Anilam 4200T CNC User manual

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CNC Motion Setup/Testing Utility
P/N 70000634A - Warranty
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Warranty
ANILAM warrants its products to be free from defects in material and workmanship for one (1)
year from date of installation. At our option, we will repair or replace any defective product upon
prepaid return to our factory.
This warranty applies to all products when used in a normal industrial environment. Any
unauthorized tampering, misuse or neglect will make this warranty null and void.
Under no circumstances will ANILAM, any affiliate, or related company assume any liability for
loss of use or for any direct or consequential damages.
The foregoing warranties are in lieu of all other warranties expressed or implied, including, but
not limited to, the implied warranties of merchantability and fitness for a particular purpose.
The information in this manual has been thoroughly reviewed and is believed to be accurate.
ACU-RITE Companies, Inc. reserves the right to make changes to improve reliability, function or
design without notice. ACU-RITE Companies, Inc. assumes no liability arising out of the
application or use of the product described herein. All rights reserved. Subject to change
without notice.
Copyright 2005 ACU-RITE Companies, Inc.

CNC Motion Setup/Testing Utility
P/N 70000634A - Contents
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Introduction ................................................................................................................... 1
Accessing the MST Utility ............................................................................................ 1
Activating the MST Screen ........................................................................................... 2
MST Soft Keys ............................................................................................................... 3
Clearing a Prompt Field or Message (F1) ........................................................................................... 4
Selecting an Axis................................................................................................................................. 4
Entering a Password ........................................................................................................................... 4
Checking Axis Resolution (F2) ............................................................................................................ 5
Detecting the Index Pulse (F3)............................................................................................................ 6
Canceling the Active MDI or Test Command ...................................................................................... 6
Activating Manual Data Input Mode (MDI)........................................................................................... 6
Balancing Motion Control Axes ........................................................................................................... 7
Servo Amplifier Test Board ................................................................................................................. 7
Test Board Installation..................................................................................................................... 8
Test Points ...................................................................................................................................... 8
Jumpers........................................................................................................................................... 8
Balancing the DSP
2
Board (F6) ........................................................................................................... 9
ANILAM Amplifier Parameter Files.................................................................................................... 11
Balancing Servo Amplifier Outputs (F6) ............................................................................................ 11
Setup Parameter Verification......................................................................................................... 11
Motion Setup and Testing (MST)................................................................................................... 14
Amplifier Faults ................................................................................................................................. 16
Tuning (F8)........................................................................................................................................ 16
Saving Final Values .......................................................................................................................... 19
Miscellaneous Tests (F9) .................................................................................................................. 20
CanTest......................................................................................................................................... 20
Save Amp Settings ........................................................................................................................ 22
Amplifier Test Link ......................................................................................................................... 22
Reset Amplifier .............................................................................................................................. 23
BackUp Amp Settings.................................................................................................................... 23
Restore from BackUp .................................................................................................................... 23
Exiting the MST Screen (F10) ........................................................................................................... 23
Setting Up and Tuning the C Axis.............................................................................. 24
Index ...................................................................................................................................... Index-1

