SPiiPlus

Setup Guide
September 2020
Document Revision: 3.02
 SPiiPlus Setup Guide

SPiiPlus

Release Date: September 2020

COPYRIGHT

© ACS Motion Control Ltd., 2020. All rights reserved.

Changes are periodically made to the information in this document. Changes are published as release notes and later
incorporated into revisions of this document.

No part of this document may be reproduced in any form without prior written permission from ACS Motion Control.

TRADEMARKS

ACS Motion Control, SPiiPlus, PEG, MARK, ServoBoost, NetworkBoost and NanoPWN are trademarks of ACS Motion Control Ltd.

EtherCAT is registered trademark and patented technology, licensed by Beckhoff Automation GmbH, Germany.

Any other companies and product names mentioned herein may be the trademarks of their respective owners.

www.acsmotioncontrol.com

[email protected]

[email protected]

NOTICE

The information in this document is deemed to be correct at the time of publishing. ACS Motion Control reserves the right to
change specifications without notice. ACS Motion Control is not responsible for incidental, consequential, or special damages of
any kind in connection with using this document.

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Revision History
Date Revision Description

September
3.02 New Release
2020

July 2020 3.01 ADK Update

No system configuration wizard (Table 2-1, section 5)

Icons
March 2019 2.70 System setup replaces EtherCAT/System setup in 2.7
DELK related parameters
SAFIN, not SAFINI in 6.10.2

Added homing methods

Updated for Auto-mapping of IOMNT
July 2018 2.60 Added Current loop auto tuning
Updated Open loop verification
Added XRMSD, XRMSM. XRMSTD, and XRMSTM

December
2.50 Replaced EtherCAT Configurator with System Setup
2017

June 2017 2.40 Reformatted with new template for SPiiPlus ADK Suite v2.40

Added support for Absolute Encoders to SLPROUT, SLVROUT,

October 2016 2.30.01
SLCROUT

Update for SPiiPlus ADK Suite v2.30

August 2016 2.30
Reformatted using new template

May 2013 2.21 Absolute encoder setup procedure

December
2.20 Update for 2.20
2012

June 2012 2.15 Added appendix explaining dual loop control

November
2.10 First release
2011

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Conventions Used in this Guide

Text Formats

Format Description

Bold Names of GUI objects or commands

BOLD + UPPERCASE ACSPL+ variables and commands

Monospace + grey
Code example
background

Italic Names of other documents

Blue Hyperlink

[] In commands indicates optional item(s)

| In commands indicates either/or items

Flagged Text

Note - includes additional information or programming tips.

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

Warning - describes a condition that may result in serious bodily injury or death.

Model - highlights a specification, procedure, condition, or statement that

depends on the product model

Advanced - indicates a topic for advanced users.

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Related Documents
Documents listed in the following table provide additional information related to this document.
The most updated version of the documents can be downloaded by authorized users from
www.acsmotioncontrol.com/downloads.

Document Description

SPiiPlus Command & Variable Describes all of the variables and commands available in the
Reference Guide ACSPL+ programming language.

SPiiPlus MMI Application Explains how to use the SPiiPlus MMI Application Studio and
Studio User Guide associated monitoring tools.

Describes the use of SpiiPlus User Mode Driver, SPiiPlus

SPiiPlus Utilities User Guide
Simulator, and UPGRADER.EXE.

C Methods, Properties, and Events for Communication with

SPiiPlus C Library Reference
the Controller.

SPiiPlus COM Library COM Methods, Properties, and Events for Communication
Reference with the Controller.

SPiiPlus .NET Library .NET Methods, Properties, and Events for Communication
Reference with the Controller.

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Table of Contents
1. Introduction 14
1.1 Scope of document 14
2. Getting Started 15
2.1 SPiiPlus Hardware Connection 15
2.2 SPiiPlus Software Installation 15
2.2.1 SPiiPlus Installation Disk 16
2.2.2 Software Installation 16
2.3 Safety Instructions 17
2.4 Product Licenses 17
2.4.1 About Licenses 17
2.4.2 License-Based Features Ordered with ACS EtherCAT Master 18
2.4.3 License-Based Features for ACS EtherCAT Slaves 19
2.4.4 Purchasing an ACS License 19
2.4.5 Entering New License String into the Controller 21
2.5 SPiiPlus Resources 21
2.5.1 Accessing SPiiPlus Programming Resources 21
2.5.2 Available SPiiPlus Resources 22
2.6 Activating SPiiPlus MMI Application Studio 22
2.7 Set Up New System 24
3. Establishing Communication with SPiiPlus MMI Application Studio 26
3.1 Setting Controller Properties 26
3.2 Connecting to the Controller 28
3.2.1 Serial Communication 28
3.2.1.1 Connecting via Serial Communication 28
3.2.1.2 Troubleshooting a Serial Connection 29
3.2.2 Ethernet Communication 29
3.2.2.1 Connecting via an Ethernet Network 30
3.2.2.2 Connecting via Ethernet Point-to-Point Communication 31
3.2.2.3 Troubleshooting Ethernet Network Connections 33
3.2.2.4 Troubleshooting Ethernet Point-to-Point Connection 34
3.3 Connecting via a Remote Host 34
3.4 Setting SPiiPlus Communication Parameters 35

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3.5 The SPiiPlus Simulator 37

3.5.1 About the SPiiPlus Simulator 37
3.5.2 Connecting to the Simulator 38
4. System Setup 40
4.1 System Setup 40
4.1.1 Supported Network Masters 40
4.1.2 Supported Network Slaves 41
4.1.3 Supported Non-ACS Units 42
4.1.4 EtherCAT Cable Length 42
4.2 Numbering and Identification of Network Units, Axes and IOs 43
4.2.1 Unit ID Numbers 43
4.2.2 Axes Numbering in ACSPL+ 43
4.2.3 I/O Numbering in ACSPL+ 43
4.2.4 Logical and Physical Assignment of Network Units, Axes and IO Variables 44
4.3 ACSPL+ Programming in a Network Environment 44
4.4 Network Operation 45
4.4.1 Power-Up Sequence 45
4.4.2 Cable Disconnection 45
4.4.3 Losing 24V Power 45
4.4.3.1 Network Monitoring 45
4.5 System Setup 46
4.5.1 Configuring the Network 46
4.5.1.1 Automatic System Setup 46
5. System Hardware Configuration 48
6. Axis Setup and Tuning 49
6.1 Principles of Motion Control 49
6.1.1 Control Loops 49
6.1.2 SPiiPlus Motion Control Algorithms 50
6.1.2.1 PI Filter 50
6.1.2.2 Low Pass Filter 51
6.1.2.3 Notch Filter 52
6.1.2.4 BI-Quad Filter 52
6.2 About the Adjuster Wizard 56
6.2.1 Working in Adjuster Wizard Task Windows 57

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6.2.1.1 Data Action Buttons 57

6.2.1.2 Adding Data to Component Database 58
6.2.1.3 Incompatibility Symbol 58
6.3 Starting Adjuster Wizard 59
6.4 Selecting Axis Setup Initial Values 60
6.5 Initialization 62
6.6 Axis Architecture 62
6.6.1 User Units 63
6.6.2 User Defined User Unit 64
6.7 Components 65
6.7.1 Motor 65
6.7.2 Drive 66
6.7.3 Feedback 66
6.7.3.1 Absolute Encoder Setup Procedure 67
6.7.4 Calculate Parameters 68
6.8 Safety and Protection 69
6.8.1 Motion Parameter Limits 70
6.8.2 Current Limits 71
6.8.3 Position Errors 73
6.8.4 Position Limits 75
6.9 Miscellaneous Definitions 75
6.9.1 Motion Completion 75
6.9.2 Enable/Disable/Brake 76
6.9.3 Dynamic Brake 78
6.9.4 Home Switch 79
6.10 Verification 79
6.10.1 Feedback 80
6.10.2 Switches 82
6.10.3 Stop, Alarm and Brake 84
6.11 Axis Setup and Tuning 85
7. Current Loop and Current Phase Offset Setup 86
7.1 Current Loop 86
7.2 Current Phase Offset 91
8. Commutation 94

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8.1 Adjuster and Commutation 94

8.1.1 Commutation Overview 94
8.1.2 Commutation Technical Details 94
8.1.3 The Adjuster Commutation Task 95
8.2 Performing the Commutation Task 96
8.2.1 Preferences 97
8.2.2 Advanced Parameters 99
8.2.3 Commutation Startup Program 100
8.2.4 Commutation Program Output Panel 102
8.3 Troubleshooting Commutation 103
9. Open Loop and Position Verification 104
9.1 Open Loop Verification 104
9.2 Position Verification 106
10. Position and Velocity Loops 109
10.1 Velocity Loop 110
10.2 Position Loop 113
11. Save to Flash 117
12. Sin-Cos Encoder Compensation 118
12.1 Activating Sin Cos Encoder Compensation 118
12.2 Sin Cos Encoder Compensation Window 119
12.2.1 Measurement Curve Display 120
12.2.2 Compensation Execution Panel 120
12.2.3 Parameters Panel 122
12.2.3.1 Advanced Tab 122
12.2.3.2 Cursors Tab 124
12.2.3.3 Statistics Tab 125
12.2.4 Running Sin Cos Encoder Compensation 126
13. Homing Programs 128
13.1 Homing Program Using Limit Switches 128
13.2 Homing Program Using Hard Stops 129
14. Protecting Application 131
14.1 Starting Protection Wizard 131
14.2 Define Protection 132
14.2.1 Setting Application Protection 133

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14.2.2 Setting Intellectual Property Protection 136

14.2.3 Setting Custom Protection 136
14.2.3.1 Custom buffer protection 136
14.2.3.2 Custom variable protection 137
14.2.3.3 Advanced protection options 138
14.2.4 Update Protection 138
14.2.5 Remove Protection 140
14.2.6 View Protection 143
14.2.7 Entering Incorrect Password 145
Appendix A. Working with a Gantry Axis 147
A.1 Overview 147
A.2 Gantry Implementation Using Connect And Depends Commands 147
A.3 Gantry Implementation 148
A.3.1 Gantry Setup and Configuration 149
A.3.2 Commutation and Homing 150
A.3.3 Gantry Operation 151
Appendix B. Dual Loop Control 153
B.1 Dual Loop Basics 153
B.2 ACSPL+ Variables 155
B.2.1 MFLAGS 155
B.2.2 SLVRAT 155
B.2.3 SLVKP 155
B.2.4 XVEL 155
B.2.5 EFAC 155
B.2.6 FACC 155
B.2.7 Routing Variables 155
B.2.7.1 SLPROUT 156
B.2.7.2 SLVROUT 157
B.2.7.3 SLCROUT 158
B.2.8 Configuring Dual Loop Control Procedure 159
B.2.8.1 AXIS Setup 159
B.2.8.2 LOAD Setup 160
Appendix C. Working with Dynamic Braking 164
C.1 About Dynamic Braking 164

