Leadshine Technology Co. ACS606 User manual

User sManual
For
ACS606
DigitalAC ServoDrive
Revision 1.0
2009All RightsReserved
Attention:Pleaseread thismanual carefullybeforeusingthe drive!
3/F, Block 2, NanyouTiananIndustrialPark, NanshanDist, Shenzhen, China
Tel: [phone] Fax: [phone]
URL: www.leadshine.com E-Mail: [e-mail]
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butnoresponsibilityisassumedforinaccuracies.
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hereintoimprovereliability,functionordesign.Leadshinedoesnotassumeany
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herein;neitherdoesit conveyanylicenseunderitspatentrightsofothers.
Leadshine sgeneralpolicydoesnotrecommendtheuseofitsproductsinlife
supportoraircraftapplicationswhereinafailureormalfunction oftheproductmay
directlythreatenlifeorinjury.AccordingtoLeadshine stermsandconditionsof
sales,theuserofLeadshine sproductsinlifesupportoraircraftapplications
assumesall risksofsuchuseandindemnifiesLeadshineagainstall damages.
©2009byLeadshineTechnologyCompanyLimited.
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Contents
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TableofContents
1. Introduction, FeaturesandApplications...................................................................1
Introduction...........................................................................................................1
Features.................................................................................................................1
Applications..........................................................................................................2
2. SpecificationsandOperating Environment..............................................................2
ElectricalSpecifications........................................................................................2
Performance Specifications...................................................................................2
MechanicalSpecifications.....................................................................................3
EliminationofHeat...............................................................................................3
OperatingEnvironmentandParameters................................................................3
3. Connections..............................................................................................................4
ConnectorConfiguration.......................................................................................4
GeneralInformation.....................................................................................4
MoreaboutI/OSignals................................................................................5
ControlSignalConnections...................................................................................6
EncoderandHall SensorConnections..................................................................7
RS232 Interface Connection..................................................................................8
TypicalConnections..............................................................................................8
4. ServoSetup..............................................................................................................9
Install EncoderandHall sensor...........................................................................10
PreparePowerSupply.........................................................................................10
RegulatedorUnregulatedPowerSupply...................................................10
SelectingSupplyVoltage............................................................................11
PrepareController...............................................................................................11
SystemConnectionsandNoisePrevention.........................................................11
WireGauge.................................................................................................11
CableRouting.............................................................................................12
Contents
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Twisted Wires.............................................................................................12
CableShielding..........................................................................................12
SystemGrounding......................................................................................12
PowerSupplyConnection..........................................................................13
5. TuningtheServo....................................................................................................13
TestingtheServo.................................................................................................13
TuningtheServo.................................................................................................14
6. PCwindowbasedTuningUsingProTuner............................................................16
IntroductiontoProTuner.....................................................................................16
BeforeTuning......................................................................................................16
ProTunerInstallation..................................................................................16
HardwareConfigurationsbeforeTuning....................................................20
ProTunerforACS606 atStartup Window..................................................21
IntroductiontoProTunerfortheACS606..................................................22
CommunicationSetup................................................................................23
SoftwareConfigurationbeforeTuning.......................................................24
CurrentLoopTuning...........................................................................................24
Position LoopTuning..........................................................................................28
Position LoopIntroduction.........................................................................28
Position aroundVelocity............................................................................28
Position aroundTorque...............................................................................28
StarttoTune...............................................................................................29
UploadandDownloadData................................................................................39
DownloadDatatoEEPROM.....................................................................39
UploadtheDatafromEEPROM................................................................39
SaveDataon Harddisk...............................................................................40
DownloadDatatoDevice..........................................................................40
ControlSignalInputMode..................................................................................42
MoreInformaitonaboutProTuner.......................................................................42
T_Speed_Partab........................................................................................42

