Neat 700 Series User manual

NEAT Servo Amplifier
700 Series High
Performance
Brush and
Brushless Servo
Motor Amplifier
New England Affiliated Technologies
620 Essex Street, Lawrence, Massachusetts 01841
Tel: [phone] Fax: [phone]
Tel: [phone] Fax: [phone]
WWW page: http://www.neat.com/users/neat
E-Mail: [email protected]
700 Series
Users Manual

A MESSAGE FROM NEAT'S PRESIDENT
Thank you for selecting New England Affiliated Technologies as your positioning equipment supplier. We
understand that you can choose from a number of competitive suppliers and are pleased that you have selected
NEAT. As you unpack and begin to use our product, we would like your conclusions as to our products'
appearance, quality, precision, and suitability to your ultimate application. By providing us with feedback in
these and other areas, you can become an active participant in our on-going program of continuous improve-
ment. At the rear of this booklet, you will find a detachable, postage-paid response card for your reactions to
our product which allows you to include additional comments. I encourage you to fill out and mail in the
response card. I am also providing several additional paths if more immediate communications are desired.
Our Customer Service department can be reached at 1-800-227-1066 extension 30. If you would like to
address your comments to me directly, I can assure you of an immediate response by calling our toll-free num-
ber and asking for extension 211. Thank you again for choosing NEAT and we look forward to serving you in
the future.
Sincerely,
Kevin J. McCarthy
President
New England Affiliated Technologies
New England Affiliated Technologies
620 Essex Street, Lawrence, Ma 01841
Phone [phone] Fax [phone]
508.685.4900 508.688.8027

Table of Contents
Release 1.0/0795 Part Number: 1030008
Preface...........................................................................................................................4
Chapter 1 Overview
Overview.........................................................................................................................5
Section 1-1 System Descriptions..................................................................................................5
Section 1-1.1 Single-Axis System......................................................................................5
Section 1-1.2 Two-Axis System..........................................................................................7
Section 1-2 700-Series Classifications..........................................................................................8
Section 1-2.1 Motor Drive Modes.......................................................................................9
Section 1-3 700-Series Chassis Types.........................................................................................10
Section 1-3.1 Single and Multi-Axis Systems..................................................................10
Section 1-4 System Cabling........................................................................................................11
The Breakout Box........................................................................................................................11
Chapter 2 Unpacking
Unpacking.....................................................................................................................12
Section 2-1 700 Unit and Related Items......................................................................................13
Section 2-1.1 Line Voltage Selection................................................................................13
Section 2-2 Other System Components.......................................................................................13
Section 2-2.1 The Motor(s)...............................................................................................13
Section 2-2.2 The Cable Set..............................................................................................14
Section 2-2.3 Controller Card and Related Items..............................................................14
Chapter 3 Initial Power Checks
Initial Power Checks....................................................................................................................16
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Chapter 4 Installing the Controller Card
Installing the Controller Card......................................................................................................17
Section 4-1 Setting the Base Address..........................................................................................17
Section 4-1.1 Setting the Default Base Address................................................................18
Section 4-1.2 Setting a Non-Standard Base Address........................................................19
Section 4-2 Installing the Card....................................................................................................20
Section 4-3 Installing the Controller Card Software...................................................................21
Section 4-3.1 Installing the COMM Software..................................................................21
Section 4-3.2 Installing the SDK Software.......................................................................22
Chapter 5 Putting Your System Together
Putting Your System Together......................................................................................................23
Section 5-1 System Cabling........................................................................................................23
Section 5-2 System Assembly Procedure....................................................................................24
Chapter 6 Tuning the Servos
Tuning the Servos........................................................................................................................26
