Leadshine Technology ACS806 User manual

User sManual
For
ACS806
DigitalAC ServoDrive
Revision 1.0
2009All RightsReserved
Attention:Pleaseread thismanual carefullybeforeusingthe drive!
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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................................................................................6
ENA, PUL, DIRInputCircuitsand Connections..................................................7
RL, FLInputCircuitsandConnections.................................................................8
Pend,ALMOutputCircuitsandConnections.......................................................9
A+,A-, B+, B-, Z+, Z-OutputCircuit..................................................................9
EncoderandHall SensorConnections................................................................10
RS232 Interface Connection................................................................................11
TypicalConnections............................................................................................11
4. ServoSetup............................................................................................................13
Install EncoderandHall sensor...........................................................................13
PreparePowerSupply.........................................................................................13
RegulatedorUnregulatedPowerSupply...................................................13
SelectingSupplyVoltage............................................................................14
PrepareController...............................................................................................14
Contents
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SystemConnectionsandNoisePrevention.........................................................14
WireGauge.................................................................................................14
CableRouting.............................................................................................15
Twisted Wires.............................................................................................15
CableShielding..........................................................................................15
SystemGrounding......................................................................................16
PowerSupplyConnection..........................................................................16
5. TuningtheServo....................................................................................................17
TestingtheServo.................................................................................................17
TuningtheServo.................................................................................................17
6. PCwindowbasedTuningUsingProTuner............................................................19
IntroductiontoProTuner.....................................................................................19
BeforeTuning......................................................................................................19
ProTunerInstallation..................................................................................19
HardwareConfigurationsbeforeTuning....................................................23
ProTunerfortheACS806 atStartup Window............................................24
IntroductiontoProTunerfortheACS806..................................................25
CommunicationSetup................................................................................26
SoftwareConfigurationbeforeTuning.......................................................27
CurrentLoopTuning...........................................................................................27
Position LoopTuning..........................................................................................31
Position LoopIntroduction.........................................................................31
Position aroundVelocity............................................................................31
Position aroundTorque...............................................................................31
StarttoTune...............................................................................................32
UploadandDownloadData................................................................................42
DownloadDatatoEEPROM.....................................................................42
UploadtheDatafromEEPROM................................................................42
SaveDataon Harddisk...............................................................................43
DownloadDatatoDevice..........................................................................43

Contents
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ControlSignalInputMode..................................................................................45
MoreInformaitonaboutProTuner.......................................................................45
T_Speed_Partab........................................................................................45
CurveSettingtab.........................................................................................46
DigitalScopeWindow................................................................................47
ErrorCheck Window..................................................................................47
7.UsingTips...............................................................................................................49
ChangePPRbyElectronicGear..........................................................................49
Position following ErrorLimit............................................................................50
SequenceChartofControlSignals......................................................................50
ProtectionFunctions............................................................................................51
Over-currentProtection..............................................................................51
Over-voltageProtection.............................................................................51
Under-voltageProtection............................................................................51
PhaseErrorProtection................................................................................51
EncoderorHall ErrorProtection................................................................51
Limit ErrorProtection................................................................................52
Position FollowingErrorProtection...........................................................52
ProtectionIndications.................................................................................52
MaximumPulseInputFrequency.......................................................................52
8. Accessories.............................................................................................................53
ACS806 AccessoriesandConnections................................................................53
MoreInformationaboutACS806 Accessories....................................................54
APPENDIX................................................................................................................58
TWELVEMONTHLIMITEDWARRANTY....................................................58
EXCLUSIONS....................................................................................................58
OBTAINING WARRANTYSERVICE..............................................................58
WARRANTYLIMITATIONS.............................................................................58
SHIPPING FAILEDPRODUCT.........................................................................59
ContactUs..................................................................................................................60
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1. Introduction, Features and Applications
Introduction
Leadshine'sfullydigitalACservodriveACS806 isdevelopedwith32-bit DSP
basedonadvancedcontrolalgorithm.SinceitsinputcommandsarePUL/DIR
signals,theuserscanupgradesteppingdrivestotheACS806 withoutchanging
controlsystems.TheACS806 canofferhighprecision,highspeedand high
reliabilityperformance,andwidelyusedininkjetprinters,engravingmachines,and
etc.Abuilt-incontrollercanbeusedfortestingandtuning.PCbasedandhandheld
configuration&tuningtoolscanmeetdifferenttuning environmentsor
requirements.
Features
lInput: 18 -80VDC,
lPeakCurrent: 18A, ContinuousCurrent: 6 A(Max), 50 -400 W
lFOC-SVPWMtechnologies
lPCbasedandhandheldconfigurationtools
lElectronicgearratefrom1/255 to255
lSelf-testfunction withtrapezoidalvelocityprofile
lSupportPUL/DIRandCW/CCWcontrolsignals
lOpto-isolated, supportsingle-endedanddifferentialinputs
lEncoderoutput
lFollowingerrorlockrangeadjustable
lOver-voltage,over-current, encoderfailureprotections
l10 latestfailuresself-recordfunction
lSmall size, surface-mounttechnology