Contents
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CurveSettingtab.........................................................................................43
DigitalScopeWindow................................................................................44
ErrorCheck Window..................................................................................44
7. UsingTips..............................................................................................................46
ChangePPRbyElectronicGear..........................................................................46
Position following ErrorLimit............................................................................47
SequenceChartofControlSignals......................................................................47
ProtectionFunctions............................................................................................48
Over-currentProtection..............................................................................48
Over-voltageProtection.............................................................................48
PhaseErrorProtection................................................................................48
EncoderorHall ErrorProtection................................................................48
Position FollowingErrorProtection...........................................................48
ProtectionIndications.................................................................................49
MaximumPulseInputFrequency.......................................................................49
8. Accessories.............................................................................................................50
ACS606 AccessoriesandConnections................................................................50
MoreInformationaboutACS606 Accessories....................................................51
APPENDIX................................................................................................................55
TWELVEMONTHLIMITEDWARRANTY....................................................55
EXCLUSIONS....................................................................................................55
OBTAINING WARRANTYSERVICE..............................................................55
WARRANTYLIMITATIONS.............................................................................55
SHIPPING FAILEDPRODUCT.........................................................................56
ContactUs..................................................................................................................57
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1. Introduction, Features and Applications
Introduction
Leadshine'sfullydigitalACservodriveACS606 isdevelopedwith32-bit DSP
basedonadvancedcontrolalgorithm.SinceitsinputcommandsarePUL/DIR
signals,theuserscanupgradesteppingdrivestotheACS606 withoutchanging
controlsystems.TheACS606 canofferhighprecision,highspeedand high
reliabilityperformance,andwidelyusedininkjetprinters,engravingmachines,and
etc.Abuilt-incontrollercanbeusedfortestingandtuning.PCbasedandhandheld
configuration&tuningtoolscanmeetdifferenttuningenvironmentsorrequirements.
TheACS606 candrivebothDCbrushless and ACservomotors.Butit ismore
suitablefortheDCbrushless servomotors.ComparetoACS806, ACS606 hasless
I/Othushassmallersizeand highercost-effective
Features
lInput: 18 -60VDC,
lPeakCurrent: 15A, ContinuousCurrent: 6 A(Max), 10 -200 W
lFOC-SVPWMtechnologies
lPCbasedandhandheldconfigurationtools
lElectronicgearratefrom1/255 to255
lSelf-testfunction withtrapezoidalvelocityprofile
lSupportPUL/DIRandCW/CCWcontrolsignals
lOpto-isolated, supportsingle-endedanddifferentialinputs
lFollowingerrorlockrangeadjustable
lOver-voltage,over-current, encoderfailureprotections
l10 latestfailuresself-recordfunction
lSmall size, surface-mounttechnology

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Applications
Suitableforlargeandmediumautomationmachinesandequipments,suchasinkjet
printers,engravingmachines,electronicmanufacturingequipments,specialNC
machines,pickandplacedevices,packingdevices, andso on. Particularlyadapttothe
applicationsrequirehighspeed,highprecision, andlowmotornoise.
2. Specifications andOperatingEnvironment
ElectricalSpecifications(Tj =25 /77℉)
ACS606
Parameters Min. Typical Max. Unit
Peakoutputcurrent 0 - 15 A
Continueoutputcurrent 0 - 6 A
Supplyvoltage +18 - +60 VDC
Logicsignalcurrent 7 10 16 mA
Pulseinputfrequency 0 - 200 kHz
Isolationresistance 500 MΩ
Currentprovidedtoencoder - - 100 mA
PerformanceSpecifications(withBLMSeriesMotors)
lPosition following error:+/-1 count
lVelocityaccuracy:+/-2rpm
lMaximumacceleration speed(NoLoad):80 rpm/ms2
lMaximumspeed:3000 rpm
lAllowablelowspeedreaches1 rpm
lPositioningaccuracy:+/-1 count
lSuitablefor18 -60 VDCAC/DCservomotors
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MechanicalSpecifications (unit:mm[inch])
Figure1:Mechanicalspecifications
EliminationofHeat
lDrive sreliableworkingtemperatureshouldbe<70 [158 ],and motor
workingtemperatureshouldbe<80 [176 ].
lItisrecommendedtomountthedriveverticallytomaximizeheatsinkarea.
OperatingEnvironmentand Parameters
Cooling Natural coolingorForcedcooling
Environment Avoiddust, oil fog andcorrosivegases
AmbientTemperature 0－50 (32 －122 )
Humidity 40%RH－90%RH
OperatingEnvironment
Vibration 5.9m/s2 Max
StorageTemperature -20 －65 (-4 －149 )
Weight Approx. 280g(9.87oz)

