Leadshine ACS606 User manual

User sManual
For
ACS606
DigitalACServo Drive
Revision 1.0
2009 AllRightsReserved
Attention:Pleaseread thismanual carefullybeforeusing thedrive!
3/F,Block2, NanyouTianan IndustrialPark,Nanshan Dist,Shenzhen, China
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URL: www.leadshine.com E-Mail: [e-mail]
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butnoresponsibilityisassumedforinaccuracies.
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hereintoimprovereliability,functionordesign.Leadshinedoesnotassumeany
liabilityarisingoutoftheapplicationoruseofanyproductorcircuitdescribed
herein;neitherdoesitconveyanylicenseunderitspatentrightsof others.
Leadshine sgeneral policydoesnotrecommendtheuseofitsproductsinlife
supportoraircraftapplicationswhereinafailureormalfunctionof theproductmay
directlythreatenlifeor injury.AccordingtoLeadshine stermsand conditionsof
sales,theuserofLeadshine sproductsinlifesupportoraircraftapplications
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©2009byLeadshineTechnologyCompanyLimited.
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Contents
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TableofContents
1.Introduction,FeaturesandApplications...................................................................1
Introduction...........................................................................................................1
Features.................................................................................................................1
Applications..........................................................................................................2
2.Specificationsand OperatingEnvironment..............................................................2
Electrical Specifications........................................................................................2
PerformanceSpecifications...................................................................................2
MechanicalSpecifications.....................................................................................3
Eliminationof Heat...............................................................................................3
OperatingEnvironmentandParameters................................................................3
3.Connections..............................................................................................................4
ConnectorConfiguration.......................................................................................4
GeneralInformation.....................................................................................4
MoreaboutI/OSignals................................................................................5
ControlSignalConnections...................................................................................6
EncoderandHallSensor Connections..................................................................7
RS232Interface Connection..................................................................................8
TypicalConnections..............................................................................................8
4.ServoSetup..............................................................................................................9
InstallEncoder and Hallsensor...........................................................................10
PreparePowerSupply.........................................................................................10
RegulatedorUnregulatedPower Supply...................................................10
Selecting SupplyVoltage............................................................................11
PrepareController...............................................................................................11
SystemConnectionsand Noise Prevention.........................................................11
WireGauge.................................................................................................11
Cable Routing.............................................................................................12
Contents
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TwistedWires.............................................................................................12
Cable Shielding..........................................................................................12
SystemGrounding......................................................................................12
PowerSupplyConnection..........................................................................13
5.TuningtheServo....................................................................................................13
Testing theServo.................................................................................................13
TuningtheServo.................................................................................................14
6.PCwindowbasedTuningUsingProTuner............................................................16
IntroductiontoProTuner.....................................................................................16
BeforeTuning......................................................................................................16
ProTunerInstallation..................................................................................16
HardwareConfigurationsbeforeTuning....................................................20
ProTuner for theACS606 atStartupWindow............................................21
IntroductiontoProTuner for theACS606..................................................22
CommunicationSetup................................................................................23
SoftwareConfigurationbeforeTuning.......................................................24
CurrentLoopTuning...........................................................................................24
Position Loop Tuning..........................................................................................28
Position LoopIntroduction.........................................................................28
Position aroundVelocity............................................................................28
Position aroundTorque..............................................................................28
StarttoTune...............................................................................................29
UploadandDownloadData................................................................................39
DownloadDatatoEEPROM.....................................................................39
UploadtheDatafromEEPROM................................................................39
SaveData onHarddisk...............................................................................40
DownloadDatatoDevice..........................................................................40
ControlSignalInputMode..................................................................................42
MoreInformaitonaboutProTuner......................................................................42
T_Speed_Partab........................................................................................42

