USAutomation Accuriss 57 Series User manual

®
USA57 Revision 1.2
Accuriss
™
57 Series
Integrated Motor, Drive & Control System
USA57
USER’S MANUAL

USA57 Revision 1.2 2
©2010 USAutomation, Inc.
All rights reserved
USAutomation©AccurissTM Series User's Guide
This manual, as well as the software described in it, is furnished under license and may be used
or copied only in accordance with the terms of such license. The content of this manual is
furnished for informational use only, is subject to change without notice and should not be
construed as a commitment by USAutomation. USAutomation assumes no responsibility or
liability for any errors or inaccuracies that may appear herein.
Except as permitted by such license, no part of this publication may be reproduced, stored in a
retrieval system or transmitted, in any form or by any means, electronic, mechanical, recording,
or otherwise, without the prior written permission of USAutomation.
USAutomation, Inc.
23011 Moulton Parkway
Suite J2
Laguna Hills, CA 92653
[phone]
[phone] fax
www.usautomation.com

USA57 Revision 1.2 3
Contents
Contents.......................................................................................................3
Revision Notes ...............................................................................................5
Product Returns..............................................................................................6
Unpacking.....................................................................................................6
Part Number Configuration .................................................................................7
Dimensions and Connection Pin out ......................................................................8
Mounting the USA57 ........................................................................................9
Mounting a Load to the USA57 ............................................................................9
Speed Torque Curves..................................................................................... 10
Accuriss Communications ................................................................................ 12
Starter Kit ................................................................................................... 12
Command Set Table................................................................................. 14
Programming Examples .................................................................................. 75
Appendix A.................................................................................................. 80
Homing Algorithm in Detail.......................................................................... 80
Appendix B.................................................................................................. 83
Device Response Packet............................................................................ 83
Command Response Modification ................................................................. 86
Appendix C ................................................................................................. 87
Heat Dissipation ...................................................................................... 87
Appendix D ................................................................................................. 88
Step Loss Detection using an Opto-sensor....................................................... 88
Appendix E.................................................................................................. 89
Position Correction Mode and Overload Report Mode.......................................... 89
Appendix F.................................................................................................. 95
Appendix G ................................................................................................. 99
Appendix H ............................................................................................... 100

USA57 Revision 1.2 4
Appendix I................................................................................................. 101
Appendix J ................................................................................................ 103

USA57 Revision 1.2 5
Revision Notes
Rev Description Date
1.0 Version 1 released 6/14/10
1.1 Changes to text to correct errors 6/18/10
1.2 Update part number, update error correction 7/26/10

USA57 Revision 1.2 6
Using This Manual
The Accuriss Series is a unique motor, drive and control all in one package. The USA57 is the
57mm version in this series and it is designed to be interactively controlled with a computer or
other industrial controller or may be preprogrammed to run complex subroutines from programs
stored in non-volatile RAM.
This manual provides the basic information necessary to unpack, set up, and configure the
USA57. If additional information is required beyond what is presented here, please refer to the
Support section of our website or contact USAutomation Applications Engineering.
Product Returns
All returns for warranty or out-of-warranty repairs must first receive an RMA (Return Material
Authorization) number. Please contact USAutomation Customer Service Department with
information about the return and an RMA number will be issued if warranted.
Products returned to the factory will be examined and tested for failure mode and cause.
USAutomation Customer Service will contact the customer with the repair cost if the required
repair is out of warranty.
Unpacking
Carefully remove the USA57 from its shipping box and inspect the unit for any evidence of
shipping damage. Report any damage immediately to USAutomation. Please save the shipping
box for damage inspection or its use in returning product if necessary.
Please observe the following guidelines for handling and mounting of your USA57:
Do not drop the unit on any hard surface or subject it to any impact loads. Dropping the
unit or other impact loads may result in bearing damage or misalignment.
Do not drill holes into the motor. Drilling holes into the unit can generate particles and
machining forces that may affect the operation of the unit. USAutomation can supply the
USA57 with modifications to your drawing. Please contact the factory for a quote.
Do not expose the USA57 to mist, spray or submersion in liquids.
Do not disassemble the USA57. Unauthorized adjustments may alter the specifications
and void the product warranty.