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3. Connections
ConnectorConfiguration
GeneralInformation
FeedbackSignalConnector
Pin Signal Description I/O
1 EA+ EncoderchannelA+input I
2 EB+ EncoderchannelB+ input I
3 EGD Signalground GND
4 HW HallsensorWinput I
5 HU HallsensorU input I
6 FG Ground terminalforshielded GND
7 EZ+ Reserve I
8 EZ- Reserve I
9 HV HallsensorVinput I
10 NC Not Connected -
11 EA- EncoderchannelA-input I
12 EB- EncoderchannelB-input I
13 VCC +5V@100mAmax. O
14 NC Not Connected -
15 NC Not Connected -
Control SignalConnector
Pin Signal Description I/O
1 PUL+ Pulsesignalinput+ I
2 PUL- Pulsesignalinput- I
3 DIR+ Directionsignal input+ I
4 DIR- Directionsignal input- I
5 ENA+ Enablesignalinput + I
6 ENA- Enablesignalinput - I
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RS232 CommunicationConnector
Pin Signal Description I/O
1 NC Not connected -
2 +5V +5VpoweronlyforSTU. O
3 TxD RS232transmit. O
4 GND Ground. GND
5 RxD RS232receive. I
6 NC Not connected -
HighVoltageConnector
Pin Signal Description I/O
1 U MotorphaseU O
2 V MotorphaseV O
3 W MotorphaseW O
4 +Vdc DCpowerInput(18-60VDC) I
5 GND PowerGround. GND
MoreaboutI/O Signals
Signal Description
PUL+/PUL-
Pulseinputsignal.Insinglepulse(pulse/direction)mode,thisinputrepresents
pulsesignal,eachrisingorfallingedgeactive(softwareconfigurable);4-5Vwhen
PUL-HIGH,0-0.5VwhenPUL-LOW.Indoublepulsemode(pulse/pulse),this
inputrepresentsclockwise(CW)pulse，activeatbothhigh levelandlow level . For
reliableresponse,pulsewidthshouldbelongerthan0.85μs.Seriesconnect
resistorsforcurrent-limitingwhen+12Vor+24Vused. ThesameasDIRandENA
signals.
DIR+/DIR-
Directionsinputsignal.Insingle-pulsemode,thissignalhaslow/highvoltage
levels,representingtwodirectionsofmotorrotation;indouble-pulsemode
(softwareconfigurable),thissignaliscounter-clock(CCW)pulse，activeatboth
highlevel andlowlevel.Forreliablemotionresponse,DIRsignal shouldbeahead
ofPULsignalby5μsatleast.4-5VwhenDIR-HIGH, 0-0.5VwhenDIR-LOW.
ENA+/ENA-
Enableinputsignal. Thissignalusedforenabling/disablingthedrive.Highlevel
forenablingthedriveand lowlevelfordisablingthedrive.Usuallyleft
UNCONNECTED (ENABLED).

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ControlSignalConnections
TheACS606 has3differentiallogicinputstoacceptEnable,PulseandDirection
controlsignals.Theseinputsareisolatedtominimizeoreliminateelectricalnoises
coupledontothecontrolsignals.Recommendusetwistedwiresandshieldingcable
forcontrolsignalstoincreasenoiseimmunityininterferenceenvironments.Keep
thesewiresfarawayfromthepowerlines.Infigure2, inputcircuit forthesecontrol
signalsandconnectionstoatypicalmotioncontrollerisillustrated.Figure3
illustratesconnectionstothecontrollerwithcommon-anodeoutputs.
Figure2:Connectionstocontrollerwithdifferential outputs
Figure3: connectionstocontrollerwithCommon-Anodeoutputs
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Encoderand Hall SensorConnections
TheACS606 canacceptbothincrementalencoderandhall effectsensorinputsfor
motorshaftpositionfeedbacks. Notethattwisted-pairshieldedcablingprovidesthe
bestimmunityinelectricallynoisyenvironments.
TheACS606 hasthe+5Vpowertosupplytheencoder&hall sensor.If theencoder
and hall sensordrainsless than100mA,theACS606 cansupplythemdirectly,and
connectitasFigure7. Iftheencoderdrainsmorethan50mA,useanexternalDC
supplyandconnectit asFigure8.
Figure7:TheACS606suppliestheencoderdirectly
Figure8:Usingexternal DCpowersupplytosupplytheencoder

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RS232 Interface Connection
Figure9:RS232interfaceconnection
TypicalConnections
AtypicalconnectionoftheACS606 isshownasFigure10. Pleaseconsult “Control
SignalConnections”and “EncoderandHall SensorConnections”formore
informationaboutcontrollerandencoderconnections.
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Figure10:Typical connectionoftheACS606
4. ServoSetup
Beforeyoustarttheservo,youcanfollowthebelowsteps.