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C.2 Dynamic Brake - Safety Verification 164

C.2.1 Dissipation And Peak Current – Drive Verification 164
C.2.2 Dissipation and Peak Current – Motor Verification 167
C.2.3 Braking Torque Verification 167
C.2.4 Dynamic Brake - Verification Example 167
C.2.4.1 Linear Motor 167
C.2.4.2 Rotary Motor 168
C.2.5 Dynamic Brake Operation Procedure 169
Appendix D. ASDF Measuring Motion Performance 172
D.1 Measuring Settling Time 172

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List Of Figures
Figure 2-1. SPiiPlusMMI Application Studio Startup Window 23
Figure 3-1. SPiiPlus Controller Properties Window 27
Figure 3-2. RS-232 Serial Connection 28
Figure 3-3. Types of Ethernet Connection 30
Figure 5-1. Motion Control System Schematic 49
Figure 5-2. Control Loops 50
Figure 5-3. PI Filter Schematic 51
Figure 5-4. PI Filter Frequency Response 51
Figure 5-5. Bi-Quad Configured as a Notch Filter 53
Figure 5-6. Bi-Quad Configured as a 2nd Order Lead FIlter 54
Figure 5-7. Bi-Quad Configured as a 2nd Order Lag FIlter 55
Figure 5-8. Bi-Quad Configured as a 2nd Order Low Pass FIlter 56
Figure 7-1. Commutation Options 101
Figure 9-1. Velocity and Position Loop Adjustment - General Layout 110
Figure 9-2. Velocity Loop Motion Manager Panel 111
Figure 9-3. Example Scope Display of Well Adjusted Velocity Loop 113
Figure 9-4. Position Loop Manager Panel 114
Figure 9-5. Example Scope Display of Well Adjusted Position Loop 116
Figure 12-1. Homing 128
Figure 14-1. Typical Gantry 147
Figure 14-2. Gantry Axis Profile Generation 148
Figure 15-1. Dual Loop System 153
Figure 15-2. Controller in Dual Loop Block Diagram 154
Figure 17-1. Dynamic Brake Implementation by the Digital Drive 164
Figure 18-1. Measuring Settling Time (Piezoceramic Motor Example) 172

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List of Tables
Table 2-1. Tool Use Requirement 18
Table 2-2. ACS EtherCAT Master License-Based Features 18
Table 5-1. Digital Outputs for Brake Control in SPiiPlus 77
Table 5-2. Digital Outputs for Brake Control in MC4U 78
Table 16-1. SLPROUT Values 156
Table 16-2. SLVROUT Values 157
Table 16-3. SLCROUT Values 158
Table 17-1. Three-Phase Motor Specifications - Linear Motor 167
Table 17-2. Three-Phase Motor Specifications - Rotary Motor 168

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1. Introduction

1. Introduction
1.1 Scope of document
This guide provides guidance in how to configure and adjust SPiiPlus systems to work with
supported types of motors and feedback devices. The guide applies to SPiiPlus stand-alone motion
controllers and modules as well as MC4U Control Modules with NT motion controllers and modules
installed.
The principle application employed for setting up SPiiPlus systems is the SPiiPlus MMI Application
Studio which is supplied with the CD package accompanying all SPiiPlus products.
Setting up the SPiiPlus system basically involves:
> Establishing communication between the SPiiPlus MMI Application Studio and the
controller.
> Where an EtherCAT network is involved, the SPiiPlus MMI Application Studio System Setup
is employed to configure the network.
> If an MC4U Control Module is employed, the SPiiPlus MMI Application Studio System
Configuration Wizard is used for establishing its configuration.
> After the above have been accomplished, the SPiiPlus MMI Application Studio Adjuster
Wizard tool is employed to establish the nature of the control loops. Various types of
control loops and how they are set up are given.

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2. Getting Started

2. Getting Started
This chapter provides the basics for setting up a SPiiPlus system.

2.1 SPiiPlus Hardware Connection

Installation and the electrical interface information for specific motion controllers is provided in the
hardware guide associated with the motion controller 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

When an MC4U unit is not supplied bus voltage, a component failure fault will be
reported. The fault is system wide and will prevent all axes from operating unless the
fault is masked or bus voltage is supplied to the power supply. When a component
failure is reported, the affected power supply is identified by its I2C address, access the
System Information Viewer (see SPiiPlus MMI Application Studio User Guide) to
determine the faulty unit.

2.2 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 in the following Microsoft® Windows® environments:
> Windows® Vista SP1 and later (32-bit and 64-bit)
> Windows® 7 (32-bit and 64-bit)
> Windows® 8 (32-bit and 64-bit)
> Windows® 10 (32-bit and 64-bit)
> Windows® Server 2003 (32-bit and 64-bit)
> Windows® Server 2008 (32-bit and 64-bit)

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> Windows® Server 2008 R2 (64-bit)

Windows® XP SP2 (64-bit) and Windows® XP SP3 (32-bit) are no longer supported.

Each new version of SPiiPlus software is installed in a new folder (with the new version name)
under C:\Program Files\ACS Motion Control\SPiiPlus ADK Suite vx.xx

For SPiiPlus system software previous to v2.30, the file directory is under C:\Program
Files\ACS Motion Control\SPiiPlusNT Suite x.xx.

2.2.1 SPiiPlus Installation Disk

The SPiiPlus ADK Suite 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 Application Studio – Windows-based software tool for configuring, adjusting,
programming and monitoring the motion.
SPiiPlus Simulator - Windows-based controller simulator that runs on the PC without any
connected hardware. The SPiiPlus Simulator can communicate with the SPiiPlus MMI Application
Studio and be used to debug programs and to simulate motion trajectory (with zero following
error), inputs, outputs and faults.
SPiiPlus Utilities - The SPiiPlus User Mode Driver, which provides the communication link between
the host computer and the motion controller.
SPiiPlus Documentation – Data sheets and user guides documentation for the SPiiPlus products.
All the documents are in PDF format.
Training Files - Microsoft PowerPoint® presentations and ACSPL+ code examples.
MATLAB Simulink Files – Models of the SPiiPlus single and dual loop control algorithms.

ACS Motion Control recommends using the most updated SPiiPlus tools and
documentation.

2.2.2 Software Installation

To install the SPiiPlus software package:
1. Insert the SPiiPlus ADK Suite installation CD into the PC.
2. Follow the on-screen installation instructions.

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2.3 Safety Instructions

The safety procedures outlined in this section, along with safety instruction detailed in
the documentation of each network element, must be carefully observed in order to
achieve safe and optimal operation of ACS networking provisions.

Make sure that the following guidelines are addressed and observed prior to powering or handling
any of the network elements:
> Installation and maintenance must be performed by qualified personnel only. Such a
person must be trained and certified to install and maintain high power electrical
equipment, servo systems, power conversion equipment and distributed networks.
> Prior to powering up the system, ensure that all network components are connected to
earth grounding.
> Keep all equipment covers close and secured during all time.
> Maintenance should be performed only after the relevant network element has been
powered down, and all associated and surrounding moving parts have settled in their safe
mode of operation. Certain drives require longer times in order to fully discharge. Follow
the hardware guide of each element and observe the residual discharge time specified.
> Avoid contact with electrostatic-sensitive components and take the required precautions.

2.4 Product Licenses

2.4.1 About Licenses
Licenses (sent as software strings) are keys used to set certain general properties of the network,
such as the required number of axes, special features and type and number of non-ACS network
elements.

The license string allows controller options only for the specific controller and cannot
be used for another controller.

The network units are initially ordered and delivered with a pre-defined configuration and feature
set. This set consists of product-specific features, such as, number of axes, number of Sin-Cos
encoders, hardware configuration parameters. These features are stored in the products
themselves. Other network parameters, such as special servo features and number of total axes,
and number of non-ACS IO devices, are stored in the master controller. For example, a UDMnt-2 can
be ordered with none, with 1 or 2 Sin-Cos multiplies, in one or two axes configuration. On the
network level, the master controller can be ordered with or without ServoBoost™ as a special
servo feature.
The ordered master controller is factory pre-programmed to the maximum number of axes,
number of non-ACS servo axes, non-ACS stepper axes and non-ACS IO nodes. ServoBoost™ and
other customized servo algorithms are ordered at the Master/Network level as well.

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The number of network elements (units and EtherCAT nodes) is limited up to the maximal number
listed defined in Table 2-2. The limitation may result from the specific master chosen, by the
resulting number of supported nodes, and the required axes.
In order to change a network’s configuration, that relates to network-level features, after the initial
order, the user may have to obtain a specific software license. Changing network configuration
(addition or subtraction of units, adding, removing or replacing modules within the MC4U, or adding
programmable features) may require modification of the network configuration in addition to the
above described software license., as outlined in Table 2-1.
Table 2-1. Tool Use Requirement

System
Action Obtain License
Setup

Changing order of units (cabling only) within a

Yes No
given network
Changing DIP switch number Yes No
Yes (only in case limits are
Addition of units Yes
exceeded)
Removal of units Yes No
Modifying MC4U configuration No See Note
Adding axes (MC4U, ACS units or non-ACS) Yes Yes
Adding non-ACS IO units Yes Yes

A license is needed when a network modification (addition of a unit or units, or MC4U

axes by addition of modules) increases the total number of network axes beyond the
ordered axes (defined by the master) and specified minimal CTIME and when it
increases the total license-based master or slave features.

2.4.2 License-Based Features Ordered with ACS EtherCAT Master

The following features are ordered, pre-programmed and delivered in any ACS EtherCAT Master.
Table 2-2. ACS EtherCAT Master License-Based Features

Factory
Requirement Description
Setting

Total All servo axes in the network (4, 8, 16, 32, or 64). Two
As
number of performance levels of MPUs within NTM controllers are
ordered
axes supported, as function of needed axes and CTIME.

Input As
Optional algorithm.
Shaping ordered

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Factory
Requirement Description
Setting

Customized
As
servo Support of customized servo features, such as ServoBoost™.
ordered
algorithms

Number of Servo and stepper axes provided by (certified) non-ACS

As
non-ACS EtherCAT drives. Refer to ACS price list for detailed upgrade
ordered
servo axes information

Number of
Axes provided by (certified) non-ACS EtherCAT drives. Refer to As
non-ACS
ACS price list for detailed upgrade information ordered
stepper axes

Number of
IOs provided by (certified) non-ACS EtherCAT devices. Refer to As
non-ACS I/O
ACS price list for detailed upgrade information ordered
nodes

In order to change any of these parameters after the network has been delivered, the user has to
obtain a new license from ACS.

2.4.3 License-Based Features for ACS EtherCAT Slaves

ACS EtherCAT Slave units are delivered according to the ordered configuration, which addresses
the product type, number of axes, hardware configuration, and number of Sin-Cos encoders.

Once delivered, however, no changes to the ordered configuration can be made in the
field. If changes are required, the product has to be returned to ACS to effect the
change.

