SPiiPlus Setup Guide

Version 5.20
V e r s i o n 5 . 2 0 , October 30, 2006
COPYRIGHT
Copyright ® 1999 - 2004 ACS MotionControl Ltd.
Changes are periodically made to the information in this document. Changes are published as release
notes and are be incorporated into future revisions of this document.
No part of this document may be reproduced in any form without prior written permission from ACS
MotionControl.
TRADEMARKS
ACS MotionControl, PEG and SPii are trademarks of ACS MotionControl Ltd.
Visual Basic and Windows are trademarks of Microsoft Corporation.
Any other companies and product names mentioned herein may be the trademarks of their respective
owners.

Website: http://www.AcsMotionControl.com
Information: [email protected]
Tech Support: [email protected]

ACS MotionControl, Inc.

14700 28th Ave North - Suite 25
Plymouth, MN 55447
Tel: 800-545-2980
Tel. 763-559-7669
Fax. 763-559-0110

ACS MotionControl, Ltd.

Ramat Gabriel Industrial Park
POB 5668
Migdal HaEmek, 10500
ISRAEL
Tel: (972) (4) 6546440
Fax: (972) (4) 6546443
NOTICE
The information in this document is deemed to be correct at the time of publishing. ACS MotionControl
reserves the right to change specifications without notice. ACS MotionControl is not responsible for
incidental, consequential, or special damages of any kind in connection with using this document.

October 30, 2006 ii Setup Guide

SPiiPlus Setup Guide

Changes in Version 5.20

Page Change
Chapter 5.4 timing diagrams moved to the ACSPL+ Command Reference
Appendices describing Cogging Compensation and Control Loops removed from
the document.

October 30, 2006 iii Setup Guide

SPiiPlus Setup Guide Version 5.20

Table of Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Organization of this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Related SPiiPlus Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 The SPiiPlus Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.4 Conventions Used in this Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
1.5 Required Knowledge for Using This Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 SPiiPlus Hardware Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3 SPiiPlus Software Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
3.1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3.2 Using Programming Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4 Communication Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.1 Communication with the Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
4.1.1 How to Communicate with the Simulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4.1.2 Communicating with the Simulator Via Ethernet . . . . . . . . . . . . . . . . . . . . . . . 14
4.2 Communication via PCI Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.1 Configuring the Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.2.2 Establishing PCI Bus Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
4.3 Serial RS-232/422 Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.3.1 Troubleshooting a Serial Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.4 Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.5 Network Ethernet Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5.1 Verifying TCP/IP Support on the Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5.2 Changing the Controller TCP/IP Address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.5.3 Establishing Ethernet Network Communication with the Controller . . . . . . . . . 21
4.5.4 Troubleshooting Ethernet Network Connections . . . . . . . . . . . . . . . . . . . . . . . . 22
4.6 Ethernet Point-to-Point Communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6.1 Configuring the Host . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.6.2 Establishing Ethernet Point-to-Point Communication . . . . . . . . . . . . . . . . . . . . 24
4.6.3 Configuring the Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.6.4 Troubleshooting Ethernet Point-to-Point Connection . . . . . . . . . . . . . . . . . . . . 25
5 Axis Configuration and Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.1 Selecting Axis Setup Initial Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2 User Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
5.2.1 User Units of Measure (EFAC Variable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5.2.2 Updating Other Variables with a Changed EFAC Value . . . . . . . . . . . . . . . . . . 29
5.2.3 Verifying User Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.3 Protections and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.1 Emergency Stop Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3.2 Axis Limit Logic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3.3 Axis Following Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
5.3.4 State Transition Delays for Following Error Thresholds . . . . . . . . . . . . . . . . . . 36
5.3.5 Maximum Velocity And Acceleration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.3.6 Axis Maximum Current (Torque) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
5.3.7 Safety Faults Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

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SPiiPlus Setup Guide Version 5.20

5.4 Mechanical Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.4.1 Setting Up a Mechanical Brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
5.5 Virtual Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.5.1 Configuring a Virtual Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.6 Single and Dual Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.6.1 Calculation the Gear Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.6.2 Configuring the Dual Loop Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.7 Servo Drives (DC Brush, DC Brushless) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.7.1 Setting Up a Remote (HSSI) Servo Drive Connection . . . . . . . . . . . . . . . . . . . 46
5.7.2 Setting Up a Direct Connected Servo Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.8 Servo (DC Brush, DC Brushless) Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
5.8.1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting Up a Servo Motor 49
5.9 Stepper Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.9.1 Setting Up a Stepper Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.9.2 Correcting Stepper Position Using Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.10 Feedback Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.10.1 Encoder Input Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.10.2 Encoder Timing Limitations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.10.3 Configuring Digital Encoder Feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.10.4 Configuring Feedback: Sin-Cos . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.10.5 Configuring Feedback: Analog Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.11 Calculating Parameters of Axis Control Loop, Motor, Drive and Feedback . . . . 61
5.12 DC Brushless (AC Servo) Drive Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.12.1 Adjusting Bias for a DC Brushless (AC Servo) Motor Drive . . . . . . . . . . . . . . 62
6 Current Loop Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
6.2 Adjusting an Axis Current Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
7 Commutation for DC Brushless (AC Servo) Motors . . . . . . . . . . . . . . . . . . . . 66
7.1 Commutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
7.2 Commutation Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2.1 Commutation Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
7.2.2 Automatic Commutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
7.3 Commutation Startup Program . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
7.4 Commutation Startup Program Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.5 Troubleshooting Commutation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
8 Open Loop and Index Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
8.1 Feedback, Drive Command and Index Verification . . . . . . . . . . . . . . . . . . . . . . . 80
9 Position and Velocity Loops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
9.2 Adjusting the Velocity Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
9.3 Adjusting the Position Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
9.4 Advanced Position & Velocity Loop Variables . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.4.1 Friction Number (SLFRC) Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.4.2 Using the Notch Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10 Motion Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.1 Criteria for Determining Whether Motor is in Position . . . . . . . . . . . . . . . . . . . . 92

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10.1.1 Defining Motor In-Position Criteria . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

10.2 Motion Profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.2.1 Setting Motion Profile Variables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11 Saving, Copying, and Protecting Axis Variables . . . . . . . . . . . . . . . . . . . . . . . 95
11.1 Saving Variable Values to the Controller's Flash Memory . . . . . . . . . . . . . . . . . . 95
11.2 Duplicating Configuration And Adjustment from One Axis to Another . . . . . . . 96
11.3 Protecting Data from Unintended Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.3.1 Activating Protected Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
11.3.2 Other Protection-Related Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
11.3.3 Deactivating Protected Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
12 Homing Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
12.1 Homing Program Using Limit Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
12.2 Homing Program Using Hard Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
13 Appendix A: Nanomotion Piezo Ceramic Motors . . . . . . . . . . . . . . . . . . . . . 103
13.1 Dead Zone Mechanism . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1.1 Dead Zone Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.2 Zero Velocity Feed Forward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13.2.1 Zero Velocity Feed Forward Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
13.3 Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
14 Appendix B: Netzer Precision Electric EncoderS™ . . . . . . . . . . . . . . . . . . . 110
14.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
14.2 Netzer Precision ACSPL+ Programs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
14.2.1 Hardware Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
14.2.2 Software Setup for First Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
14.2.3 Subsequent Powerups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
14.2.4 Netzer_Startup.prg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
14.2.5 Position_Retrieval.prg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
15 Appendix C: Working with a Gantry Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.2 Gantry Implementation Using Connect And Depends Commands . . . . . . . . . . . 117
15.3 Gantry Implementation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
15.3.1 Gantry Setup and Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
15.3.2 Commutation and Homing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
15.3.3 Gantry Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
16 Appendix D: Working with Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . 124
16.1 About Dynamic Braking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
16.2 Dynamic Brake - Safety Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
16.2.1 Dissipation And Peak Current – Drive Verification . . . . . . . . . . . . . . . . . . . . . 125
16.2.2 Dissipation and Peak Current – Motor Verification . . . . . . . . . . . . . . . . . . . . . 127
16.2.3 Braking Torque Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
16.2.4 Dynamic Brake - Verification Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
16.3 Dynamic Brake Operation Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
17 ASDF Measuring Motion Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
17.1 Measuring Settling Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

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SPiiPlus Setup Guide

List of Tables
Table 1 Related SPiiPlus Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Table 2 Collateral Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Table 3 Document Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Table 4 Digital Outputs for Brake Control in SPiiPlus PCI. . . . . . . . . . . . . . . . . . . . . . . 42
Table 5 Digital Outputs for Brake Control in SPiiPlus CM or SPiiPlus SA. . . . . . . . . . . 42
Table 6 Dual Loop Axis Pairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Table 7 HSSI Modules and HSSI Channel Resources Consumed . . . . . . . . . . . . . . . . 47
Table 8 HSSI Axis Allocations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Table 9 Third Party Supported Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Table 10 Stepper Motor Feedback Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Table 11 Programmable encoder sampling rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Table 12 Recommended Digital Encoder Input Frequencies (E_FREQ) . . . . . . . . . . . . 56
Table 13 E_FREQ and PEG Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Table 14 Analog Feedback per Axis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Table 15 Limiting Factors for Velocity Loop Tuning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Table 16 Three-phase Motor Specifications - Linear Motor. . . . . . . . . . . . . . . . . . . . . . 128
Table 17 Three-phase Motor Specifications - Rotary Motor . . . . . . . . . . . . . . . . . . . . . 129
Table 18 Motor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

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SPiiPlus Setup Guide

List of Figures
Figure 1 Main Panel – Firmware Field . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 2 Stop Programs and Motors Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 3 SPiiPlus MMI Communication Dialog - Simulator. . . . . . . . . . . . . . . . . . . . . . . 14
Figure 4 SPiiPlus MMI Communication Dialog - PCI . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 5 RS-232 Serial Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 6 RS-422 Serial Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 7 SPiiPlus MMI Communication Dialog - Serial. . . . . . . . . . . . . . . . . . . . . . . . . . 18
Figure 8 Types of Ethernet Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Figure 9 Communication Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 11 Communication. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Figure 12 TCP/IP Properties Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 13 Microsoft TCP/IP Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 14 Communication Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 15 Initial Value Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 16 EFAC Parameter Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Figure 17 Safety Monitor Example with Inverted Emergency Stop Input . . . . . . . . . . . . . 40
Figure 18 Dual Loop Control Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 19 A Quad B Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 20 Pulse-Direction Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Figure 21 Up-Down Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Figure 22 AC Servo Bias Adjustment Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Figure 23 Current Loop Adjustment Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Figure 24 Typical Current Loop Adjustment Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Figure 25 Commutation Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Figure 26 Commutation Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Figure 27 Preferences Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Figure 28 Generate Startup Program Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Figure 29 Open Loop Verification Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Figure 30 Feedback Configuration Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Figure 31 Position and Velocity Loops Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Figure 32 Position & Velocity Loop Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Figure 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Figure 34 Example of Good Velocity Loop Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Figure 35 Typical Position Loop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Figure 36 In Pos Generation Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 37 Motor Position Profile - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 38 Motor Position Profile - Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 39 Configurator Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 40 Save to Flash Dialog. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure 41 Copy Axis Dialog . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Figure 42 Communication Viewer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Figure 43 Protection Status Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Figure 44 Communication Viewer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 45 Protection Status Message. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Figure 46 Homing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Figure 47 NanoMotion Tab in Position and Velocity Loops Dialog Box . . . . . . . . . . . . . 104
Figure 48 Dead Zone Mechanism. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Figure 49 Improved Settling Time Using Zero Velocity Feed Forward . . . . . . . . . . . . . . 106
Figure 50 Settling with SLZFF=0 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

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Figure 51 Settling with SLZFF=300 counts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Figure 52 Typical Gantry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Figure 53 Gantry Axis Profile Generation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Figure 54 Dynamic Brake Implementation By The Digital Drive . . . . . . . . . . . . . . . . . . . 124
Figure 55 Measuring Settling Time (Piezoceramic Motor Example). . . . . . . . . . . . . . . . 133

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1 Introduction
This guide describes how to configure and adjust SPiiPlus motion control products to work with
supported types of motors and feedback devices.
This guide applies for the following SPiiPlus motion control product lines:
• SPiiPlus PCI-4/8 controllers
• SPiiPlus SA stand-alone controllers
• SPiiPlus CM control modules (controllers with integrated drives)

Note
The term “controller” is used in this guide whenever information
applies for both controllers and control modules. If information applies
to only one of these product groups, the group is stated explicitly.

Supported types of motors include:

• DC brush
• DC brushless with three phases
• Pulse-Direction stepper
• Piezo ceramic from Nanomotion (http://www.nanomotion.com/) - supported only by
SPiiPlus PCI.
Supported types of feedback devices include:
• quadrature encoder
• pulse-direction encoder
• up-down encoder
• sin-cos encoder (ordering option)
• analog input
• rotary and linear Electric Encoders™ from Netzer Precision
(http://www.netzerprecision.com/)

This guide describes the procedures for setting up SPiiPlus controllers as summarized below:

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1.1 Organization of this Guide

• “SPiiPlus Hardware Connection” on Page 6
• “SPiiPlus Software Installation” on Page 7
• “Communication Setup” on Page 11
• “Axis Configuration and Setup” on Page 26
• “Current Loop Adjustment” on Page 64
• “Current Loop Adjustment” on Page 64
• “Current Loop Adjustment” on Page 64
• “Position and Velocity Loops” on Page 83
• “Motion Defaults” on Page 92
• “Saving, Copying, and Protecting Axis Variables” on Page 95
• “Homing Programs” on Page 100
• “Appendix A: Nanomotion Piezo Ceramic Motors” on Page 103
• “Appendix B: Netzer Precision Electric EncoderS™” on Page 110
• “Appendix C: Working with a Gantry Axis” on Page 117
• “Appendix D: Working with Dynamic Braking” on Page 124
• “ASDF Measuring Motion Performance” on Page 132

1.2 Related SPiiPlus Tools

Table 1 Related SPiiPlus Tools
Tool Description
SPiiPlus MMI A multipurpose user interface with the controller including:
Program management, Motion management, Communication
terminal, Four channel digital oscilloscope, Safety and I/O
signals monitor, Signal tuning and adjustment, and a fully
interactive simulator.
SPiiPlus MultiDebugger An interactive tool for SPiiPlus ACSPL+ multiprogramming
that includes: Progress window for monitoring the status and
simultaneous debugging of up to 10 programs, normal and
step-by-step execution, programmable breakpoints, and a
fully interactive simulator.
SPiiPlus SPiiDebugger A developing and debugging environment for real-time
motion control algorithms inside of SPii processor.
SPiiPlus Utilities The SPiiPlus Upgrader allows upgrading or downgrading of
the controller firmware.
The SPiiPlus Emergency Wizard allows firmware recovery in
case of damage or loss of communication to the controller.

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1.3 The SPiiPlus Documentation

Table 2 Collateral Documentation
Document Description
SPiiPlus PCI-4-8 Hardware Installation and hardware connection with the SPiiPlus PCI 4
Guide or 8 axes
SPiiPlus CM Hardware Guide Installation and hardware connection with the SPiiPlus
Control Module
SPiiPlus Setup Guide Communication, configuration and adjustment procedures
for SPiiPlus motion control products.
SPiiPlus ACSPL+ Command set and high level language for programming
Programmer's Guide SPiiPlus controllers.
SPiiPlus MMI User’s Guide Software tools reference guide.
SPiiPlus MultiDebugger Multiprogramming and debugging environment for ACSPL+
User’s Guide programs.
HSSI Expansion Modules High-Speed Synchronous Serial Interface (HSSI) for
Guide expanded I/O, distributed axes, and nonstandard devices.
SPiiPlus Library Reference C++ and Visual Basic® libraries for host PC applications.
This guide is applicable for all the SPiiPlus motion control
products
SPiiPlus Utilities User’s Guide Firmware upgrade and recovery procedures.
SPiiPlus COM Library COM Methods, Properties, and Events for Communication
Reference Guide with the Controller
SPiiPlus FRF Analyzer User’s The SPiiPlus FRF (Frequency Response Function)
Guide Analyzer™ is a powerful servo analysis GUI for ACS
MotionControl SPiiPlus motion controllers.
SPiiPlus SA and SA-LT Installation and hardware connection with the SPiiPlus SA
Hardware Guide and SPiiPlus SA-LT Controllers
SPiiPlus 3U Hardware Guide Installation and hardware connection with the SPiiPlus 3U
Controller

1.4 Conventions Used in this Guide

Several text formats and fonts, illustrated in Table 3, are used in the text to convey information
about the text.

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Table 3 Document Conventions

Document Description
Bold ACSPL+ command names. Software tool menus, menu
items, dialog box names, and dialog box elements.
Italic Emphasis or an introduction to a key concept. In a command
syntax, specifies a variable name or other information that the
user provides.
Monospace Code examples.
Italic monospace Information in code examples that the user provides.
ALL CAPS Names of keys on the keyboard. For example, SHIFT.
blue italic Names of other documents.
blue underlined Cross references, web pages, and e-mail addresses.
| Symbol used in nested menu items and dialog box options
leading to a final action. For example, the sequence
Debug | New Watch | Real-time |
directs the user to open the Debug menu, choose the New
Watch command, and select the Real-time option.

Note
Highlights an essential operating or maintenance procedure,
condition, or statement

Model
Model Dependent Text Here!

CAUTION
Caution describes a condition that may result in damage to
equipment.

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A warning describes a condition that may result in serious

bodily injury, or death!

1.5 Required Knowledge for Using This Guide

SPiiPlus controllers are programmed using ACSPL+, a proprietary high level language
optimized for motion control. Familiarity with ACSPL+ is necessary for working with the
controller. ACSPL+ is described in detail in the SPiiPlus ACSPL+ Programmer's Guide.
ACSPL+ libraries are provided for host programming in other high level languages. The library
for C, C++, and Visual Basic are described in the SPiiPlus C Library Reference.

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2 SPiiPlus Hardware Connection

Installation and the electrical interface information for the controller is provided in the
hardware guide and includes the following:
• * installation: either standalone or PC-based
• * power supply connection
• * communication (with a PC) connection
• * encoder connection (for closed-loop control) – per axis
• * direct connection to a servo drive (controller or control module) or to a servo motor
(control module only) – per axis
• limit switch connections – per axis
• emergency stop button connection
• pulse-direction stepper drive connection – per axis
• digital I/O connection
• analog I/O connection
• HSSI-network module connections (remote axes and I/O expansion)
* required

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3 SPiiPlus Software Installation

All SPiiPlus motion control products use the same software (firmware for controller, high-level
language libraries for host programs, and Windows-based tools for host-based controller setup
and controller program development).
SPiiPlus software can be installed on Windows ® 95, 98, NT, 2000, ME and XP.
Each new version of SPiiPlus software is installed in a new folder (with the new version name)
under C:\Program Files\ACS MotionControl\SPiiPlus x.xx.
The SPiiPlus ADK (Advanced Development Kit) installation CD includes:
Firmware – system-level software that runs on the controller's MPU (motion processing unit).
The version of the firmware is identical to the version of the SPiiPlus CD installation and
supplied for maintenance/backup purposes. Each product is provided by ACS with the most
updated firmware released version (unless otherwise is required).
SPiiPlus MMI – Windows-based software tool for configuring, adjusting, programming and
viewing variables.
SPiiPlus MultiDebugger - Windows-based software tool for ACSPL+ application
programming and debugging.
SPiiPlus C Libraries – C, C++, and Visual Basic libraries for PC host programming in these
high level languages. Includes sample projects for Visual C++ and Visual Basic.
SPiiPlus Simulator - Windows-based controller simulator that runs on the PC without any
connected hardware. The SPiiPlus Simulator can communicate with the SPiiPlus MMI,
SPiiPlus MultiDebugger, or the SPiiPlus C Library. It can be used to debug programs and to
simulate motion trajectory (with zero following error), inputs, outputs and faults.
SPiiPlus Utilities - Windows-based software tools for upgrading or replacing firmware.
SPiiPlus Documentation – Complete documentation for the SPiiPlus software tools, the
SPiiPlus C Library, and the SPiiPlus controller hardware. All the documents are in PDF format.
In addition, the software tools include online help.
Training Files - Microsoft PowerPoint® presentations and ACSPL+ code examples.
MATLAB Simulink Files – Models of the SPiiPlus single and dual loop control algorithms.