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InstallEncoderand Hall sensor
EncoderandHall sensorprovideinformation ofthemotorshaftpositionand rotor
magneticfieldorientation.TheoutputsignalsfromtheHall sensorhaveabsolute
phaseinformationwhichisusedatmotorstartup.If yourmotorhasno encoderand
hall sensor,youmusthaveanencoder(morethan200 lines)and hall sensorproperly
mountedonthemotorbeforeyoustart.
Therearesomemoduleswhichcanoutputsignalsbothforencoderandhall sensor.
Pleaseassembletheselectedmoduleaccordingtoitsfactorymanual.Leadshinealso
offerBLMseriesDCbrushless servomotorsformatchingtheACS606. Pleaseuse
shieldedcablesand separateencodersignalcablefrominterferencesources,suchas
motorwiresandpowerwiresatleast5 cm.
PreparePowerSupply
RegulatedorUnregulatedPower Supply
BothregulatedandunregulatedpowersuppliescanbeusedtosupplytheDrive.
However,unregulatedpowersuppliesarepreferredduetotheirabilitytowithstand
currentsurge.Ifregulatedpowersupplies(suchasmostswitchingsupplies.)are
indeedused,it isimportanttohavelargecurrentoutputrating toavoidproblemslike
currentclamp,forexampleusing4Asupplyfor3Amotor-driveoperation.Onthe
otherhand,ifunregulatedsupplyisused,onemayuseapowersupplyoflower
currentratingthanthatofmotor(typically50%～70%ofmotorcurrent).Thereason
isthattheDrivedrawscurrentfromthepowersupplycapacitoroftheunregulated
supplyonlyduring theON durationofthePWMcycle,butnotduringtheOFF
duration.Therefore,theaveragecurrentwithdrawnfrompowersupplyis
considerablylessthanmotorcurrent.Forexample,two3Amotorscanbewell
suppliedbyonepowersupplyof4Arating.
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Selecting Supply Voltage
TheACS606 canactuallyoperatewithin+18 ~+60VDC,includingpowerinput
fluctuation andbackEMFvoltagegeneratedbymotorcoilsduringmotorshaft
deceleration.Theratedvoltageofthemotorisanimportantparameterwhenselecting
supplyvoltage.Generallyspeaking,donotuseapowersupplyvoltagemorethan5
voltsoftheratedvoltageofthemotor.Highervoltagemaycausebiggermotor
vibrationatlowerspeed,anditmayalsocauseover-voltageprotectionorevendrive
damage.
PrepareController
Prepareacontrollerwithpulseanddirection signals.However,theACS606 hasa
built-inmotioncontrollerforself-testandServoTuning.Thebuilt-inmotioncontroller
cangeneratecontrolsignalwithtrapezoidalvelocityprofile.
SystemConnectionsand NoisePrevention
Afterfinishingtheabovesteps,youcanconnectyourservosystem.Beforeyoustart,
makesurethatthepowerisoff.Connectyoursystemaccording toprevious
connectiondiagrams, andpayattentiontothefollowingtipswhenwiring.
Wire Gauge
Thesmallerwirediameter(lowergauge),thehigherimpedance.Higherimpedance
wirewill broadcastmorenoisethanlowerimpedance wire.Therefore,whenselecting
thewiregauge,it ispreferabletoselectlowergauge(i.e.largerdiameter) wire.This
recommendationbecomesmorecriticalasthecablelengthincreases. Usethefollowing
tabletoselecttheappropriatewiresizetouseinyourapplication.
Current(A) Minimumwiresize(AWG)
10 #20
15 #18
20 #16

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CableRouting
All contentsensitivesignalwiresshouldberoutedasfarawayfrommotorpower
wiresand Drivepowerwiresaspossible.MotorpowerandDrivepowerwiresare
majorsourcesofnoiseandcaneasilycorruptanearby signal.Thisissuebecomes
increasinglyimportantwithlongermotorpowerandDrivepowerwireslengths.
TwistedWires
Twistedwireseffectivelyincreasenoiseimmunity.Thesuccessivetwistseliminate
noisetransientsalongthelengthofthecable.Bothsignalcablesand powercables
shouldbeofthetwistedand shieldedtype.Differentialsignalwiresshouldbetwisted
asapair.Thecombinationoftwistedpairwiresandadifferentialsignalsignificantly
addstonoiseimmunity.Powerwiresshouldbetwistedasagroupalongwiththe
ground(orchassis)wire, ifavailable.
CableShielding
All signalwiresshouldbebundledand shieldedseparatelyfromDrivepowerand
motorpowerwires.Powerwiresshouldalsobebundledandshielded.When
groundingashield,therule-of-thumbistodosoatthe ‘source ofpowerwhile
leavingtheothershieldendopen.Forexample,inthecaseofmotorpowerwires,this
wouldbethedriveside.Ideally,twistedpairsshouldbeindividuallyshieldedand
isolatedfromtheoutershield,whichencompassesall wireswithinthecable. However,
sincethistypeofstringentshieldingpracticeisoftennotrequired,typicalcablesdo
notprovideisolationbetweeninnerandoutershields.
SystemGrounding
Goodgroundingpracticeshelpreduce themajorityofnoisepresentinasystem.All
common groundswithinanisolatedsystemshouldbetiedtoPE(protectiveearth)
througha ‘SINGLE lowresistancepoint.AvoidingrepetitivelinkstoPEcreating
groundloops,which isafrequentsource ofnoise.Centralpointgrounding should also
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beappliedtocableshielding;shieldsshouldbeopenononeendandgroundedonthe
other.Closeattentionshouldalsobegiventochassiswires.Forexample,motorsare
typicallysuppliedwithachassiswire.IfthischassiswireisconnectedtoPE,butthe
motorchassisitselfisattachedtothemachineframe,whichisalsoconnectedtoPE,a
groundloopwill becreated. Wiresusedforgrounding shouldbeofaheavygaugeand
asshortaspossible.Unusedwiringshouldalsobegroundedwhensafetodososince
wiresleftfloatingcanactaslargeantennas, whichcontributetoEMI.
Power Supply Connection
NEVER connectpowerandgroundinthewrongdirection,becauseit will damage
theACS606 drive.Thedistance betweentheDCpowersupplyofthedriveand the
driveitselfshouldbeasshortaspossiblesincethecablebetweenthetwoisasource
ofnoise.Whenthepowersupplylinesarelongerthan50 cm,a1000µF/100V
electrolyticcapacitorshouldbeconnectedbetweentheterminal “GND”and the
terminal “+VDC”.Thiscapacitorstabilizesthevoltagesuppliedtothedriveaswell
asfiltersnoiseonthepowersupplyline. Pleasenotethatthepolaritycannotbe
reversed.
Itisrecommended tohavemultipledrivestoshareonepowersupplytoreduce costif
thesupplyhasenoughcapacity.Toavoidcross interference, DONOT daisy-chain
thepowersupplyinputpinsofthedrives.Instead,pleaseconnectthemtopower
supplyseparately.
5.TuningtheServo
TestingtheServo
You maywishtosecurethemotorsoit can tjumpoffthebench.Turnonthepower
supply,thegreen(Power) LEDwilllight.TheACS606 hasdefaultparametersstored
inthedrive.Ifthesystemhasnohardwareandwiringsproblem,themotorshouldbe
lockedandthedriveshouldbeready.

