3.6.1.6. S-Save the Teach Program...................................3-35
3.7. Sample Programs.............................................................................. 3-36
CHAPTER 4: PARAMETERS................................................................................ 4-1
4.1. Introduction........................................................................................ 4-1
4.2. Servo Loop Parameters....................................................................... 4-4
4.2.1. PRM:0 Proportional Velocity Gain KP...............................4-5
4.2.2. PRM:1 Integral Velocity Gain KI .......................................4-5
4.2.3. PRM:2 Proportional Position Gain KPOS ..........................4-5
4.2.4. PRM:3 Incremental Change for KP .....................................4-6
4.2.5. PRM:4 Incremental Change for KI ......................................4-6
4.2.6. PRM:5 Incremental Change for KPOS ................................4-7
4.2.7. PRM:6 Servo “In Position” Tolerance................................4-7
4.2.8. PRM:7 Servo Peak Current Limit .......................................4-8
4.2.9. PRM:8 Servo RMS Limit....................................................4-8
4.2.10. PRM:9 Servo RMS Current Timeout..................................4-9
4.2.11. PRM:10 Servo Velocity Trap..............................................4-9
4.2.12. PRM:11 Integral Clamp ....................................................4-10
4.2.13. PRM:12 Position Error Trap.............................................4-10
4.2.14. PRM:13 Servo Update Rate..............................................4-11
4.2.15. PRM:14 Encoder Resolution.............................................4-11
4.2.16. PRM:15 Electrical Cycles/Mechanical Revolution...........4-12
4.2.17. PRM:16 Hall Effects Available.........................................4-13
4.2.18. PRM:17 Initialization Current...........................................4-13
4.2.19. PRM:18 Velocity Feedforward VFF.................................4-14
4.2.20. PRM:20 Operating Mode..................................................4-14
4.2.21. PRM:22 Position Save ......................................................4-15
4.2.22. PRM:23 Reload Saved Position on Power-Up..................4-15
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Table of Contents BA Intellidrive User’s Manual
vi Aerotech, Inc. Version 1.4
4.2.23. PRM:24 Saved Position ....................................................4-16
4.2.24. PRM:26 Low Pass Filter ...................................................4-16
4.2.25. PRM:27 Phase Offset........................................................4-17
4.2.26. PRM:29 Input Command Offset........................................4-17
4.2.27. PRM:30 Default Velocity..................................................4-18
4.2.28. PRM:31 Jog Value............................................................4-18
4.2.29. PRM:32 In Position Bit......................................................4-19
4.2.30. PRM:33 Dead Band Wait Time ........................................4-19
4.2.31. PRM:34 Thermistor Polarity..............................................4-19
4.2.32. PRM:36 Position Mode......................................................4-20
4.2.33. PRM:37 Estop Action ........................................................4-21
4.2.34. PRM:38,39 Current Offset Adjustment..............................4-21
4.2.35. PRM:40 Registration Input.................................................4-21
4.2.36. PRM:41 Encoder Scale Factor...........................................4-22
4.2.37. PRM:42 I/O Read Time Delay...........................................4-22
4.2.38. PRM:43 Trajectory Type ...................................................4-23
4.2.39. PRM:44 Encoder Fault Enable...........................................4-23
4.2.40. PRM:45 Estop Polarity.......................................................4-23
4.2.41. PRM:46 Send ACK after move completes.........................4-24
4.2.42. PRM:47 In Position Output Polarity .................................4-24
4.2.43. PRM:52 RMS Method ......................................................4-24
4.3. Limit Parameters...............................................................................4-25
4.3.1. PRM:60 Limit Check ........................................................4-25
4.3.2. PRM:61 Limit Type ..........................................................4-25
4.3.3. PRM:62 Home Direction...................................................4-25
4.3.4. PRM:63 Home Type .........................................................4-26
4.3.5. PRM:64 Home Velocity....................................................4-26
4.3.6. PRM:65 Home Ending Offset ...........................................4-26
4.3.7. PRM:66 Home Marker Velocity......................................4-27
4.3.8. PRM:67 Negative Software Limit.....................................4-27
4.3.9. PRM:68 Positive Software Limit.......................................4-27
4.3.10. PRM:69 Deceleration Distance.........................................4-28
4.3.11. PRM:70 +/- Limit Reset Distance .....................................4-28
4.3.12. PRM:71 Check Move Against Software Limits ................4-28
4.3.13. PRM:72 Marker Type ........................................................4-29
4.3.14. PRM:73 Offset to Marker...................................................4-29
4.3.15. PRM:74 Program Execution...............................................4-29
4.3.16. PRM:75 Home Velocity Out..............................................4-30
4.3.17. PRM:76 Marker Polarity....................................................4-30
4.3.18. PRM:77 Output Disable.....................................................4-30