2.4.4 Purchasing an ACS License

In order to increase, or change, any of the capabilities listed in above, the user has to obtain a
license from ACS Motion Control. The license is purchased from ACS as a product.
In order to obtain a new license, the user has to provide the following information to ACS:
> The report generated by the SPiiPlus MMI Application Studio System Information Viewer.
> The requested features
To generate the System Information Report:
1. In the SPiiPlus MMI Application Studio select Toolbox > Utilities > System Information
Viewer. The System Information window listing the data for all components is displayed:

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2. Click Save ( ) on the toolbar. The browser is displayed.

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3. Browse to the location where you want to save the information and click Save.
The data is saved in a file with an .ini extension. It is this file that you send to ACS Motion Control
when purchasing a new license.

2.4.5 Entering New License String into the Controller

The new license string is entered into the controller by copying the following command:
#SCO “license string” (that is sent from ACS Motion Control) into the SPiiPlus MMI Application Studio
Communication Terminal and executing it.
After entering the license string, the controller has to be restarted.

2.5 SPiiPlus Resources

2.5.1 Accessing SPiiPlus Programming Resources
The SPiiPlus program group can be accessed from Windows: Start > Programs > SPiiPlus NT Suite,
for example:

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2.5.2 Available SPiiPlus Resources

Items that you can access in this manner are:
> SPiiPlus product data sheets in PDF format
> SPiiPlus training documents in PowerPoint format
> SPiiPlus product user guides
> SPiiPlus MMI Application Studio
> SPiiPlus MMI Application Studio Help file
> SPiiPlus User Mode Driver

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.

2.6 Activating SPiiPlus MMI Application Studio

SPiiPlus MMI Application Studio can be activated either from the Windows Start menu:

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Or by double-clicking on the Windows Desktop.

The SPiiPlus MMI Application Studio startup window is displayed.

Figure 2-1. SPiiPlusMMI Application Studio Startup Window

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For a complete description of the elements making up the SPiiPlus MMI Application Studio Startup
window, see SPiiPlus MMI Application Studio User Guide.

2.7 Set Up New System

The steps to be followed when setting up your new ACS Motion Control system are:
1. Establishing Communication with SPiiPlus MMI Application Studio
You first have to establish communication with the controller in order to set all the parameters in
the steps that follow.
2. System Setup

3. System Setup
SPiiPlus technology enables you to link several devices (ACS Motion Control devices as well as
certain approved non-ACS devices) together in a master/slave configuration. Once all the devices
have been physically connected, you have to perform this step to establish the parameters of the
network.
4. System Hardware Configuration
In this step you use the System Setup Component to scan your system in order to define the
physical parameters of each device. This step involves: defining the configuration in the database,
verifying that the configuration is correct, and then loading the configuration data into the master
controller. Once this step is complete, the master controller knows what type of devices are in the
system and what they are controlling.
The physical parameters include:
> Whether the device is a motion controller or I/O device
> Whether the controller is a master or slave
> The motherboard being used (for MC4U units)
> Power supply that is installed (for MC4U units)
> Drivers that are installed (for MC4U units)
> Axes to which the devices are connected
> I/O connections
5.
In this step you begin by defining the motion parameters for each axis through the Adjuster
Wizard. Then you proceed to adjust the motion parameters based on the nature of the axis
parameters as well as the motors that are being driven. The adjustment of the specific types of
motion parameters is covered in Current Loop and Current Phase Offset Setup, Commutation, Open
Loop and Position Verification, Position and Velocity Loops, and Save to Flash.
6. Protecting Application
At this point, the controller has been in the configuration mode, meaning that it can be written to.
Changing the controller mode to Protected limits changes that can be made to controller variables
and program buffers. The Protected mode can be useful once you have completed configuration

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and adjustment and want to protect the controller from changes that could be caused
unintentionally.
Further specialized motion application considerations are covered in the appendices.

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3. Establishing Communication with SPiiPlus MMI Application Studio

3. Establishing Communication with SPiiPlus MMI

Application Studio
This is the first operation that must be performed before you can start setting up your system.
There are three types of communication:
> RS-232 serial connection
> Ethernet connection which can be either point-to-point (direct to controller) or over a
network
> Remote connection through a host connected to the motion controller
This chapter also provides details for connecting to the SPiiPlus Simulator utility.
The steps in establishing communication are:
1. Set controller properties
2. Connect to the controller

If you have more than one SPiiPlus Motion Controller in your system, use the SPiiPlus
MMI Application Studio Add Controller function and repeat the communication setup
for each motion controller. See SPiiPlus MMI Application Studio User Guide for details
on this function.

Communication setup for each type of channel is described here using the SPiiPlus MMI Application
Studio SPiiPlus Controller Properties dialog window through which you configure the controller’s
communication settings.

Certain parameters, such as logging and remote connections, can also be set using
SPiiPlus User Mode Driver - see SPiiPlus Utilities User Guide.

3.1 Setting Controller Properties

To set controller properties - double-click the controller in the Workspace Tree, as shown:

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The SPiiPlus Controller Properties window is displayed:

Figure 3-1. SPiiPlus Controller Properties Window

1. In the General tab enter an identifying name in the Controller Name field.
2. Enter the connection timeout value, in milliseconds, in the Connection Timeout field.

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3.2 Connecting to the Controller

3.2.1 Serial Communication

The SPiiPlus MMI Application Studio serial communication is not intended to be used for
safety purposes.

All SPiiPlus motion control products include two RS-232 serial communication channels (COM1 and
COM2). The default settings of RS-232 are: 8 data bits, no parity and a regular stop bit.

Figure 3-2. RS-232 Serial Connection

3.2.1.1 Connecting via Serial Communication

To connect the host computer to the SPiiPlus Motion Controller by way of the serial port:
1. In the General tab select Serial.

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2. Select the communication port from the Port dropdown list.

3. Select the baud rate from the Rate dropdown list.

4. Click Connect ( ).

3.2.1.2 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.

3.2.2 Ethernet Communication

Two types of Ethernet connections are supported:
1. Network - in which the PC communicates via a network with the Ethernet port of the
controller.
2. Point-to-Point - in which the PC is connected directly via the Ethernet cable to the
Ethernet port of the controller.
These two types of Ethernet connections are illustrated in Figure 3-3.

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Figure 3-3. Types of Ethernet Connection

3.2.2.1 Connecting via an Ethernet Network

To connect the host computer to the motion controller via an Ethernet network:
1. In the General tab select Ethernet.

2. Select the IP Address from the Controller IP Address dropdown list.

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The factory default TCP/IP address is 10.0.0.100.

3. Select Network from the Network Type dropdown list.

4. Click Connect ( ).

3.2.2.2 Connecting via 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.

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

To connect the host computer to the motion controller via point-to-point Ethernet:
1. In the General tab select Ethernet.

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2. Select the IP Address from the Controller IP Address dropdown list.

The factory default TCP/IP address is 10.0.0.100.

3. Select Point to Point from the Network Type dropdown list.

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4. Click Connect ( ).

3.2.2.3 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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If two controllers have the same IP, an error message (code 165) appears. Later, to
connect via Ethernet network to the controller with a unique IP, you should reboot the
controller by right- clicking the controller in the Workspace Tree and selecting
Controller Reboot:

3.2.2.4 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 is selected in the SPiiPlus MMI Application Studio.

3.3 Connecting via a Remote Host

To connect to the motion controller through a remote host:
1. In the General tab select the Remote Connection checkbox.

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2. Enter the IP of the remote computer in the Remote Address field.

3. Enter the port number of the remote computer in the Remote Port field.
4. If the remote computer has login requirements, click Login Details:

Enter the Domain name, Username and Password.

5. Click Connect to Remote Server ( ).

3.4 Setting SPiiPlus Communication Parameters

Once you have established a communication connection with your SPiiPlus Motion Controller, you
have the option of setting certain communication parameters and store them into the controller’s
flash memory
1. In the SPiiPlus Controller Properties window, click the Communication Parameters tab:

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This tab enables you to set the following communication parameters:

> COMMFL
> DISPCH
> BAUD
> TCPIP
> TCPIP2
> TCPPORT
> UDPPORT
For details on these options see the SPiiPlus MMI Application Studio User Guide.

2. Once you have set the parameters, click Save to Flash ( ). The Save to Flash
window is displayed:

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3. Enter your user name in the User field.

4. Enter the application name in the Application field.
You can, if you desire, enter free text remarks in the Remarks field.

By default all data is selected. You have the option of selecting the data you want to
load into the controller by clicking (thereby deselecting) the checkbox of the data you
do not want to be saved.

5. Click Save.

3.5 The SPiiPlus Simulator

This section describes using the SPiiPlus Simulator. For complete details of the Simulator see the
SPiiPlus Utilities User Guide.

3.5.1 About the SPiiPlus Simulator

The SPiiPlus Simulator allows you to work with the SPiiPlus MMI Application Studio, SPiiPlus C Library
or SPiiPlus COM Library without being physically connected to a controller, drives, or motors. The
Simulator thus is a powerful tool for use during application development and debugging before
connecting to actual hardware.
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

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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, however TIME=1 is not equal to 1 millisecond as when working with a real SPiiPlus.
> Some hardware-based programming features, including: Index, MARK, PEG, and analog I/O
(AIN and AOUT).
> Some SPiiPlus MMI Application Studio Communication Terminal commands: #HWRES,
#RESET, #U, #IR, #SI, #SIR .
> The write/read commands.
> The SPiiPlus MMI Application Studio Application Saver and Application Loader.

The Simulator does, however, provide limited support for SPiiPlus MMI Application
Studio Adjuster Wizard.

3.5.2 Connecting to the Simulator

This section provides the procedure for connecting to the SPiiPlus Simulator via the SPiiPlus MMI
Application Studio, for other methods see the SPiiPlus Utilities User Guide.
To connect to the Simulator:
1. Click Workspace on the SPiiPlus MMI Application Studio Menu bar, and select Add
Controller.

The Connect to Controller dialog is displayed.

2. Click Simulator.

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3. Click Connect ( ). The “controller” is added to the Workspace Tree.

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4. System Setup
4.1 System Setup
The system setup process includes setting up the EtherCAT network and configuring the units
connected to the network.
ACS network solutions are based on a master device and multiple network elements, connected
over an EtherCAT cable. The combination of EtherCAT technology and ACS network capabilities
ensure that the master and all network elements are tightly time-synchronized.
An ACS EtherCAT network consists of a master (see Supported Network Masters ) that is always
positioned as the first network element. The subsequent elements can be any combination of ACS
and non-ACS EtherCAT network elements (see Supported Network Slaves ). A daisy chain cabling is
used to connect the master to the network elements: The master is connected by a single
EtherCAT cable to the first “slave”, which connects to the second “slave”, which in turn connects to
the third one. This process is repeated until the last “slave” element is reached. The EtherCAT cables
support bi-directional, full duplex communication.

No redundancy cable, or ring topology, is supported.