Note
ACS MotionControl recommends using the most updated SPiiPlus tools
and documentation.

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CAUTION
The SPiiPlus MMI, MultiDebugger and the firmware version should
all come from same SPiiPlus ADK CD installation version.

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3.1 Installation
1. Insert the SPiiPlus ADK installation CD into the PC.
2. Follow on-screen installation instructions.
3. If an earlier version of SPiiPlus ADK is already installed, it is recommended to select a
Repair installation.

Note
First time installation includes LabView® runtime version. A reboot of
the PC is required to complete the SPiiPlus software installation.

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3.2 Using Programming Resources

The SPiiPlus program group is accessed from the Windows Start menu and is used to start:
• SPiiPlus MMI
• SPiiPlus Utilities
• SPiiPlus documentation (PDF format)
The SPiiPlus installation folder contains two sub-folders of particular interest to users:
• ACSC: contains SPiiPlus C libraries for C, C++, and Visual Basic. Also includes sample
projects for Visual C++ and Visual Basic.
• SPiiPlus Training: contains presentations about ACSPL+ and SPiiPlus C library
programming and sample programs.

Note
For the simulator to be accessible to a host application, a copy of the
simulator executable file, sb4.exe, must be in the same folder as the
application executable file.

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4 Communication Setup
The chapter covers:
• Communicating with the SPiiPlus Simulator
• Communicating with the physical motion control product via PCI Bus (SPiiPlus PCI only),
RS-232 serial connection, or Ethernet (option). The Ethernet connection can be either point-
to-point (PC direct to controller) or network (PC via LAN or other network to controller).
The supported connection types vary according to the motion control product model and
options ordered.
Communication setup for each type of channel is described here using the Communication
dialog box of the SPiiPlus MMI software tool. The Communication dialog box configures the
controller's communication settings.
Once you have made the required hardware connection (except in the case of the Simulator) and
configured the channel as described below, click Connect to establish communication.
If communication is successful, the following occur:
• In the Communication dialog box, the communication indicator turns green.
• SPiiPlus PCI-4/8 only: Green LED on controller board will flicker during communication.
• In the SPiiPlus MMI Main Panel, the Firmware field displays the controller firmware
version and the active communication channel.
• The Stop Programs and Motors window opens. The window remains open for as long as
SPiiPlus MMI is open.

The Stop Programs and Motors button is NOT an Emergency

Stop. When you click on the button, it issues commands to
stop motors and interrupt program execution. Auto routines
continue to run.

Figure 1 Main Panel – Firmware Field

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Figure 2 Stop Programs and Motors Window

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4.1 Communication with the Simulator

The SPiiPlus Simulator allows the user to work with the SPiiPlus MMI, SPiiPlus
MultiDebugger, or SPiiPlus C Library without being physically connected to a controller,
drives, or motors.
The Simulator is a powerful tool for use during application development and debugging.
The Simulator emulates all programming features of the controller, except for the following:
• Feedback from real motors: Instead the simulator sets the feedback values equal to the
reference values, which is equivalent to ideal motors with zero following error. This means
the feedback position and reference position are equal (or, in terms of the associated
ACSPL+ variables: FPOS=RPOS).
• Real time operation: The simulator emulates the controller time and supplies the TIME
variable, but 1 value of TIME is not equal to 1 millisecond like working with a real
SPiiPlus.
• Some hardware-based programming features, including: Index, MARK, PEG, and analog
I/O.
• Some immediate commands: #HWRES, #RESET, #PROTECT, #UNPROTECT, #U,
#IR, #SI.
• The write/read commands.
• The SPiiPlus MMI features: Application Saver, Application Loader.
The Simulator provides limited support for SPiiPlus MMI Adjuster and Configurator.

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4.1.1 How to Communicate with the Simulator

1. Open SPiiPlus MMI | Communication | Simulator.

Figure 3 SPiiPlus MMI Communication Dialog - Simulator

2. Click Connect to establish the communication channel with the Simulator.

3. Click Close to exit the Communication dialog box.

4.1.2 Communicating with the Simulator Via Ethernet

The following procedure instructs you on how to communicate with the simulator from a host
application and/or MMI via Ethernet. This form of communication allows you the following:
• Debugging host applications with the MMI tools. The MMI and the host application
communicate with the same simulator.
• Full simulation of the controller Flash memory including Read and Write commands and
using the Application Saver Loader tool.

1. Verify that the simulator (sb4.exe) resides in WINDOWS \SYSTEM or

WINNT\SYSTEM32 directory.
2. On drive C:\ create the folder SB4.
3. In C:\SB4, create the following folders:
• BAT
• DSP
• STARTUP
• USER

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4. In C:\SB4\BAT, create the text file sbauto.bt.The text file has the following string: set
network=1.
5. Execute the simulator by selecting Start | Run and entering the following command with the
latest simulator path. For example:
C:\Program Files\ACS MotionControl\SPiiPlus 5.00\BIN\sb4.exe" f c:\sb4 tcpd
The simulator finds the network settings of the host and displays them on the console.

6. Connect to simulator by either of the following options:

• From the MMI - type in the TCP/IP address displayed on the console in the
Communication Dialog Remote Address field.

• From the host application - choose and Ethernet connection with TCP/IP address
displayed on the console.

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4.2 Communication via PCI Bus

Model

This section is only applicable for SPiiPlus PCI controllers.

4.2.1 Configuring the Host

1. Once the SPiiPlus PCI card has been installed in a PCI slot, upon power up of the PC a New
Hardware Found dialog box will be displayed.
2. Use the Browse dialog box to locate file sb1218pci.inf, in your most recent SPiiPlus
installation directory (default path: C:\Program Files\ACS MotionControl\ SPiiPlus X.XX).

4.2.2 Establishing PCI Bus Communication

1. Open SPiiPlus MMI | Communication | PCI Bus. The MMI scans the PCI bus for
installed controller cards. If at least one SPiiPlus PCI card is found, the Slot field becomes
enabled.

Figure 4 SPiiPlus MMI Communication Dialog - PCI

2. If multiple controller cards are installed, choose the required card in the Slot field.
3. Click Connect to establish the communication channel with the SPiiPlus PCI card.
4. Click Close to exit the Communication dialog box.

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4.3 Serial RS-232/422 Communication

All SPiiPlus motion control products include two serial communication channels (COM):
• RS-232
• RS-422
The default settings of RS-232 and RS-422 are: 8 data bits, no parity and a regurlar stop bit.

PC SPiiPlus

RS-232

Rx Rx

Tx Tx

GND GND

Figure 5 RS-232 Serial Connection

PC Control
Module
RS-422
Rx+ Tx+
Rx- Tx-
Tx+ Rx+
Tx- Rx-
Gnd Shield

Figure 6 RS-422 Serial Connection

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1. Open MMI | Communication | Serial.

Figure 7 SPiiPlus MMI Communication Dialog - Serial

2. Specify the host computer serial Port (COM1, COM2, etc.) that is connected to the
controller.
3. The Rate of the host port, which is set here, must match that of the controller port to which
it is connected. Normally, this can be done by selecting Auto, which automatically detects
the controller rate. (The controller rate can be accessed in MMI | Configurator |
Communication Parameters.)
4. Click Connect to establish the communication channel with the SPiiPlus serial port.
5. Click Close to exit the Communication dialog box.

4.3.1 Troubleshooting a Serial Connection

• Inspect the cable and connectors.
• If a communication error message appears right after you click Connect, check that the
COM port on the PC host is not being used by another application.
• Check that the communication port specified in the Port field corresponds to the COM port
on the PC host that the cable is connected to.
• Older computers: try a lower baud rate.

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4.4 Ethernet Communication

Ethernet is a communication option that must be ordered with the controller.
Two types of supported Ethernet connections are supported, illustrated in Figure 8.
1. Network Ethernet Communication (Page 20) in which the PC communicates via a
network with the Ethernet port of the controller.
2. Ethernet Point-to-Point Communication (Page 23) in which the PC is connected directly
via Ethernet cable to the Ethernet port of the controller

Networked Ethernet
Communication

SPiiPlus Controller or
Network Control Module

PC with Ethernet Card

Point-To-Point Ethernet
Communication

SPiiPlus Controller or
Control Module

PC with Ethernet Card

Figure 8 Types of Ethernet Connection

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4.5 Network Ethernet Communication

The controller may be equipped with a 10M or 100M Ethernet adapter for a 10/100BASE-T
network interface. The Ethernet interface includes one RJ-45 type connector.
If your PC host is already connected to a local Ethernet Network, you only need configure the
controller and to connect it to the same network.

Note
Ethernet communication is an ordering option and is not available for
all products. While the physical Ethernet port may be present on the
controller, it will not work unless the controller was ordered with the
correct firmware!

4.5.1 Verifying TCP/IP Support on the Host

Verify that the TCP/IP protocol is installed on your PC:
1. From the Start button in the Windows Task Bar choose Settings | Control Panel |
Network. The Network dialog box appears.

There will be a list of the network protocols that are installed on your PC. Depending on
your version of Windows, the list may be called: “network components” (95/98) “network
protocols” (NT), “connection uses the following items” (XP), etc.
2. Verify that TCP/IP Protocol is in the list. If it isn't, ask your network administrator to install
it.
3. Verify that the TCP/IP Protocol is selected and click OK.

4.5.2 Changing the Controller TCP/IP Address

The controller cannot automatically obtain a TCP/IP address from the network server. The
static TCP/IP address must be manually entered to the controller.
1. Ask the network administrator to reserve a static TCP/IP address on the network.
2. Establish serial communication with the controller (see Section 4.3, Page 17). (If the
controller is a PCI model, you can establish PCI communication (see Section 4.2, Page 16)
with the controller instead.
3. Open MMI | Setup | Configurator | Communication Parameters.

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Figure 9 Communication Parameters

4. In the TCP/IP Address field, enter the address that you received from the network
administrator (factory default is 10.0.0.100).
5. Close both the Communication Parameters and Configurator. The following
confirmation request will appear.

Figure 10
6. Click Yes. The SPiiPlus MMI saves the new TCP/IP address in the controller non-volatile
(flash) memory.
7. The new TCP/IP address is not active immediately. To make the new value active, you must
restart the controller by clicking Application | Restart (#HWRES) on the MMI Main
Panel.
8. Proceed to establish Ethernet network communication.

4.5.3 Establishing Ethernet Network Communication with

the Controller
1. Open MMI | Communication | Ethernet.

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Enter the TCP/IP address

provided by the system
administrator

Select Network
connection

Figure 11 Communication
2. Enter the Remote Address, which is the TCP/IP address that you configured in the
controller (factory default: 10.0.0.100).
3. In the Connection field select Network.
4. Click Connect to establish the network communication channel with the SPiiPlus Ethernet
port.
5. Click Close to exit the Communication dialog box.

4.5.4 Troubleshooting Ethernet Network Connections

• Check that you are using Path-Through 10/100BASE-T cable.
• Inspect the cable and the connectors.
• Check that the network hardware/software (adapter, drive, TCP/IP protocol) is properly
installed and configured to the PC host.
• Check that the TCP/IP address reserved for the controller is unique in the network.
• Check that the right TCP/IP address is configured in the controller.
• Check that the right TCP/IP address is entered in the Communication dialog box.
• If you can communicate with the controller, but an occasional error occurs, check that
Network Connection is selected (not Point-to-Point) in the Communication dialog box.

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4.6 Ethernet Point-to-Point Communication

If you want to make a point-to-point (direct) Ethernet connection between the PC and the
controller, bear in mind that the connection requires a dedicated Ethernet card.

Note
Ethernet Point-to-Point Communication requires a 10/100BASE-T
Crossover cable.

4.6.1 Configuring the Host

1. From the Start button in the Windows Task Bar choose Settings | Control | Network.
2. Select the TCP/IP Protocol and click OK.
3. If the TCP/IP protocol is not installed, ask your network administrator to properly install the
TCP/IP protocol. If it appears several times, select the instance related to the Ethernet
adaptor card that will be used for connection with the controller.
4. Open the TCP/IP Properties dialog box.

Figure 12 TCP/IP Properties Dialog

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5. On the IP Address tab, select Specify an IP Address.

6. Enter the number 10.0.0.101 in the IP Address field, and 255.255.255.0 in the Subnet Mask
field.

Note
The IP Address for the PC has to be different than that of the controller.

7. Set the other tabs as follows (recommended):

• WINS Configuration: Disable WINS Resolution
• Gateway: Clear all Installed Gateways
• DNS Configuration: Disable DNS
8. If the following dialog box appears, click Yes.

Figure 13 Microsoft TCP/IP Message

9. Restart the PC host to make the settings active.

4.6.2 Establishing Ethernet Point-to-Point Communication

1. Open MMI | Communication | Ethernet.

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Figure 14 Communication Dialog

2. Enter the Remote Address. You must enter the TCP/IP address configured in the controller
(factory default is 10.0.0.100).
3. In the Connection Parameters field select Point-to-Point.
4. Click Connect. Once communication is established the Communication indicator turns
green, the Firmware box on the Main Panel displays the controller version and the
communication channel being used, and the Stop Programs and Motors button appears.
5. Click Close.

4.6.3 Configuring the Controller

The controller is manufactured with a default TCP/IP address 10.0.0.100. You do not need to
change this address in order to establish Ethernet point-to-point connection.

4.6.4 Troubleshooting Ethernet Point-to-Point Connection

• Check that you are using a Crossover 10/100BASE-T cable.
• Inspect the cable and the connectors.
• Check that the network hardware/software (adapter, drive, TCP/IP protocol) is properly
installed and configured on the PC host.
• Check that the default TCP/IP address was not changed in the controller and that the proper
TCP/IP address 10.0.0.100 is selected in the MMI.

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5 Axis Configuration and Setup

For each axis, the controller needs to be configured and adjusted. Controller operating variables
are stored in data structures called standard variables.

5.1 Selecting Axis Setup Initial Values

1. Open MMI | Setup | Adjuster | Initial Values.

Figure 15 Initial Value Dialog

2. For an axis that has already been adjusted and requires only modification, select Start from
current values. (To view what was changed during the last adjustment session, click View
Previous Session Information.)

Note
For an axis that has not been adjusted or where it is preferable to start
from scratch, select Load default values.

5.2 User Units

The units for motion travel in which the controller will be configured are user-selectable. The
user unit can be millimeters, microns, nanometers, degrees or any other unit that defines a
distance for a linear axis or an angle for a rotary axis.
The user unit is defined per axis. By default, the user unit is the encoder count. For example,
for a quadrature encoder with resolution of 500 lines per millimeter, each default user unit
equals 2µm/4 = 0.5µm.

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Examples of where user units can be useful:

• Programming in standard units like millimeters or degrees is more intuitive than
programming in feedback resolution units (counts).
• In a multi-axis environment, each axis could have a different feedback resolution. A motion
command applied to a group of axes (for example, PTP XYZ, 1000) will initiate a
different length of travel for each of the axes, depending on the feedback resolution. User
units for each axis can be defined to compensate for different feedback resolutions, such that
the command will generate the same length of travel for each axis.
• User units make it easier to change feedback devices. The program does not have to be
modified for the resolution of the new feedback device.
The standard variable EFAC defines the user units as a function of the encoder counts.

Note
The user units can be defined at any time in the configuration and
adjustment process. It is generally recommended to define them at the
beginning. This way setting values for configuration and protection
variables will be easier and less prone to errors.

CAUTION
EFAC variable relates with many other configuration variables.
While changing the EFAC variable via the MMI | Configurator, all
relevant configuration variables are being updated automatically.
Therefore, we recommend to change the EFAC variable only via
the Configurator and not from other places like Terminal or any
application program.

5.2.1 User Units of Measure (EFAC Variable)

1. Open MMI | Setup | Configurator
2. Select the axis.
3. Select the user units for the axis by defining EFAC. The formula to use for calculating
EFAC depends on whether the axis is rotary or linear (see below).

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5.2.1.1 Defining User Units for a Rotary Axis

Required user unit per mm

EFAC =
Feedback resolution] lines per mm [x internal multiplier

Note
For sin-cos encoders (note: support for these is an ordering option), the
internal multiplier is user-configured. The controller's internal encoder
multiplier is derived from the E_SCMUL variable, which defines the
multiplier as a power of 2. (MMI | Setup | Configurator | Encoder
Parameters.)

5.2.1.2 Defining User Units for a Linear Axis

5.2.1.3 Examples: User Unit Definition

• Example 1 (rotary motor):
• Feedback resolution: 2000 lines/rotation
• Internal multiplier: x4
• Required user unit: 360 degrees per rotation
EFAC = 360/(2000x4) = 0.045
• Example 2 (linear motor):
• Feedback resolution: 2 micron (500 lines/mm)
• Internal multiplier: x4
• Required user unit: mm
EFAC = 1/(500x4) = 0.005
• Example 3 (linear motor, sin-cos encoder):
• Encoder resolution: 500 lines/mm
• Internal multiplier: x64
• Required user unit: mm
EFAC = 1/(500x64) = 0.00003125
• Example 4 (rotary motor connected to ball screw):

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Load Motor

• Feedback resolution: 2000 lines/ rotation

• Gear ratio: 1 motor rotation=500μm (0.5mm) motion of load
• Internal multiplier: x4
• Required user unit: μm (micron)
EFAC = 1/(2000 x4 x(1/500))= 0.0625

5.2.2 Updating Other Variables with a Changed EFAC Value

Some other standard variables depend on the EFAC value. To automatically scale these
variables after changing EFAC, click Yes when the following message appears:

Figure 16 EFAC Parameter Message

5.2.3 Verifying User Units

Notes
1. These procedures are applicable only if the motor can be moved by
hand.
2. If the feedback counting direction is the reverse of what you expect,
(for example the count is positive when the motor rotates
counterclockwise whereas you expect a negative count), the count
can be inverted – see Open Loop and Index Verification, Page 80

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5.2.3.1 For a Rotary Axis:

1. Open MMI | Motion Manager. Select the axis and click Zero Feedback Position.
2. Rotate the motor one full revolution by hand.
3. Check the Feedback Position. It should match the defined user unit. For example, if the
user unit is degrees, then the feedback position should be around 360 (or -360).