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If themotorjumpsslightlyandtheredLEDimmediatelyturnson(flickers),then
eitherthemotorortheencoderiswiredinreversal.Openthetuningsoftware
ProTunerand checkdrivestatusbyclicking Err_check.Ifit s PhaseError,then
exchangemotorwiresorencoderinputsandtryagain.If it s EncoderError,please
checkencoderanditswirings,andthentryagain.Ifit still doesn tworkafteryou
followedall oftheprevioussteps,pleasecontactusat [e-mail].
If theredLEDisoff andthemotorisnormal,thenyou canstarttotunetheservo
withselectedtool.PCbasedtuningsoftware ProTuner andhandheldsmall servo
tuningunit STU areavailablefortheACS606.
TuningtheServo
Aservosystemiserror-driven.The “Gain”ofthesystemdetermineshowhardthe
servotriestoreducetheerror.Ahigh-gainsystemcanproducelargecorrecting
torqueswhentheerrorisverysmall.Ahighgainisrequirediftheoutputisrequired
tofollowtheinputfaithfullywithminimalerror.
Aservomotoranditsloadbothhaveinertia,whichtheservoamplifiermust
accelerateanddeceleratewhileattempting tofollowachangeattheinput.The
presence oftheinertiawill tendtoresultinover-correction,withthesystem
oscillatingbeyondeithersideofitstarget.It scalledUNDERDAMPEDstatus.See
Figure11. Thisoscillationmustbedamped,buttoo muchdampingwill causethe
responsetobesluggish,namelycausethesystemtogetintoanOVERDAMPED
state. Whenwetuneaservo,wearetryingtoachievethefastestresponsewith littleor
noovershoot,namelygetaCRITICALLYDAMPEDresponse.
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Figure11:Stepandimpulseresponses
Asmentionedinpreviouscontents,theACS606 isadigitalservodriveanditsinput
commandisPUL/DIRsignal.Inotherwords,stepresponsejustexistsineachstep
commandsignal.Foreachstepcommand signalisaverysmall movement,so
OVERSHOOTandSETTLING TIMEbetweeneachstepareverysmall,causing
youhardlycansee astepresponsesuchasFigure11, eveniftheSETPOINTisa
verylargequantityandtheaccelerationisveryhigh.
However,ifyoutrytoevaluateperformancesofthedigitalservobyinvestigatingits
positiontracking-errororpositionfollowingerror,youmayfindit smucheasier
thaninvestigatingitsstepresponse.Theeasiestwaytogetatracking-erroror
positionfollowingerrorresponseistoinduce animpulseloadonthemotor.See
Figure11 at “time20”.
LeadshineoffersaWindowsbasedsetupsoftware ProTuner toitscustomersfor
evaluatingservoperformances.Small servotuningunit STU (optional)isavailable
too, andit sforfieldtuningwithoutPC.
TuningservosystemsformedbytheACS606 canbesummarizedasthefollowing
rules:

