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
3

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.
4

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
5

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.
6

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.
7
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.
8

Figure 1-3 700-Series Classifications
For example, a "703" would indicate that the unit is a 3-axis system and that it has a medium-power, PWM
motor drive.
Section 1-2.1  Motor Drive Modes
There are two modes of motor drive: Linear and Pulse Width Modulation (PWM). In LINEAR drive, power to
the motor(s) is varied by controlling the amplitude of the driving waveforms. In PWM drive, power to the
motor(s) is varied by controlling the duty cycle of a high-frequency (* 30 kHz) square wave.
The advantages and disadvantages of each are described in Table 1-1.
Table 1-1 Comparison of LINEAR and PWM Motor Drive
You will notice a sort of symmetry: the advantage of one is the disadvantage of the other.
As Figure 1-3 shows, there are two variants to the PWM mode: medium-power and high-power.
9
ADVANTAGE
Free of the noise that results from
the PWM high-frequency wave
Very little power dissipation in the
driving transistors
DISADVANTAGE
Heat problem. Must dissipate
power in the driving transistors
Noise resulting from the PWM
action
LINEAR
PWM

Section 1-3  700-Series Chassis Types
Section 1-3.1  Single and Multi-Axis Systems
The chassis for the multi-axis system is 19" long by 5" high. Figure 1-3, Front and Rear Panels of Multi-
Axis Systems shows the front and rear panels.
Front Panel
There is only one control on the front panel:
* the Emergency Stop switch
Rear Panel
Note the connectors on the rear panel:
* The 25-pin connector is cabled to the Breakout box and is located on the right-hand side of the
amplifier unit.
* The 9-pin connector is cabled to the motor (one for a single-axis, two for a 2-axis, etc.). The 9-pin
connector is adequate for motor currents up to 3 amp continuous, 5 amp peak.
* The 15-pin connector is located to the left of the 9-pin connector and devotes three pins, in parallel,
to each motor lead. The 15-pin connector is recommended when motor currents exceed the above values.
Also on the rear panel are the power switch, AC receptacle, the motor and AC fuses, the voltage selection
switch, and the fan.
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Figure 1-4 Front and Rear Panels of Multi-Axis Systems
Section 1-4  System Cabling
The Breakout Box
One component not shown up to this point is the Breakout Box. This is a convenience for making connections
between the Controller card, Servo Amplifier, and Motor(s). Use of the Breakout Box is described in Chapter 5.
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2
Unpacking
This chapter provides a "checklist" so that you can be certain every, necessary component has been shipped to
you.
There are different checklists depending on what you have purchased. You may have purchased a 700 unit
only, or a complete system which includes, among other things, the controller card and the items associated
with it (a controller card manual, Breakout box, and software drivers). The most commonly used controller
card belongs to the NEAT-1000 family. Although other controllers are available, this manual lists the associated
items for cards of the NEAT-1000 family only.
Figure 2-1 provides a "roadmap" in the form of a flow diagram. It will help to guide you through the chapter.
Figure 2-1 "Roadmap" for the Various Unpacking Options
Section 2-1, 700 Unit and Related Items, lists the 700 unit and all of its related items. Everyone should use
this "checklist".
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Section 2-1  700 Unit and Related Items
The following items have been shipped to you:
 700 Unit Servo Amplifier
- see Figure 1-4
 A power cord for the 700 unit
 A 700-Series Servo Amplifier manual
Now that you have checked your shipment against this list, if you have purchased a 700 unit only, proceed to
the next chapter. If you have purchased an entire system, proceed to Section 2-2, System Components.
Section 2-1.1  Line Voltage Selection
To change the AC line input voltage, pop open the hinged cover on the AC line receptacle module. This can
be done by simply slipping a screwdriver into the slot on the far right and opening the cover. This reveals the
red, plastic fuse holder assembly which can be removed by prying gently on either its top or bottom. To
inspect or replace fuses, simply remove the assembly. To change the line voltage setting, rotate the assembly
180 degrees before reinstalling. Close the cover, confirming both the line voltage setting and that the AC
power switch is set to zero (off) before installing the AC cord.
Section 2-2  Other System Components
Refer back to Figure 2-1. Please check that your shipment includes the following:
 The motor(s) (these may be mounted to a positioning table)
 The cable set
 The Controller card and its related items as follows:
- a controller card manual
- the Breakout Box
- the supporting software driver diskettes
Section 2-2.1  The Motor(s)
If you have ordered a one, two, three, or four-axis system, it is likely that the motors will be mounted to a
positioning table with motor mounts that include 9-pin or 15-pin connectors for cabling connections. Please
refer to Figure 2-2, A Typical 2-Axis Positioning Table.
13