The number of supported elements is determined by the type of master used, and the software
version installed. The axes and IO numbering is determined through the System Setup Wizard, a
component of the SPiiPlus MMI Application Studio, as detailed in the following sections and by
setting the front panel DIP switches on ACS network elements that contain them.

4.1.1 Supported Network Masters

The following ACS Motion Control units can serve as a network master:
> SPiiPlusNTM Network Manager
SPiiPlusNTM-32 and SPiiPlusNTM-64 are stand-alone master controllers which differ by the
maximal number axes they support. The controllers support both ACS and non-ACS
network elements in various combinations. The SPiiPlusNTM-32 supports up to 32 axes and
64 nodes. The SPiiPlusNTM-64 supports up to 64 axes and 64 nodes.
> SPiiPlusNT motion controllers
The SPiiPlusNT product line consists of:
> SPiiPlusNT-LT Motion Controller
The SPiiPlusNT- LT motion controller is an economical 4 or 8-axis (local) controller
network master.The controller can be housed in an MC4U or installed as a stand-alone.
The controller consists of three interconnected boards: a base driver board, an MPU,
and an Ethernet board. SPiiPlusNT- LT supports up to 32 axes and 64 nodes.
> SPiiPlusNT- HP Motion Controller
The SPiiPlusNT- HP motion controller is a high performance, 8-axis (local) controller
network master. The controller can be housed in an MC4U or installed as a stand-
alone.

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The controller consists of three interconnected boards: a base driver board, an MPU,
and an Ethernet board. SPiiPlusNT- HP supports up to 64 axes and 64 nodes.
> SpiiPlusNT-NP Motion Controller
The SPiiPlusNT-NP motion controller is a NanoPWM dual axis 2 or 4 (local) network
master. The controller can be housed in an MC4U or installed as a stand-alone.
The controller consists of three interconnected boards: a base driver board, an MPU,
and an Ethernet board. SPiiPlusNT- NP supports up to 64 axes and 64 nodes.
> SPiiPlusNT-LD Motion Controller
SPiiPlusNT-LD is the same as SPiiPlusNT-HP but includes an additional module for linear
drivers.
> SPiiPlusSC motion controller
SPiiPlusSC is a technology that leverages modern PC power and open architecture for
high-performance motion control. ACS and non-ACS party servo drives and I/O devices
are connected to the PC by means of real-time network EtherCAT. The SPiiPlusSC
implements both multi-axes motion control and EtherCAT Master.

4.1.2 Supported Network Slaves

The ACS units that may be employed as slaves in the network are:
> SPiiPlusDC motion controllers
The SPiiPlusDC product line consists of:
> SPiiPlusDC- LT Motion Controller
The SPiiPlusDC- LT motion controller is an economical, 4 or 8-axis drive slave controller
that can be incorporated in any network being controlled by any ACS EtherCAT master
controller to which it is slaved. SPiiPlusDC- HP/LT motion controllers provide servo
control over 4 or 8 local axis, and receives trajectories via EtherCAT protocol from the
master SPiiPlusNT-HP.
> SPiiPlusDC- HP
The SPiiPlusDC- HP motion controller is a high performance, 4 or 8-axis drive slave
controller that can be incorporated in any network being controlled by any ACS
EtherCAT master controller to which it is slaved. SPiiPlusDC- HP motion controllers
provide servo control over 4/8 local axis, and receives trajectories via EtherCAT
protocol from the master SPiiPlus NT-HP.
> SPiiPlusDC-NP
The SPiiPlusDC- NP motion controller is a NanoPWM dual axis drive slave controller that
can be incorporated in any network being controlled by any ACS EtherCAT master
controller to which it is slaved. SPiiPlusDC- NP motion controllers provide servo control
over 2/4 local axis, and receives trajectories via EtherCAT protocol from the master
SPiiPlus NT-NP.
> SPiiPlusDC-LD
SPiiPlusDC-LD is the same as SPiiPlusDC-HP but includes an additional module for linear
drivers.
> PDMnt Network Interface

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The PDMnt is a network module designed for controlling external drives and I/Os. There
are three PDMnt versions:
> PDMnt-4 - A 4-axes Pulse/Dir interface for step and servo motors.
> PDMnt-8/8-D - An 8 x digital output and 8 x digital input that can operate off 5Vdc or
24Vdc and can be configured either as a sink or source.
> PDMnt-4-8/8-D - Combines the PDMnt-4 and PDMnt-8/8-D for providing a 4 x
Pulse/Dir interface, 8 x digital inputs and 8 x outputs
> SPiiPlus IOMnt EtherCAT Module
The SPiiPlus IOMnt EtherCAT Module is a 32 input and 32 output ACS EtherCAT network
element. The product is configured, controlled and monitored by an ACS master and
matching software tools.
> SPiiPlus SDMnt Control Module
The SPiiPlus SDMnt Multi-Axis Step Motor EtherCAT Control Module is a panel mounted,
four or eight axis EtherCAT slave module designed for running step motors. It can run
seven two-phase unipolar step motors and one two-phase bipolar motor.
> SPiiPlus UDMnt
The SPiiPlus UDMnt (Universal Drive Module) is a dual-axis card designed for incorporation
in the MC4U Control Module to enable control peripherals over the Ethernet.
Details of the above units can be found in their respective Hardware Guide.

4.1.3 Supported Non-ACS Units

Currently the following non-ACS units have been certified for use within an ACS network:
> Copley Controls Accelnet (Plus Panel Ethercat)
> Sanyo Denki SanMotion RS2 with EtherCAT Interface
> Yaskawa SGDV Sigma 5
> Emerson (Control Technix) Digitax ST
Non-ACS devices are divided into two main groups:
1. Qualified Motion Drives with high-level support:
> Servo
> Stepper
2. All other non-ACS slaves are classified as I/O devices.

4.1.4 EtherCAT Cable Length

The length of the cable between two adjacent network elements can be up to 100m using ACS
certified components and cables. ACS has performed formal tests with 50m cables between
adjacent network elements.

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4.2 Numbering and Identification of Network Units, Axes and IOs

4.2.1 Unit ID Numbers
A network unit’s identification (ID) is determined automatically by the system at power up
following a master reset according to the physical order of the units in the network and in a
sequential order.

A 'unit' is a network entity. As an example, an 8 axes MC4U is represented in the

System Setup component as 'Network unit 0', or ID=0. Numbering starts at 0, up to the
number of units in the network.

The IDs are assigned a number starting from 0. In some of ACS products, a physical switch exists on
the product's panel: the DIP switch, which can be set by the user according to the following:
> When set to 00 (binary) – this is a don’t care setting.
> When set to a non-zero value – it is checked by the system to detect changes of same-
type units. This feature is used to distinguish between any identical and adjacently position
units. In the System Setup MMI component the DIP is represented as DIP: 0 or other value.
The network assigns ID numbers to units sequentially (starting from 0) as a function of number of
nodes.

4.2.2 Axes Numbering in ACSPL+

The firmware reads the units’ axes and assigns them automatically, sequentially, according to the
units’ positions in the network. The units’ configurations from the controller’s and drives’ memory,
as stored in the master, are checked by the system at power up. A warning is issued in the
following cases:
> A unit has not been configured and thus does not have a configuration file
> A conflict between the configuration file and the actual hardware settings read by the
controller, hardware does not support the assignment.
Axes’ assignment must be consecutive within each unit but may have gaps between the units and
does not have to be ordered. The following assignments are valid:

MC4Unt-8 UDMnt-2 SDMnt-8

8-15 0, 1 19-22

When changing the order of units in the network, the axes’ numbering (logical names that have
been assigned) can be maintained. This is done by the System Setup MMI component, which checks
the new assignments validity and warns of conflicts.

4.2.3 I/O Numbering in ACSPL+

> Digital In and Out
Digital I/O variables IN(n) and OUT(n) are assigned sequentially by the System Setup MMI
component as function of the detected hardware’s number of IN and OUT ports.

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As an example, a 32 bit vector assigned to a unit (32 in and out, maximum, in IOMnt, and as
function of suppported I/Os in other units), and addressed by bit: IN(3).5 where 3, the
index, is set in the System Setup MMI component, and 5 is the bit number to which the
default is assigned by the tool and can be changed by user. The variable IN(3).xx is
assigned to a certain unit and cannot be split – no two units can have the same IN(X)
assigned to them.
> Analog In and Out
Analog I/O variables AIN(n) and AOUT(n), n=0 to 999, are assigned sequentially by the
System Setup component as function of the detected hardware's number of AIN and
AOUT ports.

4.2.4 Logical and Physical Assignment of Network Units, Axes and IO Variables
Variables’ names have to change when network units change locations. Since the units’ position
has changed, their IDs change, and, as a result, the axes assignment changes. In order to maintain
the logical names of the axes and I/Os and thus leave the application unchanged, the System Setup
MMI component data has to be updated.
As an example, the following ‘before’ and ‘after’ (UDMnt-1 has been removed from the network)
configurations demonstrate the automatic axis assignment which results following the units’ order
change, and the assignment after user’s intervention. An NTM master (not shown) is assumed:
Before:

UDMnt-2 UDMnt-1 MC4U

ID 0 1 2

Axes 0, 1 2 3, 4, 5, 6

After:

UDMnt-
MC4U Remarks
2

ID 0 1

2, 3, 4,
Axes 0, 1 Default assignment
5

3, 4, 5, Assignment through System Setup MMI component by

Axes 0, 1
6 user

4.3 ACSPL+ Programming in a Network Environment

Some non-ACS network elements the commands: ECIN and ECOUT. These are used for low level
programming which involve direct mapping of the EtherCAT telegram to user defined ACSPL+
variables.

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Until version 2.60, controlling IOMNT units required using ECIN and ECOUT. ACSPL+ IN and OUT
variables were not allocated to IOMNT. Version 2.60 supports auto-mapping of IOMnt to ACSPL+ IN
and OUT variables.
For backwards compatibility, a new bit #IOMNTMAP in S_SETUP variable should be set to 1.
Refer to the SPiiPlus Command & Variable Reference Guide.

4.4 Network Operation

4.4.1 Power-Up Sequence
An ACS master has to be powered up, or reset, after all its slave units have reached their stable
operational mode. This mode is reflected in the ACS master unit as the MPU_ON LED blinking green.
The network unit is identified and monitored in the following way:
> An ACS master unit is monitored constantly, thus powering up or re-connecting a unit is
detected immediately.
> A non-ACS unit is detected only at the master’s power up or reset process. As a result of
reconnection or powering up a non-ACS unit it must be accompanied by restarting the
network.
If the master is powered up after all the slaves are up, the master resets and reloads the network.

4.4.2 Cable Disconnection

After a cable is reconnected, all disconnected units are redetected and the FCLEAR ALL command
has to be issued (see SPiiPlus Command & Variable Reference Guide). Encoder data of the
disconnected units is maintained (as long as the unit has maintained its power), so that upon
reconnection the drive’s position is maintained.