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1. If servosystemisUNSTABLE,thenthefirstthingoftuningistostabilize
thesystem.Youcanincrease DerivativeGain of PositionLoop (Kd)or
decrease ProportionalGain ofPositionLoop(Kp)or IntegralGain of
Position Loop(Ki).
2. If servosystemisUNDERDAMPED,thenincreaseKdordecreaseKpor
Ki.
3. If servo systemisCRITICALLYDAMPED,thenstoptuningand
downloadtheparametersettingstotheDrive sEEPROM.
4. If servo systemisOVERDAMPED,thendecreaseKdorincreaseKpor
Ki.
6. PCwindowbasedTuningUsingProTuner
IntroductiontoProTuner
Asaprofessionaltuningtool,ProTunerhasbeendevelopedspeciallyforall
Leadshinedigitaldrives.Itcanbealsousedtoconfiguretheservodriveformany
settingssuchascontrolsignalmodes,numberofmotorpoles,positionfollowing
errorlimit,default movedirection,andetc.ThemostimportantfeatureisProTuner
offersthenumericmethodfortuning position-loop parameters(Kp,Kd,Ki)and
giveavisualization result synchronouslyforuserstoevaluatetheperformance ofthe
system.
Before Tuning
ProTuner Installation
TheProTuneriswindowsbasedsetupsoftwarefortuningLeadshine sdigitaldrives.
Itcanruninwindowssystems,includingWin95/Win98/WindowsNT/Windows2000
/WindowsXP.AndtheselectedPCshouldhave1serialportatleastfor
communicatingwiththedrive.
Doubleclick “ProTuner_All_Setup_V1.0.exe”tobegininstallingthe ProTuner. See
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Figure12. Click Next toenterthe “LicenseAgreement”window. See Figure13.
Figure12:Begintoinstall theProTuner
Figure13:Licenseagreement
Choose “Iagree tothetermsofthislicenseagreement”and click Next tocontinue
installation.Theusercanenteruser sinformationinthefollowingwindow.See
Note:ProTuner_All_Setup_V1.0.exe canbeusedforallLeadshinedigitaldrives.Usercan
getitfromeitherLeadshineCDorwebsite.Pleasegetthelatestversionfrom
http://www.leadshine.com.

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Figure14. Afterenteringtheuser sinformation,click Next toselectinstallationfolder,
whereyou wouldliketoinstall the ProTuner. See Figure15.
Figure14:User sinformationsettings
Figure15:Installationfoldersettings
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Figure16:Shortcutfoldersetting
Setthe “ShortcutFolder”inFigure16andcontinuetoinstallthe ProTuner by
followingFigure17 andFigure18. An InstallationSuccessful windowwill appearif
the ProTuner isinstalledsuccessfully. See Figure19.
Figure17:Installationinformationsummarization

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Figure18:InstallingtheProTuner
Figure19:Finishinstallation
Note: Leadshinealsooffersspecialversion ProTunerwhichdoesnotneedinstallation. Pleasevisit
ourwebsite www.leadshine.com forlatestProTuner.
Hardware Configurationsbefore Tuning
ProTunerusesPCRS232 portto communicatewith theACS606. TheACS606 hasa
RJ-11connectorinwhichaspecialRS232 cableisconnectedtoPCRS232 port.
BeforeopeningProTunertotunetheACS606, thefollowing configurationmustbe
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achievedasfigure20.
1. Apowersupplywhichhassufficientoutputcurrentatrelatedvoltage;
2. DCbrushless servoorACservomotor（powerrange:10 –200W）with
encoderandhall sensorfeedback.
3. DesktoporlaptopwithoneRS232 communicationportatleastoraUSB
toRS232 adapter. RecommendusingDesktopwithRS232 port.
4. AspecialRS232 cableofferedbyLeadshineinwhichoneendisaRJ-11
connectorandtheotherendisaDB9 connector.
Figure20:ConfigurationandconnectionsbeforeTuning
Note:
1. If it isthefirstinstallation,stronglyrecommendedthattunetheACS606
and servomotorwithoutmotorshaftcouplingtoanyload.Afterbasic
valuesoftheparametersareachieved,connectthemotortotheloadfor
furthertuning.Thesebasicparameterscanalsobeusedforotherdrives
withthesameservomotors.
2. Pleasedoublechecktheconnectionsandmakesurethemotorwouldnot
jumpoffbeforepoweringonthedriveifstartatahighacceleration.
3. InordertosetupcommunicationbetweenthedriveandProTuner,the
ACS606 shouldbepowered.
ProTuner forACS606atStartupWindow
PowerontheACS606. ThegreenLEDindicatorshouldbeon andthemotorshaft
shouldbelockediftheservosystemisOK.Pleaserefertothe protectionfunctions