Contents
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CurveSettingtab.........................................................................................43
DigitalScopeWindow...............................................................................44
ErrorCheckWindow..................................................................................44
7.Using Tips...............................................................................................................46
ChangePPRbyElectronic Gear..........................................................................46
Position followingError Limit............................................................................47
Sequence ChartofControlSignals......................................................................47
ProtectionFunctions............................................................................................48
Over-currentProtection..............................................................................48
Over-voltage Protection.............................................................................48
PhaseErrorProtection................................................................................48
Encoder orHallError Protection................................................................48
Position FollowingErrorProtection...........................................................48
ProtectionIndications.................................................................................49
MaximumPulse InputFrequency.......................................................................49
8.Accessories.............................................................................................................50
ACS606AccessoriesOverview andConnections...............................................50
MoreInformationaboutACS606 Accessories....................................................51
APPENDIX................................................................................................................55
TWELVEMONTHLIMITEDWARRANTY....................................................55
EXCLUSIONS....................................................................................................55
OBTAININGWARRANTYSERVICE..............................................................55
WARRANTYLIMITATIONS.............................................................................55
SHIPPINGFAILEDPRODUCT........................................................................56
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1.Introduction,FeaturesandApplications
Introduction
Leadshine'sfullydigitalACservodriveACS606isdevelopedwith32-bitDSP
basedonadvancedcontrolalgorithm.Since itsinputcommandsarePUL/DIR
signals,theuserscanupgradesteppingdrivestotheACS606 withoutchanging
controlsystems.TheACS606 canofferhigh precision,highspeedandhigh
reliabilityperformance,andwidelyusedininkjet printers,engravingmachines,and
etc.Abuilt-incontrollercanbeusedfor testing andtuning.PCbasedand handheld
configuration&tuning toolscanmeetdifferenttuningenvironmentsor requirements.
TheACS606candrivebothDCbrushless andACservomotors.Butitismore
suitablefortheDCbrushlessservomotors.ComparetoACS806,ACS606 hasless
I/O thushassmallersizeandhighercost-effective
Features
lInput:18- 60VDC,
lPeakCurrent:15A, ContinuousCurrent:6A(Max), 10-200 W
lFOC-SVPWMtechnologies
lPCbasedandhandheldconfigurationtools
lElectronicgearratefrom1/255 to255
lSelf-testfunctionwithtrapezoidal velocityprofile
lSupportPUL/DIRand CW/CCW controlsignals
lOpto-isolated,supportsingle-endedanddifferential inputs
lFollowingerror lockrangeadjustable
lOver-voltage,over-current,encoder failureprotections
l10latestfailuresself-recordfunction
lSmallsize,surface-mounttechnology

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Applications
Suitable forlargeandmediumautomationmachinesandequipments,suchasinkjet
printers,engraving machines,electronicsmanufacturing equipments,specialNC
machines,pickandplacedevices,packingdevices,andsoon. Particularlyadapttothe
applicationsrequirehighspeed, high precision,andlowmotornoise.
2. Specificationsand OperatingEnvironment
ElectricalSpecifications(Tj =25 /77℉)
ACS606
Parameters Min. Typical Max. Unit
Peak outputcurrent 0 - 15 A
Continueoutputcurrent 0 - 6 A
Supplyvoltage +18 - +60 VDC
Logicsignal current 7 10 16 mA
Pulseinputfrequency 0 - 200 kHz
Isolationresistance 500 MΩ
Currentprovidedtoencoder - - 100 mA
Performance Specifications (with BLMSeries Motors)
lPositionfollowing error :+/-1 count
lVelocityaccuracy:+/-2rpm
lMaximumacceleration speed(NoLoad) :80 rpm/ms2
lMaximumspeed:3000rpm
lAllowablelowspeedreaches1rpm
lPositioning accuracy:+/-1count
lSuitablefor18- 60VDCAC/DCservomotors
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MechanicalSpecifications (unit: mm[inch])
Figure1: Mechanical specifications
EliminationofHeat
lDrive sreliableworkingtemperatureshouldbe<70 [158 ],andmotor
workingtemperatureshouldbe<80 [176 ].
lItisrecommendedtomountthedriveverticallytomaximize heat sinkarea.
OperatingEnvironmentand Parameters
Cooling Naturalcooling orForced cooling
Environment Avoiddust, oilfogandcorrosivegases
Ambient Temperature 0－50 (32 －122 )
Humidity 40%RH－90%RH
Operating Environment
Vibration 5.9m/s2 Max
Storage Temperature -20 －65 (-4 －149 )
Weight Approx. 280g(9.87oz)