CNC Motion Setup/Testing Utility
P/N 70000634A
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1
Introduction
This section describes how to use the ANILAM Motion Setup/Testing
(MST) Utility. The MST provides commands that carry out motion-specific
setup and testing in order to tune the servo system and the Proportional,
Integral, and Derivative (PID) filter parameters of a CNC.
A basic knowledge of machine operation and programming is required.
Refer to the 4200T CNC Programming and Operations Manual,
P/N 70000412, for details on how to program and operate the control.
Setup includes the following procedures:
Servo Amplifier Balancing
Servo Amplifier Signal Gain Setting (motor step response is displayed
in open loop)
Instructions are provided for amplifier balancing and signal gain setting
when using the ANILAM AC Brushless Digital Servo Amplifiers and
motors. The servo amplifiers provided by ANILAM are completely digital;
parameter settings are done by communicating to the amplifier using the
Servo Amplifier Communications Cable, P/N 33001389, between the
amplifier's J1 connector and the CNC's RS-232 port. The digital amplifier
eliminates the need for adjusting trim pots and provides overall better
performance. Make sure cable is connected when doing any amplifier
adjustments; disconnect cable when done. If using amplifiers not
provided by ANILAM, follow the manufacturer's guidelines for balancing,
signal gain setting, and overall adjustments.
The CNC provides the following troubleshooting tools:
Detection of Index Pulse
Detection of counts between index pulses (actual resolution)
Tuning for the optimal PID values
The following General Status information is displayed:
Display of active CNC status codes
Display of machine position, feedrates, RPM, dwell, and override
Accessing the MST Utility
Access the Motion Setup/Testing Utility (MST) from the Software Options
Screen. This screen activates automatically once the CNC has started
successfully.
To activate the MST Utility:
1. Start the CNC.
2. Press (F10) to continue, as prompted. The Software Options screen
is displayed.
3. Highlight Motion Setup/Testing, and press ENTER. The MST screen
activates.

CNC Motion Setup/Testing Utility
P/N 70000634A
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Activating the MST Screen
The axis positions displayed in Figure 1 correspond to the current
position. The Graphic Area displays step responses for the Signal Gain
and Tuning functions. Refer to Figure 1 and Table 1.
General Status
Graphics Area
Active Status Codes
Prompt Area
Message Area
Soft Keys
4MSTSCRN
Figure 1, CNC Motion Setup/Testing Screen
Table 1, MST Screen Areas
MST Screen Area Description
General Status Shows Active Modes, Machine Position for each axis,
RPM, Dwell, Spindle Speed and Feedrate, Active Axis,
and other information regarding the status of the CNC.
Graphic Area Displays step responses for the Signal Gain and Tuning
functions.
Prompt Area Displays messages regarding information that must be
entered.
Active Status Codes Active G-codes.
Message Area Displays error messages.
Soft Keys Function keys (F1–F10) located below the LCD on the
console used to activate the functions, as labeled.

CNC Motion Setup/Testing Utility
P/N 70000634A
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MST Soft Keys
NOTE: Select an active axis before you select an MST command
(F1–F10).
NOTE: MST soft keys are displayed while the MST screen is active.
Access MST utility features using the labeled soft keys located below the
screen on the console. Press the corresponding soft key (F1–F10) to
activate the function.
Refer to Table 2 for soft key names and functions.
Table 2, MST Soft Key Functions
Soft Key Name Function
F1 ClrFld
Clears prompt field in SigGain and Tuning tests.
F2 ResChk Calculates the resolution of the active axis.
Troubleshooting tool.
F3 IndexP
Detects Index Pulse and displays an indicator over
the Active Axis line of the MST screen.
Troubleshooting tool.
F4 Manual Cancels active MDI or test command.
F5 MDI Activates an MDI prompt.
F6 Balance Sends out the signal needed to Balance the outputs
of the system (0.0 VDC). Used to balance the
Motion Control Board and the Servo Amplifiers.
F7 SigGain Allows you to set the servo amplifier signal gain for
the active axis.
F8 Tuning Activates the Tuning Pop-Up menu, which allows the
CNC to determine optimum PID filter values from the
specified parameters and save the results.
F9 Misc Miscellaneous tests displays a pop-up menu with
options for CanBus Test. For AC motors only
additional options display on the pop-up menu:
Amplifier Test Link, Reset Amplifier, Backup Amp
Settings, and Restore from Backup. These tests can
only be activated with the Servo Amplifier Test Board
installed. See “Servo Amplifier Test Board.”
F10 Exit Returns the CNC to the Software Options screen.
(SHIFT+F4) Home Performs a Homing Sequence on all axes configured
for homing.