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tochecktheerrorsifredLEDindicatorblinks.
Open ProTuner andthestartup windowappearsasfigure21. FortheACS606,
pleaseselectthe ACS606 inACServo tab thenclickOK button.
Figure21:Startup WindowofProTuner
Introductionto ProTuner fortheACS606
1. MainWindow
Many oftheLeadshineproductshavesimilaruserinterfaceslikefigure22.
Figure22:MainwindowofProTunerfortheACS606
DriveSelect
StatusBar
MainMenu
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2. Menu BarandSubmenu
Figure23:ProTunermenuforACS606
CommunicationSetup
Select Option->ComConfig,adialoguewindowforsetting theRS232
communicationparameterswouldappearasfigure24. Selectacorrectport
according totheactualportused.Clickthe ‘Open buttontoestablish
communicationbetweentheACS606 andProTuner.Thecaptionofthebutton
shouldchangeto ‘Close ifcommunicationhasbeensuccessfullyestablished.Click
thisbuttonagaintoreleasethecommunication.
Figure24:Establishandreleaseserialcommunication
CommunicationSetupCommunicationRelease

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Software Configurationbefore Tuning
Someparametersmustbeconfiguredbeforetuningthedriveandthemotor.Select
Tuning->PositionLoop toopentheposition-loopwindow.Settheparameters
according tothedescriptioninfigure25.
Figure25:SoftwareconfigurationbeforeTuning
CurrentLoopTuning
FormostoftheACS606 driveswhichareshippedwithLeadshine sBLMseries
servomotors, Leadshinewill tunethecurrentloop beforesendingthemtocustomers.
CurrentLoop tuningisareservedfunction,andwhenopeningthecurrenttuning
SettheEncoderLinesaccordingtoencoderspecification.The
inputnumbershouldbe4timesoftheactualencoder
lines/resolutionsince theACS606 decodestheencodersignalsin
X4mode.(Ie.4000for1000linesEncoder)
Setnumberofpolepairsoftheservo motoraccording
tomotormanual(ForLeadshineBLMseriesDC
brushlessservo motor,it is2;ForLeadshineACM
seriesACservo motor, itis4.)
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windowbyselecting Tuning->CurrentLoop, apasswordinputwindowwill appear.
Leadshinejustofferspasswordtosomecustomersfortuningcurrentloop,
whilemostofcustomersjustneedtotunethepositionloopparametersiftheyuse
thedriveswithLeadshine sBLMseriesservomotors.If youusetheACS606 with
servomotorsfromothermanufacturers,thecurrentlooptuningmaybeneeded.
Pleasecontact [e-mail] forthepasswordtotunethecurrentloop.
Figure26Current-looptuningwindow（Kp=10000）
Tostartthecurrent-looptuning, pleaseenteratargetvalueintheI-testfield(unit: A).
Thentakethefollowingstepstogetoptimalstepresponse.
1. GiveKpavalueandsetKi0. Clickthe ‘Start buttonandobservethegreen
curveinthewindow.
2. If theresponseisanover-dampedresponseasshowninfigure26, increaseKp
until getanunder-dampedresponseasfigure27.
3. Ifgetalargeovershootresponseasshowninfigure28,decreaseKptogeta
smallerovershootresponseasfigure27.
Target Curve
ActualCurve
Proportional Gain
(0~65535) Integral Gain (0~65535) Command Value (0~6)
Clicktostart test

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4. Aftergettingasmall overshootresponse,increaseKitoreduce thesteady-state
erroruntil getacriticallydampedresponse. Seefigure29.
Figure27:StepresponsewithbetterKpofcurrent-loop(Kp=17000)
Figure28:ResponsewithHighKpofcurrent-loop(Kp= 24000)
BegintoOvershoot
LargeOvershoot
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Figure29:StepresponsewithbetterKpandKi of
current-loop(Kp=17000,Ki=400)
5. AtthatmomentKpand Kiofthecurrentloopisnearlyoptimum.Toreduce the
raisetimepleaseincreaseKp,andincreaseKitoreduce thesteady-stateerror.You
canusethemousetodragarectangleto zoominthecurseformoredetail. Clickany
place ofthewindowtozoomout. Seefigure30.
Figure30:Dragarectangletozoomin