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Applications
Suitableforlargeandmediumautomationmachinesandequipments,suchasinkjet
printers,engravingmachines,electronicsmanufacturingequipments,specialNC
machines,pickandplacedevices,packingdevices, andso on. Particularlyadapttothe
applicationsrequirehighspeed,highprecision, andlowmotornoise.
2. Specifications andOperatingEnvironment
ElectricalSpecifications(Tj =25 /77℉)
ACS806
Parameters Min. Typical Max. Unit
Peakoutputcurrent 0 - 18 A
Continueoutputcurrent 0 - 6 A
Supplyvoltage +18 - +80 VDC
Logicsignalcurrent 7 10 16 mA
Pulseinputfrequency 0 - 600 kHz
Isolationresistance 500 MΩ
Currentprovidedtoencoder - - 100 mA
PerformanceSpecifications(withACMSeriesServo Motors)
lPosition following error:+/-1 count
lVelocityaccuracy:+/-2rpm
lMaximumacceleration speed(NoLoad):80 rpm/ms2
lInputfrequencyupto600 kHz
lMaximumspeed:4000 rpm
lAllowablelowspeedreaches1 rpm
lPositioningaccuracy:+/-1 count
lSuitablefor18 -80 VDCACservomotors
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MechanicalSpecifications (unit:mm[inch])
166[ 6.535]
50[ 1.969]
97[3.819]
5[ 0.197]
22[ 0.866]
3[ 0.118]
R1.5[ 0.059]
3[ 0.118]
3[0.118]
150[5.906]
15.5[ 0.610]
32[1.260]
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. 450g(15.88oz)

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3. Connections
ConnectorConfiguration
GeneralInformation
Digital&AnalogI/O Connector
Pin Signal Description I/O
1 ENA+ Enablesignalinput + I
2 ENA- Enablesignalinput - I
3 PUL+ Pulsesignalinput+ I
4 PUL- Pulsesignalinput- I
5 DIR+ Directionsignal input+ I
6 DIR- Directionsignal input- I
7 FL Positivelimit signalinput I
8 RL Negativelimitsignalinput I
9 SGND Signalground GND
10 Pend+ Inpositionsignal output+ O
11 Pend- Inpositionsignal output- O
12 ALM+
Alarmoutputsignal+ O
13 ALM- Alarmoutputsignal- O
14 NC Not connected -
15 NC Not connected -
16 NC Not connected -
17 FG Ground terminalforshield GND
18 SGND Signalground GND
19 +5V +5V@10mApowersupply O
20 A+ EncoderchannelA+output O
21 A- EncoderchannelA-output O
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22 B+ EncoderchannelB+output O
23 B- EncoderchannelB-output O
24 Z+ EncoderchannelZ+output O
25 Z- EncoderchannelZ-output O
26 SGND Signalground GND
Halls&EncoderConnector
Pin Signal Description I/O
1 EA+ EncoderchannelA+input I
2 EB+ EncoderchannelB+ input I
3 EGND
Signalground GND
4 HallW+
HallsensorW+input I
5 HallU+
HallsensorU+ input I
6 FG Ground terminalforshielded GND
7 EZ+ EncoderchannelZ+ input I
8 EZ- EncoderchannelZ-input I
9 HallV+
HallsensorV+ input I
10 HallV- HallsensorV-input I
11 EA- EncoderchannelA-input I
12 EB- EncoderchannelB-input I
13 VCC +5V@100mAmax. O
14 HallW-
HallsensorW-input I
15 HallU-
HallsensorU-input I
HighVoltageConnector
Pin Signal Description I/O
1 PE Motorcaseground GND
2 U MotorphaseU O
3 V MotorphaseV O
4 W MotorphaseW O
5 Rbrake
Brakeresistorconnection(VDC-RBrake) I
6 +Vdc DCpowerInput(18-80VDC) I
7 GND PowerGround. GND