5.2.3.2 For a Linear Axis:

1. Open MMI | Motion Manager. Select the axis and click Zero Feedback Position.
2. Measure a known distance (for example, 10cm) from the axis current position.
3. Mark the axis current position and the target position.
4. Move the axis by hand to the target position.
5. Check the Feedback Position. The feedback position should match the defined user unit.
For example, if the measured distance was 10cm and the user unit is one micron, the
feedback position should be around 1,000,000 (or –1,000,000).

5.3 Protections and Faults

For a detailed description of safety-related features of SPiiPlus controllers, see Safety Control
in the SPiiPlus ACSPL+ Programmer's Guide.

5.3.1 Emergency Stop Logic

Once the motion control application hardware has been connected to the controller, you must
verify that the controller properly identifies the emergency stop signal.

You must verify that the emergency stop circuit and the
controller's emergency stop logic are working correctly before
initiating any motor movement!

For information about the emergency stop hardware connection, refer to the controller's
hardware guide.

5.3.1.1 Verifying Emergency Stop Logic

1. Power on the controller.

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2. Open the SPiiPlus MMI and establish communication (see Chapter 4, Communication
Setup) with to the controller via any communication channel.
3. From the Main Window click Safety Monitor.
4. In the Safety Monitor window, locate the Emergency Stop Input indicator.

5. Release the physical emergency stop switch.

6. In the Safety Monitor window, observe the effect on the color of the Emergency Stop
Input indicator (red or gray depending on the logic).
7. Activate the physical emergency stop switch.
8. In the Safety Monitor window, verify that the color of the Emergency Stop Input
indicator has changed state as a result (from red or gray or vice versa, depending on the
logic).

9. From the Main window, open the Adjuster from the Setup menu.
10. Select an axis and click Safety Parameters.
11. In the Safety Parameters window, in the System Faults group, locate the Emergency
Stop line.

12. In the Emergency Stop line, select the associated S_FMASK and S_FDEF bits. (The
S_FMASK bit determines that the controller will check periodically for the emergency stop
fault, the S_FDEF bit determines that if the emergency stop fault is detected, the default
handling process will automatically be applied.)

13. Release the physical emergency stop switch.

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14. In the Safety Parameters window, in the Emergency Stop line, observe the associated
S_FAULT indicator. (S_FAULT reports the existence of the associated fault).

15. In the Safety Parameters window, if the S_FAULT indicator for Emergency Stop is red,
select the associated S_SAFINI bit and verify that as a result, the S_FAULT indicator is
now gray. (S_SAFINI inverts the logic of the system fault inputs. For example, if a fault
signal is wired so that the high signal state indicates the fault, when the corresponding
S_SAFINI bit is set, the low signal state will indicate the fault.)

16. Activate the physical emergency stop switch.

17. Verify that the S_FAULT indicator turned red as a result.
18. Release the physical emergency stop switch.
19. Verify that the S_FAULT indicator turned green as a result.

5.3.2 Axis Limit Logic

For information about the limit switch hardware connections, refer to the controller's hardware
guide.
The limit procedures described here apply for both left and right limits and for each axis.

If your application includes limit switches, you must verify that

the limit switch circuits and the controller's limit switch logic
are working correctly before initiating any motor movement.

If your application doesn't include physical limit switches, proceed as follows:

1. Open MMI | Setup | Adjuster.
2. Select the axis and click Safety Parameters.

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3. In the Motor Faults group, clear the FMASK bits for the Right Limit and Left Limit. (The
default value for these bits is 1, which would cause the controller to poll the limit switch
inputs for faults generated by nonexistent switches.)

If your application does include physical limit switches, you must verify that the controller
properly identifies the left (counting down) and right (counting up) limit switch signals. The
following sections describe how to do so.

5.3.2.1 Verifying Axis Limit Switch Logic

Note
The names of variables used with axis level variables, such as limits,
are the same as those used with system level variables, such as
emergency stop. The difference is that the system variables begin with
“S_”. For example, FMASK is the axis-level variable related to
S_FMASK!

1. Open MMI | Safety Monitor.

2. Verify that the physical limit switch is released.
3. In the Safety Monitor window, note the color of the (Right or Left) Limit indicator (red
or gray).

4. Activate the physical limit switch.

5. In the Safety Monitor window, verify that the color of the Limit indicator has changed state
as a result (from red or gray or vice versa, depending on the logic).

6. Open MMI | Setup | Adjuster.

7. Select any axis and click Safety Parameters.
8. In the Right Limit (or Left Limit) line select the associated FMASK and FDEF bits. (The
FMASK bit determines that the controller will check periodically for the limit fault, the

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FDEF bit determines that if the limit fault is detected, the default handling process will
automatically be applied.)

9. Release the physical limit switch.

10. In the Safety Parameters window, if the FAULT indicator for the Limit is red, select the
associated SAFINI bit and verify that as a result, the FAULT indicator is now gray.
(SAFINI inverts the logic of the system fault inputs. For example, if a fault signal is wired
so that the high signal state indicates the fault, when the corresponding SAFINI bit is set,
the low signal state will indicate the fault.)
11. Activate the physical limit switch.
12. Verify that the FAULT indicator turned red as a result.
13. Release the physical limit switch.
14. Verify that the FAULT indication turned gray as a result.

5.3.2.2 Setting Axis Left And Right Software Limits

When the motion of the axis has limited travel between two physical boundaries (hard stops),
the user can define left (when counting down) and right (when counting up) software limit
positions.
Typically a software limit would be set to serve as a warning before the axis reaches the
corresponding physical limit switch. The software limits are defined in user units.

Note
The axis is moved manually in the following procedure. If that isn't possible,
it is recommended to wait till the motor is configured and then to jog the
motor to the desired software limit position.

1. Open MMI | Motion Manager and move the physical axis manually to the zero position.
2. In the Motion Manager window, click Zero Feedback Position.
3. Move the axis manually to the left (counting down) until you reach the position that you
want to define as the software left limit.
4. In the Motion Manager window, find the Feedback Position (FPOS) and record it.
5. Open MMI | Setup | Adjuster.
6. Select the axis and click Safety Parameters.
7. In the Safety Parameters window, in the Software Left Limit field, enter the position that
you recorded in step.

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8. Move the axis manually to the right (counting up) until you reach the position that you want
to define as the software right limit.
9. In the Motion Manager window, again find and record the Feedback Position (FPOS).
10. In the Safety Parameters window, in the Software Right Limit field, enter the new
feedback position that you recorded.

5.3.3 Axis Following Errors

A following error occurs when there is a difference between the reference (desired) position
(RPOS) and the feedback (actual) position (FPOS). A following error fault occurs when the
following error exceeds a user-defined threshold. Following errors are defined per axis and in
user units.
There are two following error faults:
• PE (position error): A following error fault that is still considered part of normal operation.
Normally, the user can program a condition based on this fault. See more in the SPiiPlus
ACSPL+ Programmer's Guide.
• CPE (critical position error): A following error fault that is considered an abnormal
operation. See more in the SPiiPlus ACSPL+ Programmer's Guide.
Each of these faults has three user-defined thresholds. The applicable threshold depends on the
current motor state:
• Idle (motor not moving): ERRI (position error in idle state), CERRI (critical position error
in idle state).
• Constant velocity: ERRV, CERRV
• Acceleration: ERRA, CERRA
For example, when the motor is in idle state, the criteria for determining whether there is a PE
fault is ERRI and the criteria for determining whether there is a CPE fault is CERRI.

Note
It is recommended to assign high following error fault thresholds for
the duration of the configuration and adjustment process. This will
accommodate the process while maintaining a measure of safety.

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5.3.3.1 Setting Axis Following Error Thresholds

1. Open MMI | Setup | Adjuster.
2. Select the axis you want to configure and click Safety Parameters.
3. For both the Position Error and the Critical Position Error, enter the maximum
acceptable error (in user units) for each of the motor states.

5.3.4 State Transition Delays for Following Error

Thresholds
If required, delays can be configured to cause the controller, after changing motor state, to wait
before it starts to check whether the following error has exceed the threshold associated with
the new state.
The controller provides two delay variables:
• DELI - Time (milliseconds) to wait on transition from acceleration state to idle state
• DELV - Time (milliseconds) to wait on transition from acceleration to constant velocity
state.
The following diagram illustrates the use of these delays when checking for a PE fault for a
typical motion profile:

V
PE > ERRI PE > ERRA PE > ERRV PE > ERRA PE > ERRI

DELV DELI

t
:

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In the Safety Parameters window, enter the DELI and DELV values.

5.3.5 Maximum Velocity And Acceleration

The maximum velocity and acceleration that the controller is allowed to generate can be defined
per axis in user units. If these limits are exceeded, a fault is generated.

5.3.5.1 Setting Axis Velocity And Acceleration Limits

1. Open MMI | Setup | Adjuster.
2. Select the axis and click Safety Parameters.

3. Enter the Maximum Velocity (XVEL) for the axis.

CAUTION
The maximum velocity variable (XVEL) is used as a scale factor for
other adjustment variables. Therefore, it is important to define a
proper value for it. Defining a value that is not reasonable for the
feedback characteristics and required velocity of your application
will lead to poor adjustment results.

4. Enter the Maximum Acceleration (XACC) for the axis.

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5.3.6 Axis Maximum Current (Torque)

The controller supports the following current fault and limits (per axis):
• Overcurrent fault (CL bit): as defined by the maximum allowed RMS (XRMS) which is
calculated for the length of time defined by the RMS time constant (XRMST).
• XCURI limit: Maximum allowed current when the motor is idle.
• XCURV limit: Maximum allowed current when the motor is moving.

Note
When working with third party drives the controller converts the
current command to 10V ptp.

The current limits are defined as a percentage of the maximum current (torque) command.

If the drive is capable of generating higher peak or continuous

current than the motor is rated for, the current limits must be
set correctly to prevent damage to the motor.

5.3.6.1 Setting Axis Maximum Current/Torque Limits

1. Open MMI | Setup | Adjuster.
2. Select the axis and click Safety Parameters.

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3. Enter the Idle (XCURI) limit. It is recommended to set this value at the minimum current
level required by the motor to keep the axis in position. The value should not exceed the
XCURV value.
4. Enter the Motion (XCURV) limit state according to the formula: XCURV = [allowed
motor peak current / drive peak current] x 100. Refer to the drive and motor specifications
for these peak values.
5. Enter the RMS (XRMS) limit according to the formula: XRMS = [allowed motor nominal
current / drive peak current] x 100. Refer to the drive and motor specifications for these
values.
6. Enter the RMS Time Constant in msec (XRMST). This is the time interval for checking
whether an overcurrent fault has occurred (meaning that XRMS has been exceeded).
The overcurrent fault activation time is according to the following formula:
fault activation = -ln(1-(XRMS/DCOM)^2)*XRMST
For example: if XRMS=50, DCOM = 100 and XRMST = 3300 msec
fault activation = -ln (0.75)*3300 = 950msec

Example: Setting current (torque) limits:

• Drive specification: peak current 20A, nominal (continuous) 10A.
• Motor specification: peak current 10A, nominal (continuous) 3A.
In this case:
• XCURI = minimum current level required by the motor to keep the axis in position, and
less than XCURV (which is 50%).
• XCURV = (10/20)*100 = 50%.
• XRMS = (3/20)*100 = 15%.

5.3.7 Safety Faults Verification

1. Open MMI | Safety Monitor.
2. Verify that all fault indicators are green, indicating that no fault is present.
For faults with dedicated inputs, the Safety Monitor shows the state of both the input and the
fault. The logic of the fault state is determined by the related bit in variable SAFINI or
S_SAFINI. Depending on the bit state, the fault state is determined to be either the associated
input state or the inverse of the input state.

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For example, in the Safety Monitor window, shown in Figure 17, the Emergency Stop Input
is red, indicating the physical input is high. However, the Emergency Stop Fault is green (fault
not active). This result occurs because the S_SAFINI.#ES bit has been set, causing the
controller to invert the logic of the Emergency Stop input.

Figure 17 Safety Monitor Example with Inverted Emergency Stop Input

5.4 Mechanical Brake

For each axis the controller can activate a mechanical brake which has a normally applied logic.
Typically, the mechanical brake is used to keep the position of the axis while the drive is
disabled.
The controller provides a mechanism that automatically activates the brake when the drive is
disabled and deactivates the brake when the drive is enabled.

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Model
SPiiPlus PCI: Brake activation is done via a digital output that is
reconfigured to perform that task.
SPiiPlus CM: Brake activation is done via a dedicated brake output
without any need for configuration.

In addition, you can define delays for these operations. For example, you may want the
controller to wait 50ms once the drive is enabled before releasing the brake.
Refer to the ACSPL+ Command & Variable Reference for enable command timing diagrams
using positive and negative BOFFTIME values, and disable command timing diagrams using
positive and negative BONTIME values.

CAUTION
The controller is designed to work with a normally-applied brake:
meaning that the brake will be released when the signal is 1.

5.4.1 Setting Up a Mechanical Brake

1. Open MMI | Setup | Configurator.
2. Select the axis and click Motor Flags.
3. In the Motor Flags (MFLAGS) dialog box, select the Mechanical Brake bit (23). This
configures the controller so that brake activation/deactivation will be triggered by a drive
disable/enable command.

4. Enter a value for the Brake Off Time (BOFFTIME). This value determines how long to
wait (milliseconds) after enabling the drive before deactivating the brake.
5. Enter a value for the Brake On Time (BONTIME). This value determines how long to wait
(milliseconds) after activating the brake before disabling the drive.

6. SPiiPlus PCI only: It is necessary to configure a digital output as the brake output. The
output will carry the command to activate (output signal: 0) or deactivate (output signal: 1)
the brake. The output will not be available for other digital output purposes while assigned
to the brake. The command syntax is:

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setconf (29, output number, 2)

where output number is axis-specific (see Table 4 and Table 5). For example, the command
setconf (29, 8, 2) assigns output 8 to control the C axis mechanical brake.
This command can be sent to the controller via: MMI | Terminal or it can be included in a host
or controller program.

Note
This output assignment must be declared every time the controller is
powered up.

Table 4 Digital Outputs for Brake Control in SPiiPlus PCI

Digital Output Controls Mechanical Digital Output Controls Mechanical
Brake for Axis Brake for Axis
OUT0.0 X OUT0.6 B
OUT0.1 Y OUT0.7 -
OUT0.2 Z OUT0.8 C
OUT0.3 - OUT0.9 D
OUT0.4 T OUT0.10 -
OUT0.5 A OUT0.11 -

Table 5 Digital Outputs for Brake Control in SPiiPlus CM or SPiiPlus SA

Digital Output Controls Mechanical Brake for Axis
OUT1.0 X
OUT1.1 Y
OUT1.4 A
OUT1.5 B

7. Open the MMI | Terminal.

8. Send the following command line: enable <axis> where <axis> is the name of the
axis (X, Y, etc.).
9. Verify that the mechanical brake is deactivated by the command.
Verify that mechanical brake is activated by the command line:
disenable <axis>

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Model
To set a digital output to work as a general purpose output after it
was defined to control a mechanical brake:
In SPiiPlus PCI: In the MMI | Configurator | Motor Flags
(MFLAGS) dialog box, unselect the Mechanical Brake bit (23).
Send the setconf (29, output number, 0) command.
In SPiiPlus CM or SA: In the MMI | Configurator | Motor Flags
(MFLAGS) dialog box, unselect the Mechanical Brake bit (23).

5.5 Virtual Axis

One or more of the SPiiPlus axe can be defined as a virtual axis. A virtual axis is normally not
connected to any hardware. Instead it is used as a master axis for one or more slaved axes
(connected to real motors). Each slave axis can be related to the virtual axis with a user-defined
gear ratio.

5.5.1 Configuring a Virtual Axis

1. To define a virtual axis, run a program with the following ACSPL+ commands:

MFLAGS<axis number>.17=0 ! Allow non-default connect command

CONNECT RPOS<axis number>.=0 ! Define axis as virtual axis
STOP ! End program

2. To re-define a virtual axis as a normal axis, run a program with the following ACSPL+
commands:

MFLAGS<axis number>.17=0 ! Allow non-default connect command

CONNECT RPOS<axis number>.=APOS>axis number! Define axis as normal axis
STOP ! End program

Note
Do not mix a virtual axis with a dummy axis (MFLAGS bit 0). Setting
an axis as a dummy will:
1. Free both of the analog outputs of the axis for general purpose use.
2. ENABLE command for the axis drive is blocked.

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5.6 Single and Dual Loop Control

The controller supports two control feedback configurations per axis:
• Single Loop (default) – control of the axis is based on one feedback source.
• Dual Loop – control of the axis is based on two feedback sources.
Dual loop control is commonly used when there is poor stiffness between the motor and the load
(for example, in belt-driven systems). Dual loop control for such applications does not suffer
from the drawbacks of single loop control, such as reduced dynamic performance due to the
poor stiffness and backlash between the motor and the load.
(Detailed block diagram of Single loop control and dual loop control can be found in Control
Loop Block Diagrams on Page 140.)
Examples of applications that benefit from dual loop control:
• Linear stage drive with a screw (linear encoder for stage position, rotary encoder for motor
velocity and for brushless software commutation for a brushless motor).
• Printer drum drive with a flexible belt (rotary encoder for drum position, rotary encoder for
motor velocity and for brushless software commutation for a brushless motor).
• A high-inertia antenna driven by a high-ratio gear motor (rotary encoder for antenna
position, rotary encoder for motor velocity and for brushless software commutation for a
brushless motor).
Dual loop control works as follows:
1. Load position feedback is used as input for the position loop.
2. Motor position feedback is used as input for the velocity loop.
Dual loop control can only be used for axes X, Y, Z, and/or T. In each case, a second axis is
defined as a dummy axis, respectively: A, B, C or D. For example, if dual loop control is used
for axis Y, then a dummy B axis must be defined as well. Therefore, dual loop control always
consumes two of the total available controller axes.
Figure 18 illustrates a sample dual loop application. A feedback device (#1) is located on the
motor shaft and used as input for the velocity loop. A second feedback device (#2) is located
next to the load and used as input for the position loop.

B e lt

Gear
M o to r

#2
P o s itio n lo o p
V e lo c ity lo o p
fe e d b a c k
fe e d b a c k
#1 M o v in g
th e lo a d

Figure 18 Dual Loop Control Example

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5.6.1 Calculation the Gear Ratio

Before configuring the dual loop control, obtain the gear ratio between the velocity loop
feedback and the position loop feedback. If the gear ration is unknown, find it according to the
following procedure:
1. Open MMI | Motion Manager.
2. Select both controller axes that represent the velocity loop feedback and the position loop
feedback (for example, X and A).
3. Click Zero Feedback Position.
4. Disable both axes.
5. Manually move the axis.
6. Check the position of the velocity loop feedback and of the position loop feedback.
7. Calculate the gear ration by dividing the position loop feedback value with the velocity loop
feedback value.
8. Record this value for the dual loop control configuration.