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3. Connections
ConnectorConfiguration
GeneralInformation
FeedbackSignal Connector
Pin Signal Description I/O
1 EA+ EncoderchannelA+ input I
2 EB+ Encoderchannel B+ input I
3 EGD Signal ground GND
4 HW Hall sensorWinput I
5 HU Hall sensorU input I
6 FG Ground terminalforshielded GND
7 EZ+ Reserve I
8 EZ- Reserve I
9 HV Hall sensorV input I
10 NC NotConnected -
11 EA- EncoderchannelA-input I
12 EB- Encoderchannel B-input I
13 VCC +5V@ 100 mAmax. O
14 NC NotConnected -
15 NC NotConnected -
Control SignalConnector
Pin Signal Description I/O
1 PUL+ Pulse signalinput + I
2 PUL- Pulse signalinput - I
3 DIR+ Directionsignalinput+ I
4 DIR- Directionsignalinput- I
5 ENA+ Enablesignal input + I
6 ENA- Enablesignal input - I
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RS232CommunicationConnector
Pin Signal Description I/O
1 NC Notconnected -
2 +5V +5VpoweronlyforSTU. O
3 TxD RS232transmit. O
4 GND Ground. GND
5 RxD RS232receive. I
6 NC Notconnected -
HighVoltageConnector
Pin Signal Description I/O
1 U MotorphaseU O
2 V MotorphaseV O
3 W MotorphaseW O
4 +Vdc DC powerInput (18-60VDC) I
5 GND PowerGround. GND
More about I/OSignals
Signal Description
PUL+/PUL-
Pulseinputsignal.Insinglepulse(pulse/direction)mode,thisinputrepresents
pulsesignal, each rising orfalling edge active(softwareconfigurable);4-5Vwhen
PUL-HIGH,0-0.5Vwhen PUL-LOW.Indoublepulsemode (pulse/pulse),this
inputrepresentsclockwise(CW)pulse，activeat bothhigh level and low level. For
reliableresponse,pulsewidthshouldbelongerthan0.85μs.Seriesconnect
resistorsforcurrent-limiting when+12Vor+24Vused.The sameasDIRand ENA
signals.
DIR+/DIR-
Directionsinputsignal.Insingle-pulsemode,thissignalhaslow/high voltage
levels,representing twodirectionsofmotorrotation;indouble-pulsemode
(softwareconfigurable),thissignaliscounter-clock(CCW)pulse，activeatboth
highlevelandlowlevel. Forreliablemotionresponse,DIRsignalshouldbe ahead
ofPULsignalby5μsat least. 4-5VwhenDIR-HIGH, 0-0.5Vwhen DIR-LOW.
ENA+/ENA-
Enableinputsignal.Thissignalused forenabling/disabling the drive.Highlevel
forenabling thedriveand lowlevelfordisabling the drive.Usuallyleft
UNCONNECTED (ENABLED).

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Control Signal Connections
TheACS606has3differentiallogicinputstoacceptEnable,PulseandDirection
controlsignals.Theseinputsareisolatedtominimize oreliminateelectricalnoises
coupledontothecontrolsignals.Recommendusetwistedwiresandshieldingcable
forcontrolsignalstoincreasenoiseimmunityininterferenceenvironments.Keep
thesewiresfarawayfromthepowerlines. Infigure2,inputcircuitforthesecontrol
signalsandconnectionstoatypicalmotioncontrollerisillustrated.Figure3
illustratesconnectionstothecontroller withcommon-anodeoutputs.
Figure2: Connectionstocontrollerwithdifferential outputs
Figure3: connectionstocontroller withCommon-Anodeoutputs
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EncoderandHall SensorConnections
TheACS606 canacceptbothincremental encoderandhalleffectsensorinputsfor
motorshaftposition feedbacks. Notethattwisted-pairshieldedcablingprovidesthe
bestimmunityinelectricallynoisyenvironments.
TheACS606hasthe+5Vpowertosupplytheencoder&hallsensor.Iftheencoder
andhallsensordrainsless than100mA,theACS606 cansupplythemdirectly,and
connectitasFigure7.Iftheencoderdrainsmorethan50mA,useanexternalDC
supplyand connectitasFigure 8.
Figure7: The ACS606suppliesthe encoderdirectly
Figure8: Usingexternal DCpowersupplytosupplythe encoder

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RS232 InterfaceConnection
Figure9: RS232 interfaceconnection
Typical Connections
Atypical connectionoftheACS606 isshownasFigure10.Pleaseconsult “Control
SignalConnections”and “EncoderandHallSensorConnections”formore
informationaboutcontrollerandencoderconnections.
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Figure10:Typicalconnection ofthe ACS606
4. Servo Setup
Beforeyoustarttheservo,youcanfollowthebelowsteps.