4.4. Communications/Startup Parameters................................................4-31
4.4.1. PRM:90 Baud Rate............................................................4-31
4.4.2. PRM:91 Service Request (SRQ) Character.......................4-31
4.4.3. PRM:92 Displayable Digits...............................................4-31
4.4.4. PRM:94 Unit Address.......................................................4-32
4.4.5. PRM:95 Enable/Disable Daisy Chain - Places in
Remote Mode.....................................................................4-32
4.4.6. PRM:96 Autorun Program on Power-Up..........................4-32
4.4.7. PRM:97 Bootup Program Name .......................................4-33
4.4.8. PRM:98 Status on Power-Up ............................................4-33
4.4.9. PRM:99 External Enable Polarity.....................................4-33
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BA Intellidrive User’s Manual Table of Contents
Version 1.4 Aerotech, Inc. vii
4.4.10. PRM:100 Display Type......................................................4-34
4.4.11. PRM:101 General Fault Output .........................................4-34
4.4.12. PRM:102 Fault Output Polarity .........................................4-34
4.5. Miscellaneous................................................................................... 4-35
4.5.1. PRM:200 Position Scale Factor ........................................4-35
4.5.2. PRM:201 Default Ramp Time ..........................................4-35
4.5.3. PRM:202 Filter Cutoff......................................................4-35
4.5.4. PRM:204 Autotune Distance..............................................4-36
4.5.5. PRM:205 Autotune Velocity Loop Bandwidth..................4-36
4.5.6. PRM:206 Autotune Damping Factor..................................4-37
4.5.7. PRM:207 Start Frequency..................................................4-37
4.5.8. PRM:208 Autotune Sampling Time...................................4-37
4.5.9. PRM:209 Clock/Direction Multiplier ...............................4-38
4.5.10. PRM:210 Acceleration......................................................4-38
CHAPTER 5: REGISTERS..................................................................................... 5-1
5.1. Introduction........................................................................................ 5-1
5.1.1. RG1 Program Bytes Remaining...........................................5-1
5.1.2. RG2 BAI Status....................................................................5-1
5.1.3. RG3 Position Feedback........................................................5-2
5.1.4. RG4 Velocity Feedback .......................................................5-2
5.1.5. RG5 Position Command.......................................................5-2
5.1.6. RG6 Position Error...............................................................5-2
5.1.7. RG7 Current Command........................................................5-2
5.1.8. RG8 Firmware Version........................................................5-2
5.1.9. RG9 Velocity Command......................................................5-3
5.1.10. RG12 A/D Input...................................................................5-3
5.1.11. RG14, RG15 Timers ............................................................5-3
CHAPTER 6: MODE OF OPERATION................................................................ 6-1
6.1. Introduction........................................................................................ 6-1
6.2. Modes of Operation............................................................................ 6-1
6.3. Indexing Mode ................................................................................... 6-1
6.4. Clock and Direction............................................................................ 6-3
CHAPTER 7: TECHNICAL DETAILS.................................................................. 7-1
7.1. Introduction........................................................................................ 7-1
7.2. BAI Control Board Jumper Selections............................................... 7-1
7.3. The I/O Port....................................................................................... 7-2
7.3.1. Restore/Reset Signal ...........................................................7-3
7.3.2. Clock/Direction Inputs Signals.............................................7-3
7.3.3. Estop Input Signal................................................................7-3
7.3.4. Thermistor Input Signal........................................................7-4
7.3.5. Analog Inputs.......................................................................7-4
7.3.6. Opto-Isolated Inputs.............................................................7-4
7.3.7. Opto-Isolated Outputs..........................................................7-5
7.4. Encoder/Limits/Hall Effects Port P3 .................................................. 7-7
7.4.1. Encoder Interface.................................................................7-8
7.4.2. Limits Interface....................................................................7-8
7.4.3. Hall Effect Interface.............................................................7-9
7.5. Servo Amplifier Specifications......................................................... 7-13
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Table of Contents BA Intellidrive User’s Manual
viii Aerotech, Inc. Version 1.4
7.6. AC Input and Motor Wiring.............................................................7-15
7.6.1. Minimizing EMI Interference.............................................7-15
7.6.2. Minimizing 50/60 HZ Line Interference ............................7-17