5.6.2 Configuring the Dual Loop Control

1. Open MMI | Setup | Configurator.
2. Decide which axis will be the dual loop axis (X,Y,Z or T). Look up the associated dummy
axis in Table 6 and select the dummy axis in the Configurator window.

Table 6 Dual Loop Axis Pairs

Dual Loop Axis Dummy Axis
X A
Y B
Z C
T D

3. Click Motor Flags (MFLAGS) to open the Motor Flags window.

4. Select Dummy Axis (Bit #0).
5. In the Configurator window, select the axis to be defined as dual loop.
6. Determine the user units for the position loop feedback by entering a value for the Encoder
Factor (EFAC). The feedback resolution is that of the load position feedback device. See
Section 5.2.1, User Units of Measure (EFAC Variable) on Page 27 for an explanation of
the EFAC formula.
7. Determine the user units for the velocity loop feedback by entering a value for the
Secondary Encoder Factor (E2FAC) as follows:
a) Open MMI | Setup | Adjuster.
b) Select the dual loop axis.
c) Open Axis Setup | General (tab).
d) For Control Configuration select Dual Loop.

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e) Click the Position Feedback tab.

f) Enter the value of the gear ratio as defined in the “Calculation the Gear Ratio” on
Page 45.
g) Click the Velocity Feedback tab.
h) Define the feedback device variables (per specifications of the motor position feedback
device) – see Section 5.10, Feedback Devices on Page 55.
i) Click the Position Feedback tab and define feedback device variables.

Note
In single loop control, the feedback position is represented by the FPOS
variable.
In dual loop control, the load (position loop) feedback position is
represented by FPOS and the motor (velocity) feedback position by
F2POS.
For example, in the MMI | Terminal, the command:
?X_FPOS,?X_F2POS

will display the two feedback values for the X axis.

5.7 Servo Drives (DC Brush, DC Brushless)

The controller provides two options for interfacing with an external servo drive:
• Remote (HSSI) connection: drive commands are sent via an HSSI channel (a high speed
serial communications link implemented over Ethernet-type cable) to an interface module
(like the HSSI-ED2) or to a drive module (like the HSSI-SA-1).
• Direct connection: one (or two depending on the type of motor) 10V ptp drive commands
are sent directly to the drive.

Model
SPiiPlus CM includes integrated digital drives with fixed axis assignments.
For these drives, the Drive tab in the Axis Setup window is irrelevant
(because the values are already defined in the controller).

5.7.1 Setting Up a Remote (HSSI) Servo Drive Connection

Each SPii processor supports one HSSI channel. The number of SPii processors in the
controller depends on the controller model (refer to the controller's hardware guide). Each HSSI

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channel is divided into four registers. The number of registers consumed by the HSSI module(s)
connected to the channel, depends on the module type, seeTable 7.

Table 7 HSSI Modules and HSSI Channel Resources Consumed

HSSI Module Description Registers Consumed
HSSI-ED2 Interface for two distributed axes 4
HSSI-IO16 Additional 16 digital inputs and 16 1
digital outputs
HSSI-SA-1 Distributed servo drive 2

The HSSI channel number and register that the controller allocates to the drive command
depend on the axis, as described in Table 8.

Table 8 HSSI Axis Allocations

Axis HSSI Axis HSSI
(channel:register) (channel:register)
X HSSI 0:0 A HSSI 0:2
Y HSSI 1:0 B HSSI 1:2
Z HSSI 2:0 C HSSI 2:2
T HSSI 3:0 D HSSI 3:2
Set the drive connection as follows”
1. Open MMI | Setup | Adjuster.
2. Select the axis and click Axis Setup | General (tab).
3. For the Drive Connection, select Remote.

When the HSSI Manager window is open, the controller loses

communication with all the HSSI modules.
Before opening the HSSI Manager, disable all HSSI remote
axes.

4. Open the Tools (menu)| HSSI Manager. This window is used to establish communication
between the controller and the module(s) at the other end of each HSSI communication
channel.

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5. Click Reconnect. The controller automatically detects all connected HSSI modules and
starts communicating with them.

5.7.2 Setting Up a Direct Connected Servo Drive

The controller supports three types of third party drives, described in Table 9, for servo (DC
brush and DC brushless) motors.

Model
SPiiPlus PCI-4/8 does not support drives with single-ended current
command inputs.

Table 9 Third Party Supported Drives

Supported Direct-Connected Servo Drive SPiiPlus Product
1. DC brush drive having one 10V ptp differential SPiiPlus PCI - up to eight exes
current command input.
SPiiPlus CM via HSSI-ED2 – up to
seven exes

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Table 9 Third Party Supported Drives

2. Three-phase DC brushless drive having two 10V SPiiPlus PCI - up to eight exes.
ptp differential current command inputs. The SPiiPlus CM- none (can be done by
controller performs the commutation. integrated drives only)
3. Three-phase DC brushless drive having one 10V SPiiPlus PCI - up to eight exes.
ptp differential current command input. The drive SPiiPlus CM via HSSI-ED2 – up to
performs the commutation. seven exes.

1. Open MMI | Setup | Adjuster.

2. Select the axis and click Axis Setup | Drive (tab).
3. In the Axis Setup window, from the Edit Database menu, select Drive | Database Name.
Create a new drive database file. This database file is contain the data of all the axes of the
machine.
4. In the Drive tab fields select/enter the following:
a) Name: drive manufacturer and model name.
b) Type: Select from the list.
c) DC Bus Voltage [V]: refer to drive's specifications.
d) Nominal Current [A]: refer to drive's specifications.
e) Peak Current [A]: refer to drive's specifications.
f) Description: other relevant information.
5. From the Edit Database menu, select Drive | Add Item to save the new drive description.
6. Open MMI | Setup | Configurator.
7. Enter a value (milliseconds) for Enable Time (ENTIME). This field determines the
interval allowed between when the drive enable signal is sent and when the drive needs to
be successfully enabled. Refer to the drive's specifications to determine this value.

5.8 Servo (DC Brush, DC Brushless) Motors

The controller supports two types of servo motors:
• DC brush motor.
• Three-phase DC brushless motor.

5.8.1 Setting Up a Servo Motor

1. Open MMI | Setup | Adjuster.
2. Select the axis and click Axis Setup.
3. Select the Motor tab.
4. From the Edit Database menu select Motor | Database Name.

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5. Create a new motors database file. The same database file is used for all the axes.
6. In the Motor tab fields, select/enter the following:
a) Name: motor manufacturer and model name.
b) Topology: Rotary or Linear.
c) Type: DC Brush or DC Brushless
d) Nominal Current [A]: refer to motor's specifications.
e) Description: other relevant information.
7. In Edit Database menu select Motor| Add Item to save the new motor description.

5.9 Stepper Drives

Note
The controller's PEG output and Mark input features (see descriptions
in SPiiPlus ACSPL+ Programmer's Guide) are only available for
stepper motors if at least one of the following bits is set: MFLAGS.5 or
MFLAGS.6.

The controller supports drives for pulse–direction (P-D) stepper motor. Up to half the number
of axes supported by the controller can be stepper motors. Only the X, Y, Z and T axes can be
used for stepper motor control.
Stepper motor control is open loop only. However a feedback device can be used with a stepper
motor for reading the position (it will not affect the control of the motor).
The configuration of MFLAGS bits 4, 5, and 6 determines the stepper motor feedback
configuration.

Table 10 Stepper Motor Feedback Configurations

MFLAG. MFLAG. MFLAG. Feedback Description
4 5 6
1 0 0 None • open-loop control,
• no encoder installed,
• FPOS always equal to RPOS

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Table 10 Stepper Motor Feedback Configurations

MFLAG. MFLAG. MFLAG. Feedback Description
4 5 6
1 1 0 Stepper To • open-loop control,
Encoder • no encoder installed,
Loop
• FPOS always equal to RPOS
• stepper output internally wired to
encoder input
This configuration is used mostly to enable
the encoder interface features (Mark, PEG).
PEG and MARK are based in this case on
RPOS and not on the exact feedback
position, which is unknown.
1 0 1 Encoder • open-loop control
Feedback • encoder installed
• FPOS equal to actual encoder position
When the motor is disabled, RPOS is equal
to FPOS (like for any type of motor). Once
the motor is enabled, the controller starts
with RPOS=FPOS, but then the control
continues in open loop. If eventually a
difference between RPOS and FPOS
appears, the controller never corrects it
automatically. However, the user application
can verify the difference and introduce
correction if required.

5.9.1 Setting Up a Stepper Drive

1. Open MMI |Setup | Configurator.
2. Select the axis name (X, Y, Z or T only).
3. Click Motor Flags (MFLAGS) to open the Motor Flags window.

4. Select bit 4 and bit 5 or 6 as follows:

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• P/D Stepper (bit 4): defines the axis as a stepper motor.

• Stepper-To-Encoder Loop (bit 5): enables the pulses of the stepper motor commands to be
read as if they were encoder position input – by the position feedback (FPOS) variable of
the stepper axis.
• Stepper With Encoder Feedback (bit 6): enables encoder feedback from the stepper axis
to be read to the position feedback (FPOS) variable of the stepper axis. This will not affect
the control of the motor (position error remains zero).
5. Open MMI | Setup | Configurator | Step Motor Parameters.

6. Define the Pulse Width (STEPW) per the stepper drive specifications. Verify the Pulse
Width length per the following equation:
For a rotary axis:

1000
(Maximum planned velocity (RPM)/60)
STEPW <
Number of SPiiPlus pulses to make one rotation

For a linear axis:

1000
Maximum planned velocity (meter/sec)
STEPW <
Number of SPiiPlus pulses to move 1 meter

7. Define the Step Factor (STEPF) as follows:

a) Take the number of steps of the stepper motor (for example 200 per rotation).
b) Take the multiplication factor of your stepper (or micro-stepper) drive (for example
x256).
c) Determine the number of SPiiPlus pulses required to make one rotation (steps x factor)
or move one user unit. In the example cited in steps A and B, this would be 51,200 pulses
(200x256=51,200).
d) Define STEPF as follows:
For a rotary axis:

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Number of user units per rotation

STEPF =
Number of SPiiPlus pulses to make one rotation

For a linear axis:

Required user unit (like mm, cm)

STEPF =
Number of SPiiPlus pulses to move one user unit

Note the following three examples:

• Example 1 (rotary motor):
• User unit per rotation: default (EFAC=1)
• Number of motor steps: 200 steps
• Stepper drive multiplication factor: x256
• Number of SPiiPlus pulses to make one rotation: 200x256 = 51,200
• Required STEPF: 51,200/51,200 = 1
Remark: In this case a command of PTP/R,51,200 will cause one rotation of the motor.
• Example 2 (rotary motor):
• User unit per rotation: degree (360 per rotation)
• Number of motor steps: 200 steps
• Stepper drive multiplication factor: x256
• Number of SPiiPlus pulses to make one rotation: 200x256 = 51,200
• Required STEPF: 360/51,200 = 0.0070312
Remark: in this case a command of PTP/R,360 will cause one rotation.
• Example 3 (linear axis):
• User unit: mm
• Number of steps of the stepper motor per mm: 200 steps
• Stepper drive multiplication factor: x1 (no multiplication).
• Number of SPiiPlus pulses to move one mm: 200
• Required STEPF: 1/200 = 0.005
Remark: in this case a command of PTP/R,1 will cause a 1mm movement.

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If you select the Stepper with Encoder Feedback option, verify

that the direction of motion matches the direction of the
feedback counting. You can invert feedback counting using
Invert Encoder Direction, located at MMI | Setup | Adjuster |
Open Loop Verification | Feedback Configuration | Invert
Encoder Direction.

5.9.2 Correcting Stepper Position Using Feedback

Advanced
This topic is for users who are familiar with SPiiPlus ACSPL+
programming.

When the stepper axis is equipped with a feedback device, the controller can correct the position
reached at the end of each motion to the desired position.
Such an implementation can be done by running the following program continuously:

! This program corrects the stepper target position by feedback

! Change the stepper position by the DesiredPosition variable
GLOBAL INT DesiredPosition !Declare variable called DesiredPosition
INT STEPPER_TARG_RAD !Declare variable called STEPPER_TARG_RAD
INT STEPPER_TARG_RAD !Declare variable called STEPPER_TARG_RAD
INT AXIS !Declare variable called AXIS
AXIS=1 !Define AXIS number (X=0, Y=1...).
STEPPER_TARG_RAD=2
WHILE 1 ! Run forever
TILL (MST(AXIS).#ENABLED=1 & MST(AXIS).#MOVE=0)
! Wait till the drive is enabled
IF ABS(DesiredPosition-FPOS(AXIS))>STEPPER_TARG_RAD
!Check the final position
PTP/RE (AXIS), DesiredPosition-FPOS(AXIS)
!Correct the position
END
END

In this case, change the DesiredPosition value to initiate the stepper motion.

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5.10 Feedback Devices

The controller supports both digital and analog feedback.
The following digital incremental encoders (with differential lines) are supported:
• a quad b (quadrature) & index
• clock-dir & index
• up–down & index
The following analog feedback devices (with differential lines) are also supported:
• sin-cos & index incremental encoder (ordering option)
• other feedback device via controller's analog input

Note
The controller also supports Netzer Precision absolute encoders, see
Page 112.

5.10.1 Encoder Input Clock

Advanced
This chapter about encoder clock and timing is informative for
advanced users.

The encoder is represented in the controller as a synchronous state machine that is activated by
a clock, with programmable frequency in the SPii processor:
Table 11 Programmable encoder sampling rates
E_FREQ variable Encoder maximum sampling rate
2 5MHz
20 40MHz
60 120MHz

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Notes
1. The clock frequency (E_FREQ) can be selected for the X, Y, Z, and
T axes only. Each of these axes is paired in the controller with a
second axis (X with A, Y with B, Z with C, and T with D).
When the frequency is set for the primary axis (X, Y, Z, T), the same
frequency is automatically applied to its secondary axis.
2. For a Sin-Cos encoder, the clock frequency (E_FREQ) is
automatically set to 2 (5MHz) which applies automatically to the
related secondary axis as well.

The maximum rate of A quad B counting, pulse-direction counting, and up-down counting that
the SPiiPlus can handle is equal to half the frequency of the clock. This means that the
maximum rate of a digital encoder channel can be 60MHz, 20MHz (default) or 2.5MHz.
The encoder signals are filtered by a three-stage digital filter. The higher the clock frequency,
the less filtering is done. For a 5 MHz clock, an input signal that is not stable for at least 600
nanoseconds (3 clock cycles), is considered to be noise and is ignored. For a 120MHz clock,
signals that are not stable for 25 nanoseconds are considered noise and ignored.
An edge separation between the two encoder input channels must be at least 1 clock cycle. If
the separation is less, it is considered a simultaneous transition, which is results in a miscount
and an encoder fault.

Table 12 Recommended Digital Encoder Input Frequencies (E_FREQ)

Maximum Frequency Recommended E_FREQ
up to 2 million counts/sec 2 (5MHz)
2 to 12 million counts/sec 20 (40MHz)
12 million counts /sec and higher 60 (120MHz)

The frequency of the encoder clock also affects Position Event Generator (PEG) accuracy. PEG
is a controller feature where position events trigger output pulses with sub microsecond delay.

Table 13 E_FREQ and PEG Delay

Clock Frequency (MHz) PEG Delay
2 < 1.27microsec
20 < 240nsec
60 < 115nsec

5.10.2 Encoder Timing Limitations

Figure 19–Figure 21 illustrate the following timing limitations
• A Quad B Timing
• Pulse – Direction Timing

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• Up – Down Timing

8 clocks minimum
1 clock minimum
4 clocks minimum
A
channel

B
channel

4 clocks minimum

Figure 19 A Quad B Timing

1 clock minimum 1 clock minimum

CLK

DIR 1 clock minimum

1 clock minimum 1 clock minimum

Figure 20 Pulse-Direction Timing

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1 clock minimum 1 clock minimum

UP
DOWN

1 clock minimum
Figure 21 Up-Down Timing

5.10.3 Configuring Digital Encoder Feedback

1. Open MMI | Setup | Adjuster.
2. Select the axis and click Axis Setup.
3. Click the Position Feedback tab (single loop control) or Velocity Feedback tab (dual loop
control).
4. From the Edit Database menu, select Encoder | Database Name. Create a new encoder
database file. The same database file is used for all the axes.
5. In the Position/Velocity Feedback tab fields select/enter the following:
a) Name: encoder manufacturer and model name.
b) Topology: Rotary or Linear.
c) Type: select Quadrature, Up-Down, or Pulse-Direction.
d) Encoder Frequency: select (for X, Y, Z and T axes only) according to the Encoder
Timing Limitations, Page 56.
e) *Lines Per Revolution (*if Topology value is Rotary): Enter a value or select from the
list. According to the encoder's specifications.
f) **Lines (**if Topology value is Linear): Select the units: per mm or per inch then
enter a value or select from the list –refer to the encoder's specifications.
g) External Multiplier: If no external multiplier is necessary, select 1 (default). If an
external multiplier is used, select the multiplication factor.
h) Internal Multiplier: Always 4 for a digital encoder.
i) *Counts per revolution (*if Topology value is Rotary): The product of the Lines Per
Revolution x External Multiplier x Internal Multiplier.

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j) **Counts per mm/inch (**if Topology value is Linear): The product of the Lines x
External Multiplier x Internal Multiplier.
k) Description: other relevant information.
6. From the Edit Database menu, select Encoder| Add Item to save the new encoder
description.

5.10.4 Configuring Feedback: Sin-Cos

Model
SPiiPlus PCI requires jumper configuration for sin-cos encoder
operation. Refer to the SPiiPlus PCI Hardware Guide.

1. Open MMI | Setup | Adjuster.

2. Select the axis and click Axis Setup.
3. Click the Position Feedback tab (single loop control) or Velocity Feedback tab (dual loop
control).
4. From the Edit Database menu, select Encoder | Database Name. Create a new encoder
database file. The same database file is used for all the axes.
5. In the Position/Velocity Feedback tab fields select/enter the following:
a) Name: encoder manufacturer and model name.
b) Topology: Rotary or Linear.
c) Type: Select Sin-Cos.

Note
Support for sin-cos feedback is optional and must be included in the
product order. If the controller doesn’t support sin-cos feedback, the
following error message will be displayed when you click Calculate
Parameters and Close.

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d) *Lines Per Revolution (*if Topology value is Rotary): Enter a value or select from the
list. According to the encoder's specifications.
e) **Lines (*if Topology value is Linear): Select the units: per mm or per inch then enter
a value or select from the list –refer to the encoder's specifications.
f) Internal Multiplier Factor: Select the multiplication factor to achieve the feedback
resolution you require. A high multiplication factor can be used to achieve higher
feedback resolution and better dynamic performance. However, the quality of the sin and
cosine input signals are limiting factors. It is recommended to start with a low
multiplication factor and increase it until the required resolution is achieved with minimal
degradation in performance (for example, increased position error).