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InstallEncoder andHallsensor
Encoderand Hallsensorprovideinformationofthemotorshaftpositionandrotor
magnetic fieldorientation.TheoutputsignalsfromtheHallsensor haveabsolute
phaseinformation whichisusedat motorstartup.Ifyourmotor hasnoencoderand
hallsensor,you musthaveanencoder(morethan200 lines)andhallsensor properly
mountedonthemotorbefore youstart.
Therearesomemoduleswhichcanoutputsignalsbothforencoderandhallsensor.
Pleaseassembletheselectedmoduleaccording toitsfactorymanual.Leadshinealso
offerBLMseriesDCbrushless servomotorsformatching theACS606.Pleaseuse
shieldedcablesandseparateencodersignal cablefrominterferencesources,suchas
motor wiresandpower wiresat least5cm.
PreparePower Supply
RegulatedorUnregulatedPowerSupply
BothregulatedandunregulatedpowersuppliescanbeusedtosupplytheDrive.
However,unregulatedpowersuppliesarepreferredduetotheirabilitytowithstand
currentsurge. Ifregulatedpowersupplies(suchasmostswitchingsupplies.)are
indeedused,itisimportanttohavelargecurrentoutputratingtoavoidproblemslike
currentclamp,forexample using4Asupplyfor3Amotor-driveoperation.Onthe
otherhand,ifunregulatedsupplyisused,onemayuseapowersupplyoflower
currentratingthanthatofmotor(typically50%～70%ofmotorcurrent). Thereason
isthat theDrivedrawscurrentfromthepowersupplycapacitor oftheunregulated
supplyonlyduringtheON duration of thePWMcycle,butnotduring theOFF
duration.Therefore,theaveragecurrentwithdrawnfrompowersupplyis
considerablylessthanmotorcurrent.Forexample,two3Amotorscanbewell
suppliedbyonepower supplyof 4Arating.
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SelectingSupplyVoltage
TheACS606canactuallyoperate within+18~+80VDC,includingpowerinput
fluctuationandbackEMFvoltagegeneratedbymotorcoilsduringmotor shaft
deceleration. Theratedvoltageofthemotorisanimportantparameter whenselecting
supplyvoltage. Generallyspeaking,do notuseapowersupplyvoltagemorethan5
voltsof theratedvoltageofthemotor.Highervoltagemaycausebiggermotor
vibration atlowerspeed,andit mayalsocauseover-voltageprotection or evendrive
damage.
PrepareController
Prepareacontrollerwithpulseand directionsignals.However,theACS606hasa
built-inmotioncontrollerforself-testandServoTuning.Thebuilt-inmotioncontroller
cangeneratecontrolsignalwithtrapezoidalvelocityprofile.
SystemConnectionsandNoisePrevention
Afterfinishingtheabovesteps,youcanconnectyour servo system.Beforeyoustart,
makesurethat thepowerisoff.Connectyoursystemaccordingtoprevious
connection diagrams, and payattentiontothefollowingtipswhenwiring.
WireGauge
Thesmallerwirediameter(lowergauge), thehigherimpedance.Higherimpedance
wirewill broadcastmorenoisethanlowerimpedancewire.Therefore,whenselecting
thewiregauge, itispreferabletoselectlowergauge(i.e.largerdiameter)wire.This
recommendation becomesmorecriticalasthecablelengthincreases.Usethefollowing
table toselecttheappropriatewiresizetouseinyour application.
Current(A) Minimumwiresize(AWG)
10 #20
15 #18
20 #16

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Cable Routing
Allcontentsensitivesignalwiresshouldberoutedasfarawayfrommotor power
wiresandDrivepowerwiresaspossible.Motor powerand Drivepowerwiresare
majorsourcesofnoiseandcaneasilycorruptanearby signal.Thisissuebecomes
increasinglyimportantwithlonger motorpowerandDrivepower wireslengths.
TwistedWires
Twistedwireseffectivelyincreasing noiseimmunity.Thesuccessivetwistseliminate
noisetransientsalongthelengthofthecable.Bothsignalcablesand powercables
shouldbeof thetwistedand shieldedtype.Differentialsignalwiresshouldbetwisted
asapair.Thecombinationoftwistedpairwiresandadifferential signal significantly
addstonoiseimmunity.Powerwiresshouldbetwistedasagroupalongwiththe
ground(or chassis)wire,ifavailable.
Cable Shielding
AllsignalwiresshouldbebundledandshieldedseparatelyfromDrivepowerand
motorpowerwires.Powerwiresshouldalsobebundledandshielded.When
groundingashield,therule-of-thumbistodo soatthe ‘source ofpowerwhile
leaving theothershieldendopen.Forexample,inthecaseofmotorpowerwires,this
wouldbethedriveside. Ideally,twistedpairsshouldbeindividuallyshieldedand
isolatedfromtheoutershield,whichencompassesallwireswithinthecable. However,
sincethistypeof stringentshielding practiceisoftennotrequired,typical cablesdo
notprovideisolation betweeninner andouter shields.
SystemGrounding
Goodgroundingpracticeshelpreduce themajorityof noisepresentinasystem.All
commongroundswithinanisolatedsystemshouldbetiedtoPE(protectiveearth)
through a ‘SINGLE lowresistancepoint.AvoidingrepetitivelinkstoPEcreating
groundloops, whichisafrequentsource ofnoise.Centralpointgroundingshouldalso
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beappliedtocable shielding;shieldsshouldbeopenononeendandgroundedon the
other.Closeattentionshouldalsobegiventochassiswires.Forexample,motorsare
typicallysuppliedwithachassiswire.IfthischassiswireisconnectedtoPE,butthe
motorchassisitselfisattachedtothemachineframe,whichisalsoconnectedtoPE, a
ground loop willbecreated.Wiresusedfor groundingshouldbe ofaheavygaugeand
asshortaspossible.Unusedwiringshouldalsobegroundedwhensafetodo sosince
wiresleftfloating canactaslargeantennas, whichcontributetoEMI.
Power SupplyConnection
NEVER connectpowerandground inthewrongdirection,becauseitwill damage
theACS606drive. Thedistance betweentheDCpowersupplyofthedriveandthe
driveitselfshouldbeasshortaspossible sincethecablebetweenthetwoisasource
ofnoise.Whenthepowersupplylinesarelongerthan50cm,a1000µF/100V
electrolyticcapacitorshouldbeconnectedbetweentheterminal “GND”andthe
terminal “+VDC”.Thiscapacitorstabilizesthevoltagesuppliedtothedriveaswell
asfiltersnoiseon thepowersupplyline. Pleasenote that thepolaritycannotbe
reversed.
Itisrecommendedtohavemultipledrivestoshareonepowersupplytoreducecostif
thesupplyhasenoughcapacity.Toavoidcross interference, DONOT daisy-chain
thepowersupplyinputpinsofthedrives.Instead,pleaseconnectthemtopower
supplyseparately.
5.TuningtheServo
TestingtheServo
Youmaywishtosecurethemotorsoit can tjumpoffthebench.Turnonthepower
supply,thegreen(Power)LEDwilllight.TheACS606 hasdefaultparametersstored
inthedrive.Ifthesystemhasnohardwareandwiringsproblem,themotor shouldbe
lockedand the driveshouldbe ready.