CNC Motion Setup/Testing Utility
P/N 70000634A
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Clearing a Prompt Field or Message (F1)
Press ClrFld (F1) to clear an erroneous entry. This soft key is available
during the Signal Gain and Tuning tests.
Selecting an Axis
NOTE: Select an active axis before you select an MST command
(F1–F10). If you do not select an axis, the CNC displays an
Error message that prompts you to select an axis.
Use the following keypad keys to select and activate the corresponding
axes:
X
Activates/Deactivates X-axis
Z
Activates/Deactivates Z-axis
S
or
S
Activates/Deactivates Spindle Axis
The CNC displays the active axis in the upper-left corner of the General
Status area of the MST Screen.
Entering a Password
When you enter the MST Utility and press Balance (F6), SigGain (F7), or
Tuning (F8), the CNC prompts for the password. Type the appropriate
password and press ENTER. Refer to 4200T CNC Setup Utility Manual,
P/N 70000414, “Section 1, Password Restricted Parameters.”
The soft key activates. If you have entered the password successfully,
the CNC will not prompt for the password again, unless you exit and
re-enter the MST Utility.
X
Z
S C

CNC Motion Setup/Testing Utility
P/N 70000634A
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Checking Axis Resolution (F2)
Refer to Figure 2. Press ResChk (F2) to calculate the actual resolution
for the active axis. In the Graphic Area of the screen, the actual
resolution and the resolution in the Setup are displayed for comparison.
In addition the screen displays:
The number of times the system tested for resolution (Total Cycles:)
The number of times the encoder lines detected do not match the
number of encoder lines in the setup (Errors:). An error indicates that
something is wrong, either in the setup parameters or in the hardware.
The actual number of encoder lines found by the test (Encoder Lines:)
The resolution and counts per revolution found. (Encoder
Resolution:)
NOTE: Resolution should be four times the number of encoder lines.
Once this test is activated, you must move the axis for at least two
encoder revolutions via MDI Mode, Jog Mode, or manual move. The
CNC performs the calculation continuously until motion stops.
NOTE: This test is not available for axes with linear encoders.
NOTE: Do not perform this test during Rapid Mode. Use it in Feed
Mode only.
4RESCHK
Figure 2, CNC Resolution Check (ResCheck) Screen

CNC Motion Setup/Testing Utility
P/N 70000634A
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Detecting the Index Pulse (F3)
Refer to Figure 1, CNC Motion Setup/Testing Screen. When you press
IndexP (F3), the CNC displays a flashing “I” each time it detects an Index
Pulse. The flashing “I” replaces the axis name (X, Z, or S) of the active
axis. The index pulse indicator (flashing “I”) for the spindle axis is
displayed on the RPM field. The figure shows the axis display when the
CNC has detected an index pulse in the (active) X-axis. Refer to
Figure 3.
To detect an index pulse:
1. Move the active axis to check for the presence of an index pulse.
2. On systems with rotary encoders with index pulses, the index pulse
should be detected once per revolution.
3. On systems having linear scales, the index pulse should be detected
where the linear scale specifies location of the index pulse.
Index Pulse
Indicato
r
I
Z
Figure 3, Index Pulse Indicator
Canceling the Active MDI or Test Command
Press Manual (F4) to cancel an active MDI or test command.
Activating Manual Data Input Mode (MDI)
Press MDI (F5) to activate the MDI prompt. (Refer to the 4200T CNC
Programming and Operations Manual, P/N 70000412, for information on
MDI programming.)

CNC Motion Setup/Testing Utility
P/N 70000634A
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Balancing Motion Control Axes
To balance the outputs properly, all connections between the CNC and
the servo amplifiers must be complete.
Perform all adjustments on one axis at a time. Make the adjustments in
the following order:
1. Select an axis
2. Balance the Motion Control Board outputs
3. Balance the Servo Amplifier outputs
4. Set Servo Amplifier gain
5. Repeat for all axes
Servo Amplifier Test Board
Each CNC that uses ANILAM AC motors and amplifiers, P/N 33001279,
includes a Servo Amplifier Test Board, P/N 33001399. During machine
operation, the board provides convenient access to critical signals for
alignment and troubleshooting. Refer to Figure 4.
NOTE: The test board works only with amplifiers supplied by ANILAM.
ACTESTBOARD
Figure 4, ANILAM Servo Amplifier Test Board, P/N 33001399