Figure 2-2 A Typical 2-Axis Positioning Table
Section 2-2.2 The Cable Set
Along with your cable set will come a cabling diagram that will instruct you on the placement for each cable
in your set. Each cable is numbered and the diagram refers to each cable by its number.
You are urged to make certain that every cable referenced in the diagram has been shipped.
Section 2-2.3  Controller Card and Related Items
If you are using a controller card that does not belong to the NEAT-1000 family, please familiarize yourself
with the manual supplied by the controller card's manufacturer.
Figure 2-3 shows a card from the NEAT-1000 family.
Figure 2-3 The NEAT-1000 Controller Card (partial chip complement)
The NEAT-1000 card is approximately 13" long. Figure 2-3 shows only those components referenced in this
manual.
14

There are three items associated with the Controller card:
1. A manual for the NEAT-1000 Controller card entitled: DMC-1000 Technical Reference Guide
2. The Breakout Box
Figure 2-4 shows the Breakout Box used with the NEAT-1000 Controller card.
Figure 2-4 Breakout Box Used with NEAT-1000 Controller Card
As stated previously, the Breakout Box is used for convenient cable connections between the Controller card,
the Amplifier unit, and the Motor(s).
3. Software drivers for the Controller card. The Software Drivers for the Controller card are on two,
floppy disks (either 3.5" or 5.25"). These two disks are labeled: SDK and COMM.
This completes the checklist. Please proceed to Chapter 3, Initial Power Checks.
15

3
Initial Power Checks
Certain steps must be taken before power is applied to your 700 unit. Perform each of these steps in the order
given. Make sure that the AC power cord is removed from the rear panel AC receptacle before proceeding.
1. Inspect for obvious, physical damage. If you find that your unit has been damaged in shipping,
please proceed to Chapter 8, Customer Service.
2. Remove each of the motor fuses and examine them to make certain they are in working order. For
the locations of the fuses, see Figure 1-4.
3. Check that your unit is configured for the correct line voltage for your area (either 110V AC or
220V AC). To do this, simply examine the voltage label visible through a window on the right side of
the rear panel AC line receptacle. This will display either 115V or 230V depending upon the voltage
setting.
4. To change the AC line input voltage, pop open the hinged cover on the AC line receptacle module.
This can be done by simply slipping a screwdrive into the slot on the far right and opening the cover.
This reveals the red, plastic fuse holder assembly which can be removed by prying gently on either its
top or bottom. To inspect or replace fuses, simply remove the assembly. To change the line voltage
setting, rotate the assembly 180 degrees before reinstalling. Close the cover, confirming both the line
voltage setting and that the AC power switch is set to zero (off) before installing the AC cord.
5. To apply AC power to the unit, simply press the top of the ON-OFF switch (marked 1). The AC
power switch is located in the rear panel AC line receptacle.
16

4
Installing the Controller Card
This chapter explains how to install your NEAT-1000 controller card and its supporting software. If you have
purchased a different controller card, please call NEAT's Service Department at 1-800-227-1066 for assistance.
Section 4-1  Setting the Base Address
Before the card can be installed into your machine, the correct base address must be set. This address is set
using the 7 position DIP switches, A2-A8, shown in Figure 4-1.
17
Figure 4-1 The NEAT-100 Controller Card

Please note the locations of these components:
 the front connector, J2
 the top-edge connectors, J3 and J5
 the 7 position DIP switch into which we will set the base address
All other components are shown strictly for orientation.
Before installing the card, you must set the correct base address using the DIP switches. The default base
address is 1000 (dec).
Section 4-1.1  Setting the Default Base Address
The default base address of 1000 (dec) is 3e8H (hex). Figure 4-2 shows an expanded view of how the default
number is set using the DIP switches.
Figure 4-2 Setting the Default Base Address
For each switch element, UP is a 0; DOWN is a 1. The complete hex number is made up of 12 bits. It
includes two understood, fixed 0's at the lower-order end, and a fixed 001 at the high-order end.
18