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IfthemotorjumpsslightlyandtheredLEDimmediatelyturnson(flickers), then
eitherthemotorortheencoderiswiredinreversal.Openthetuningsoftware
ProTunerandcheckdrivestatusbyclicking Err_check.Ifit s PhaseError,then
exchangemotor wiresor encoderinputsand tryagain.If it s EncoderError,please
checkencoderanditswirings,and thentryagain.Ifitstill doesn twork afteryou
followedall oftheprevioussteps,pleasecontactusat [e-mail].
IftheredLEDisoffandthemotor isnormal,thenyoucanstarttotunetheservo
withselectedtool.PCbasedtuningsoftware ProTuner andhandheldsmallservo
tuning unit STU areavailablefor theACS606.
TuningtheServo
Aservosystemiserror-driven.The “Gain”ofthesystemdetermineshowhard the
servotriestoreducetheerror.Ahigh-gainsystemcanproducelargecorrecting
torqueswhentheerrorisverysmall.Ahighgainisrequirediftheoutputisrequired
tofollowtheinputfaithfullywithminimal error.
Aservomotoranditsloadbothhaveinertia,whichtheservoamplifiermust
accelerateanddecelerate whileattemptingtofollowachangeattheinput.The
presenceoftheinertia willtendtoresultinover-correction,withthesystem
oscillatingbeyondeithersideof itstarget.It scalledUNDERDAMPEDstatus.See
Figure11.Thisoscillationmustbedamped,buttoomuchdampingwillcausethe
responsetobesluggish,namelycausethesystemtogetintoanOVERDAMPED
state.Whenwetuneaservo,wearetrying toachievethefastestresponsewithlittleor
noovershoot,namelygetaCRITICALLYDAMPEDresponse.
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Figure11:Stepandimpulseresponses
Asmentionedinpreviouscontents,theACS606isadigitalservodriveanditsinput
command isPUL/DIRsignal.Inotherwords,stepresponsejustexistsineachstep
command signal.Foreachstepcommandsignalisaverysmallmovement,so
OVERSHOOTandSETTLINGTIMEbetweeneachstepareverysmall,causing
youhardlycansee astepresponsesuchasFigure11,eveniftheSET POINTisa
verylargequantityand theaccelerationisveryhigh.
However,ifyou trytoevaluateperformancesofthedigital servobyinvestigatingits
positiontracking-erroror positionfollowing error,youmayfind it smucheasier
thaninvestigatingitsstepresponse.Theeasiestwaytogetatracking-erroror
positionfollowing error responseistoinduceanimpulseloadon themotor.See
Figure11at “time20”.
LeadshineoffersaWindowsbasedsetup software ProTuner toitscustomersfor
evaluatingservoperformances.Small servotuning unit STU (optional)isavailable
too,andit sfor fieldtuning withoutPC.
TuningservosystemsformedbytheACS606canbesummarizedasthefollowing
rules:

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1. IfservosystemisUNSTABLE, thenthefirstthing oftuningistostabilize
thesystem.Youcanincrease DerivativeGain of PositionLoop (Kd)or
decrease ProportionalGain of PositionLoop (Kp)or IntegralGain of
Position Loop (Ki).
2. IfservosystemisUNDERDAMPED,thenincreaseKdordecreaseKpor
Ki.
3. IfservosystemisCRITICALLYDAMPED,thenstoptuning and
downloadtheparameter settingstotheDrive sEEPROM.
4. IfservosystemisOVERDAMPED,thendecreaseKdor increaseKpor
Ki.
6. PCwindowbasedTuning UsingProTuner
IntroductiontoProTuner
Asaprofessionaltuning tool,ProTunerhasbeendevelopedspeciallyforall
Leadshinedigitaldrives.Itcanbealsousedtoconfiguretheservodriveformany
settingssuchascontrolsignalmodes,numberofmotorpoles,positionfollowing
errorlimit,defaultmovedirection,andetc.ThemostimportantfeatureisProTuner
offersthenumeric methodfortuningposition-loopparameters(Kp,Kd,Ki)and
giveavisualizationresultsynchronouslyforuserstoevaluatetheperformance ofthe
system.
BeforeTuning
ProTunerInstallation
TheProTuneriswindowsbasedsetup softwarefortuning Leadshine sdigitaldrives.
Itcanruninwindowssystems,includingWin95/Win98/WindowsNT/Windows2000
/WindowsXP.AndtheselectedPCshouldhave1serialportatleastfor
communicatingwiththedrive.
Doubleclick “ProTuner_setup.exe”tobegininstallingtheProTuner.SeeFigure12.
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Click Next toenter the “LicenseAgreement”window.See Figure 13.
Figure12:Begintoinstall the ProTuner
Figure13: Licenseagreement
Choose “Iagree tothetermsofthislicenseagreement”andclick Next tocontinue
installation.Theusercanenteruser sinformation inthefollowingwindow.See
Figure14.Afterentering the user sinformation,click Next toselectinstallation folder,
whereyou wouldliketoinstallthe ProTuner. See Figure 15.

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Figure14:User sinformationsettings
Figure15:Installationfoldersettings
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Figure16: Shortcutfoldersetting
Setthe “ShortcutFolder”inFigure16andcontinuetoinstallthe ProTuner by
following Figure17andFigure18.An InstallationSuccessful windowwill appearif
the ProTuner isinstalledsuccessfully.SeeFigure19.
Figure17:Installation information summarization

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Figure18: Installing the ProTuner
Figure19: Finishinstallation
Note: Leadshine alsooffersspecialversion ProTunerwhichdoesnotneedinstallation.Pleasevisit
ourwebsite www.leadshine.com forlatestProTuner.
Hardware ConfigurationsbeforeTuning
ProTunerusesPCRS232 porttocommunicate withtheACS606. TheACS606 hasa
RJ-11connectorinwhichaspecial RS232cableisconnectedtoPCRS232port.
BeforeopeningProTunertotunetheACS606,thefollowingconfigurationmustbe
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achievedasfigure20.
1. Apower supplywhichhassufficientoutputcurrentatrelatedvoltage;
2. DCbrushless servoorACservomotor（powerrange:10 –200W）with
encoder andhallsensor feedback.
3. Table PC/Notebook withone RS232 communicationportatleastor aUSB
toRS232adapter. RecommendusingTablePCwithRS232port.
4. AspecialRS232cableofferedbyLeadsineinwhichoneend isaRJ-11
connector andthe otherendisaDB9connector.
Figure20: Configurationand connectionsbeforeTuning
Note:
1. Ifitisthefirstinstallation,stronglyrecommendedthattuningtheACS606
andACservomotorwithoutmotorshaftcouplingtoanyload.After basic
valuesoftheparametersareachieved,connectthemotortotheloadfor
furthertuning.Thesebasicparameterscanalsobeusedforotherdrives
withthesameservomotors.
2. Pleasedoublechecktheconnectionsand makesurethemotorwouldnot
jumpoffbefore poweringonthedriveifstartatahighacceleration.
3. Inordertosetupcommunication betweenthedriveandProTuner,the
ACS606shouldbe powered.
ProTunerfortheACS606at Startup Window
Poweron theACS606.ThegreenLEDindicator shouldbeonandthemotorshaft
shouldbelockediftheservosystemisOK.Pleaserefertothe protectionfunctions