CNC Motion Setup/Testing Utility
P/N 70000634A
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Test Board Installation
IMPORTANT: Press E-STOP to de-energize servos before installing the
test board.
1. Remove the cable attached to J2 of the Servo Amplifier you wish to
monitor and connect it to P1 of the test board.
1. Attach W1 of the test board to J2 of the servo.
2. Re-energize the servos.
Test Points
Refer to Table 3 for a description of test points and signals.
Table 3, Servo Amplifier Test Board: Test Points and Jumpers
Test Point Pin Signal
TP1 1
Command Signal
TP2 3
Common for all servo signals and potentiometers.
All readings are referenced to TP2.
P2-1 4
Motor Current output monitor. The scale factor is
1V = 7.5A.
P2-2 5
Analog Out
P2-3 6
+Limit In
P2-4 7
–Limit In
P2-5 8
Clamp input from the SCB. When pulled to chassis
ground, the servo’s output is forced to 0 VDC.
P2-6 9
Fault output. When the servo card is faulted, the
output is pulled low.
P2-7 3
Common
JMP1 1 Signal. If JMP1 is removed, the Command signal
will open at Pin 1 of J1.
JMP2 3 Common. If removed, JMP2 will open the common
line at Pin 3 of J1.
Jumpers
While troubleshooting, you can remove jumpers to isolate the Servo
Amplifier from the DAC outputs of the Motion Control Board during
troubleshooting. If Pin 2 of JMP1 and JMP2 are shorted together, the
Servo Amplifier’s input is fixed at 0 VDC; this can be useful in
troubleshooting balance problems.

CNC Motion Setup/Testing Utility
P/N 70000634A
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Balancing the DSP
2
Board (F6)
On systems that use an ANILAM Servo Amplifier Board (see Figure 6,
Digital Brushless AC Servo Amplifier, P/N 33001279), measurements for
this procedure can be made at the J2 input connector with the Servo
Amplifier Test Board, (see Figure 4, ANILAM Servo Amplifier Test Board,
P/N 33001399).
NOTE: If ANILAM did not provide the servo amplifiers, follow the
guidelines for balancing supplied by the manufacturer.
Refer to Figure 5, ANILAM DSP2 Board Balance Pots, P/N 33001102.
Measure command voltages across TP1 and TP2 of the test board.
NOTE: These signals can also be found on Pin #1 and Pin #3 of the J2
input connector on the ANILAM Servo Amplifier Board.
All DSP
2
Boards are adjusted at the factory and should be within limits.
Only balance the DSP
2
Board if it is not at 0 VDC (±0.001 V).
NOTE: On 4200T systems, the DSP
2
Board is located inside the CNC
console. Open the CNC chassis by loosening the thumbscrews
and opening the cover. Balance the DSP
2
Board with the
servos off, initially. Next, verify the DSP
2
Board balance with
the servos on, and correct for voltage offset as required.
1. Press Balance (F6) to output a zero voltage signal to the axis.
2. Press
START.
3. Refer to Figure 5, ANILAM DSP2 Board Balance Pots, P/N 33001102.
Make adjustments for axis outputs 0–3 on the DSP
2
Board at
potentiometers R108-R111 respectively.
4. Adjust the potentiometer for the selected axis until the voltage across
the pins is 0 VDC (±0.001 V).
5. Press MANUAL (F4) to cancel the test.
Table 4, Axis Output Port Assignments
Port Axis
0 X
1 C/S
2 Z

CNC Motion Setup/Testing Utility
P/N 70000634A
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33001102
Output Balance Pot
Port 0
Port 1
Port 2
Port 3
Figure 5, ANILAM DSP
2
Board Balance Pots, P/N 33001102