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PositionLoopTuning
PositionLoopIntroduction
Position looptuningisdependantonthemechanicalload,andthereforewill change
withanymechanicalsystemchanges.Positionlooptuningshouldbeperformedwith
themotorinstalledinthesystem.Thepositionloopcanbeclosedaroundvelocityor
torquemode(depending on whetherthevelocityloop isenabledordisabled).Ifit is
closedaroundvelocitymode,thepositionloopalgorithmoutputbecomesthenew
velocitysetpoint.Ifitisclosedaroundtorquemode,thepositionloopalgorithm
outputbecomesthenewtorquesetpoint.Therearesomeimportantdifferencesinthe
tuningprocess andapplicationofthesetwoapproaches.
Positionaround Velocity: Thismodeismostcommonin"contouring"application,
whereapositiontrajectorymustbetrackedveryclosely.Thevelocityloopprovides
additional"stiffness", andkeepsthedynamicpositionerrorsminimal,sincethe
systemnowreactstonotjustpositionerrors,butalsovelocityerrors(whichcanbe
interpretedaspositionerrorchanges).Itisimportanttostartwithastableyet
responsivevelocityloop.Typically,itissufficienttojustusethepositionloop
proportionalgain.Feedforwardgaincanbeaddedtoimprovetrackingperformance
(i.e.minimizethedifference betweencommandedandactualposition).Thevelocity
loopisdisabledincurrentversionACS606, and it adopts Positionaround Current
(Torque)mode.
Positionaround Torque: Thismodeismostcommoninpoint-to-pointapplications,
whereactualmotionbetweenstartand endpointisnotverycritical.Inthiscase,
velocityloop tuningcanbeavoided.Thiscanbeadvantageousifthevelocity
feedbackispoor(e.g.lowresolutionencoder,poorencoderquadrature.). Inthiscase,
thetuningprocess requiresthatthepositionloopproportionalandderivative
gainare increasedsimultaneously, unless thesystemhassufficientfriction,in
whichcasenoderivativegainisnecessary. Once astableresponseisachieved,
integralgaincanbeaddedtoimprovestiffness. Itisbesttouseastepcommand
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withtheprofilerenabledasareferencesignalduringtuning.
Drivetuningisamulti-stepprocess thatinvolvespropertuningofuptothree different
servoloops,namelycurrentloop,velocityloopandpositionloop.You caneithertune
thepositionlooparoundthevelocityloop,oraroundthecurrentloop.Generally,it is
mucheasiertotuneaposition looparoundavelocityloop becauseonlythe
proportionalgainisneeded.Whentuningpositionaroundthecurrentloop,ahigh
derivativegainmaybenecessaryontopofbothproportionalandintegralgains.
Startto Tune
Settheparametersand selectthecurvesdisplayedin DigitalMonitor before
starting self-testandtuning.SeeFigure31 and Figure32 fortheparametersforthe
tuninginthispaper.Whenwetuneaservo,wearetryingtoachievethefastest
responsewithlittleornoovershoot,namelygetaCriticallyDampedresponse.
Figure31:Self-test motion settingsforthetuning

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Figure32:DigitalScopesettingsforthetuning
Asmentionedabove, theACS606 adoptspositionaroundcurrent(torque)mode, and
whentuningpositionaroundthecurrentloop,ahighderivativegainmaybe
necessaryontopofbothproportionalandintegralgains.Here,wesetKp=2000,
Ki=0, Kd=1000 first,and theself-testresult isshowninFigure33.
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Figure33:Positionfollowingerrorcurveandvelocitycurve(Kp=2000,Ki=0andKd=1000)
It sveryeasytoseefromthevelocitycurve(Greenline)thatthesystemisunder
damped.Thiswillcausesystemoscillatingbeyondeithersideofitstarget, soit must
bedamped.Figure26 showstheresult afterincreasing Kdto3500. IntheFigure34,
theoscillationismuchsmallerthanthatofFigure33. You cangetevensmaller
oscillationwhenincreasingKdto7000. See Figure35.

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Figure34:Positionfollowingerrorcurveandvelocitycurve(Kp=2000,Ki=0andKd=3500)
Figure35:Positionfollowingerrorcurveandvelocitycurve(Kp=2000,Ki=0andKd=7000)
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AlthoughasmoothvelocitycurvehavebeengotteninFigure35, wecansee thatthe
positionfollowingerrorisstill too largetoaccept.And thiscanbeimprovedby
increasingKivalue.SeeFigure36. However,wecansee thesystemresponsein
Figure35 isalready OverDamped,namelytoomuchdampinghascausedthe
responsetobesluggish.ThiscanbeimprovedbyincreasingKporreducingKd.See
Figure37 andFigure38. HerewetrytoimprovetheperformancesbyincreasingKp.
Figure36:Positionfollowingerrorcurveandvelocitycurve(Kp=2000,Ki=500andKd=7000)

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Figure37:Positionfollowingerrorcurveandvelocitycurve(Kp=4000,Ki=500andKd=7000)
Figure38:Positionfollowingerrorcurveandvelocitycurve(Kp=6000,Ki=500andKd=7000)
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IncreaseKdcanreduce velocityovershoot,andgetabettervelocitycurveinas
showninFigure39.
Figure39:Positionfollowingerrorcurveandvelocitycurve(Kp=6000,Ki=500andKd=8500)
Since positionfollowingerrorisstill largeduring constantspeedperiod inFigure39,
wetrytoincreaseKitoimprovesystem sperformances.Figure40, Figure41, and
Figure42 showtheresult afterincreasingKi.FromFigure42, wecansee thattoo
muchKiwill causepositioncurveovershoot.