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toclear the errorsif redLEDindicator flickers.
Open ProTuner andthestartupwindowappearsasfigure21.FortheACS606,
pleaseselectthe ACS606 inACServotabthenclickOKbutton.
Figure21: StartupWindowofProTuner
IntroductiontoProTuner forthe ACS606
1. MainWindow
Many oftheLeadshine productshavesimilar user interfaceslikefigure22.
Figure22:MainwindowofProTunerfortheACS606
DriveSelect
StatusBar
MainMenu
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2. Menu Barand Submenu
Figure23: Menu ofProTunerforthe ACS606
CommunicationSetup
Select Option->ComConfig,adialoguewindowfor settingtheRS232
communicationparameterswouldappearasfigure24.Selectacorrectport
accordingtotheactualportused.Clickthe ‘Open buttontoestablish
communicationbetweentheACS606andProTuner.Thecaption of thebutton
shouldchangeto ‘Close ifcommunicationhasbeensuccessfullyestablished.Click
thebuttonagaintoreleasethecommunication.
Figure24: Establishand releaseseriescommunication
CommunicationSetupCommunicationRelease

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SoftwareConfigurationbefore Tuning
Someparametersmustbeconfiguredbeforetuning thedriveandthemotor.Select
Tuning->PositionLoop toopentheposition-loopwindow.Settheparametersas
accordingtothedescription infigure 25.
Figure25: SoftwareconfigurationbeforeTuning
Current LoopTuning
For mostoftheACS606driveshavebeenbeing soldtothecustomerswith
Leadshine sACMseriesservomotors,Leadshinewilltunethecurrentloopbefore
sending drives&motorsoutofthefactory.CurrentLooptuningisareserved
Setthe EncoderLinesaccordingtoencoderspecification.The
inputnumbershouldbe4timesofthe actualencoder
lines/resolutionsincethe ACS606decodesthe encodersignalsin
X4mode.(Ie.4000for1000 linesEncoder)
Setnumberofpolepairsofthe servomotoraccording
tothe motormanual.(ForLeadShineBLMseriesDC
brushlessservo motor,thisvalue is2.)
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function,and when openthecurrenttuningwindowby selecting
Tuning->CurrentLoop, apasswordinputwindowwillappear. Leadshine just
offerspasswordtosomecustomersfortuningcurrentloop,whilemostof
customersjustneedtotunethepositionloopparametersiftheyusethedriveswith
Leadshine sACM seriesservomotors. If youusetheACS606 withACservomotors
fromothermanufacturers,thecurrentloop tuningmaybeneeded.Pleasecontact
[e-mail] for thepasswordtotunethecurrentloop.
Figure26Current-looptuning window（Kp=10000）
Tostartthecurrent-looptuning,pleaseenteracommandvalueintheI-testtextbox
(unit:A). Thentake followingstepstogetoptimizationstepresponse.
1. EnteravalueintheKptextboxandsetKi tozero.Clickthe ‘Start button and
observethegreencurveinthewindow.
2. Iftheresponseisanover-dampedresponseasshowninfigure26,increaseKp
untilgetanunder-dampedresponseasfigure27.
3. Ifget alargeovershootresponseasshowninfigure28,decreaseKptoget a
CommandCurve
Actual Curve
Proportional Gain
(0~65535) IntegralGain (0~65535) CommandValue (0~6)
Clicktostarttest

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smallerovershootresponseasfigure27.
4. Aftergettingasmall overshootresponse,increaseKi toreducethesteady-state
error untilget acriticallydampedresponse. See figure 29.
Figure27: StepresponsewithbetterKpofcurrent-loop(Kp= 17000)
Figure28: ResponsewithHighKpofcurrent-loop(Kp=24000)
BegintoOvershoot
Large Overshoot
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Figure29: StepresponsewithbetterKpandKi of
current-loop(Kp=17000,Ki=400)
5. AtthatmomentKpandKi of thecurrentloop isnearlyoptimum.Toreducethe
raisetimepleaseincreaseKp,andincreaseKi toreduce thesteady-stateerror.You
canusethemousetodragarectangletozoominthecurseformoredetail. Clickany
placeofthewindowtozoomout.Seefigure30.
Figure30: Dragarectangletozoomin