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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 -
MoreaboutI/O Signals
Signal Description
ENA+/ENA-
Enableinputsignal. Thissignalusedforenabling/disablingthedrive.Highlevel
forenablingthedriveand lowlevelfordisablingthedrive.Usuallyleft
UNCONNECTED (ENABLED).
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.
FL/RL
Positiveornegativelimitinputsignal.Usesignalgroundforreference.0-0.5Vis
Lowlevelinputand 4-5VisHighLevelinput.Theactivelevelcanbesetwith
configurationtoolssuchasProTuner,STU-ACS. Ifactiveatlowlevel, FL/RLmust
bekeptathighlevelfornormaldriveoperation,andthedrivewillshort-circuit the
motorcoilstostop themotorimmediatelywhenFL/RLturntolowlevel.Ifactive
athighlevel,FL/RLmustbekeptatlowlevelfornormaldriveoperation,and the
drivewill short-circuitthemotorcoilstostopthemotorimmediatelywhenFL/RL
turntohighlevel.PleaseselectactiveathighlevelwhenRL/RLisnot connected.
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Pend+/Pend-
Inpositionsignaloutput.OCoutput,high impedancewhenthepositionerroris
morethan2pulsesandlowimpedance whentheposition errorisless than2pluses.
ALM+/ALM-
Alarmsignaloutput. OCoutput, highimpedance whentheworkingstatusis
normalandlowimpedancewhenover-voltage,over-current,phaseerror,encoder
error,limit error,positionfollowingerrorhappens.
A+/A-/B+
/B-/Z+/Z- Encoderfeedbacksignalsoutput,usuallyofferedtothecontrollerforexternal velocity/position loop.
ENA, PUL, DIRInputCircuitsandConnections
TheACS806 has3differentiallogicinputstoacceptEnable,PulseandDirection
controlsignals.Theseinputsareisolatedtominimizeoreliminateelectricalnoises
coupledontothecontrolsignals.Recommendusetwistedwiresandshieldingcable
forcontrolsignalstoincreasenoiseimmunityininterferenceenvironments.Keep
thesewiresfarawayfromthepowerlines.Infigure2, inputcircuit forthesecontrol
signalsandconnectionstoatypicalmotioncontrollerisillustrated.Figure3
illustratesconnectionstothecontrollerwithcommon-anodeoutputs.
Figure2:Connectionstocontrollerwithdifferential outputs

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Figure3: connectionstocontrollerwithCommon-Anodeoutputs
RL, FLInputCircuitsand Connections
Recommend usingthe+5VsupplyoutputpinDigital & Analog I/OforFL/RLinput.
Figure4:Input circuit andconnectionsforRLandFL
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Pend, ALMOutputCircuitsandConnections
Figure5:Outputcircuit andconnectionforPendandALM
A+, A-,B+, B-,Z+, Z-OutputCircuit
Figure6: A+,A-, B+, B-,Z+, Z-output circuit