CNC Motion Setup/Testing Utility
P/N 70000634A
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ANILAM Amplifier Parameter Files
If using the ANILAM AC Brushless Servo Amplifier (refer to Figure 6,
Digital Brushless AC Servo Amplifier, P/N 33001279) make sure that the
amplifier's communications cable, P/N 33001389, is connected between
the amplifier J1 and the CNC. All servo amplifier settings are done
digitally through the communications cable and the CNC. Parameter
settings can be sent from the CNC to the amplifier and vice versa. The
parameter settings are saved on the CNC in C:\P4T under the filename
DIGAMP-*.BK (where * corresponds to the specific axes).
It is recommended that after making any amplifier parameter settings that
these settings be saved on the CNC for easy restore, if needed. To save
the parameter settings on the CNC:
1. Select the Axes
2. Press Misc (F9)
3. Select Backup Amp Settings
For later restore of the saved parameter settings from the backup:
1. Select the Axes
2. Press Misc (F9)
3. Select Restore from Backup
Balancing Servo Amplifier Outputs (F6)
Refer to “Servo Amplifier Test Board.”
Use the following procedures for:
•Setup parameter verification
•Motion setup and testing (MST)
Setup Parameter Verification
Refer to Figure 6, Digital Brushless AC Servo Amplifier, P/N 33001279.
1. At the Software Options menu, select Setup Utility.
2. Select Builder Setup.
3. Select General Axis.
4. Select Digital Amplifier Settings.

CNC Motion Setup/Testing Utility
P/N 70000634A
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NOTE: Step 5 values are valid only when you are using ANILAM AC
Brushless Digital Servo Amplifiers. If using amplifiers not
provided by ANILAM, follow the manufacturer's guidelines for
balancing, signal gain setting, and overall adjustments.
5. Verify the following Digital Amplifier Settings menu values as follows
and change as required:
•Balance adjustment (mV): 0.5
•Signal Gain adjustment (%): 0.10
•Compensation adjustment (%): 0.02
6. Select Active digital amplifiers, to display the Active Digital
Amplifiers menu. Press ENTER to toggle to Enable when using
ANILAM AC amplifiers. Toggle to Disable when using any other
amplifier.
IMPORTANT: For ANILAM AC Brushless Digital Servo Amplifiers, set
Active digital amplifiers to ENABLE. If using amplifiers not provided by
ANILAM, set to DISABLED.
7. Press Exit (F10) to exit the Digital Amplifier Setting menu and display
the General Axis Setup Menu.
8. Select Invert DAC Output, and press ENTER to toggle to Yes, if
necessary.
9. Press Exit (F10) until you return to the Software Options startup
screen.

CNC Motion Setup/Testing Utility
P/N 70000634A
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ACU-RITE COMPANIES INC.
+-
J7 J1 J2 J3 TB1
AMPLIFIERAC
Figure 6, Digital Brushless AC Servo Amplifier, P/N 33001279

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Motion Setup and Testing (MST)
1. At the Software Options menu, select Motion Setup/Testing.
2. Press and release the E-STOP button.
3. Press the
SERVO RESET to energize the system.
4. Select an axis to be tested by pressing the corresponding key on the
keypad (X, Z, or S).
5. Press Balance (F6) to perform the balance test on the selected
amplifier (axis) and display the balance test screen. Refer to
Figure 7.
4200BALANCE
Figure 7, Balance Test Screen
6. Use the keypad up and down ARROW keys to change the axis offset
until the selected axis reads: +0000. Use the left and right ARROW
keys to change the Offset value.
7. To cancel the balance test, press MANUAL (F4); otherwise, press
SigGain (F7) to perform the signal gain test for the selected amplifier.