It is the responsibility of the operator to ensure that the required precautions are
taken prior to reconnecting the cables so that no personnel are endangered.

4.4.3 Losing 24V Power

If any unit has lost its 24V control power-feed, after being repowered, the entire network has to be
restarted.

4.4.3.1 Network Monitoring

In order to perform network monitoring in order to check that all units are communicating with
master, and verify the status of critical parameters, the following commands are available:

Command Meaning

Read EtherCAT State - a variable whose bits represent the various stages of
?ECST
the network

?ECERR EtherCAT error - network error code

#LOG Displays last 100 errors reported by the firmware

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4.5 System Setup

ACS Motion Control’s NT technology allows several units to be chained together using EtherCAT.
System Setup enables you to configure a single or multiple Unit Control Module along with stand-
alone NT modules and non-ACS units as a network.
Use System Setup to:
> Define the system configuration
> Update the system configuration
You can setup the system either automatically or manually.

You should run the automatic system setup on initialization and whenever the system
is changed.

4.5.1 Configuring the Network

4.5.1.1 Automatic System Setup
To activate System Setup:
1. In the Workspace right-click the controller.
2. Select Add component > Setup> System Setup.
The System Configuration window opens.
3. In the Automatic Setup tab, press Execute.

4. Approve the message about the controller being rebooted.

The system is setup automatically. This may take several minutes to complete.
5. When the setup is complete, click OK.

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The Setup results will look like this:

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5. System Hardware Configuration

The SPiiPlus MMI Application Studio System Configuration Wizard is used for configuring the
devices in a network. Your system hardware can be a single device (such as a single MC4U), or it
may be a series of devices that are linked together through an EtherCAT network. There are three
possible types of devices:
> MC4U control modules
> ACS Motion Control I/O modules (such as the SPiiPlus IOMnt) and Drive modules (such as
the SPiiPlus UDMnt)
> ACS-certified non-ACS modules (such as Sanyo Denki SanMotion RS2)
When configuring a new system, the wizard requires two steps:
> Defining the hardware configuration in the database
> Loading the hardware configuration into the master controller flash memory

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6. Axis Setup and Tuning

Axis configuration and setup is accomplished using the SPiiPlus MMI Application Studio Adjuster
Wizard. You use the Adjuster Wizard to set the parameters for the:
> Axis architecture
> Drive
> Motor
> Feedback
This chapter covers using the Adjuster Wizard to setup initial motion-related values for the SPiiPlus
Motion Controller in the system. For complete details of using the Adjuster Wizard see the SPiiPlus
MMI Application Studio User Guide.

6.1 Principles of Motion Control

A general motion control system can be divided into:
> Controller – control laws
> Drive – power converter
> Machine – plant, motors and feedback devices
The plant receives two types of signals:
> Controller output from the drive
> Disturbances

Figure 5-1. Motion Control System Schematic

Your goal in using the Adjuster Wizard is to make the plant follow the command “as good as
possible” despite the presence of disturbances while ensuring that the system is stable. Through
the Adjuster Wizard you adjust the parameters of the control laws in order to attain a quick, stable
command response.
Control laws must be set with enough margins to accommodate reasonable changes in the system,
and from system to another, such as a change in motor constant, driver gain, etc.

6.1.1 Control Loops

Ideal motion control is attained through properly tuned cascaded control loops:
> Current loop (external / internal drive)

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> Velocity loop

> Position loop

Figure 5-2. Control Loops

The position loop generates a command to the velocity loop, and the velocity loop generates a
command to the current loop.
In general, an inner loop should be faster than an outer loop, specifically:
> Current response should be faster than velocity response
> Velocity response should be faster than position response
By faster we mean with higher bandwidths, at a higher frequency zone. Typical bandwidth values
are:
> Current loop – 0.5 kHz- 1 kHz
> Velocity loop – 50 Hz – 200 Hz
> Position loop – 10 Hz – 50 Hz

6.1.2 SPiiPlus Motion Control Algorithms

Elements used in the SPiiPlus control algorithm are:
> PI filter
> Low pass filter
> Notch filter

6.1.2.1 PI Filter
The proportional-integral (PI) filter is a basic control element. It is included in the current loop and
velocity loop. In certain cases also in the position loop.
The PI is the sum of two signals:
> The proportional term (SLxKP) provides responsiveness, and affects the bandwidth (how
fast the response is)
> The integral term (SLxKI) ensures that the average error is driven to zero.

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Figure 5-3. PI Filter Schematic

Figure 5-4 shows the frequency response of a PI filter.

Figure 5-4. PI Filter Frequency Response

> The proportional gain dominates the higher frequency zone.

> The integrator gain dominates the lower frequency zone.
> The frequency of the PI zero is always at: SLxKI/20 Hz

6.1.2.2 Low Pass Filter

SPiiPlus provides a second order low-pass filter. In many cases, it can be used to increase the overall
bandwidth of the velocity loop. It attenuates high frequency noise and resonances (a phenomenon
in which the plant has high gain around one frequency).
The second order low-pass filter attenuates all signal components above a certain frequency. The
frequency is specified by the SLVSOF variable.
Filter damping is determined by the SLVSOFD variable.
In many cases a proper reduction of the low pass filter bandwidth (relative to its default value)
allows to further increase the velocity gain. The major disadvantage of the second order low pass
filter is that it affects stability by adding a significant amount of phase lag and thus reducing the
phase margin.

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Usually, SLVSOF has to be 10-20 times above the velocity loop bandwidth. As a rule of thumb: set
SLVSOF=SLVKI.

6.1.2.3 Notch Filter

SPiiPlus provides a Notch Filter. In many cases, it can be used to increase the overall bandwidth of
the velocity loop. The Notch filter attenuates only a narrow band of frequencies and is usually set
above the bandwidth of the velocity loop.
Notch Filter advantage is less phase lag contribution in comparison to the low-pass filter. The Notch
Filter disadvantages are:
> Usually the transfer function of the plant has to be known in order to place the Notch Filter
properly.
> The Notch bandwidth has to be sufficiently wide. Resonant frequencies may vary slightly in
different machines of the same kind. The resonant frequency may also depend on the
position of the axes.
The Notch filter parameters are:
> SLVNFRQ – Notch frequency
> SLVNWID – Notch width (3 dB points)
> SLVNATT – Attenuation (absolute units)

6.1.2.4 BI-Quad Filter

A Bi-Quad filter is added to the velocity loop control in addition to the existing 2nd order Low-pass
and Notch filters.

The Bi-Quad filter is the most general 2nd order filter. It has two poles and two zeros. It can be
thought of as a high-pass filter in series with a low-pass filter. The transfer function of the Bi-Quad
filter is as follows:

Where:
> ωN and ωD are the numerator (high-pass filter zero) and denominator (low-pass filter pole)
frequencies, respectively.
> ζ N and ζ D are the numerator and denominator damping ratios, respectively.

The corresponding ACSPL+ parameters are:

> SLVB0NF, SLVB0DF - numerator and denominator frequencies in [Hz]. Range: 0.1 -
4000 [Hz].
> SLVB0ND, SLVB0DD - numerator and denominator damping ratios. Range: 0.01 - 1.
> MFLAGS bit 16 is used to activate the filter (by default the filter is off).

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The Bi-Quad filter can be used to compensate mechanical resonances, improve stability margins
and system bandwidth.

The Bi-Quad filter can be configured as an additional Notch using the following formulas:
1. Set the numerator and denominator frequencies equal to the Notch frequency in[Hz]:

2. Set the numerator damping ratio equal to half the ratio between the Notch width and
Notch frequency:

Maximal recommended ratio between width and frequency= 1/3.

3. Set the denominator damping ratio equal the numerator damping ratio times the Notch
attenuation (in absolute value):

Below there are several examples that demonstrate the generality of the Bi-Quad filter.

Figure 5-5. Bi-Quad Configured as a Notch Filter

SLVB0NF = SLVB0DF
SLVB0ND<SLVB0DD

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Figure 5-6. Bi-Quad Configured as a 2 nd Order Lead FIlter

This kind of filter is used to improve the phase margin

SLVB0NF < SLVB0DF
In the example the damping ratios are equal:
SLVB0ND=SLVB0DD =0.707

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Figure 5-7. Bi-Quad Configured as a 2 nd Order Lag FIlter

This kind of filter is used to improve the gain margin

SLVB0NF > SLVB0DF
In the example the damping ratios are equal:
SLVB0ND=SLVB0DD =0.707

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Figure 5-8. Bi-Quad Configured as a 2 nd Order Low Pass FIlter

SLVB0NF > SLVB0DF

6.2 About the Adjuster Wizard

The Adjuster Wizard provides tuning in terms of high-level parameters, namely parameters that
have a clear meaning for you. Once you have assigned high-level parameters, the Adjuster Wizard
automatically transforms them into low-level parameters, that is, controller parameters.
Since the Adjuster Wizard works together with the SPiiPlus MMI Application Studio Scope
monitoring tool, it provides interactive tuning. The Adjuster Wizard sends a trial signal to the motor
and automatically selects suitable Scope settings and sends the low-level parameter values. The
Scope displays the motor response and you can immediately view the results.
The controller needs to be configured and adjusted for each axis. The adjustment procedure
affects both the volatile and non-volatile memory of the controller. The Adjuster Wizard maintains
the high- level adjusted values for each component separately on your computer. Only after you
have selected Save to Flash, does the Adjuster Wizard save the values into low-level parameters in
the controller.

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Some operations during the adjustment process may cause the motor to begin moving
unexpectedly. Some of the limits and safety features may be temporarily disabled. To
avoid personal injury or damage to the equipment, check the following before starting
the adjustment process:
> Verify that NOTHING (people, electrical cables, or other obstacles) is in the path
of the motor or objects connected to the motor.
> Verify that the motor is securely anchored and that proper safety barriers,
stops, and/or limits are installed.

You must run the Adjuster Wizard for each new SPiiPlus Motion Controller in the
system.

The adjustment procedure affects both the volatile and non-volatile memory of the controller. The
Adjuster Wizard keeps the controller memory in-sync with the application database.
The Adjuster Wizard maintains the high-level adjusted values for each component separately on
your computer. Only after you have selected Save to Flash, does the Adjuster Wizard save the
values into low-level parameters in the controller.

If the controller is shut off during an adjustment session and the data has not been
saved to the controller’s flash memory, the synchronization will be lost and the
adjustment session must be repeated.

6.2.1 Working in Adjuster Wizard Task Windows

There are several elements that are common to most of the Adjuster Wizard task windows. These
are:

6.2.1.1 Data Action Buttons

There are five data action buttons:

Add an item to the field.

Edit the data fields.

Deletes the item from the database.

Import data from a previously saved file on the computer.

When you click this button, a browser window is displayed, for example:

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Drill down to the subdirectory containing database files and select the file, all
Adjuster database files have an awd file extension. Then click Open.