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Encoderand Hall SensorConnections
TheACS806 canacceptbothincrementalencoderand Hall Effectsensorinputsfor
motorshaftpositionfeedbacks. Notethattwisted-pairshieldedcablingprovidesthe
bestimmunityinelectricallynoisyenvironments.
TheACS806 hasthe+5Vpowertosupplytheencoder&hall sensor.If theencoder
and hall sensordrainsless than100mA,theACS806 cansupplythemdirectly,and
connectitasFigure7. Iftheencoderdrainsmorethan50mA,useanexternalDC
supplyandconnectit asFigure8.
Figure7:TheACS806suppliestheencoderdirectly
Figure8:Usingexternal DCpowersupplytosupplytheencoder
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RS232 Interface Connection
Figure9:RS232interfaceconnection
TypicalConnections
AtypicalconnectionoftheACS806 isshownasFigure10. Pleaseconsult “Digital
and AnalogI/O”and “Encoderand hall sensorConnections”formoreinformation
aboutcontrollerand encoderconnections.

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Figure10:Typical connectionoftheACS806
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4. ServoSetup
Beforeyoustarttheservo,youcanfollowthebelowsteps.
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
offerACMseriesACservomotorsformatchingtheACS806. Pleaseuseshielded
cablesandseparateencodersignalcablefrominterference sources,suchasmotor
wiresandpowerwiresatleast5 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

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considerablylessthanmotorcurrent.Forexample,two3Amotorscanbewell
suppliedbyonepowersupplyof4Arating.
Selecting Supply Voltage
TheACS806 canactuallyoperatewithin+18 ~+80VDC,includingpowerinput
fluctuation andbackEMFvoltagegeneratedbymotorcoilsduringmotorshaft
deceleration.Theratedvoltageofthemotorisanimportantparameterwhenselecting
supplyvoltage.Generallyspeaking,donotuseapowersupplyvoltagemorethan5
voltsoftheratedvoltageofthemotor.Highervoltagemaycausebiggermotor
vibrationatlowerspeed,anditmayalsocauseover-voltageprotectionorevendrive
damage.
PrepareController
Prepareacontrollerwithpulseanddirection signals.However,theACS806 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.
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Current(A) Minimumwiresize(AWG)
10 #20
15 #18
20 #16
CableRouting
All contentsensitivesignalwiresshouldberoutedasfarawayfrommotorpower
wiresand Drivepowerwiresaspossible.MotorpowerandDrivepowerwiresare
majorsourcesofnoiseandcaneasilycorruptanearby signal.Thisissuebecomes
increasinglyimportantwithlongermotorpowerandDrivepowerwireslengths.
TwistedWires
Twistedwireseffectivelyincreasingnoiseimmunity.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.

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SystemGrounding
Goodgroundingpracticeshelpreduce themajorityofnoisepresentinasystem.All
common groundswithinanisolatedsystemshouldbetiedtoPE(protectiveearth)
througha ‘SINGLE lowresistancepoint.AvoidingrepetitivelinkstoPEcreating
groundloops,which isafrequentsource ofnoise.Centralpointgrounding should also
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
theACS806 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.
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5.TuningtheServo
TestingtheServo
You maywishtosecurethemotorsoit can tjumpoffthebench.Turnonthepower
supply,thegreen(Power) LEDwilllight.TheACS806 hasdefaultparametersstored
inthedrive.Ifthesystemhasnohardwareandwiringsproblem,themotorshouldbe
lockedandthedriveshouldbeready.
If themotorjumpsslightlyandtheredLEDimmediatelyturnson(flickers),then
eitherthemotorortheencoderiswiredinreversal.Openthetuningsoftware
ProTunerand checkdrivestatusbyclicking Err_check.Ifit s PhaseError,then
reversalmotorwiresorexchangeencoderinputsandtryagain.Ifit s EncoderError,
pleasecheckencoderanditswirings,andthentryagain.If it still doesn tworkafter
youfollowedall oftheprevioussteps,pleasecontactusat [e-mail].
If theredLEDisoff andthemotorisnormal,thenyou canstarttotunetheservo
withselectedtool.PCbasedtuningsoftware ProTuner andhandheldsmall servo
tuningunit STU areavailablefortheACS806.
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