CNC Motion Setup/Testing Utility
P/N 70000634A
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8. Select 2for the time (i.e., 2 seconds). Refer to Figure 8. The
following screen will be displayed:
4200SIGGAIN
Figure 8, Signal Gain Test Screen
IMPORTANT: Steps 9–13 apply only to ANILAM brushless AC
amplifiers. For other amplifiers, refer to the manufactures
guidelines to set the signal gain in the amplifier.
9. Use the keypad up and down ARROW keys to change the signal gain
until FEED: reads: 20.0 or 10% of Rapid.
10. To cancel the signal gain test, press MANUAL (F4); otherwise, press
Misc (F9) to display the Miscellaneous Menu.
11. Select Save Amp Settings to save the amplifier settings to the
amplifier.
12. Press Misc (F9) to display the Miscellaneous Menu
13. Select BackUp Amp Settings to backup the amplifier settings to a file
on the CNC. The backup filename is DIGAMP-*.BK where ‘*’ is the
selected axis name (i.e., X, Z). This file is stored on the hard disk
drive.
14. Repeat steps in “Setup Parameter Verification” and “Motion Setup and
Testing (MST)” for each amplifier axis.

CNC Motion Setup/Testing Utility
P/N 70000634A
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Amplifier Faults
ANILAM amplifiers do not require any scheduled maintenance, although it
is a good idea to occasionally check for dust build up or other
contamination.
If an amplifier should cease to operate or one or more of the fault Light
Emitting Diodes (LEDs) are lit, refer to Table 5.
NOTE: A fault can on be caused by abnormal conditions. Locate and
correct the cause of the fault before repeated recycling of power
to the amplifier to prevent possible damage.
Table 5, Amplifier – LED Indicators
Red Green Condition
Off Off No power
Off On Enabled
On Off Fault
On On Inhibit
Tuning (F8)
NOTE: ANILAM recommends that you set signal gain and balance the
servo amplifier, as discussed in previous text, before tuning.
CAUTION: Most machines will operate correctly with the default
filter parameters. Only qualified technicians who have
knowledge of motion control tuning parameters should
use this tool.
The Tuning function can determine optimum values within constraints you
specify. The default values are usually correct for most machines. To
fine-tune, enter values manually or use this test. Refer to Figure 10,
Tuning Parameters Test Results Screen.
The Tuning Test has a setup screen that enables you to configure the
extent of the test. Check the setup parameters, run the test, and then
save the results. Refer to Figure 9 and Table 6, Tuning Test Parameters.
Tuning Setup
1. Tune Ki ..............
2. Tune Kd .............
3. Tune All Axis ......
4. Match Axis Lag ...
No
No
No
No
Figure 9, Tuning Setup Menu

CNC Motion Setup/Testing Utility
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Table 6, Tuning Test Parameters
Parameter Function
Tune Ki Switches integral tuning ON or OFF. [Default: No]
Tune Kd Switches derivative tuning ON or OFF.
[Default: No]
Tune All Axis If set, tunes all axes sequentially. [Default: No]
Match Axis Lag If set, calculates the inch/min/mil (Imm) of each
axis, chooses the smallest one and matches the
inch/min/mil of the other axes to the smallest by
decreasing Kp. Tune All Axis must be set to use
this option. [Default: No]
If you have selected Kd (derivative gain), the CNC begins by measuring
derivative sampling time (Ds). It measures the time between 10% and
90% of the final velocity (rise time) and divides it by five. A portion of this
time is determined to be the Ds.
WARNING: If you select the Kd test, you must have at least 2.5”
(63 mm) of travel in the positive (+) direction.
Next, the CNC calculates Kp (proportional gain). If the current overshoot
is smaller than the set one, Kp is increased by 1. If it is larger, Kp is
decreased by 0.1.
If you have selected Ki (integral gain), the CNC then calculates Ki and Il
(integral limit). If the lag between the commanded position and the actual
position is not zero, Il is increased by 5 and this portion of the test is
repeated.
The CNC calculates Kd, if selected. The CNC will attempt to decrease
the overshoot until the set value (Kd overshoot) is matched. When this
condition is not matched, Kd is increased by 2.
If you have chosen to test only one axis, the test is completed at this
point. If you have chosen to test multiple axes, and have not selected
“Lag Matching” the test will repeat the procedure on each axis in turn,
until complete.
If you have chosen all axes and Lag Matching, the CNC calculates the
inch/min/mil (Imm) of each axis being tested and matches the
inch/min/mil to the lowest value of all axes tuned.