6.2.1.2 Adding Data to Component Database

When you define the values for the Motor, Drive and Feedback components, the following action
buttons are available:

Active if you have entered a

component name that is
not in the database. Clicking
this button adds the data to
the Component database
under the component
name.

Active if you have made

changes to the data that
exists in the database.
Clicking this button puts
changes into the
Component database.

Deletes all changes you

have made to the data
fields.

6.2.1.3 Incompatibility Symbol

The Incompatibility Symbol indicates that the value in the component field is incompatible with
what you have defined in previous windows.
You should return to a previous window and change the value with which it is in conflict, or, if
possible, change the value in the field in the current window. In any case you should resolve all
conflicts before continuing.

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This symbol can be ignored when an element is not yet defined. For example, a Drive
has been defined but not the Motor.

6.3 Starting Adjuster Wizard

1. In the Toolbox click Setup to display the Setup list of tools.
2. Click Adjuster Wizard in the list of tools.
The Adjuster Wizard Select Task window is displayed in the workspace.

You can also activate the Adjuster Wizard using the right-click Add Component option
of the Workspace Tree.

3. Select the axis by clicking the Axis Selector field and then select the axis from the
dropdown list:

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The Adjuster Wizard must be run for each axis in the system.

6.4 Selecting Axis Setup Initial Values

You use the Set initial values option to set the values that the Adjuster is to use at the start of the
adjustment process: You have two choices:
> Existing Values - using the values that have been built into the Adjuster Wizard database.
> Default Values - using factory default values that have been set in the controller.
When you select this option, a prompt window is displayed:

If you have already run the Adjuster for another axis, you have the option of copying
values from this axis into the current axis by selecting Copy Values From Axis. When
you select this option, you choose the axis whose values are to be used from the
Select Axis To Copy From (which becomes active when you select this option)
dropdown list:

Click Yes to load the values.

To setup the axis values select Setup New System or Controller from the Task window and click
Next. There are nine steps in this task:
Initialization
In this step you provide information that serves to identify the database containing the high-level
parameter values.
Axis Architecture

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In this step you define the electro-mechanical structure of the controller’s working application as
well as the units for measuring feedback.
Components
In this step you define the parameters governing the:
> Drive
> Motor
> Feedback
Once you have defined these, you trigger the Adjuster to calculate the optimal values for the high-
level parameters and you load them into the system.
Safety and Protection
In this step you define the parameters for:
> Motion limits
> Current limits
> Postion errors
> Position limits
Miscellaneous Definitions
In this step you define the parameters for such things as:
> Motion completion
> Enable/Disable/Brake
> Dynamic brake
> Home switch
Verification
In this step the Adjuster Wizard runs various verification tests for such things as:
> Feedback
> Motor
> Switches
> Stop. Alarm, and Brake
This enables you to see where you need to adjust the values of the parameters.
Axis Setup and Tuning
In this step you are given the opportunity to refine your values and fine tune your system.
Save to Flash
Once your high-level values are correct for your system, in this step you save the low-level values
to the controller flash.
Final Page
This step is your exit point from the Adjuster Wizard.

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6.5 Initialization
Initialization serves only for tracking purposes.

1. Enter your name in the User Name field (optional - this field may be skipped).
2. Enter the name of your application or the ID of the machine for which the controller is
being employed in the Application/Machine field (optional - this field may be skipped).

You will note that Adjuster has extracted the controller’s firmware version, S/N and
P/N from the controller and filled in these fields.

3. Enter the date in the Date field - its format is: mm/dd/yyyy.
4. Enter any remarks you want in the Remarks field (optional - this field may be skipped).
5. Click Next.

6.6 Axis Architecture

In this step you are to define the general parameters of the feedback mechanism to include the
electro-mechanical characteristics of the motion and how feedback is to be measured and from
what.
Data must be entered in all the fields. The data is entered by selecting the appropriate value from
the dropdown list of each field.

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Once you have entered all the required data for this step, click Next to advance to the next task.

6.6.1 User Units

User Units
Of particular import in this step is the setting of User Units to be used by Adjuster Wizard in
measuring feedback. 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
2mm/4 = 0.5mm.
The User Unit is applied to the EFAC variable. EFAC is a 64 member (one for each possible axis) real
array used for defining a factor between the raw feedback in encoder counts and the FPOS value
calculated by the controller. See SPiiPlus Command & Variable Reference Guide for complete
details.
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.

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6.6.2 User Defined User Unit

You use Advanced Parameters to make your own definitions of the User Unit.
To display Advanced Parameters select User defined from the Units dropdown list, for example:

The Advanced Parameters panel is displayed:

The Advanced Parameters option should be used with caution. Badly defined units
may cause serious problems with measuring the actual feedback.

1. Enter a unique parameter name in User Defined Unit Name.

2. Enter a mathematical expression in Function, you can use the standard arithmetical
operations:
> + (Add)
> - (Subtract)
> * (Multiply)
> / (Divide)
The function is used as a conversion factor applied to the selected standard unit. For
example: 2.71828*1.41421 (e times the square root of 2).
3. Select a standard unit from the dropdown list in the of field.
4. Enter a correction factor (if different than 1) in Correction Factor. The correction factor is
used to correct the difference between actual movement (as measured by a laser
interferometer) and the software commanded move (indicated in the user units).

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The EFAC variable relates to many other configuration variables. While changing the
EFAC variable via the Adjuster, all relevant configuration variables are automatically
updated. Therefore, we recommend changing the EFAC variable only via the Adjuster
and not from other places, such as SPiiPlus MMI Application Studio Communication
Terminal or any application program

6.7 Components
The Components step consists of defining the values for:
> Motor
> Drive
> Feedback
At the end of the step the Adjuster Wizard calculates the parameters that are to be used and
inserts them into the appropriate program variables.

The screen shots presented in this step are for example only. The actual fields that
appear depend on the values set in the Axis Architecture step. See SPiiPlus MMI
Application Studio User Guide for details of working with these windows.

6.7.1 Motor
The first component for which you need to enter values is the Motor.

Data must be entered in all the fields. The data is entered by selecting the appropriate value from
the dropdown list of each field or entering the values taken from the motor’s technical data sheet.

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In entering the values the incompatibility icon ( ) may appear. Check the tool-tip. If it
states that there is incompatibility between components that have not been set yet,
ignore it. Continue to set component values.
However, do not forget to go back after all the components have been set up and
ensure that it no longer appears. If it still appears, then resolve it by changing the
component's values or changing the Axis Setup values.

Once you have entered all the values, click Next to define the Drive component.

6.7.2 Drive
The second component for which you need to enter values is the Drive.

Data must be entered in all the fields. The data is entered by selecting the appropriate value from
the dropdown list of each field or entering the values taken from the drive’s technical data sheet.

In entering the values the incompatibility icon ( ) may appear. Check the tool-tip. If it
states that there is incompatibility between components that have not been set yet,
ignore it. Continue to set component values.
However, do not forget to go back after all the components have been set up and
ensure that it no longer appears. If it still appears, then resolve it by changing the
component's values or changing the Axis Setup values.

Once you have entered all the values, click Next to define the Feedback component.

6.7.3 Feedback
The third component for which you need to enter values is the feedback.

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The Feedback component can be either the Motor, the Load, or both depending on
what you defined in Feedback Topology in the Axis Architecture step.

Data must be entered in all the fields that are active (many, you will note, have already been
selected by Adjuster from data that you have previously entered for the Drive and Motor
components). The data is entered by selecting the appropriate value from the dropdown list of
each field or entering the values directly in the fields.
For absolute encoders, see Absolute Encoder Setup Procedure.

In entering the values the incompatibility icon ( ) may appear. Check the tool-tip to
see what is causing the incompatibility. If it is a value of a previously set up component,
then return to the component and either change the component’s value, or make
changes in the Axis Setup.

Make sure that all component incompatibilities are resolved before continuing.

Click Next to advance to calculate and apply the feedback parameters.

6.7.3.1 Absolute Encoder Setup Procedure

To setup the absolute encoder, use the following procedure:

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1. Prior to the setup, verify that the controller has a license for the specific encoder type, as
well as hardware support. This can be verified by using the SPiiPlus MMI Application Studio
System Information Viewer or the #SI command.
2. Use the SPiiPlus MMI Application Studio Adjuster Wizard to do the following:
> Up to the Components:Feedback step, setup the axis normally.
> In the Components:Feedback step, type the encoder parameters.
> Set the encoder parameters as follows:

For details of the variables and their permissible values, see the SPiiPlus ACSPL+
Command & Variable Reference Guide.

> Type Absolute Encoder BiSS-C: in the Communication Terminal, set the absolute
encoder BiSS-specific parameters E_PAR_A and E_PAR_B according to technical
documentation for the encoder.
> For Type Absolute Encoder HIPERFACE: in the Communication Terminal, set the
absolute encoder HIPERFACE-specific parameter E_SCMUL according to technical
documentation for the encoder.
> Return to the Adjuster Wizard and click Next.
> In the Calculate Parameters step, click Calculate Parameters and then click Apply changes.
3. Continue to setup the axis using the Adjuster Wizard.

6.7.4 Calculate Parameters

At this stage, the Adjuster Wizard verifies that the Axis Architecture, Motor, Drive and Feedback
definitions are all compatible with each other.
If an inconsistency is detected, a prompt is displayed about it with recommended solutions.

If there are no inconsistencies, click: .

The Adjuster Wizard calculates the values for the controller parameters and displays a table with
each parameter name, its old and its new value, for example:

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Click: and click Next to advance

to the next step.

6.8 Safety and Protection

The Safety and Protection step enables you to set certain safety and protection variables. There
are a total of four possible types of Safety and Protection parameters that you can set.

The actual number of parameter types and parameters available to you depends on
what you defined in the Axis Architecture and Components steps.

The Adjuster Wizard displays values it has calculated in the window of each type. You have the
option of changing these within the limits of valid values. For details of the variables and their
permissible values see the SPiiPlus ACSPL+ Command & Variable Reference Guide.

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6.8.1 Motion Parameter Limits

This window is used for entering the Maximum Velocity and Maximum Acceleration Limits values.
> MAXIMUM VELOCITY (XVEL) [UNITS/SEC] - The maximum allowed value is automatically
calculated based on motor parameters that were defined in Components step. Letting the
mouse cursor linger on the field displays a tool-tip guiding you in permissible values.

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.

> MAXIMUM ACCELERATION (XACC) [UNITS/SEC²] - The Adjuster puts in a value based on
motor parameters that were defined in Components step. Letting the mouse cursor linger
on the field displays a tool-tip guiding you in permissible values.