Note
The controller supports sin-cos encoder input rates of up to 250,000
sine/cosine periods per second.

g) *Counts per revolution (*if Topology value is Rotary): The product of the Lines Per
Revolution x Internal Multiplier.
h) **Counts per mm/inch (**if Topology value is Linear): The product of the Lines x
Internal Multiplier.
i) Description: other relevant information.
6. From the Edit Database menu, select Encoder| Add Item to save the new encoder
description.

Note
While having an interpolated position with a sin-cos encoder, the Index,
PEG and MARK position will NOT be based on the exact interpolated
position of the axis but only on fix x4 interpolated factor.

5.10.5 Configuring Feedback: Analog Input

Other types of analog feedback devices can be connected to the controller via the controller's
analog inputs. The axes are mapped to feedback via the analog inputs as follows:

Table 14 Analog Feedback per Axis

Analog Input Feedback for Axis
AIN0 X
AIN4 Y
AIN8 Z
AIN12 T

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Table 14 Analog Feedback per Axis

Analog Input Feedback for Axis
AIN2 A
AIN6 B
AIN10 C
AIN14 D

1. Open MMI | Setup | Adjuster.

2. Open MMI | Setup | Adjuster.
3. Select the axis and click Axis Setup.
4. Click the Position Feedback tab (single loop control) or Velocity Feedback tab (dual loop
control).
5. From the Edit Database menu, select Encoder | Database Name. Create a new encoder
database file. The same database file is used for all the axes.
6. In the Position/Velocity Feedback tab fields select/enter the following:
a) Name: encoder manufacturer and model name.
b) Topology: Rotary or Linear.
c) Type: select Analog Input
d) *Resolution: Select the volts per units (*choices for /unit change depending whether
Topology value is Rotary or Linear). Then enter a value or select from the list –refer to
the encoder's specifications.
e) Description: for free text if needed
7. In Edit Database menu select Encoder| Add/Replace Item.

5.11 Calculating Parameters of Axis Control

Loop, Motor, Drive and Feedback
1. After you have completed changes in the Axis Setup window, click Calculate Parameters
and Close.
2. The Calculate Parameters window appears. This window lists all the involved
configuration parameter. The new parameters that the user defined (and other calculated
parameters based on the new definitions) will be saved in the RAM memory only after the
OK button is pressed. For each parameter the “Current Value” shows the parameter value
as exists in the RAM and the “Calculated Value” as will be saved to the RAM after the OK
button is pressed. The “Modified” column shows if the parameter value was changed.
3. Click OK to save the changes to the RAM.

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5.12 DC Brushless (AC Servo) Drive Bias

One of the motor-drive configurations that the controller supports is a three-phase DC brushless
(AC servo) motor connected to an external drive with two drive command inputs (also known
as a UV drive).
Theoretically, the drive should produce zero voltage in the three phases when the controller
drive commands are zero. In a case where the drive outputs have a bias voltage when the
controller commands are zero, this can be corrected with the SLBIASA and SLBIASB
variables. If the external drive is a current drive, it must be connected to the motor while doing
the bias adjustment. If it is a voltage drive, it doesn’t have to be connected.

Note
Bias adjustment for a of DC brush motor drive is also supported, see
“Open Loop and Index Verification” on Page 80.

5.12.1 Adjusting Bias for a DC Brushless (AC Servo) Motor

Drive
1. Configure the DC brushless motor, the drive, and the feedback as explained earlier in this
chapter.
2. Verify that the drive is connected to the controller.
3. Verify that the drive is connected to the motor (current drive only).

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4. Use two voltmeters. Connect the first between phases R and S and the second between S
and T.

If the motor is connected, enabling the drive may cause a

motor jump. Verify that the axis travel is clear of obstacles.
Be ready to engage the Emergency Stop switch.

5. Open MMI | Setup | Adjuster | DC Brushless Bias Adjustment.

6. Click Enable to enable the drive (or drive-motor combination in the case of a current drive).
7. Change the R and S offset variables (Figure 22) and watch the voltmeter reading. Try to
bring both voltmeters readings as close to zero as possible.

Figure 22 AC Servo Bias Adjustment Dialog

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6 Current Loop Adjustment

Model
SPiiPlus CM: Current loop adjustment is required for the integrated digital
drives of the SPiiPlus CM.
For all other drive types, there is no current loop adjustment and this
chapter is irrelevant.

6.1 Overview
SPiiPlus CM control modules comprise a controller and integrated digital drives. The current
control of these internal drives must be adjusted by the user.

6.2 Adjusting an Axis Current Loop

1. Open Setup | Adjuster | Current Loop Adjustment

Figure 23 Current Loop Adjustment Dialog

2. For Integrator Gain (SLIKI), enter 0.
3. For Gain (SLIKP), enter 100.
4. For Current (% of Peak Current), enter 10.
5. For Pulse Length, enter 4 msec.
6. Click Scope Autoset to open the SPiiScope.

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7. Increase the proportional Gain (SLIKP) until the response waveform approximates a
square and a small overshoot appears.
8. Increase the Integrator Gain (SLIKI) by hundreds, until you get a narrow overshoot of
10% to 20%.
9. Continue steps 7 and 8 till the motor response is satisfactory. Typical current loop
adjustment results are shown in Figure 24.

Note
During current loop adjustment, a relatively strong noise may emanate
from the Control Module. This sound is normal.

Figure 24 Typical Current Loop Adjustment Results

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7 Commutation for DC Brushless (AC

Servo) Motors

7.1 Commutation
To understand how the controller provides software commutation for DC brushless (AC Servo)
motors, it helps to first look at hardware commutation in DC brush motors.
In a DC brush motor, a fixed magnetic field created by permanent magnets in the stator interacts
with the armature current flowing in the rotor winding. The interaction of the current-carrying
conductors with the magnetic field produces a torque (or force in the case of a linear motor).
This torque/force is at its maximum value when the magnetic field vector is perpendicular to
the resultant current vector.
The mechanical commutator of a DC brush motor distributes the motor current among the
windings such that the resultant current vector remains perpendicular to the magnetic field
vector at any position and speed. This process is referred to as commutation.
In a DC brushless/AC servo motor, an electronic drive takes the place of the mechanical
commutator, keeping the resultant current vector perpendicular to the magnetic field vector by
controlling the phase currents.
There are two types of drives for 3-phase DC brushless/AC servo motors:
1. 1 Input Drive. This drive receives a single current command from the controller (10V ptp),
reflecting the desired current amplitude, and takes care of the commutation by itself. From
the controller point of view, this case does not differ from that of a DC brush motor – so
there is no controller (software) commutation.
2. 2 Input Drive. The drive receives two current commands from the controller, reflecting
desired current for two of the motor phases. In this case the controller is responsible for
commutation.
The desired current for two of the motor phases will be:
IA = I * cos (φ)
IB = I * cos (φ+ 120º)
where I is the amplitude of the current command and is the commutation angle (also referred
to as commutation phase) measured in electrical degrees.
The third phase current is dependent on the first two phase currents:
IC = -(IA + IB)
The three-phase currents generate a resultant current vector.
The commutation angle is dependent on the motor position:
φ= k * CP + θ
where CP is the motor position, k is a conversion factor between position units and electrical
degrees, and θ is an offset.

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The k factor is a constant that depends on the (rotary) motor’s number of poles (or linear motor's
magnetic pitch) and the encoder resolution. The SPiiPlus MMI Adjuster calculates k
according to the motor and encoder variables that you specified in “Axis Configuration and
Setup” on Page 26).
The θ offset keeps the resultant current vector perpendicular to the magnetic field. This offset
is determined by the controller during the commutation setup process. During this process a
current vector is generated, according to an arbitrary commutation phase φ0. A position CP0
where the magnetic field of the motor aligns with this current vector is called a detent point.
The offset θ can be calculated at the detent point as:
θ = φ0 – K * CP0 + 90°
Once this relation is known, the current vector can be kept perpendicular to the magnetic field,
thereby achieving maximum motor performance (maximum torque/current ratio).
Since the commutation angle,φ, depends on the motor position, the offset has to be determined
only once for an absolute encoder but after every power-up for an incremental encoder – since
the motor position is not known.
Therefore, when working with an incremental encoder and a DC brushless motor, commutation
setup must be executed after every powerup.
Commutation Terminology:
Commutation Adjustment – Commutation process carried out with the SPiiPlus MMI
Adjuster as part of setting up the controller.
Commutation Startup Program – ACSPL+ program that can be generated automatically
during the Commutation Adjustment. The program is used to retrieve commutation. It can be
executed after every powerup (once the system has been setup). The startup program can be
based either on bringing the motor to a detent point (usually involves movement) or on
automatic commutation (commut command), which is fast commutation retrieval using a
closed-loop algorithm (and involving almost no motor movement).

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At First Adjustment of the Axis

Commutation for a brushless motor can be done in one of three ways:

Option 1 Option 2 Option 3

Commutation Adjustment Commutation Adjustment Commutation Adjustment

Commutation Startup Program

Commutation Startup
Generation Based on Detent
Program Generation Based
Point or on an Absolute
on Auto-Commutation
Position (i.e., the Index)

After Each
Powerup

Direct commut Command Commutation Startup Startup Commutation Startup

Execution Program Execution Program Execution

After each powerup the commutation should be retrieved. This can be done by a COMMUT
command from the current motor position or by a commutation startup program that retrieves
the commutation offset at the index/other absolute position.

Figure 25 Commutation Options

The SPiiPlus MMI Adjuster is used to perform Commutation Adjustment and, optionally, to
generate a startup program.

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7.2 Commutation Adjustment

Commutation Adjustment is required at the first system startup.
The SPiiPlus MMI Adjuster executes a program that performs Commutation Adjustment
setup. The program supports several commutation schemes (procedures). You select the most
appropriate scheme for your application. In most cases, the commutation scheme will include
the following steps:
1. Find a detent point.
2. Identify the phase sequence.
3. (Optional): Verify variables (number of poles or magnetic pitch, encoder resolution) by
moving the motor several magnetic pitches and comparing the encoder feedback with the
expected results.
4. (Optional): Move to the index and save the commutation phase at that point to the controller
flash memory.

7.2.1 Commutation Adjustment Procedure

Model
SPiiPlus CM: Current loop adjustment must be done before starting
Commutation Adjustment Setup.

Note
In both Commutation Adjustment and Commutation Startup programs
that are NOT based on automatic commutation the motor is moved by
moving the current vector, which pulls the rotor with it.

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When the current vector is aligned with the magnetic field during
commutation, the motor can jump. The maximum jump is one
magnetic pitch (180 electrical degrees) of the motor in either direction.
If the motor bumps into an obstacle, the commutation setup algorithm
will attempt recovery. The recovery may involve additional abrupt
moves.
To prevent possible damage or injury, it is recommended that the
motor be initially positioned at least one magnetic pitch away from
any obstacles.

1. Open MMI | Setup | Adjuster | Commutation.

Figure 26 Commutation Dialog

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2. Select one of the two Commutation Program options:

• Standard: Starts with built-in default commutation scheme.
• User Defined: Enables Browse button for selecting a commutation program that was saved
in a file (in this case the user needs to prepare his own Commutation Startup program.
3. Select the desired Buffer for the commutation execution. (The controller supports up to 9
simultaneously executing program buffers.) Usually, you will want to select an empty
buffer to avoid overwriting an existing program.
4. Click Preferences to open the Preferences dialog box. The Preferences dialog box defines
the commutation scheme and variables for the commutation process.

Figure 27 Preferences Dialog

5. Enter an Excitation Current. This determines the amplitude of the current vector that is
used for commutation setup. The value should not exceed the nominal current ratings of the
drive and the motor. The default value is 0.95 × XRMS - see Section 5.3.6.1, “Setting
Axis Maximum Current/Torque Limits” on Page 38.

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Note
The following considerations must be taken into account:
• Due to friction and load, a low excitation current may result in poor
alignment between the current vector and the magnetic field,
resulting in unsatisfactory commutation. It is recommended to set
the excitation current high enough to generate torque/force that is at
least four times higher than the friction and load. For a rotary motor,
Torquemax = KT x Iexcitation.
• On the other hand, too high an excitation current with a low friction
system (inadequate damping) may result in excessive oscillation
and even in mechanical damage.

6. Enter a Search Velocity. This determines the velocity of the current vector during the
commutation process. During this process the motor position follows the current vector in
order to align the magnetic axes. It is recommended to set a velocity lower than one
magnetic pitch per second and higher than one fifth of a magnetic pitch per second.
7. Enter a Settling Time. This determines the time assigned to the motor for settling at detent
points.
8. Enter an Commutation Adjustment Offset. This determines the initial value of the
commutation phase. It therefore determines the initial orientation of the current vector and
the initial detent point. By properly setting this offset you can avoid initial jump in a system
with a predefined startup position. For other systems, the offset can be used to determine a
specific target position for the initial jump.
9. Select a Commutation Scheme. In all the schemes except the powerup position scheme,
the following steps are performed:
a) Settle at a first detent point.
b) Move the current vector to identify the phase sequence. Correct for wrong polarity
automatically.
c) If the feedback indicates that the motor has moved less than 50% of the expected distance,
it is assumed to have run into an obstacle and the program tries to recover in the opposite
direction.
d) Retrieve the commutation phase according to the selected scheme. Considerations when
selecting a Commutation Scheme:
• Based on detent point (first scheme): If the feedback device has no index, this is the only
scheme that can be used. If the feedback device does have an index it is recommended
to use one of the “index” schemes so that the index can be used as an absolute reference
point for commutation phase retrieval at subsequent powerups.
• Based on index (six schemes): Saves the value of the commutation phase at the index
position. This value can be used at subsequent system powerups to achieve the same
commutation result. Six variations of this scheme are available:
• First index in positive direction
• First index in negative direction

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• First index next to right limit switch

• First index next to left limit switch
• First index next to right hard stop (if the system is not equipped with limit
switches)
• First index next to left hard stop (if the system is not equipped with limit
switches)
e) Based on known powerup position: Useful when an axis always starts from a known
position. For example, a vertical axis.
10. Select or enter a Maximum Search Distance. This sets the maximum allowed distance for
searching for targets (index or limits). It is recommended to set the variable according to the
operational distance.
11. Select Display Detailed Commutation Results to receive commutation phase data (in
electrical degrees).
12. Select Verify Motor & Feedback Parameters to have the system verify the encoder and
motor variables during the Commutation Adjustment process. If the variables seem to be
configured wrong, a general message will be displayed stating that improperly configured
variables are a possible reason for failure. Once corrected you will be able to continue. In a
case of more than 20% deviation between the defined and measured pitch, the commutation
process reports failure.

CAUTION
Deviation between defined and measured pitch does not necessarily
indicate poor commutation quality. For example, incorrect definitions of
feedback variables may be compensated for by high friction, thus the
deviation may be low but the commutation will be poor.

13. Click OK and in the Commutation dialog box, click Start Commutation Program. If the
commutation process finishes successfully, bit 9 (Commutation OK) of MFLAGS is set.

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Note
If changes are made to the motor, encoder, or their wiring, then full
adjustment procedure including Commutation Adjustment must be
repeated.

7.2.2 Automatic Commutation

CAUTION
.Automatic Commutation will perform well only if the axis has been
configured and the position and velocity loops have been adjusted.

If any hardware change is made to the motor, encoder, or their

wiring, for example, reconnection of motor or encoder phases,
Commutation Adjustment without automatic commutation
must be executed again.

Automatic commutation is a way to retrieve the commutation offset automatically, using

closed-loop control.
Commutation setup (without using automatic commutation) is required once: during
Commutation Adjustment. Once this has been done, automatic commutation is recommended
at every controller powerup.
Advantages of automatic commutation:
• Minimizes initial jump.
• Allows closed-loop motion already at startup.
• Minimizes problems with vertical axes.
• Minimizes problems when the axis is in proximity to a hard-stop.
• Minimizes problems when the working area is smaller than the electrical cycle.
• Allows fast commutation retrieval.
After completing the initial system setup and adjustment, there are two options for executing
automatic commutation in subsequent powerups:
Use the ACSPL+ command: COMMUT <axis> (see the SPiiPlus ACSPL+ Programmer's

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Guide).
Use a Startup Program generated with Automatic Commutation selected.

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7.3 Commutation Startup Program

A commutation startup program is a simple ACSPL+ program (program that runs on the
controller) that retrieves commutation. Typically, you will want to make the startup program
(together with a homing program) part of the controller's AUTOEXEC routine, which ensures
that the startup program is run after every controller powerup.

Note
Commutation adjustment must be carried out after the very first
controller startup (and after any change to motor, encoder, or their
wiring). The startup program is used after all subsequent powerups.

The startup program follows the same scheme that was used for the Commutation Adjustment
but with only the following steps:
1. Find a detent point.
2. (If the commutation phase was saved in Commutation Adjustment): Move to the index and
read the commutation phase for that point from the controller flash memory.
Normally the phase sequence and motor and encoder variables do not change after
Commutation Adjustment so they are not addressed by the startup program.
Usually the startup programs are based on bringing the motor to a detent point (which involves
a movement of the motor. Nevertheless, there is an option to generate start up programs based
on Automatic Commutation, see Section 7.2.2, Page 74. This option affects the execution of
the Commutation Schemes as follows:
• Detent point scheme: Movement of the axis is minimal.
• Index scheme: The axis moves to the index in closed-loop (commutated) motion.
• Powerup position scheme: not affected.

7.3.0.1 Generating a Commutation Startup Program

When the current vector is aligned with the magnetic field

during commutation, the motor can jump. The maximum jump
is one magnetic pitch (180 electrical degrees) of the motor in
either direction. If the motor bumps into an obstacle, the
commutation setup algorithm will attempt recovery. The
recovery may involve additional abrupt moves.
To prevent possible damage or injury, it is recommended that
the motor be initially positioned at least one magnetic pitch
away from any obstacles.

1. Open MMI | Setup | Adjuster | Commutation.

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2. If necessary, modify preferences.

3. Select Generate Startup Program to generate the startup program.

Figure 28 Generate Startup Program Dialog

4. Select where to save the startup program.
5. Select Automatic Commutation if desired (recommended).
6. Click Generate.
7. If this is the initial axis setup, continue to Open Loop, Index Verification, and Axis
Adjustment. After those steps, you can return and perform automatic commutation, if
required.

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7.4 Commutation Startup Program Test

1. Open MMI | Setup | Adjuster | Commutation.
2. Click on Test Startup Program to run the startup program.
Progress messages are displayed in the Commutation Program Output area of the
window.

Note
In single loop control, commutation retrieval is based on the primary
index (IND variable), while in dual loop control it is based on the
secondary index (E2IND).

Advanced
The startup program includes a local variable (SP_Fail_Code) that
stores a termination code in the event that the program fails. You can
check SP_Fail_Code to investigate the cause of a failure.
To check the code, open MMI | Terminal and enter the
command?<buffer_number>: SP_Fail_Code. Then look the code
up in the following table.
For example, assuming that the startup program is in buffer 1, enter the
command:?1: SP_Fail_Code.