Section 6-1 Theory......................................................................................................................26
Section 6-2 Tuning Procedure.....................................................................................................27
Section 6-3 System Operation.....................................................................................................27
Chapter 7 Connector Pinouts
Connector Pinouts........................................................................................................................28
Chapter 8 Customer Service
Section 8-1 Return Instructions...................................................................................................30
Section 8-2 Shipping Procedures................................................................................................31
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List of Figures
Figure 1-1 Single-Axis System.....................................................................................................5
Figure 1-2 Two-Axis System........................................................................................................7
Figure 1-3 700-Series Classifications...........................................................................................9
Figure 1-4 Front and Rear Panels of Multi-Axis Unit.................................................................11
Figure 2-1 "Roadmap" for the Various Unpacking Options........................................................12
Figure 2-2 A Typical 2-Axis Positioning Table...........................................................................14
Figure 2-3 The NEAT-1000 Controller Card (partial chip complement).....................................14
Figure 2-4 Breakout Box Used with NEAT-1000 Controller Card..............................................15
Figure 4-1 The NEAT-100 Controller Card.................................................................................17
Figure 4-2 Setting the Default Base Address...............................................................................18
Figure 4-3 Example of a Non-Standard Base Address................................................................19
Figure 4-4 Controller Card and the Auxiliary Connector Adapter...............................................20
Figure 5-1 System Cabling..........................................................................................................23
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Preface
This manual describes the NEAT 700-Series Servo Amplifier Units. The 700-Series is really an entire class of
units which differ one from the other both in regard to the number of axes, and also the mode of motor drive.
A 700-Series Servo Amplifier (hereafter 700-Series or just 700) is a component in a closed-loop position-con-
trol system. The system is controlled by a user-program in a PC-based controller card. The 700-Series is the
link between the Controller card and the servomotors in that, for each axis, it accepts a position-error voltage
from the controller, amplifies it, and derives suitable driving waveforms for the servomotors.
The Overview in Chapter 1 briefly describes how a NEAT position-control system works and the role that a
700-Series unit plays in that system. Subsequent chapters tell you how to set up, cable together, and operate
your system.
The systems described in this manual have a great many variants:
they may be 1-axis, 2-axis, 3-axis, or 4-axis systems
the motors may be brush motors or brushless motors
the mode of motor drive may be either Linear or Pulse Width Modulation (PWM)
This manual addresses all of these needs and, at the same time, enables the user to quickly "zero-in" on his/her
particular configuration.
The body of the manual consists of chapters followed by appendices. All of the information that you will need
is contained in the chapters. We urge you to read the manual from beginning to end. The appendices contain
technical information needed by NEAT engineers and technicians for maintenance purposes.
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Overview
The 700-Series Servo Amplifier (hereafter 700-Series, or just 700) is a component in a NEAT closed-loop
position-control system. The system is driven by a user-program in a PC-based controller card. The 700-
Series is the link between the Controller card and the servomotors in that, for each axis, it accepts a position-
error voltage from the controller, amplifies it, and forms suitable waveforms for the servomotors.
This manual describes the various NEAT systems that are available. For a first-time buyer however, the obvi-
ous question is: which system will best fit my needs? First-time buyers should discuss their requirements with
a NEAT applications engineer before purchasing any equipment.
Section 1-1  System Descriptions
This section will illustrate the role played by the 700-Series for both a single-axis and a 2-axis system.
Section 1-1.1  Single-Axis System
Figure 1-1, Single Axis System, shows the principal components of a single-axis NEAT position-control system.
Figure 1-1 Single-Axis System
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The components and their functions are as follows:
Controller Card (mounted in an IBM-PC slot)
The Controller card mounts into an IBM-PC card slot. It processes the instructions in the user's pro-
gram and, from that, continually generates a position command output. This is compared with the position
feedback from the motor's position encoder. The result (following PID - proportional, integral, derivative
processing) is a position error signal to the 700-Series Servo Amplifier. This error signal input is a + 10V,
single-ended signal.
NOTE: Sinusoidal commutation, an available option, is not discussed in this manual. For
sinusoidal commutation, the error signal is a + 5V balanced pair.