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6.8.2 Current Limits

This window is used for defining motor and drive protection parameters:
> Maximum Current In Idle State (XCURI) - The Adjuster Wizard automatically calculates the
value from the maximum torque/force required during standstill to overcome gravitation,
friction, etc.
If the value cannot be automatically calculated, that is, you have not specified gravitation,
friction, etc., the parameter XCURI is set to default.
If you want to set values other than the value displayed, letting the mouse cursor linger on
the field displays a tool-tip guiding you in permissible values. 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.
> Maximum Current In Moving State (XCURV) - The value is automatically calculated
according to minimum of either maximal acceleration (XACC) or motor peak current that
you have specified.
If you want to set values other than the calculated one, letting the mouse cursor linger on
the field displays a tool-tip providing guidance in changing maximal acceleration or motor
peak values. XCURV = [allowed motor peak current / drive peak current] x 100. Refer to
the drive and motor specifications for these peak values.
> Overcurrent Fault detection - The following numeric controls defines Overcurrent Fault
detection criterion:
> RMS CURRENT LIMIT (XRMS, XRMSD, XRMSM) - The value is automatically calculated
based on motor/drive parameters that were defined in the Components step.
If you want to set values other than the calculated ones, letting the mouse cursor
linger on the field displays a tool-tip guiding you in permissible values for the motor
and/or drive current limits. XRMS, XRMSD, or XRMSM = [allowed motor nominal current
/ drive peak current] x 100. Refer to the drive and motor specifications for these
values.

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> RMS CURRENT TIME CONSTANT (XRMST, XRMSTD, XRMSTM) [MS] - This is the time
interval for checking whether an overcurrent fault has occurred.The overcurrent fault
activation time is according to the following formula:

For example: if XRMS=50, DCOM = 100 and XRMST = 3300 msec, then fault activation
time = -ln (0.75)*3300 = 950msec.
To calculate the fault activation time for XRMSD use XRMSTD; for XRMSM use
XRMSTM.
If you click the Advanced down arrow, the Adjuster displays a graph of the Overcurrent Fault
Detection:

When you change parameter values, you can see the effect on the graph.
Setting current (torque) limits example:
> 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%.

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6.8.3 Position Errors

This window is used for defining Critical Position Errors criteria:

> Critical Position Error While Idle (CERRI)
> Critical Position Error While In Constant Velocity (CERRV)
> Critical Position Error While Accelerating (CERRA)
If you click the Advanced down arrow, the Adjuster displays the following:

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.

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> 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 the idle state), CERRI (critical position error
in the idle state).
> Constant velocity: ERRV (position error in while in the constant motion state), CERRV
(critical position error in while in the constant motion state)
> Acceleration: ERRA (position error in while in the accelerating state), CERRA (critical
position error in while in the accelerating state)
For example, when the motor is in the 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.

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. Once the process is completed, the thresholds should
be reduced to minimal levels.

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.
> Moving-to-Idle Transition Delay (DELI) Time (milliseconds) to wait on transition from
acceleration state to idle state.
> Accelerating-to-Moving Transition Delay (DELV) Time (milliseconds) to wait on transition
from acceleration to constant velocity state.

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6.8.4 Position Limits

This window defines Software Position Limits and enables you to select:
> Allow Soft Upper Position Detection (SRLIMIT) - If Software Right Limit Mask is selected,
then the controller examines the fault and kills the motion that is beyond the defined limit.
> Allow Soft Lower Position Detection (SLLIMIT) - If Software Left Limit Mask is selected,
then the controller examines the fault and kills the motion that is beyond the defined limit.

6.9 Miscellaneous Definitions

The Miscellaneous Definitions step enables you to set certain variables. There are a total of four
possible types of variables that you can set.

The actual number of parameter types and parameters available to you depends on
what you defined in the Axis Architecture and Components steps.

The Adjuster displays values it has calculated in the window of each type. You have the option of
changing these within the limits of valid values. For details of the variables and their permissible
values see the SPiiPlus ACSPL+ Command & Variable Reference Guide.

6.9.1 Motion Completion

There are two variables, both optional, for which you can enter values:
> Target Radius (TARGRAD)
> Settling Time (SETTLE)
To aid your understanding a diagram is included showing the meaning of the two variables.

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6.9.2 Enable/Disable/Brake
This window is used for defining the Enable operation and Mechanical Brake timing.

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The variables you can define are:

> Protracted Enable - This is optional, but if you select it, you must put a value in Enable
Delay (ENTIME). The controller delays the Enable GUI by ENTIME mSec.
> Use Mechanical Brake - You need to select this only if the application has a mechanical
brake; otherwise leave it unselected. If you select it, you have to enter values for:
> Brake Release Time (BOFFTIME) - This value can be positive or negative and sets
when the brake is released.
> Brake Activation Time (BONTIME) - This value can be positive or negative and sets
when the brake is applied.

You are also informed of the Digital Output variable (OUTx.x) that will contain the state
of brake. Make sure that you include it in your program to test the brake status.

The Digital Output variables for the SPiiPlus family of products are given in the following tables.
Table 5-1. Digital Outputs for Brake Control in SPiiPlus

Digital Output Controls Mechanical Brake for Axis

OUT1.0 0

OUT1.1 1

OUT1.4 4

OUT1.5 5

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Table 5-2. Digital Outputs for Brake Control in MC4U

Digital Output Controls Mechanical Brake for Axis

OUT0.0 0

OUT0.1 1

OUT0.2 4

OUT0.. 5

OUT0.4 2

OUT0.5 3

OUT0.6 6

OUT0.7 7

6.9.3 Dynamic Brake

This window enables you to activate (or deactivate) the dynamic brake.

This option is active only for those axes having a built-in drive.

You activate a dynamic brake by:

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> Selecting Use Dynamic Brake (this sets the MFLAGS#DBRAKE bit for the axis), and then
> Entering a Threshold Velocity (VELBRK) value.
Refer to SPiiPlus ACSPL+ Command & Variable Reference for details.
Braking will occur when the following two conditions are met:
1. The motor is disabled.
2. The feedback velocity (FVEL) is less than VELBRK.

6.9.4 Home Switch

This window enables you to specify a digital input (IN) to signal when the motor is in its home
position.

The Home Switch can be None or you can select the digital input variable from the Home Switch
dropdown list:

6.10 Verification

If you have Sin-Cos encoders in the system, before doing this step, perform Sin Cos
Encoder Compensation Window and then return.

The Verification step examines the values you have entered and verifies that they are valid.
Verification is performed on the following:

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> Feedback devices

> Limit switches
> Hardware Emergency Stop
> Mechanical Brake
There are three “LED” indicators used throughout the Verification windows:

Indicates that the item passed verification

Indicates that the item failed verification

Indicates that the item is not active

6.10.1 Feedback
This window verifies that the feedback values are valid.

Depending on what you defined in Components, the window displays the values for:
> Load
> Motor

If you have defined both Load and Motor as feedback components, there is one page
for Load and one page for Motor.

In this window:

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> Check that there are no encoder faults.

> Check that encoder counts in the right direction. If it does not, click the Encoder Direction
Inversion check box to reverse the direction
> Check that the index is working properly by manually moving the motor. The motor should
be moved slowly to ensure that each index is latched and displayed.
> Check that calculated distance between indexes is correct.
To set the feedback (FPOS) to a particular value:
1. Enter a value in the Set To field.

2. Click - this resets the position and the Adjuster starts counting from this
position.
You can view a list of the last latched indexes by clicking the down arrow of the Last latched
indexes list. To clear this list click Clear List.
There are two LEDs in this window relevant to the encoder:
> Encoder Not Connected Fault (FAULT.#ENCNC) - green indicates that this fault was not
detected.
> Encoder Error Fault (FAULT.#ENC) - green indicates that no encoder fault was detected.
If you selected Hall Sensors in Components: Feedback, the following is displayed:

The connection sequence of the three Hall Sensors is not important. You only have to verify that
the three Hall sensors are connected and the Hall counter counts 0,1,2,3,4,5 or vice versa. It does
not matter if the Hall counters count opposite to the encoder. This will be identified and taken care
of during .
The diagram shows:
> Feedback Position (FPOS) - the position in user units.

> Hall State - the Hall State transitions: 0ª 1ª 2ª 3ª 4ª 5 or 5ª 4ª 3ª 2ª 1ª 0.

The history of the Hall State transitions is displayed under the diagram.
To test the Hall Sensors:

Rotate the motor by hand in one direction. The diagram should show the expected Hall state
transitions.

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Rotate the motor by hand in opposite direction. The diagram should show the expected Hall
state transitions.

Correcting Feedback Values that Fail Verification

Where feedback values fail verification:
1. Return to the Components:Feedback step by clicking Components in the Task List, then
click Feedback. The Components:Feedback window is displayed.

2. Click Edit ( ) and enter a new value or values.

Those values that can be changed are displayed in bold face. Values that cannot be
changed are grayed out.

3. Click Update in Database and click Next. The Components:Calculate Parameters window is
displayed.

4. Click Calculate Parameters then click Apply changes.

Adjuster recalculates the values of the low-level controller parameters and applies them
to the appropriate variables.
5. Click Verification in the Task List to return to Verification and check if the new value(s) pass
verification.

6.10.2 Switches
This window is used for verifying the that actual limit switches are properly connected.

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Verification of Switch Operability

The LEDs indicate if the switches are properly connected or not. The switches are:
> Upper Position Limit (SAFINI.#RL)
> Lower Position Limit (SAFIN.#LL)
that you set in Safety and Protection:Position Limits.

If you have selected a digital input variable in MISCELLANEOUS DEFINITIONS:HOME

SWITCH, its value is also displayed.

To verify that the switches are properly connected manually move the motor into the switch and
check if the Fault LED turns red.
If it does not turn red, this means that there is something wrong with the switch. Check its
connection and if it is operational.
Fault Detection Settings
You have the options of:
> Enable/disable fault detection (FMASK.#RL for upper limit, FMASK.#LL for lower limit) by
selecting the appropriate check box.

If the bit is empty, the controller does not detect the fault.

> Inverting the detection logic (SAFINI.#RL for upper limit and SAFINI.#LL for lower limit) by
selecting the appropriate check box.

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Feedback Setting
To set the feedback (FPOS) to a particular value:
1. Enter the value in the Set To field.

2. Click - this resets the position and the Adjuster starts counting from this
position.

6.10.3 Stop, Alarm and Brake

This window verifies the status of Hardware Emergency Stop and Mechanical Brake.

The window shows the status of the:

> Hardware Emergency Stop (S_SAFIN.#ES)
> Drive Fault / Laser Fault (SAFIN.#DRIVE)
You have the options of:
> Enable/disable fault detection (S_FMASK.#ES for Hardware Emergency Stop and S_
FMASK.#DRIVE for Drive Fault / Laser Fault) by selecting the appropriate checkbox.

If the bit is empty, the controller does not detect the fault.

> Inverting the detection logic (S_SAFINI.#ES for Hardware Emergency Stop and
SAFINI.#DRIVE for Drive Fault / Laser Fault) by selecting the appropriate checkbox.
To set the feedback (FPOS) to a particular value:
1. Enter the value in the Set To field.