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responsetobesluggish,namelycausethesystemtogetintoanOVERDAMPED
state. Whenwetuneaservo,wearetryingtoachievethefastestresponsewith littleor
noovershoot,namelygetaCRITICALLYDAMPEDresponse.
Figure11:Stepandimpulseresponses
Asmentionedinpreviouscontents,theACS806 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.
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TuningservosystemsformedbytheACS806 canbesummarizedasthefollowing
rules:
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

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/WindowsXP.AndtheselectedPCshouldhave1serialportatleastfor
communicatingwiththedrive.
Doubleclick “ProTuner_All_Setup_V1.0.exe”tobegininstallingthe ProTuner. See
Figure12. Click Next toenterthe “LicenseAgreement”window. See Figure13.
Figure12:Begintoinstall theProTuner
Figure13:Licenseagreement
Note:ProTuner_All_Setup_V1.0.exe canbeusedforallLeadshinedigitaldrives.Usercan
getitfromeitherLeadshineCDorwebsite.Pleasegetthelatestversionfrom
http://www.leadshine.com.
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Choose “Iagree tothetermsofthislicenseagreement”and click Next tocontinue
installation.Theusercanenteruser sinformationinthefollowingwindow.See
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 theACS806. TheACS806 hasa
RJ-11connectorinwhichaspecialRS232 cableisconnectedtoPCRS232 port.
BeforeopeningProTunertotunetheACS806, thefollowing configurationmustbe

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achievedasfigure20.
1. Apowersupplywhichhassufficientoutputcurrentatrelatedvoltage;
2. ACservo orDCbrushless servomotor （powerrange:50 –400W）with
encoderandhall sensorfeedback.
3. TablePC/NotebookwithoneRS232 communicationportatleastoraUSB
toRS232 adapter. RecommendusingTablePCwithRS232 port.
4. AspecialRS232 cableofferedbyLeadsineinwhichoneendisaRJ-11
connectorandtheotherendisaDB9 connector.
Figure20:ConfigurationandconnectionsbeforeTuning
Note:
1. If it isthefirstinstallation,stronglyrecommendedthattuningtheACS806
and ACservo motorwithoutmotorshaftcouplingtoany load.Afterbasic
valuesoftheparametersareachieved,connectthemotortotheloadfor
furthertuning.Thesebasicparameterscanalsobeusedforotherdrives
withthesameservomotors.
2. Pleasedoublechecktheconnectionsandmakesurethemotorwouldnot
jumpoffbeforepoweringonthedriveifstartatahighacceleration.
3. InordertosetupcommunicationbetweenthedriveandProTuner,the
ACS806 shouldbepowered.
ProTuner fortheACS806 atStartupWindow
PowerontheACS806. ThegreenLEDindicatorshouldbeon andthemotorshaft
shouldbelockediftheservosystemisOK.Pleaserefertothe protectionfunctions
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tocleartheerrorsifredLEDindicatorflickers.
Open ProTuner andthestartup windowappearsasfigure21. FortheACS806,
pleaseselectthe ACS806 inACServo tab thenclickOK button.
Figure21:Startup WindowofProTuner
Introductionto ProTuner fortheACS806
1. MainWindow
Many oftheLeadshineproductshavesimilaruserinterfaceslikefigure22.
Figure22:MainwindowofProTunerfortheACS806
DriveSelect
StatusBar
MainMenu