We note that there are two servo loops:
 a loop entirely inside of the amplifier unit that forces the motor current waveforms to be
proportional to the position-error input
 the overall position-control loop (this loop is closed inside the Controller card)
As noted above, the Controller card is a PID (proportional, integral, derivative) processor. Processing a deriva-
tive term makes the system more responsive to sudden changes. Processing an integral term assures that any
position will, in time, be brought to zero. Without integral-term processing, this may not always be possible.
700-Series Servo Amplifier Unit
The 700 Unit, as shown, consists of both an amplifier subassembly and a Power Supply Unit (PSU) for each
axis, ensuring freedom from cross talk between amplifier axes.
The Servo Amplifier unit accepts a position-error signal from the Controller card and generates a set of drive
currents to the motor that are proportional to this error signal. These drive currents can be selected to drive
either single coil brush type motors, or three phase brushless motors.
In the event that brushless motors are selected, the motor returns position-encoding signals obtained from Hall-
effect sensors.
NOTE: Do not confuse Hall-sensor feedback with the feedback from the position encoder.
They have quite different purposes. The following section, Motor(s) and Positioning Table,
explains this.
These feedback signals are fed to waveform-logic circuits in the amplifier. The result, when applied to the
motor windings, is a net magnetic field that is constantly "pulling" the motor in the desired direction. Brush
motors incorporate their own electro-mechanical commutation and require no Hall sensors.
Inputs from the controller card enter the 700 unit at the 25-pin REMOTE connector. Signals passing
between the 700-Series unit and the motor are brought out on both a 9-pin and a 15-pin connector.
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Motor(s) and Positioning Table
The motor(s) will most likely be driving a positioning table. Motor travel will be sensed either by:
 a rotary encoder mounted onto the motor shaft, or
 a linear encoder mounted onto the positioning table
In either case, the encoder signals are fed back to the Controller card to enable it to close the servo positioning
loop.
Why both the Hall-sensor feedback and the encoder feedback?
 the Hall-sensor feedback allows the amplifier to generate the proper current waveforms for
brushless motors
 the encoder feedback tells the Controller card what the motor's current position is.
Section 1-1.2  Two-Axis System
Figure 1-2 shows a block diagram of a two-axis system.
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Figure 1-2 Two-Axis System
We see that there are two, independent servo loops; one for the X-axis, and the other for the Y-axis.

Controller Card
The controller card is now processing two axes simultaneously; sending out an error signal for each, and
receiving position feedback for each.
There are several types of Controller cards to choose from. A commonly-used card (and the one upon which
this manual is principally based) is the NEAT-1000 family. The members of this family are:
 NEAT-1010 for single-axis systems
 NEAT-1020 for 2-axis systems
 NEAT-1030 for 3-axis systems
 NEAT-1040 for 4-axis systems
700-Series Servo Amplifier
The 700-Series contains an amplifier unit for each axis and a 9-pin and 15-pin connector for each motor.
The nine pin connector is adequate for motor currents up to 3 amp continuous, 5 amp peak. The 15-pin
connector devotes three pins, in parallel, to each motor lead. The 15-pin connector is recommended when
motor currents exceed the above values. All input signals from the Controller card pass through the single 25-
pin connector at the left.
Motors
In this case, two motors are driving a 2-axis positioning table.
Now that we have examined a 2-axis system, it should be clear what the block diagram of a 3 and 4-axis sys-
tem would look like.
Section 1-2  700-Series Classifications
The NEAT 700-Series units are, in fact, a whole class of units. They are classified in two ways:
 according to the number of axes (1, 2, 3, or 4)
 according to the type of motor drive (either Linear or Pulse Width Modulation)
In general, a 700-Series unit will have the designation 7XY where:
 X indicates the type of motor drive (either Linear or PWM)
 Y indicates the number of axes (1, 2, 3, or 4)
Figure 1-3 shows these classifications.
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