USA57 Revision 1.2 7
Part Number Configuration
The part number for the Microstage USA57 is determined as follows:

USA57 Revision 1.2 8
Dimensions and Connection Pin out
Part # “L” Dimension
USA57-2106 2.96 in.
USA57-2206 3.75 in.
Accuriss Pinout Color Code
Pin # Function
1 Power Ground (-V) Black
2 Output 1 White/Brown
3 Direction (DIR) Input White/Yellow
4 Opto isolated STEP & DIR +5VDC Power Input White/Red
5 Input 2 Violet
6 Internal Power for Opto-sensors Orange
7 Input 3 Gray
8 RS485 A Yellow
9 +12 to +40 VDC (+V) Red
10 Output 2 White/Black
11 STEP Input White/Orange
12 Signal Ground Blue
13 Input 1 Brown
14 Input 4 Green
15 RS485 B White
16 N/C

USA57 Revision 1.2 9
Mounting the USA57
Threaded mounting holes are located on the front of the Accuriss 57. There are four thru holes
with a 0.200 in. diameter. See Dimensions section for exact locations.
Mounting a Load to the USA57
The Accuriss 57 has 0.250 in. diameter shaft for mounting the load (see dimensions page).
Care should be used in isolating the motor bearing from thrust and axial loads. It is not
advisable to couple loads to the Accuriss shaft with a solid coupling as that may impose radial
loads on the motor bearings which will shorten the life of the motor. A flexible coupling, such as
those made by Helical (www.heli-cal.com), should be used.

USA57 Revision 1.2 10
Speed Torque Curves
The base motor for the USA57 is a 1.8°/step 2-phase hybrid step motor. Full torque will be
available from the motor when used with a drive which has a rated output of at least 2.0 amps
per phase. Here are representative speed/torque curves for the two different lengths of motors
available. Individual applications may differ in motor performance:

USA57 Revision 1.2 11

USA57 Revision 1.2 12
Accuriss Communications
Communications to the Accuriss is possible with any RS485 compatible communication device
and any commonly available terminal program. Most computers have either an RS232 or USB
port (sometimes both). USAutomation offers software drivers for both on our web site or in our
Starter Kit. Commercially available USB to RS485 and RS232 to RS485 converters will allow
communications with the Accuriss from most computers using only a compatible terminal
program.
Also available as a software tool is the Accuriss Terminal software, which is available as a no
charge download from our web site, or it is included in our Starter Kit.
Communication Specifications
Electrical
Characteristics
In conformance with EIA-485 Use a twisted pair cable (TIA/EIA-568B CAT5e or
higher is recommended) and keep the total wiring distance including extension to
50 m (164 ft.) or less.
Baud rate Selectable from 9570 bps, 19200 bps, 38400 bps (9570 is default)
Physical layer Asynchronous mode (8 bits, 1 stop bit, no parity)
Starter Kit
The Accuriss Starter Kit is recommended for any first time user of the Accuriss 57. This kit
contains a USB to RS485 converter, an I/O break out board, two input switches, and a CD that
includes catalogs, manuals, and software.