Termination Status SP_Fail_Code

Program terminated successfully. 0
Motor error. (check MERR variable). 1
Index not found within the search range. 2
Limit switch (where limit switches are used for 3
the commutation scheme) or hard stop (where
hard stops are used for the commutation scheme)
not found within the search range.
Unable to move away from the limit switch 4
(where limit switches are used for the
commutation scheme).

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7.5 Troubleshooting Commutation

If the motor does not move during Commutation Adjustment or Commutation Startup
program execution, consider the following:
• Check the connections between the controller and the drive and motor.
• If a high friction or active load is applied, increase the Excitation Current and try again.
If Commutation Adjustment or Commutation Startup program execution displays a
message about wrong motor variables, return to the MMI | Axis Setup window and verify the
following:
• Number of Poles or Magnetic Pitch are specified correctly.
• Encoder variables are specified correctly.
If the motion failed during Commutation Adjustment or Commutation Startup program
execution, probable causes are:
• Τhe required Excitation Current is greater than the XRMS value. If the motor and drive
rating allow it, try to increase the XRMS value.
• Τhere is an obstacle in the path of the motion.
Another problem that can arise is the case where Check Motor & Feedback Parameters is
not selected in the Preferences window. Inaccurate variables can cause the commutation
process to report successful completion even though the commutation is actually wrong.
Therefore it is recommended to select this field.
• Possible reasons for failure of the commutation process:
• Hard stop: motor has bumped into a hard stop or an obstacle and is unable to move.
• Excitation current too low: results in poor field alignment.
• Inaccurate motor and feedback variables.
• Hardware problems, such as encoder or drive fault, wiring error, or bad grounding.

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8 Open Loop and Index Verification

Note
This chapter applies only for servo motors (DC brush or AC servo/DC
brushless).

Open loop verification should be performed to verify proper operation of the following:
• Feedback device count is in the expected direction and is correlated with the drive command
• Index signal is latched.
• Drive and motor hardware is connected.

8.1 Feedback, Drive Command and Index

Verification
1. Open MMI | Setup menu | Adjuster | Open Loop Verification

Figure 29 Open Loop Verification Dialog

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If the motor is connected, enabling the drive may cause a

motor jump. Verify that the axis travel is clear of obstacles.
Be ready to engage the Emergency Stop switch.

2. Click Enable to enable the drive. Verify that the indicator turns green and the button
changes to Disable (which is now the operation that it triggers).

3. Click Zero to reset the encoder position.

4. Enter 10 for the Drive Output Range. This determines that the drive command will be 10%
of the maximum. This means that the maximum drive command voltage will be +/-1V.
5. Drag the Drive Output slider slowly to the right until the motor moves. If the motor doesn’t
move (due to friction), increase the Drive Output Range (%) (with the slider or by entering
a value) until the motor moves.

Verify that the velocity gauge indicator moves to the right (same direction as you moved the
slider). If the velocity arrow moves in the opposite direction, click Feedback
Configuration and select Invert Drive Output.

If the direction of the velocity gauge is opposite to that of the

Drive Output slider, it is an indication of positive feedback. This
is likely to cause a motor run away.

Figure 30 Feedback Configuration Dialog

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6. Verify that the Feedback Position increases positively when the motor direction is positive
(in the context of the end-application) – otherwise click Feedback Configuration and
select Invert Encoder Direction.
7. Verify that the Last Index field is updated every time the motion passes the encoder index.
In a rotary motor with one index, the difference between two consecutive index readings
should equal the number of counts per revolution (assuming that the user units are counts).
8. For DC brush motor only: If there is bias (an offset) in the drive (motor moves while the
controller command is zero), then with Driver Output Range (%) set to zero, use the DAC
Offset (SLIOFFFS) field to compensate.

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9 Position and Velocity Loops

9.1 Overview
SPiiPlus MMI provides a window with a soft oscilloscope for adjusting the position loop and
velocity loop. The Position & Velocity Loops window includes tabs for variables that are
specific to dedicated features (for example, notch filter) or special capabilities (for example,
support for Nanomotion piezo ceramic motors). Since adjustment of the position and velocity
loops is dependant on the EFAC and XVEL variables, these variable values are displayed for
reference (read-only). EFAC can be modified from the Axis Setup window (see Section 5.2,
on Page 26) and XVEL from the Safety Parameters window (see Section 5.3.5, on Page 37).

CAUTION
Trying to adjust the position and velocity loops when the XVEL or
EFAC variables are not set right will produce poor results. Verify
that these variables are defined correctly (to fit your application/
requirements) before starting to adjust the loops.

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Figure 31 Position and Velocity Loops Dialog

Note
The PIV control algorithm enables you to adjust each loop separately.

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9.2 Adjusting the Velocity Loop

1. Open MMI |Setup | Adjuster | Position & Velocity Loops. The Position & Velocity
Loops window and the Scope window open.
2. Click Velocity Loop Tuning. The Position & Velocity Loops window expands with
velocity loop variables and commands.

Figure 32 Position & Velocity Loop Dialog

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Figure 33
3. In the Motion Limited By field, select a limiting factor described in Table 15. The
selection determines which other Velocity Loop Tuning fields are displayed.

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Table 15 Limiting Factors for Velocity Loop Tuning

Limit Factor Description
Time Period Appropriate for a rotary system.
In the Period field enter the time in ms to move in each direction.
Positive Direction Only Allows the motor to move in the positive direction only.
Negative Direction Only Allows the motor to move in the negative direction only.
Between Two Points Appropriate for a linear system.
To zero the feedback position, click Zero. To read the feedback
position and assign it to a Point, click the corresponding Read
button.

4. For Low Pass Filter Bandwidth, enter 650Hz.

5. For Integrator Gain, enter 0.
6. For Velocity Gain, enter 100.
7. For Integrator Limit, enter 50%.
8. Verify that the Velocity field is set to 10.
9. Click Enable to enable the drive.
10. Click Run. Reciprocated motion begins.
11. Click Scope Autoset to select the reference velocity and feedback velocity as input for the
Scope window.

For the next two steps, refer to the motion profile displayed in the Scope window.
12. In the Position & Velocity Loop window, double the Velocity Gain until the profile
approximates a square with a small overshoot.
13. Increase the Integrator Gain by hundreds, until you get a narrow overshoot of 10-20% in
the waveform.

Note
It is recommended that the Integrator Bandwidth not exceed 50Hz.
(Integrator Gain)/20 = Integrator Bandwidth

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Figure 34 Example of Good Velocity Loop Tuning

14. Continue adjusting the Velocity Gain and Integrator Gain until a satisfactory profile is
achieved, as illustrated in Figure 34.

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9.3 Adjusting the Position Loop

Before you start to adjust the position loop, configure the following parameters
• First point and Second point – to define the travel of the axis during position loop
adjustment.
• Velocity, Acceleration, Deceleration, and Jerk – to define motion profile variables. The
definitions apply only for position loop adjustment using this window. They are separate
from the motion profile definitions used by the controller during normal operation.
• Dwell – time in milliseconds to wait in each direction.
1. Select Overcurrent to enable detection of that fault.
2. To zero the Feedback Position, click Zero. To read the feedback position and assign it to
a Point, click the Read button next to the Point.
3. Set the distance between the first and second Point to be large enough that the motor will
reach a constant velocity while remaining within the system limits.
4. Select the desired variables of trial motion. Set the Velocity, Acceleration and
Deceleration to 50% of the maximum required for the motion control application.
5. Click Run. Reciprocated motion starts.
6. Click Scope Autoset. This allocates Scope channels to the position loop variables: RVEL,
FVEL, and PE.
7. Increase the Position Gain to minimize position error during acceleration and deceleration.
8. Increase the Acceleration Feedforward to minimize position error during acceleration and
deceleration.

Note
The theoretical Acceleration Feedforward can be calculated as:
ACC_FF=[2^16 x 10^7 x EFAC / ACC] x.0.1

9. To improve the adjusting results, you may change the Velocity Gain, Integrator Gain or
Low Pass Filter Bandwidth. You can also activate a notch filter, see Using the Notch
Filter, Page 91. A typical position loop profile is shown below.

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Figure 35 Typical Position Loop

Advanced
The Scope Autoset button select the RPOS, FPOS and PE variables of
the axis. Advanced users can also monitor the DOUT variable in
channel #4. It will provide an indication about the command to the
drive at any stage of the motion. The DOUT full range is between
(-32,768) to (32,767) which is translated in the range of 10V ptp analog
output command to the drive.

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9.4 Advanced Position & Velocity Loop

Variables

Advanced
This topic is for users who are familiar with SPiiPlus ACSPL+
programming.

9.4.1 Friction Number (SLFRC) Implementation

The velocity friction variable SLFRC is a percentage (range: 0% to 50%) of the maximum
output. The variable sets the initial value of the velocity-loop integrator when the motion-
profile starts. Generally, SLFRC should be set to zero. For high friction load, increasing
SLFRC shortens the start motion delay by compensating for the friction torque or force.

9.4.2 Using the Notch Filter

The notch filter is designed to attenuate mechanical resonance at a specific frequency.

Note
The motor must be disabled while the notch filter is enabled.

1. Verify that the notch filter is disabled (on the Notch tag, the Enable Notch check box is
cleared, meaning that MFLAGS bit 14 is zero).
2. Use a spectrum analyzer to measure the mechanical resonance frequency.
3. Select the Notch Filter check box and for the Notch Frequency, enter the frequency that
you have measured.
4. Set the Notch Width to 5%-10% of the notch frequency and the attenuation to 5.
5. Run a motion profile, and watch the feedback velocity response on the Scope.
6. Optimize the oscillation by changing the width and the attenuation of the filter.
Maximum allowed attenuation is 20. Maximum allowed width is 33% of the notch
frequency.

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10 Motion Defaults

10.1 Criteria for Determining Whether Motor is

in Position
Two variables determine when the motor is considered to be in position:
1. Settling Time (SETTLE) - Amount of time (in milliseconds) that position error (PE) must
stay within the Target Envelope (TARGRAD) range: -TARGRAD to +TARGRAD.
Default: 0.
2. Target Envelope (TARGARD) – Maximum PE allowed during the Settling Time
(SETTLE). PE is the difference between RPOS (motor reference position) and FPOS
(motor current feedback position). Default: 1.

10.1.1 Defining Motor In-Position Criteria

1. Open MMI | Setup | Configurator

Figure 36 In Pos Generation Dialog

2. Enter values for SETTLE and TARGRAD.

Shown in detail in
next figure
Position

S )
PO
(R
n S)
tio PO
si (F
Po n
e tio
nc si
fe
re Po
Re a ck
e db
Fe

Motion Time Time

Motion Motion
Start Complete
Event Event

Figure 37 Motor Position Profile - General

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Motion
Complete
Event

Position
TARGRAD
Target variable
position (user units)
SETTLE
Feedback variable
Position (msec)

Motion Time Time

Motion Motion
Start Complete
Event Event

Figure 38 Motor Position Profile - Detail

10.2 Motion Profile

The following variables are maximum values used when the controller generates the axis's
motion profile.
• Velocity (VEL).
• Acceleration (ACC).
• Deceleration (DEC).
• Jerk (JERK).
• Kill Deceleration (KILL) – Deceleration after the motion is killed by the user or fails due
to a fault.
• Minimum Velocity (NVEL) – Normally the motion profile starts from zero velocity.
NVEL is used to start the profile from a non-zero value (start with a “jump”). This variable
is often used with stepper motors.
• Feedback Velocity Filter (FVFIL) – Filter applied to the feedback velocity (FVEL). The
parameter does not affect servo loop - affects indication only. For nonzero FVFIL:
FVELn = (FPOSn - FPOSn-1) * K* (1 – FVFIL/100) + FVEL n-1* FVFIL/100
where K is a scaling factor that reduces FVEL to user units per second.

10.2.1 Setting Motion Profile Variables

To set the motion profile variables, open MMI | Setup | Configurator and enter variable
values.The Configurator dialog appears as in Figure 39.

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Figure 39 Configurator Dialog

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11 Saving, Copying, and Protecting Axis

Variables
The controller RAM is erased when the controller undergoes a hardware. A hardware reset can
be user initiated (HWRES command) or can be caused by an interruption in power to the unit.
Therefore, when you make changes to configuration or adjustment variables, you should save
the changes to the controller's flash memory. When the controller comes back up after a
hardware reset, it reads the values stored in the flash memory to RAM.

11.1 Saving Variable Values to the Controller's

Flash Memory
1. In SPiiPlus MMI | Adjuster, click Save To Flash.

Figure 40 Save to Flash Dialog

2. In the Configuration Parameters group, verify that the axes for which you changed
variables are selected. Selecting an axis determines that all the configuration and adjustment
variable values for that axis will be saved.

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3. Click Save to save the changed variable values.

11.2 Duplicating Configuration And

Adjustment from One Axis to Another
To save time when working with identical, or similar, axes, you can copy configuration and
adjustment data from an axis that you have already setup to one or more other axes. The copied
data can be modified as necessary.
1. Open MMI | Setup | Configurator and click Copy Axis.

Figure 41 Copy Axis Dialog

2. Select the From Axis - the source axis for the configuration and adjustment data that will
duplicated to other axes.
3. Select the To Axis - the target axis (or axes).
4. A confirmation message appears, informing you that:
• the source axis values will be saved to flash memory
• the target axes will be disabled
• the source axis values will be saved to the target axis flash memory and loaded to RAM

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11.3 Protecting Data from Unintended

Changes

Advanced
This topic is for users who are familiar with SPiiPlus ACSPL+
programming

Up to this point, the controller has been in configuration mode, meaning that it can be written
to. Changing the controller mode to protected limits changes that can be made to controller
variables. Protected mode can be useful once you have completed configuration and
adjustment and want to protect the controller from changes that could be caused
unintentionally. In protected mode, the following cannot be performed:
• Changes to configuration and adjustment variables
• Modifications to user programs.
• Operations that affect the flash memory (for example, the immediate commands: #SAVE
and #LOAD).

11.3.1 Activating Protected Mode

1. Open SPiiPlus MMI | Communication Viewer

Figure 42 Communication Viewer

The Communication Viewer provides direct communication with the controller.
2. Enter #PROTECT and press ENTER twice.

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The #PROTECT command resets the SPiiPlus Controller!

Any motion that is active will be terminated. Any data that has not
been saved to the flash memory will be lost.

3. Verify that Protected Mode is active by opening SPiiPlus MMI | Application | Protection
Status.

Figure 43 Protection Status Message

11.3.2 Other Protection-Related Features

To keep a program buffer the option to change configuration parameters in protected mode, do
the following before putting the controller into protected mode (in which case the PFLAGS
parameter will be inaccessible):
1. Open MMI | Setup | Configurator | Program Buffer Parameters.
2. In the Program Buffer Parameters dialog box, select the Program Buffer.
3. Select the Privileged Buffer (bit 4).
To determine whether protection mode is active, examine the value of the CFG (configuration)
variable:
If CFG = 0, controller is in protected mode.
If CFG = 1, controller is in configuration mode.

11.3.3 Deactivating Protected Mode

1. Open MMI | Tools | Communication Viewer.
2. Click Direct Communication.
3. Click Clear.
4. Enter #UNPROTECT and press ENTER twice.

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Figure 44 Communication Viewer

5. Verify that protected mode is inactive (controller is back in configuration mode) by opening
SPiiPlus MMI | Application | Protection Status.

Figure 45 Protection Status Message

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12 Homing Programs
When an incremental feedback device (for example, incremental encoder or analog input) is
used, the absolute position of the axis is unknown after powerup. In such cases, a homing
procedure is used.
The goal of the homing procedure is to find the absolute position of the axis based on an
accurate reference point, typically an index signal or a hard stop. The absolute position of the
axis is assigned to the position counter.
The homing procedure is as follows:
1. After powerup, move from current position in positive/negative direction to the end of travel
(usually a limit switch or a hard stop).
2. Move backward to the first index.
3. Set the reference position (RPOS) to the position of the index.
4. Move to zero (or any position).

0
Load
Left Right
Lim it Encoder Index Lim it
Switch Switch

Figure 46 Homing

Notes
1. If the axis is equipped with a DC Brushless motor, then the homing
program should also include a commutation startup program, see
“Commutation Startup Program” on Page 76.
2. The controller's programming language (ACSPL+) supports
designating the axis by name or by number. This makes it possible
to execute homing for all the axes using a simple loop.

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12.1 Homing Program Using Limit Switches

The following program is an example of a homing procedure for an X axis that is equipped with
a DC brush motor and limit switches.

! The program executes the following sequence:

! - Move to the left limit switch.
! - Move to the encoder index.
! - Wait for the left limit release.
! – Set the axis origin to the position of index.
! - Move to the origin.

INT AXIS ! Define a variable named “AXIS”.

AXIS=0 ! Define axis number (0=X axis, 1=Y axis...).
VEL(AXIS)= 2000 ! Set maximum velocity.
ACC(AXIS)= 100000 ! Set acceleration.
DEC(AXIS)= 100000 ! Set deceleration.
JERK(AXIS)= 20000000 ! Set jerk.
FDEF(AXIS).#LL=0 ! Disable the axis left limit default response.
FDEF(AXIS).#RL=0 ! Disable the axis right limit default response.

ENABLE (AXIS) ! Enable the axis drive.

JOG (AXIS),- ! Move to the left limit switch.
TILL FAULT(AXIS).#LL ! Wait for the left limit switch activation.
JOG (AXIS),+ ! Move to the encoder index.
TILL ^FAULT(AXIS).#LL ! Wait for the left limit release.
IST(AXIS).#IND=0 ! Reset the index flag.
TILL IST(AXIS).#IND ! Wait till motor reaches the index.
SET FPOS(AXIS)=FPOS(AXIS)-IND(AXIS)
! Set axis origin to the position of the index.
PTP (AXIS),0 ! Move to the origin.
FDEF(AXIS).#LL=1 ! Enable the axis left limit default response
FDEF(AXIS).#RL=1 ! Enable the axis right limit default response
STOP

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12.2 Homing Program Using Hard Stops

The following program is an example for a homing procedure of X axis that is equipped with a
DC brush motor and a hard stop (no limit switches).

! The program executes the following sequence:

! - Move to the left hard stop.
! - Move to the encoder index.
! - Set the axis origin to the position of index.
! - Move to the origin.

GLOBAL INT AXIS ! Define a global variable named “AXIS”.