7.7. BAI Amplifier Dimensions...............................................................7-19
7.7.1. Mounting Procedures for the BAI 10/20/30/50..................7-21
7.7.2. Mounting Procedures for the BAI 75/100..........................7-23
CHAPTER 8: TROUBLESHOOTING...................................................................8-1
8.1. Amplifier Related Problems ...............................................................8-1
APPENDIX A: GLOSSARY OF TERMS................................................................ A-1
APPENDIX B: WARRANTY AND FIELD SERVICE.......................................... B-1
INDEX
∇∇∇
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BA Intellidrive User’s Manual List of Figures
Version 1.4 Aerotech, Inc. ix
LIST OF FIGURES
Figure 1-1. BA-Intellidrive Amplifiers ................................................................. 1-1
Figure 1-2. BAI Indexer/Positioner Mode ............................................................ 1-2
Figure 1-3. Illustration of Local and Remote Mode.............................................. 1-3
Figure 1-4. Teach Mode (using DOS-based COM_BAI)...................................... 1-4
Figure 1-5. Teach Mode (using BAI MMI) .......................................................... 1-5
Figure 1-6. Teach Mode (using a Hand Held Terminal)....................................... 1-5
Figure 1-7. Operating Mode (Clock and Direction).............................................. 1-6
Figure 1-8. BA-Intellidrive Hardware – 10/20/30 A Models................................ 1-7
Figure 1-9. BA-Intellidrive Hardware – 50/75/100 Models................................. 1-7
Figure 1-10. Motor and AC Power Connections – 10/20/30 Models..................... 1-8
Figure 1-11. Motor and AC Power Connections – 50/75/100 Models................... 1-9
Figure 1-12. Fuse and Inrush Limiting – 10/20/30 Models.................................. 1-10
Figure 1-13. AC Input Fusing – 50/75/100 Models .............................................. 1-11
Figure 1-14. 20 – 80V Option............................................................................... 1-12
Figure 1-15. RS232 Daisy Chain .......................................................................... 1-14
Figure 2-1. Physical Setup of the BAI and Aerotech Motors (Application 1)....... 2-3
Figure 2-2. Remote Mode Configuration.............................................................. 2-4
Figure 2-3. Local Mode Configuration ................................................................. 2-4
Figure 2-4. RS-232 Connection ............................................................................2-5
Figure 2-5. BAI Display Window......................................................................... 2-6
Figure 2-6. BAI Resetting Window....................................................................... 2-6
Figure 2-7. Enter Immediate Command Screen.................................................... 2-7
Figure 2-8. DOS Editor Screen............................................................................. 2-7
Figure 2-9. File Operations Screen .......................................................................2-8
Figure 2-10. File and Parameters Transfer Screen.................................................. 2-8
Figure 2-11. File Upload Screen............................................................................. 2-9
Figure 2-12. Other Menu Options Screen............................................................... 2-9
Figure 2-13. Auto Run/Block Run Option Screen................................................. 2-10
Figure 2-14. Enter File Screen.............................................................................. 2-10
Figure 2-15. Main Screen...................................................................................... 2-11
Figure 2-16. Programs Window............................................................................ 2-12
Figure 2-17. Parameters Screen ............................................................................ 2-12
Figure 2-18. MMI Main Screen............................................................................ 2-13
Figure 2-19. MMI Text Editor Window................................................................2-14
Figure 2-20. File Transfer Window (MMI)........................................................... 2-14
Figure 2-21. Main Screen (Run Mode)................................................................. 2-15
Figure 2-22. Display Code (Main Screen) ............................................................ 2-16
Figure 2-23. Parameters Screen (BAI MMI)......................................................... 2-17
Figure 2-24. Motor Profiles Selection (Parameter Screen) ................................... 2-18
Figure 2-25. Axis Scope Window (BAI MMI)..................................................... 2-19
Figure 2-26. Axis Scope Toolbars ........................................................................2-20
Figure 2-27. Cursors Toolbar (Axis Scope Screen).............................................. 2-21
Figure 2-28. Flowchart of Overall Tuning Process............................................... 2-22
Figure 2-29. Maximize Button on the Axis Scope Window..................................2-23
Figure 2-30. Unacceptable Velocity Error............................................................ 2-25
Figure 2-31. Acceptable Velocity Error (When Adjusting Kp) ............................ 2-25
Figure 2-32. Unacceptable Position Error (When Adjusting Ki).......................... 2-26
Figure 2-33. Plot Showing an Appropriate Value for Kpos.................................. 2-27
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