USA57 Revision 1.2 13
Executing Commands
In order to execute a command or a series of commands, the following syntax should be used:
[/][Device Address][Command][Value]…{[Command]{[Value]}[R][<CR>]
Where,
/ = the start character. Data following the “/” character will be loaded into the communication
buffer.
Device Address = the device address. (Factory Preset)
Command = the command to be executed.
Value = a valid value for the command to be executed (position value, speed, etc).
Note: Up to fourteen (14) Commands and Values can be in a single command string.
R = Execute the command(s) in the communication buffer already received .
<CR> = Carriage Return+Line Feed (CR+LF) and indicates that the command string is
complete.
Example 1:
/1A1000R<CR>
“/” is the start of character. Lets Accuriss know that a command string is coming.
“1” is the device address. (This is preset at the factory)
“A” Instructs motor to move to an absolute position.
“1000” sets the absolute position to +1000 steps from the zero position.
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” tells Accuriss that the command string is complete and causes the command(s) to
be executed since the R was included in the command string.
Example 2:
Command string 1: /1A2000A0<CR>
Command string 2: /1R<CR>
For command string 1:
“/” is the start of character. Lets Accuriss know that a command string is coming.
“1” is the device address. (This is preset at the factory)
The first “A” instructs motor to move to an absolute position.
“2000” sets the absolute position to +2000 steps relative to the zero position.
The second “A” instructs motor to move to an absolute position.
“0” sets the absolute position to the zero position.
“<CR>” tells Accuriss that the command string is complete. Nothing is executed at this time
because the R command was not included in the command string.
For command string 2:
“/” is the start of character. Lets Accuriss know that a command string is coming.
“1” is the device address. (This is preset at the factory)
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” tells Accuriss that the command string is complete and causes both of absolute
position the commands to be executed since an R command is included in the command
string.

USA57 Revision 1.2 14
Command Set
Command Set Table
Command Type Description Page
A Motion
Absolute move in positive direction 16
P Motion
Index move in positive direction 17
D Motion
Index move in negative direction 18
Z Motion
Homes motor 19
z Motion
Set current position to commanded number 21
f I/O
Set home flag polarity 22
F System Control
Change direction of rotation considered positive 23
V Motion Variable
Set velocity 24
L Motion Variable
Set acceleration rate 25
B Motion Variable
Set jog distance 26
g Program Control
Set beginning loop marker 27
G Program Control
Set number of loops 28
H Program Control
Halt command and wait for condition 29
S Program Control
Skip next command and branch on condition 30
s Program Control
Store program to address 31
e Program Control
Execute stored program 32
R Program Control
Run command string 33
X Program Control
Repeat running of command string 34
m System Control
Set maximum current while moving (%) 35
h System Control
Set maximum hold current (%) 36
p Program Control
Send string to terminal 37
j System Control
Set microstep resolution 38
N System Control
Set feedback mode 39
n System Control
Set Accuriss mode 40
an I/O
Set limit switch mode 42
b Communication
Set baud rate 43
o System Control
Microstep waveform correction factor 44
M Program Control
Wait for X milliseconds 45
ar System Control
Reset the Accuriss processor 46
aP System Control
Controller Response delay 47
d I/O
Switch debounce delay 48
K Motion
Backlash compensation factor 49
aA Motion
Oscillating (Sinusoidal) motion amplitude 50

USA57 Revision 1.2 15
aW Motion Oscillating (Sinusoidal) motion frequency 51
J I/O
Turn Accuriss outputs on or off 52
?aa System Control
Read back analog to digital converter values 53
at System Control
Analog to digital converter threshold 54
?at System Control
Read back analog to digital threshold values 55
ao System Control
Position potentiometer offset value 56
am System Control
Position potentiometer multiplier value 57
ad System Control
Position potentiometer deadband value 58
aC System Control
Position correction deadband range 59
aE System Control
Encoder to microstep resolution ratio 60
au System Control
Overload detection retry limit 61
x System Control
Fine position integration period 62
ac System Control
Fine position final error range 63
u System Control
Recovery retries 64
T System Status
Terminate current command 65
?0 System Status
Return current position 66
?2 System Status
Return current maximum speed 67
?4 System Status
Return status of inputs 68
?6 System Status
Return current microstep size 69
?9 System Control
Erase all commands in EEPROM 70
?10 System Status
Return 2nd encoder or step & direction input count 71
& System Status
Return current firmware version 72
Q System Status
Return Accuriss current status 73
$ System Status
Return currently executing command 74

USA57 Revision 1.2 16
Command: A Absolute move in positive direction
Type: Motion Command
Syntax: An
Range: n = 0 to 2,147,483,648
Description: Move motor to a positive absolute position relative to the 0 (zero) position. Once
at a given absolute position, executing the same command will not move the
motor again since the absolute position has already been reached.
Example: /1A1000R<CR>
“/” Is the start character. Lets Accuriss know that a command string will follow.
“1” Is the device address, (this is preset at the factory).
“A1000” Instructs motor to move to an absolute position of positive 1000 steps from
the 0 (zero) position
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” Tells Accuriss that the command string is complete and causes the command to
be executed since an R is included in the command string.