AXIS=0 ! Define axis number (0=X axis, 1=Y axis...).
VEL(AXIS)= 500 ! Set maximum velocity.
ACC(AXIS)= 50000 ! Set acceleration.
DEC(AXIS)= 50000 ! Set deceleration.
JERK(AXIS)= 10000000 ! Set jerk.
KDEC(AXIS)= 200000 ! Set kill deceleration.
FDEF(AXIS).#CPE=0 ! Disable the default response of critical
! position error fault.
XCURV(AXIS)=??? ! XCURV is used to limit the force applied to hard
! stop (Define ??? per case.)
ENABLE (AXIS) ! Enable the axis drive.
JOG (AXIS),- ! Move slowly to the left hard stop.
TILL ABS(X_PE)>??? ! Identify the hard stop by the position
! error.(Define??? per case.)
JOG (AXIS),+ ! Move to the encoder index.
IST(AXIS).#IND=0 ! Reset the index flag - activate index circuit.
TILL IST(AXIS).#IND ! Wait for crossing the index.
SET FPOS(AXIS)=FPOS(AXIS)-IND(AXIS)
! Set axis origin to the position of the index.
PTP (AXIS),0 ! Move to the origin.
FDEF(AXIS).#CPE=0 ! Enable the default response of critical position
! error fault.

STOP

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13 Appendix A: Nanomotion Piezo Ceramic

Motors

Note
This chapter discusses Nanomotion piezo ceramic motors driven by
ab1,ab2 and ab4 amplifiers. When adjusting a motor driven by the ab5
amplifier, adjust the motor as a regular DC motor (do not enable
MFLAGS bit 7).

Model
Support for Nanomotion piezo ceramic motors is only available in
SPiiPlus PCI controllers.

Enable NanoMotion support in one of two ways:

• SPiiPlus MMI | Setup | Adjuster | Position Loop Adjustment | NanoMotion | Enable
NanoMotion (Figure 47)
• SPiiPlus MMI | Setup | Configurator | Motor Flags (MFLAGS) | NanoMotion
Piezoceramic Motor (7).

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Figure 47 NanoMotion Tab in Position and Velocity Loops Dialog Box

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13.1 Dead Zone Mechanism

This mechanism improves the settling time by taking advantage of the intrinsic motor friction.
The algorithm stops the motor when the position approaches the target within the Dead-Zone
Minimum (SLDZMIN parameter) in user units. When the error radius increases above Dead-
Zone Maximum (SLDZMAX parameter) the motor is “servoing” again.
The parameter values depend on the system specifications. Usually:
• SLDZMIN<axis> is between 1.0 to 2.0 counts
• SLDZMAX<axis> is between 4.0 to 10.0

13.1.1 Dead Zone Example

Figure 48, shows the feedback position - FPOS (green), the drive output - DOUT (red) and the
position error - PE (white).
It can be seen that when the position error is lower than the SLDZMIN parameter the controller
cuts the servo by turning off the drive-output. The motor then stays in place due to the intrinsic
friction (with zero jitter).
When the position error goes above the SLDZMAX parameter the drive output is turned on
again.

When |PE| < SLDZMIN When |PE| > SLDZMAX

then DOUT stops then DOUT resumes

Figure 48 Dead Zone Mechanism

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13.2 Zero Velocity Feed Forward

The zero velocity feed forward mechanism improves settling time by stopping the feed forward
velocity when the axis is getting close to the target position. The distance from the target is
defined by the variable SLZFF (in user units). The proper value of SLZFF depends on the total
moving mass and the resolution of the encoder. It increases with mass and encoder resolution.
Usually:
For HR1 motor with encoder resolution of 0.1μM, set SLZFF to 100 – 300 counts.
For HR8 motor with encoder resolution of 0.1μM, set SLZFF to 300 - 400 counts.

13.2.1 Zero Velocity Feed Forward Example

A comparison of Figure 48 (SLZFF=0) with Figure 49 (SLZFF=300 counts) shows a
significant improvement in settling time from 900 [msec] to 6 [msec].

Figure 49 Improved Settling Time Using Zero Velocity Feed Forward

The following figures shows the reference position (blue) and feedback position (green) with
SLZFF=0 and with SLZFF=300 counts (Figure 50 and Figure 51). The significant
improvement in settling time can be clearly observed. With SLZFF=0 the response has some
overshoot and the feedback position settles to the desired one from above. With the
SLZFF=300 counts, there is no overshoot and the feedback position settles to the desired one

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from below.

Figure 50 Settling with SLZFF=0

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Figure 51 Settling with SLZFF=300 counts

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13.3 Tuning Procedure

1. In the Safety Parameters dialog box, set an appropriate value to the maximum velocity
parameter, XVEL. This parameter is also used for determining the velocity scale factor: the
higher its value, the lower the scale factor. If XVEL is not large enough, the value of the
SLVKP parameter will be relatively small.
2. In Axis Setup define the motor as DC brush and the amplifier as DC Brush, 1 input.
3. In Open Loop Verification verify the correct polarity of the drive output.
4. In Position Loop Adjustment, enable the NanoMotion support check box.
5. Set SLDZMIN to 2 counts and SLDMAX to 10 counts.
6. Set SLZFF parameter to 300 counts.
7. Adjust Velocity and position loops. Typical value of integrator (SLVKI) is ~1000.
8. Optimize SLZFF, SLDZMIN and SLDZMAX parameters.
9. Gradually increase the static friction compensation SLFRC to reduce position error during
motion startup.
10. Note: Set the target radius parameter TARGRAD (in the Configurator) equal to
SLDZMAX.

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14 Appendix B: Netzer Precision Electric

EncoderS™

14.1 Overview
Netzer Precision Motion Sensors Ltd. (http://www.netzerprecision.com/) develops and
produces advanced absolute sin-cos encoders. This technical application note describes how to
use the SPiiPlus motion controller with sin-cos feedback from a rotary or linear Netzer Electric
Encodertm.

Note
The following description relates to rotary encoders. In the case of
linear encoders, substitute distance for revolution. For example,
instead of the ECR (electrical cycle per revolution) use electrical cycles
per distance (mm or inch).

Netzer encoders have two modes of operation:

• Coarse mode – Provides one ECR (electrical cycle per revolution), which enables absolute
position reading over a full revolution.
• Fine mode – Generates multiple ECRs. Although the encoder produces a relatively small
number of ECRs, using the SPiiPlus encoder’s optional internal sin-cos multiplier, high
feedback resolution can be achieved.
The mode of operation is selected using one of the SPiiPlus controller’s digital outputs. On
powerup, the encoder’s coarse mode is used to identify the absolute position. Then the encoder
is switched to fine mode for high-resolution operation.
If a software-commutated DC brushless motor is used, then commutation has to be done only
once: at initial setup. On subsequent powerups the commutation phase will be retrieved based
on the absolute position.

14.2 Netzer Precision ACSPL+ Programs

Two ACSPL+ programs should be used with a Netzer encoder under varying conditions:
• Netzer_Startup.prg, Page 113
• Motor Type: Only where software commutation is required (AC servo/DC brushless
motors).
• Execution: Once only: after Commutation Adjustment setup.
The program calculates the offset between the absolute position and the commutation phase and
stores it in the SLCORG (commutation origin) variable. After executing the program, you must
save SLCORG to the controller’s flash memory.
• Position_Retrieval.prg, Page 114

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• Motor Type: For every type of motor, including (AC servo/DC brushless motors).
• Execution: After every powerup.
During the program’s execution, the motor is disabled. The program retrieves the absolute
position of the axis. If the controller’s software commutation capability is used (AC servo/DC
brushless motors), the program also retrieves the commutation phase (according to the absolute
position and the SLCORG variable).

14.2.1 Hardware Setup

1. The encoder's differential sin-cos signals should be directly connected to two analog inputs
of the SPiiPlus controller.
2. The encoder's course/fine select (C/F select) wire should be connected to one of the digital
outputs of the SPiiPlus controller. This way the encoder can be switched between the two
modes by simply changing the value of the bit of the OUT variable for the connected output.

For example, if the C/F select wire is connected to digital output #0:
• OUT0.0 = 0 sets the encoder to coarse mode
• OUT0.0 = 1 sets the encoder to fine mode
Switching between the two modes is done with OUT0.0 in the appended programs.

14.2.2 Software Setup for First Usage

1. Load Position_Retrieval.prg to a buffer in the controller. If the motor is software-
commutated AC servo/DC brushless, then load Netzer_Startup.prg to a separate buffer.
2. Open SPiiPlus MMI | I/0 Monitor. The I/O are represented by interactive indicators.
3. If the indicator for the digital output connected to the C/F select wire is not on ( ), click
on it to turn it ( ). The sets the related variable, which in turn activates the output, setting the
encoder to fine mode.
4. Open SPiiPlus MMI | Adjuster | Safety Parameters. Verify that all safety variables are
defined for the desired resolution.
5. Open SPiiPlus MMI | Adjuster | Axis Setup. Set the Drive and Motor variables.
6. On the Position Feedback tab, select Sin-Cos in the Type field.
7. Enter the number of Fine Mode ECRs in the Lines per Revolution field.
8. Select the desired Internal Multiplier Factor (E_SCMUL variable) for the required
position resolution.

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Note
The resulting Counts per Revolution = ECRs × 2 E _ SCMUL . For
example, with a rotary motor where the encoder has 8 ECRs in fine
mode and the multiplier is 12, we get 32,768 counts per revolution (8 x
212). Maximum resolution can be achieved with multiplier = 16, which
yields 524,288 counts per revolution.

9. If software commutation is required (AC servo/DC brushless motor), open SPiiPlus MMI
| Adjuster | Commutation | Preferences. (The following are required only once, at initial
setup).
a) Verify that A Detent Point is selected for the Retrieve Commutation Phase at field.
b) In the Commutation dialog box, select Start Commutation Program to perform
commutation.
c) Execute the ACSPL+ program: Netzer_Startup.prg.
10. The Position_Retrieval.prg program is set to work with a rotary motor. In the case
of a linear motor, change the ENC_RES variable to equal the total encoder length in fine
mode (counts). Run Position_Retrieval.prg.
11. The program has an offset variable ABS_OFFS, which enables you to define any point as
a zero position. For example, when the feedback position = 1000, setting ABS_OFFS =
1000 and running the program again, while the motor is standing still, will define the current
position as zero.
12. Save all variables and Position_Retrieval.prg to the controller flash memory.
13. Complete all other adjustment steps and again save all variables to the flash memory.

14.2.3 Subsequent Powerups

1. Execute the ACSPL+ program, Position_Retrieval.prg after any power-up, with the motor
is disabled. It is recommended to insert the program into an AUTOEXEC routine, so that it
will be automatically be activated upon startup.

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14.2.4 Netzer_Startup.prg

! For Using Netzer Precision's Sin-Cos Electric Encoder with a SPiiPlus

Controller
!**************************************************************************
! FW version: ???
!**************************************************************************
! Remark: Coarse/ fine selection wire is connected to digital output #0
!**************************************************************************

REAL AXIS ! Axis number

REAL ABS_POS ! Absolute position (2^16 resolution)
REAL ABS_PHASE ! Absolute phase (elec. deg)
REAL COMM_PHASE ! Reconstructed commutation phase
REAL COMM_ORG ! Commutation origin
AXIS = 0
OUT0.0 = 0 ! Operate in coarse mode
WAIT 500
DISABLE(AXIS)
! Get absolute position from SPii (2^16 resolution)

if (AXIS)=0; ABS_POS = GETSPV(SP0:X_POS_ATAN) ; end

if (AXIS)=1; ABS_POS = GETSPV(SP1:X_POS_ATAN) ; end
if (AXIS)=2; ABS_POS = GETSPV(SP2:X_POS_ATAN) ; end
if (AXIS)=3; ABS_POS = GETSPV(SP3:X_POS_ATAN) ; end
if (AXIS)=4; ABS_POS = GETSPV(SP0:A_POS_ATAN) ; end
if (AXIS)=5; ABS_POS = GETSPV(SP1:A_POS_ATAN) ; end
if (AXIS)=6; ABS_POS = GETSPV(SP2:A_POS_ATAN) ; end
if (AXIS)=7; ABS_POS = GETSPV(SP3:A_POS_ATAN) ; end

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OUT0.0=1 ! Operate in fine mode

WAIT 500
! Calculate Commutation Origin
COMM_PHASE = getconf(214,AXIS) ! Get commutation phase
ABS_PHASE = (ABS_POS/POW(2,16)-FLOOR(ABS_POS/POW(2,16)))*180*SLCNP(AXIS)
If MFLAGS(AXIS).13 ! If drive output is inverted
COMM_ORG = COMM_PHASE + ABS_PHASE

else ! Drive output is not inverted

COMM_ORG = COMM_PHASE - ABS_PHASE
end
SLCORG(AXIS)= COMM_ORG - FLOOR(COMM_ORG/360)*360
Stop

14.2.5 Position_Retrieval.prg

For Using Netzer Precision's Sin-Cos Electric Encoder with a SPiiPlus

Controller
!**************************************************************************
! FW version: ???
!**************************************************************************
! Remark: Coarse/ fine selection wire is connected to digital output #0
!**************************************************************************

REAL ABS_POS ! Absolute position (2^16 resolution)

EAL AXIS ! Axis number
REAL ABS_FPOS ! Absolute position (user units)
REAL ABS_PHASE ! Absolute phase (elec. deg)
REAL COMM_PHASE ! Retrieve commutation phase
REAL ABS_OFFS ! Absolute position offset (user defined)
REAL ENC_RES ! Encoder resolution (counts per rev/length)

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!**************************************************************************
! POSITION RETRIEVAL
!**************************************************************************

AXIS = 0
OUT0.0=0 ! Operate in coarse mode
WAIT 500
DISABLE(AXIS)

! Get absolute position from SPii (2^16 resolution)

if (AXIS)=0; ABS_POS = GETSPV(SP0:X_POS_ATAN) ; end
if (AXIS)=1; ABS_POS = GETSPV(SP1:X_POS_ATAN) ; end
if (AXIS)=2; ABS_POS = GETSPV(SP2:X_POS_ATAN) ; end
if (AXIS)=3; ABS_POS = GETSPV(SP3:X_POS_ATAN) ; end
if (AXIS)=4; ABS_POS = GETSPV(SP0:A_POS_ATAN) ; end
if (AXIS)=5; ABS_POS = GETSPV(SP1:A_POS_ATAN) ; end
if (AXIS)=6; ABS_POS = GETSPV(SP2:A_POS_ATAN) ; end
if (AXIS)=7; ABS_POS = GETSPV(SP3:A_POS_ATAN) ; end
OUT0.0=1 ! Operate in fine mode

WAIT 500
! Convert absolute position to user units:
! In case of rotary motor ENC_RES = SLCPRD(AXIS)
! In case of linear motor ENC_RES = counts per total encoder length (in fine
mode)
ENC_RES = SLCPRD(AXIS) ! Change in case of linear motor
ABS_FPOS = (ABS_POS/POW(2,16)-FLOOR(ABS_POS/POW(2,16)))*ENC_RES*EFAC(AXIS)
! ABS_OFFS is an offset in absolute position
! Set it to define required "zero position"
ABS_OFFS = 0
SET FPOS(AXIS) = ABS_FPOS - ABS_OFFS
!**************************************************************************

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! COMMUTATION RETRIEVAL
! This section is relevant only to software commutated brushless motor and
can be omitted in case of DC brush motor or hardware commutation.
!**************************************************************************

! Convert Absolute Position to Electrical Degrees:

ABS_PHASE = (ABS_POS/POW(2,16)-FLOOR(ABS_POS/POW(2,16)))*180*SLCNP(AXIS)
! Reconstruct Commutation Phase
If MFLAGS(AXIS).13 ! If drive output is inverted
COMM_PHASE = SLCORG(AXIS)- ABS_PHASE
else ! drive output is not inverted
COMM_PHASE = SLCORG(AXIS)+ ABS_PHASE
end
SETCONF(214,(AXIS),COMM_PHASE)
MFLAGS(AXIS).9=1 ! Set commutation flag
stop

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15 Appendix C: Working with a Gantry Axis

15.1 Overview
Gantry motion systems incorporate two or more motors, which work simultaneously to move
an axis. Gantry axes provide flexible and efficient solutions for a wide range of applications
like: inspection systems, materials handling, pick and place, machine loading and unloading
etc.
Typical GantryFigure 52 illustrates a typical gantry system with two motors (X1, X2) that
move a single axis (X):

Figure 52 Typical Gantry

15.2 Gantry Implementation Using Connect

And Depends Commands
Implementing complex motions like gantry is made easy with the SPiiPlus axis profile
generation commands: connect and depends commands. In a gantry application, the connect
command is used to define the relation between two variables: RPOS (reference axis position)
and APOS (dummy axis position). By default, the relation between and RPOS and APOS is
1:1.
In a gantry application the connect command enables generation of an identical motion profile
for two (or more) motors – referred to as master and slave motors (see next figure). The connect
command creates and maintains a direct link (like a mechanical link) between the motion
profile of the master motor to the slave motor.
Once a connect command has defined a new relation for RPOS, the relation remains active

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until:
• A different connect relation is defined
• The controller is shutdown
• HWRESET/RESET commands are executed
The following block diagram demonstrates the axis profile generation for gantry with two
motors:

New set-point is generated

each MPU cycle Master motor

Set Point Axis Virtual Default Reference

Generation Position Connection Position
(APOS) (1:1) (RPOS) Motion
trajectory
calculation

New set-point is generated

each MPU cycle Slaved motor
Connection
Set Point Axis Virtual based on Reference
Generation Position Master Position
(APOS) APOS + Offset (RPOS) Motion
(if any) trajectory
calculation

Figure 53 Gantry Axis Profile Generation

The DEPENDS command specifies a logical dependence between a motor and axes. By default
the motor is assigned to its axis. DEPENDS is necessary whenever the CONNECT command
is used.
The SAFETYGROUP command that provides a special operation and safety mechanism for
gantry implementation as follows:
SAFETYGROUP (master axis, slaved axis, slaved axis…)
This command executes the following actions:
Copies the fault configuration from the first specified axis (master) to all subsequent axes.
Blocks the axes together in response to KILL and DISABLE operations.
After the command, all specified axes are killed or disabled at once, even if the operation is
directed to one of the axes. This applies to both the operation initiated by the commands or by
the faults.

15.3 Gantry Implementation

The following implementation is for a gantry application involving two identical motors and
feedback devices. Similar implementations can be derived for gantry applications involving

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more axes (one master motor and two or more slave motors).
Preparation for gantry implementation comprises the following steps:
1. Gantry axes setup, configuration and adjustment
2. Gantry axes commutation and homing
Once these steps have been accomplished the system is ready for normal gantry operation.
Meaning, the user needs to refer to the master axis only and the slaved axis will be operated
automatically.