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PositionLoopTuning
PositionLoopIntroduction
Position looptuning isdependantonthemechanical load,andthereforewillchange
withanymechanical systemchanges.Positionlooptuningshouldbeperformedwith
themotorinstalledinthesystem.Thepositionloopcanbeclosedaroundvelocityor
torquemode(depending onwhetherthevelocityloop isenabledor disabled).If itis
closedaroundvelocitymode,theposition loopalgorithmoutputbecomesthenew
velocitysetpoint.If itisclosedaroundtorquemode,thepositionloopalgorithm
outputbecomesthenewtorquesetpoint.Therearesomeimportantdifferencesinthe
tuning process andapplicationofthesetwoapproaches.
PositionaroundVelocity: Thismodeismostcommonin"contouring"application,
whereapositiontrajectorymustbetrackedveryclosely.Thevelocityloopprovides
additional"stiffness",andkeepsthedynamicposition errorsminimal,sincethe
systemnowreactstonotjustpositionerrors,butalsovelocityerrors(whichcanbe
interpretedaspositionerror changes). Itisimportanttostartwithastableyet
responsivevelocityloop.Typically,itissufficienttojustusetheposition loop
proportionalgain.Feedforwardgaincanbeaddedtoimprovetrackingperformance
(i.e.minimizethedifferencebetweencommandedandactualposition).Thevelocity
loopisdisabledincurrentversionACS606,anditadopts PositionaroundCurrent
(Torque) mode.
Positionaround Torque: Thismodeismostcommoninpoint-to-pointapplications,
whereactualmotionbetweenstartandendpointisnotverycritical.In thiscase,
velocitylooptuningcanbeavoided.Thiscanbeadvantageousifthevelocity
feedbackispoor(e.g.lowresolutionencoder,poorencoderquadrature.). Inthiscase,
the tuningprocess requiresthat the positionloopproportionaland derivative
gainareincreased simultaneously,unless the systemhassufficientfriction,in
whichcasenoderivativegain isnecessary.Once astableresponseisachieved,
integralgaincanbe addedto improvestiffness. Itisbesttouseastepcommand
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withtheprofilerenabledasa referencesignalduring tuning.
Drivetuning isamulti-stepprocess that involvespropertuningofuptothree different
servoloops,namelycurrentloop,velocityloopandpositionloop.Youcaneithertune
thepositionloop around thevelocityloop,or aroundthecurrentloop.Generally,itis
mucheasiertotuneaposition loop aroundavelocityloop becauseonlythe
proportionalgainisneeded.Whentuningpositionaround thecurrentloop,ahigh
derivativegainmaybenecessaryon topof bothproportionalandintegral gains.
StarttoTune
Settheparametersandselectthecurvesdisplayedin DigitalMonitor before
startingself-testandtuning.SeeFigure31andFigure32for theparametersforthe
tuning inthispaper.Whenwetuneaservo,we aretryingtoachievethefastest
responsewithlittleor noovershoot, namelygetaCriticallyDampedresponse.
Figure31:Self-testmotion settingsforthe tuning

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Figure32:Digital Scopesettingsforthe tuning
Asmentionedabove,theACS606 adoptsposition aroundcurrent(torque) mode,and
whentuningposition around thecurrentloop,ahighderivativegainmaybe
necessaryontop of bothproportionalandintegralgains.Here,weset Kp=2000,
Ki=0,Kd=1000 first,andtheself-testresultisshowninFigure33.
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Figure33:Position following errorcurveandvelocitycurve (Kp=2000, Ki=0and Kd=1000)
It sveryeasytoseefromthevelocitycurve(Greenline)thatthesystemisunder
damped.Thiswillcausesystemoscillatingbeyondeither side ofitstarget,soitmust
bedamped.Figure26showstheresultafterincreasing Kdto3500.In theFigure34,
theoscillationismuchsmallerthanthatofFigure33.Youcangetevensmaller
oscillationwhenincreasingKdto7000.See Figure 35.

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Figure34:Position following errorcurveandvelocitycurve (Kp=2000, Ki=0and Kd=3500)
Figure35:Position following errorcurveandvelocitycurve (Kp=2000, Ki=0and Kd=7000)
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AlthoughasmoothvelocitycurvehavebeengotteninFigure35, wecanseethatthe
positionfollowing error isstill toolargetoaccept.Andthiscanbeimprovedby
increasingKi value.SeeFigure36.However,we canseethesystemresponsein
Figure35isalreadyOverDamped,namelytoo muchdampinghascausedthe
responsetobesluggish.ThiscanbeimprovedbyincreasingKpor reducingKd.See
Figure37andFigure38.HerewetrytoimprovetheperformancesbyincreasingKp.
Figure36:Position followingerrorcurveand velocitycurve (Kp=2000, Ki=500and Kd=7000)

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Figure37:Position followingerrorcurveand velocitycurve (Kp=4000, Ki=500and Kd=7000)
Figure38:Position followingerrorcurveand velocitycurve (Kp=6000, Ki=500and Kd=7000)
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IncreaseKdcanreducevelocityovershoot,andgetabettervelocitycurveinas
showninFigure39.
Figure39:Position followingerrorcurveand velocitycurve (Kp=6000, Ki=500and Kd=8500)
SincepositionfollowingerrorisstilllargeduringconstantspeedperiodinFigure39,
wetrytoincreaseKitoimprovesystem sperformances.Figure40,Figure41,and
Figure42 showtheresultafterincreasingKi.FromFigure42,wecanseethattoo
muchKi willcausepositioncurveover shoot.