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2. Menu BarandSubmenu
Figure23:MenuofProTunerfortheACS806
CommunicationSetup
Select Option->ComConfig,adialoguewindowforsetting theRS232
communicationparameterswouldappearasfigure24. Selectacorrectport
according totheactualportused.Clickthe ‘Open buttontoestablish
communicationbetweentheACS806 andProTuner.Thecaptionofthebutton
shouldchangeto ‘Close ifcommunicationhasbeensuccessfullyestablished.Click
thebuttonagaintoreleasethecommunication.
Figure24:Establishandreleaseseriescommunication
CommunicationsetupCommunicationRelease
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Software Configurationbefore Tuning
Someparametersmustbeconfiguredbeforetuningthedriveandthemotor.Select
Tuning->PositionLoop toopentheposition-loopwindow.Settheparametersas
according tothedescriptioninfigure25.
Figure25:SoftwareconfigurationbeforeTuning
CurrentLoopTuning
FormostoftheACS606 driveswhichareshippedwithLeadshine sACMseries
servomotors, Leadshinewill tunethecurrentloop beforesendingthemtocustomers.
CurrentLoop tuningisareservedfunction,andwhenopeningthecurrenttuning
SettheEncoderLinesaccordingtoencoderspecification.Theinput
numbershouldbe4timesoftheactualencoderlines/resolutionsince
theACS806decodestheencodersignalsinX4mode(ie.10000for
2500linesencoder).
Setnumberofpolepairsoftheservo motoraccording
tomotormanual(ForLeadshineBLMseriesDC
brushlessservo motor,it is2;ForLeadshineACM
seriesACservo motor, itis4.)

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windowbyselecting Tuning->CurrentLoop, apasswordinputwindowwill appear.
Leadshinejustofferspasswordtosomecustomersfortuningcurrentloop,
whilemostofcustomersjustneedtotunethepositionloopparametersiftheyuse
thedriveswithLeadshine sACMseriesservomotors.If you usetheACS806 with
ACservomotorsfromothermanufacturers,thecurrentlooptuning maybeneeded.
Pleasecontact [e-mail] forthepasswordtotunethecurrentloop.
Figure26:Current-looptuningwindow
Tostartthecurrent-looptuning,pleaseenteracommand valueintheI-testtextbox
(unit: A).Thentakefollowingstepstogetoptimizationstepresponse.
1. GiveKpavalueandsetKi0. Clickthe ‘Start buttonandobservethegreen
curveinthewindow.
2. If theresponseisanover-dampedresponseasshowninfigure26, increaseKp
until getanunder-dampedresponseasfigure27.
3. Ifgetalargeovershootresponseasshowninfigure28,decreaseKptogeta
smallerovershootresponseasfigure27.
4. Aftergettingasmall overshootresponse,increaseKitoreduce thesteady-state
Proportional Gain
(0~65535) Integral Gain (0~65535) Command Value (0~6)
Clicktostart test
Command Curve
ActualCurve
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erroruntil getacriticallydampedresponse. Seefigure29.
Figure27:StepresponsewithbetterKpofcurrent-loop(Kp=25000)
Figure28:ResponsewithHighKpofcurrent-loop(Kp= 60000)
BegintoOvershoot
LargeOvershoot

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Figure29:StepresponsewithbetterKpandKi of
current-loop(Kp=25000,Ki=850)
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
loopisdisabledincurrentversionACS806, 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, theACS806 adoptspositionaroundcurrent(torque)mode, and
whentuningpositionaroundthecurrentloop,ahighderivativegainmaybe
necessaryontop ofbothproportionalandintegralgains.Here, wesetKp=800, Ki=0,
Kd=200 first, and theself-testresult isshowninFigure33.

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Figure33:Positionfollowingerrorcurveandvelocitycurve(Kp=800,Ki=0and Kd=200)
It sveryeasytoseefromthevelocitycurve(Greenline)thatthesystemisunder
damped.Thiswillcausesystemoscillatingbeyondeithersideofitstarget, soit must
bedamped.Figure26 showstheresult afterincreasingKdto800. IntheFigure34,
theoscillationismuchsmallerthanthatofFigure33. You cangetevensmaller
oscillationwhenincreasingKdto1000. See Figure35.
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Figure34:Positionfollowingerrorcurveandvelocitycurve(Kp=800,Ki=0and Kd=800)
Figure35:Positionfollowingerrorcurveandvelocitycurve(Kp=800,Ki=0and Kd=1000)