15.3.1 Gantry Setup and Configuration

1. MMI | Setup | Configurator : Set the safety parameters for the master (limits, current
values, position error etc). Copy the configuration to the identical slaved axis – see
“Duplicating Configuration And Adjustment from One Axis to Another” on Page 96.
2. MMI | Setup | Adjuster | Commutation: make commutation separately for each (if DC
brushless motor is being used).
3. MMI | Setup | Adjuster | Open loop verification: make verification in open loop
separately for each motor.
4. Load the following program to a buffer and run it:

! THIS PROGRAM IS USED TO ADJUST A GANTRY SYSTEM

INT GLOBAL M_AXIS, S_AXIS ,BUFFER !"M" FOR MASTER AXIS, "S" FOR SLAVED AXIS
M_AXIS=4 ; S_AXIS=5 ;BUFFER=7! SET HERE THE INVOLVED AXIS NUMBERS A=4, B=5

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DISABLE(M_AXIS);DISABLE(S_AXIS)
!------ Configuration variables ---------------------
ERRI(S_AXIS)=ERRI(M_AXIS)
ERRV(S_AXIS)=ERRV(M_AXIS)
ERRA(S_AXIS)=ERRA(M_AXIS)
CERRI(S_AXIS)=CERRI(M_AXIS)
CERRV(S_AXIS)=CERRV(M_AXIS)
CERRA(S_AXIS)=CERRA(M_AXIS)
DELI(S_AXIS)=DELI(M_AXIS)
DELV(S_AXIS)=DELV(M_AXIS)
SLLIMIT(S_AXIS)=SLLIMIT(M_AXIS)
SRLIMIT(S_AXIS)=SRLIMIT(M_AXIS)
XVEL(S_AXIS)=XVEL(M_AXIS)
XACC(S_AXIS)=XACC(M_AXIS)
VELBRK(S_AXIS)=VELBRK(M_AXIS)
XRMS(S_AXIS)=XRMS(M_AXIS)
XRMST(S_AXIS)=XRMST(M_AXIS)
XCURI(S_AXIS)=XCURI(M_AXIS)
XCURV(S_AXIS)=XCURV(M_AXIS)

!------ Adjustment variables ---------------------

SLPKP(S_AXIS)=SLPKP(M_AXIS)
SLVKP(S_AXIS)=SLVKP(M_AXIS)
SLVKI(S_AXIS)=SLVKI(M_AXIS)
SLVLI(S_AXIS)=SLVLI(M_AXIS)
SLVSOF(S_AXIS)=SLVSOF(M_AXIS)
SLIOFFS(S_AXIS)=SLIOFFS(M_AXIS)
SLFRC(S_AXIS)=SLFRC(M_AXIS)
SLAFF(S_AXIS)=SLAFF(M_AXIS)
SLCPA(S_AXIS)=SLCPA(M_AXIS)
EFAC(S_AXIS)=EFAC(M_AXIS)

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!------ Motion variables ---------------------

VEL(S_AXIS)=VEL(M_AXIS)
ACC(S_AXIS)=ACC(M_AXIS)
DEC(S_AXIS)=DEC(M_AXIS)
JERK(S_AXIS)=JERK(M_AXIS)
STOP

! These auto routines update the adjustment variables

! of the S_AXIS to match the M_AXIS
ON SLPKP(S_AXIS)<>SLPKP(M_AXIS); SLPKP(S_AXIS)=SLPKP(M_AXIS); RET
ON SLPKP(S_AXIS)<>SLPKP(M_AXIS); SLPKP(S_AXIS)=SLPKP(M_AXIS); RET
ON SLVKP(S_AXIS)<>SLVKP(M_AXIS); SLVKP(S_AXIS)=SLVKP(M_AXIS); RET
ON SLVKI(S_AXIS)<>SLVKI(M_AXIS); SLVKI(S_AXIS)=SLVKI(M_AXIS); RET
ON SLVLI(S_AXIS)<>SLVLI(M_AXIS); SLVLI(S_AXIS)=SLVLI(M_AXIS); RET
ON SLVSOF(S_AXIS)<>SLVSOF(M_AXIS); SLVSOF(S_AXIS)=SLVSOF(M_AXIS); RET
ON SLIOFFS(S_AXIS)<>SLIOFFS(M_AXIS); SLIOFFS(S_AXIS)=SLIOFFS(M_AXIS); RET
ON SLFRC(S_AXIS)<>SLFRC(M_AXIS); SLFRC(S_AXIS)=SLFRC(M_AXIS); RET
ON SLAFF(S_AXIS)<>SLAFF(M_AXIS); SLAFF(S_AXIS)=SLAFF(M_AXIS); RET
ON SLCPA(S_AXIS)<>SLCPA(M_AXIS); SLCPA(S_AXIS)=SLCPA(M_AXIS); RET
ON EFAC(S_AXIS)<>EFAC(M_AXIS); EFAC(S_AXIS)=EFAC(M_AXIS); RET
ON XVEL(S_AXIS)<>XVEL(M_AXIS); XVEL(S_AXIS)=XVEL(M_AXIS); RET

5. Open MMI | Adjuster | Position and Velocity Loop: adjust the maser axis normally. The
slaved axis parameters will be set identically (by the autoroutines in the program) to the
master axis.

15.3.2 Commutation and Homing

Load the following program to a buffer and run it:

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!Commutation and homing for a gantry axes

! ------------ Define axes variables -------------------------
INT GLOBAL M_AXIS; M_AXIS=4 ! Define Master axis (A axis in this example)
INT GLOBAL S_AXIS; S_AXIS=5 ! Define Slaved axis (B axis in this example)
VEL(M_AXIS)= 4000 ! Set maximum velocity
ACC(M_AXIS)= 40000 ! Set acceleration
DEC(M_AXIS)= 40000 ! Set deceleration
JERK(M_AXIS)= 400000 ! Set jerk
SAFETYGROUP(M_AXIS,S_AXIS)

!-------- Doing commutation for a brushless Master motor--------

! Use this section only for a brushless Master motor
!ENABLE (M_AXIS)
!COMMUT (M_AXIS)
!DISABLE (M_AXIS) !To allow slight movement of the S_AXIS during COMMUT
!-------- Doing commutation for a brushless Slaved motor--------
! Use this section only for a brushless Slaved motor
!ENABLE (S_AXIS)
!COMMUT (S_AXIS)

!------------Define connect functions --------------------------

MFLAGS(M_AXIS).17=0 ;MFLAGS(S_AXIS).17=0
! Turns off the Connect function default
! (FPOS = APOS)
CONNECT RPOS(M_AXIS)=APOS(M_AXIS)
DEPENDS (M_AXIS),(M_AXIS) !Master motor depends on Master axis
CONNECT RPOS(S_AXIS) = APOS(M_AXIS)
DEPENDS (S_AXIS),(M_AXIS) !Slaved motor depends on Master axis
SET APOS(M_AXIS)=0,RPOS(M_AXIS)=0, RPOS(S_AXIS)=0

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!------------Homing procedure -----------------------------------

FDEF(M_AXIS).#LL=0 ; FDEF(S_AXIS).#LL=0 ! Disable the default response of the
limit fault
ENABLE (M_AXIS); ENABLE(S_AXIS)
JOG (M_AXIS),- ! Move to the left limit switch
TILL FAULT(M_AXIS).#LL ! Wait for the left limit switch activation
! Can be written also as "TILL ABS(X_PE)>???" when no limit switches exist -
only a hard stop.
JOG (M_AXIS),+ ! Move to the encoder index
TILL ^FAULT(M_AXIS).#LL ! Wait for the left limit release
IST(M_AXIS).#IND=0 ! Reset the index flag - activate index circuit
TILL IST(M_AXIS).#IND ! Wait for crossing the index
KILL(M_AXIS,S_AXIS)
TILL ^AST(M_AXIS).#MOVE
SET FPOS(M_AXIS)=FPOS(M_AXIS)-IND(M_AXIS),
APOS(M_AXIS)=RPOS(M_AXIS),RPOS(S_AXIS)=RPOS(M_AXIS) ! Set axis origin to the
position of index = zero
FDEF(M_AXIS).#LL=1 ; FDEF(S_AXIS).#LL=1
PTP(M_AXIS),0 ! Move to the origin
STOP

15.3.3 Gantry Operation

1. After commutation and homing, issue motion commands for the master axis only, for
example:
PTP (M_AXIS), 10000. The slave axis will move automatically.
2. Enable commands should always be declared for both axes, for example:
ENABLE (M_AXIS); ENABLE(S_AXIS)

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16 Appendix D: Working with Dynamic

Braking

16.1 About Dynamic Braking

Model
Dynamic braking is supported only by SPiiPlus CM only (for X, Y
or A axis).

Dynamic braking is used to decelerate or eliminate motion of the axis while the drive is
disabled. For example the dynamic brake can decelerate the motion in a case where a critical
fault has disabled the drive during motion. Dynamic braking is executed by short-circuiting the
motor phases in the drive. In the case of a three-phase motor, this is done by simultaneously
activating the three lower transistors in the drive, as shown in Figure 54:

Three phase
motor coils
a
b
c

Figure 54 Dynamic Brake Implementation By The Digital Drive

In the case of a DC motor, two lower transistors are activated, short-circuiting the motor
armature.
During braking, the kinetic energy stored in the total moving mass / inertia of the motor is
dissipated as heat on the short-circuited phases and transistors.

CAUTION
Before implementing dynamic braking, follow the procedures described in
this chapter to prevent any damage to the control module, the motor, or the
rest of the system. In addition, we recommend measuring the actual
developed current during maximum deceleration using the MMI | Tools |
SPii Scope.

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16.2 Dynamic Brake - Safety Verification

16.2.1 Dissipation And Peak Current – Drive Verification

You must verify that the maximum current during the braking process is lower than the peak
current of the drive.

Note
All of the following formulas are designed for Star Connection
configurations, only.

The equation for maximum current calculation during braking process is for a linear motor is:
(1)
K E ⋅Vmax
I DB _ max =
3⋅ Z

where:

KE [V·s/m] - is the phase-to-phase back EMF constant

Vmax [m/s] - is the maximal linear velocity of the motor
Z=R+j x X, [Ω] is the phase impedance (the sum of a phase resistance and phase
reactance).

For a rotary motor: (2)

K E ⋅ ω max
I DB _ max =
3⋅ Z

where:

KE [V·s/rad] - is the phase-to-phase back EMF constant

ωmax [m/s] - is the maximal linear velocity of the motor
Z=R+j x X, [Ω] is the phase impedance (the sum of a phase resistance and phase
reactance).

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The inductor reactance X, [?] is:

X = ω x L=2π x f x L (3)
where:

L, [H] is the phase inductance

ω=2xπxf f, [1/s] - is the frequency of the AC flowing through the circuit. f can be
found from motor velocity as:
Vmax
f =
2 ⋅ Pitch

for the linear motor, where Pitch is 180 electrical degrees.

ω max
f =
(NP / 2)
for the rotary motor where NP is the number of poles

The linear motor impedance is found from: (4)

2
⎛ V ⎞
Z = R + (ω ⋅ L ) = R + (2 ⋅ π ⋅ f ⋅ L ) = R + ⎜ π ⋅ max ⋅ L ⎟
2 2 2 2 2

⎝ Pitch ⎠

The rotary impedance can be found from: (5)

Z = R 2 + (ω ⋅ L ) = R 2 + (2 ⋅ π ⋅ f ⋅ L ) =
2 2

2 2
⎛ ω max ⎞ ⎛ ω ⎞
= R + ⎜⎜ 2 ⋅ π ⋅
2
⋅ L ⎟⎟ = R 2 + ⎜⎜ max ⋅ L ⎟⎟
⎝ 2 ⋅ π ⋅ ( NP / 2 ) ⎠ ⎝ (NP / 2) ⎠

Therefore, equation (1) can be represented as: (6)

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K E ⋅ Vmax
I DB _ max =
2
⎛ V ⎞
3 ⋅ R + ⎜ π ⋅ max ⋅ L ⎟
2

⎝ Pitch ⎠

Equation (2) can be represented as: (7)

K E ⋅ ω max
I DB _ max =
2
⎛ ω ⎞
3 ⋅ R + ⎜⎜ 2 ⋅ π ⋅ max ⋅ L ⎟⎟
2

⎝ (NP / 2) ⎠
In addition you should verify that the drive can withstand the heat dissipation.
Assuming 2V drop on each transistor, the maximum allowed power dissipation on one
transistor is 2 × I × 1 sec
peak

Thus, in order to protect the drive, you must verify that the following relation is complied with:

• In the case of a three-phase motor:

1
2
( )
Jω 2 + Mv 2 − ΔP ≤ 6 × I peak

•
2
(
In the case of a DC motor: 1 Jω 2 + Mv 2 − ΔP ≤ 4 × I
peak )
where J [ kgm2] is the total rotating inertia, M [kg] is the total moving mass, ω [rad/sec] is the
angular velocity of the inertia and v[m/sec]is the linear velocity of the mass.

Both ω and v should be taken at the moment of activating the dynamic brake and are directly
related to the user-determined VELBRK variable. Upon disable, dynamic braking starts only
when the velocity is lower than this variable. ΔP is the power loss on the motor itself. It is
recommended to disregard this element, thus ensuring that the total dissipated energy is lower
than the allowed value of the drive.

16.2.2 Dissipation and Peak Current – Motor Verification

You must verify that the motor can withstand the dissipated heat and peak current. In some
motors excessive current can lead to demagnetization.

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16.2.3 Braking Torque Verification

You should also verify that the braking torque will not cause any damage to the mechanical
system. Maximum braking torque is given by:

R
• Tmax = KT I max ≈ KT I max for a DC brushless motor
Z

Tmax = K T I max
• , for a DC motor
where K T is the motor torque/ force constant.

16.2.4 Dynamic Brake - Verification Example

16.2.4.1 Linear Motor

A linear motor application with maximum speed of Vmax = 1 [m/s] and 20A peak drive.
Three-phase motor specifications are listed in Table 16.

Table 16 Three-phase Motor Specifications - Linear Motor

Specifications Unit Value Note
Total mass Kg 4
Motor force constant n/Arms 17.5
Motor peak current Arms 18.4
Back EMF V/m/s 15
Resistance per phase Ω 1.2
Induction per phase mH 0.4 0.4 x 10-3 [H]
Magnetic pitch (180 electrical degrees) mm 15 60.96 x 10-3
1
Kinetic energy is ⋅ 4 ⋅12 = 2 Joule. This is lower than the permitte4d 6 x 20 = 120 J of the
drive. 2

2 2
⎛ V ⎞ ⎛ 1 ⎞
Impedance is Z = R + ⎜ π ⋅ max ⋅ L ⎟ = 1.2 2 + ⎜ π ⋅
2
−3
⋅ 0.4 ⋅10 −3 ⎟ = 1.2
⎝ Pitch ⎠ ⎝ 15 ⋅10 ⎠

K E ⋅Vmax 15 ⋅1
Maximum current during braking process is I DB _ max = = = 7.2 [A]
3⋅ Z 3 ⋅1.2
This current is lower that the allowed 20A of the drive.
It is also lower that the 18.4A current of the motor, so the motor can easily withstand the current
and resulting heat dissipation.

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The braking torque will be: ≈ 17.5 ⋅ 7.2 = 89.1 [N]

2

16.2.4.2 Rotary Motor

A rotary motor application with maximum speed of:
ωmax =500000 [count/s] = 500000/8000 x 2π [rad/s]=392.7 [rad/s] and 20A peak drive.
Three phase motor specifications are listed in Table 17.

Table 17 Three-phase Motor Specifications - Rotary Motor

Specifications Unit Value Note
2
Rotor moment of inertia Kg x m 0.000015
Motor force constant N x /Arms 0.14
Motor peak current Arms 22
Back EMF V/kRPM 16
Resistance per phase Ω 1.3
Induction per phase mH 2.1 4.1 x 10-3 [H]
Number of counts per rotation counts 8000
Number of poles 6
1
Kinetic energy is ⋅ 0.000015 ⋅ 392.7 2 = 1.15 Joule. This is lower than the 6 x 20 = 120 J of
the drive. 2

2
Impedance is Z = R + ⎛⎜ ω max ⋅ L ⎞⎟ = 1.32 + ⎛⎜ 392.7 ⋅ 2.1 ⋅10 −3 ⎞⎟ = 1.3 Ω
2
2
⎜ ( NP / 2 ) ⎟
⎝ ⎠ ⎝ 6/2 ⎠

Maximum current during the braking process is

K E ⋅ ω max 16 / (1000 ⋅ 2 ⋅ π ) ⋅ 60 ⋅ 392.7 [A]
I DB _ max = = = 12.8
3⋅ Z 3 ⋅ 2.7

This current is lower than the allowed 20A of the drive.

It is also lower than the rated 22 A current of the motor, so the motor can easily withstand the
current and the resulting heat dissipation.

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12.8
The braking torque will be ≈ 0.14 ⋅ = 1.3 [N x m]
2

Table 18 Motor Specifications

Specifications Unit Quantity
Peak current Arms 18.4
Maximum continuous current - coils at 110° C Arms 5.1
Maximum continuous power loss - all coils W 115
Motor force constant N/Arms 17.5
Back EMF phase-to-phase peak V / m/s 15
Magnet pitch NM mm 30
Resistance per phase Ω 1.2
Induction per phase mH 0.4
Total mass kg 4
Encoder resolution lines/mm 250
Encoder multiplier 256

VELBRK should be
1.5 ×1000 × 250 × 256 = 96 ×106 [counts / sec]

Kinetic energy is

16.3 Dynamic Brake Operation Procedure

CAUTION
Before operating the Dynamic Brake, verify that no damage will
happen due to the dynamic Brake – see Dynamic Brake - Safety
Verification (page 125)

1. Open SPiiPlus MMI | Setup | Configurator |

2. Select the axis for dynamic braking.
3. Click Motor Flags and select Dynamic Brake Mode (bit 11).
4. Close the Motor Flags dialog box and click Safety Parameters.
5. Enter a value for the Dynamic Brake Threshold Velocity (VELBRK) - defines maximum
feedback velocity to activate dynamic brake.

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Note
For safety reasons, the default value for VELBRK is zero for all axes.

6. Dynamic braking will be activated automatically when the following two conditions are
met:
• FVEL<axis> is less than VELBRK<axis>
• the axis drive is disabled

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17 ASDF Measuring Motion Performance

17.1 Measuring Settling Time

1. Define the target position, see “Criteria for Determining Whether Motor is in
Position” on Page 92, by assigning values to SETTLE and TARGRAD variables.
2. Open SPiiPlus MMI | Scope. Figure 55 depicts a Scope configured to measure settling
time for a Nanomotion piezoceramic motor.
3. Assign a channel to monitor RVEL (reference velocity) for the axis. This shows when
the reference velocity reaches zero.
4. Assign another channel to monitor PE (position error) for the axis.
5. Assign another channel to monitor bit 5 (#MOVE) of AST (axis state) for the axis. When
motion has theoretically reached the target position, the bit will go low.
6. Assign another channel to monitor bit 4 (#INPOS) of MST (motion state) for the axis.
When motion actually reaches the target position, the bit will go high.
7. Execute the motion.
8. Drag Rider Cursor X1 to the point where AST(axis)(5) went low.
9. Drag Rider Cursor X2 to the point where MST(axis)(4) went high.
10. The settling time = X2 – X1.

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Cursor X1 Cursor X2

Theoretical end of Actual end of motion

motion (AST bit 5 low) (MST bit 4 high)

RVEL channel Settling time

AST bit 5 channel
MST bit 4 channel PE channel

Figure 55 Measuring Settling Time (Piezoceramic Motor Example)

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