USA57 Revision 1.2 17
Command: P Index move in positive direction
Type: Motion Command
Syntax: Pn
Range: 0 to 2,147,483,648 steps
Description: Move motor in a positive direction relative to the current position. The distance
to be moved is n steps. A distance n of zero will cause the motor to continuously
in the positive direction relative to the current position. The speed of the motion
will be the speed last set by the “V” (velocity) command. (Note: An endless move
can be terminated by the T command)
Example: /1P1000R<CR>
“/” Is the start character. Lets Accuriss know that a command string will follow.
“1” Is the device address, (this is preset at the factory).
“P1000” Instructs motor to move to a position 1000 steps in the positive direction
from its current position
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” Tells Accuriss that the command string is complete and causes the command to
be executed since an R is included in the command string.

USA57 Revision 1.2 18
Command: D Index move in negative direction
Type: Motion Command
Syntax: Dn
Range: n = 0 to 2,147,483,648 steps
Description: Move motor in a negative direction relative to the current position. The distance
to be moved is n steps. A distance n of zero will cause the motor to continuously
in the negative direction relative to the current position. The speed of the motion
will be the speed last set by the “V” (velocity) command. (Note: An endless move
can be terminated by the T command)
Example: /1D1000R<CR>
“/” Is the start character. Lets Accuriss know that a command string will follow.
“1” Is the device address, (this is preset at the factory).
“D1000” Instructs motor to move to a position 1000 steps in the negative direction
from its current position
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” Tells Accuriss that the command string is complete and causes the command to
be executed since an R is included in the command string.

USA57 Revision 1.2 19
Command: Z Move to home sensor
Type: Motion Command
Syntax: Zn
Range: n = 0 to 2,147,483,648
Initial Value: 400
Description: The “Z” command is used to set the maximum number of steps allowed for the
motor to move to a known position by seeking a home sensor. When issued,
the motor will turn toward the 0 position until the home opto-sensor is interrupted.
If the home sensor is already interrupted, the motor will back off of the sensor in
the opposite direction and then come back in until the home sensor is re-
interrupted. The motor position counter is set to zero. The homing motion is done
at the current speed “V”. The maximum number of steps allowed to go towards
home without encountering the sensor is defined by the Z command operand (n)
+ 400 steps. The maximum number of steps away from home (while sensor is
interrupted) is 10000 steps.
To set up the home flags:
First ensure that a positive move e.g. /1P100R moves away from home and the
home flag. If motor does not go away from home, flip the connections to only one
of the windings of the stepper.
The Default condition expects the output of the Home flag to be low when away
from the home sensor (as is the case in an opto). If the Home flag is high when
away from the home sensor (as in the case of a “Normally Open” switch) then
issue the command /1f1R to reverse the polarity that is expected of the home
flag.
Issue the command e.g. /1Z100000R or /1f1Z100000R as necessary.
Homing should be done at a slow speed, especially if homing to a narrow Index
pulse on an encoder, which may be missed at high speeds.
Opto and flag should be set up to be unambiguous, i.e. when motor is all the way
at one end of travel, flag should cut the opto, when at other end of travel flag
should not cut opto. There should only be one black to white transition possible in
the whole range of travel. Home can be done to an opto (N1 Mode) or Index
Pulse (N2 Mode). See Appendix A
Example: /1Z1000R<CR>

USA57 Revision 1.2 20
“/” Is the start character. Lets Accuriss know that a command string will follow.
“1” Is the device address, (this is preset at the factory).
“Z1000” Instructs motor to move toward a zero position a maximum of 1000 steps
“R” Instructs Accuriss to run the command(s) that are in the communication buffer.
“<CR>” Tells Accuriss that the command string is complete and causes the command to
be executed since an R is included in the command string.