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2. Click - this resets the position and the Adjuster Wizard starts counting from
this position.
If you defined a Mechanical Brake in Miscellaneous Definitions:Enable/Disable/Brake, then
you have the option in this window of defining the mechanical brake output by activating
it manually, that is, without an ENABLE command by clicking the associated box.
3. When you are done, click Next to go to the next window.

6.11 Axis Setup and Tuning

The Axis Setup and Tuning step enables you to fine tune your system. There are a total of six
possible options:

The options that are available to you depend on the definitions you entered in
Components.

> Current Loop

Current Loop enables you to adjust the current loop. Adjustments are done by entering
values in the required fields and viewing their effect on the Scope. This is covered in
Current Loop and Current Phase Offset Setup.
> Current Phase Offset
Current Phase Offset enables you to verify, and, if needed, adjust the values of the current
phase offset. This is covered in Current Loop and Current Phase Offset Setup.
> Commutation
Commutation enables you to adjust motor commutation and generate a commutation
startup program.

Commutation applies only for DC brushless (AC Servo) motors. It will appear in the
Adjuster tasks only if motors of this type have been defined as part of the system.

This is covered in Commutation.

> Open Loop Verification
Open Loop Verification enables you to check if the motor responds correctly to the drive
command, that is, the motor velocity should be in the same direction as drive command.
This is covered in Open Loop and Position Verification.
> Position and Velocity Loops
Position and Velocity enables you to tune the position and velocity loops in order to
optimize the servo system performance. This is covered in Position and Velocity Loops.
> Position Verification
Position Verification is relevant only for open loop modes and enables you to verify that
the actual move corresponds to a commanded one, and make changes where necessary.
This is covered in Open Loop and Position Verification.

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7. Current Loop and Current Phase Offset Setup

This chapter covers Current Loop and Current Phase setup and tuning procedures of the SPiiPlus
MMI Application Studio Adjuster Wizard Axis Setup and Tuning step of the Setup New System or
Controller Task.

7.1 Current Loop

Current Loop enables you to adjust the current loop.

Current Loop adjustment applies only to:

> PWM, Digital Current Control, controller-drive interface with:
> DC brushless/AC servo motor (two or three phase)
> Step motor (with feedback, close loop)
> DC brush or single phase motor
> AC induction motor
> Analog (±10V), Digital Current Control, controller-drive interface with
> Three phase DC brushless/AC servo motor
> DC brush or single phase

Two current loop tuning methods are available:

> Auto tuning - The auto tuning process calculates the current loop parameters from values
measured by the frequency response.
> Manual tuning - The manual tuning process calculates the current loop parameters from a
step response with parameters you set. Manual tuning is optional.
Auto tuning
The calculated current loop parameters are:
> The Proportional Gain (SLIKP)
> The Integrator Gain (SLIKI)
1. To start the auto tuning process, click Start Auto Tuning.

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> When the auto tuning process starts, the Start Auto Tuning button changes to
Stop Auto Tuning and the LED next to it flashes "green".
> When the auto tuning process is complete, the LED returns to "gray" and Done
shows to the right of it.

2. When the auto tuning is complete, click Next to go to the next adjustment.
Auto tuning with Use Initial Parameters During Measurement (Optional)
If necessary, the current loop auto tuning can be done from initial parameters that you set. The
parameters are:
> Motor resistance phase-to-phase
> The rectified bus voltage
> Initial excitation current
To start the Auto Tuning process with the optional Use Initial Parameters During Measurement:
1. Click Use Initial Parameters During Measurement (Optional) check box.
2. Enter the values in the applicable field.
3. Select Start Auto Tuning.

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4. When the auto tuning is complete, click Next to go to the next adjustment.
Fine Tuning
When Auto tuning is complete, a Fine Tuning process can be done. Auto fine tuning is only for
PWM drives with good linear properties. You can do fine tuning for three different types of drives :
> Weak (PWM drives with poor linear properties)
> Normal (PWM drives with good linear properties)
> Strong (PWM drives with good linear properties)
1. To start fine tuning, click Fine Tuning drop down icon to show the different tuning levels.
2. Select the applicable drive.
3. Click Fine Tune.

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4. When the fine tuning is complete, click Next to go to the next adjustment.
Manual Tuning (Optional)
If you select manual tuning, you can set the proportional gain (SLIKP) and the integrator gain (SLIKI).
1. Click the Manual Tuning check box.
2. Enter the values in the applicable field.

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3. Click Next to go to the next adjustment.

Step Response
Use step response to verify the proportional gain and integrator gain. The required parameters to
do a step response are:
> Current level
> Pulse width
1. To start the step response, click the Step Response drop down box to show the
parameter fields available.
2. Enter the parameter values.
3. Click Check Step Response. A dialog box opens and shows the message.

4. Select the applicable condition.

When the step response starts, the Check Step Respnse button changes to Stop and
the LED next to it flashes "green".

5. To make adjustments on the signal:

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> Increase the Proportional Gain (SLIKP) until the response waveform approximates a
square and a small overshoot appears, for example:

> Increase the Integrator Gain (SLIKI) by hundreds, until you get a narrow overshoot of
10% to 20%.
6. When you achieve the optimal values, click Stop. Close the Scope.
7. Click Next to go to the next adjustment.

7.2 Current Phase Offset

The Current Phase Offset window enables you to verify, and, if needed, adjust the values of the
current phase offset.
Current Phase Offset applies to Analog (±10V) controller-drive interfaces with two or 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. If, however, 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.

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There are two current phase offset variables:

> Phase R Offset (SLBIASA) which contains the maximum controller voltage output
(expressed as a percentage).
For integrated models: SLBIASA specifies the measured value of the current input bias of
Phase R.
For nonintegrated models: SLBIASA specifies the bias of the drive output. The controller
uses the value only for brushless motors commutated by the controller.
> Phase S Offset (SLBIASB) which is used for defining the maximum controller current
(expressed as a percentage).
For integrated models: SLBIASB specifies the measured value of the current input bias of
Phase S
For nonintegrated models: SLBIASB specifies the bias of the drive output. The controller
uses the value only for brushless motors commutated by the controller.
Click Enable Motor and check that the LED turns green.
If the LED turns red, this means that one or both values need to be adjusted, in which case, the
variables SLBIASA, SLBIASB have to be adjusted to bring both readings as close to zero as possible.
This can be done by a single voltmeter (or multimeter) as follows:
1. Make sure that the value of the DOUT variable is zero (you can query it from the
Communication Terminal, for example: ?X_DOUT).
2. Connect the voltmeter between phase “R” and the motor neutral point, and adjust
SLBIASA to make the reading as close to zero as possible. A typical range is ±10%. The
value can be either positive or negative.
3. Connect the voltmeter between phase “S” and the motor neutral point, and adjust
SLBIASB to make the reading as close to zero as possible.

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If the neutral point is not accessible, or the motor is connected in delta, you may create an
“artificial” neutral point by connecting three-phase resistors in parallel to the motor. The 3 resistors
should be identical, in the range of 4-10 kΩ. Then you should measure relative to the artificial
neutral as shown in the following drawing:

When you are done, click Next to go to the next window.

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8. Commutation

Commutation applies only for DC brushless (AC Servo) motors. It will appear in the
Adjuster tasks only if motors of this type have been defined as part of the system.

8.1 Adjuster and Commutation

8.1.1 Commutation Overview
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, on the other hand, 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.
SPiiPlus motion controllers support three types of drives for 3-phase DC brushless/AC servo
motors:
> Universal Internal Drive (such as SPiiPlus CM and MC4U drives). Commutation is performed
by the controller as part of its Field-Oriented Control algorithm.
> Two-Input Drive (such as SPiiPlus SA controller or SPiiPlus PCI card with a Sine Wave
Brushless Amplifier). The drive receives two current commands from the controller,
reflecting required current for two of the motor phases. In this case the controller is
responsible for commutation.
> One-Input External Drive (such as a SPiiPlus SA controller with an Analog Input Brushless
Amplifier). This drive receives a single current command from the controller (±10V),
reflecting the required current amplitude, and takes care of the commutation by itself.

Commutation needs to be done only for types 1 and 2.

8.1.2 Commutation Technical Details

The desired current for two of the motor phases will be:
IA = I * cos (ɸ)

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IB = I * cos (ɸ+ 120°)

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:
ɸ = k * CP + Ɵ .
where CP is the motor position, k is a conversion factor between position units and electrical
degrees, and Ɵ is an offset.
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 Adjuster calculates k according to the motor and
encoder variables that you specified in Axis Setup and Tuning.
The Ɵ 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 Ɵ 0. A position CP0 where the
magnetic field of the motor aligns with this current vector is called a detent point. The offset Ɵ can
be calculated at the detent point as:
Ɵ = Ɵ 0 – 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 depends on the motor position, the commutation process has to be
done only once for an absolute encoder but after every power-up for incremental quadrature and
Sin/Cos encoders – 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. For this reason you can use Adjuster to generate
and store a Commutation Startup Program.

8.1.3 The Adjuster Commutation Task

The 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 both of the motor and the encoder.
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.
The Commutation Startup Program is an ACSPL+ program that is used to retrieve commutation. It
can be executed upon every powerup (once the system has been setup). The startup program can

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be based either on bringing the motor to a detent point (usually involves movement) or on
automatic commutation (COMMUT command see SPiiPlus ACSPL+ Command & Variable Reference
Guide), which is fast commutation retrieval using a closed-loop algorithm (and involving almost no
motor movement).

8.2 Performing the Commutation Task

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.

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.

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When the page is first displayed, Preferences and Advanced Parameters are not
displayed. It is strongly recommended that you expand both and view all the options
available to you.

8.2.1 Preferences

When initially setting Preferences, you should first use the default values (by clicking
). This will set the commutation parameters in accordance with the
settings you have entered in previous steps of the Adjuster.

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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, XRMSD, or XRMSM.
Things you should consider:
> Due to friction and load, a low excitation current may result in poor
Excitation alignment between the current vector and the magnetic field,
Current resulting in unsatisfactory commutation.
> 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.
It is recommended starting the commutation process with an excitation
current of 0.4 x XRMS, XRMSD, or XRMSM. If the results are not successful,
repeat this task with higher excitation current values.

Determines the velocity of the current vector during the commutation

process. During this process the motor position follows the current vector
Search
in order to align the magnetic axes. It is recommended to set a velocity
Velocity
lower than one magnetic pitch per second and higher than one fifth of a
magnetic pitch per second.

Settling
Determines the time assigned to the motor for settling at detent points.
Window Time

In all the schemes except the powerup position scheme, the following
steps are performed:
> Settle at a first detent point.
> Move the current vector to identify the phase sequence.
Automatically correct for wrong polarity.
> 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
Retrieve direction.
Commutation > Retrieve the commutation phase according to the selected
Phase at scheme.
Considerations when selecting a Commutation Scheme:
1. Based on detent point: 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.
2. Based on index: Saves the value of the commutation phase at the
index position. This value can be used at subsequent system

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powerups to achieve the same commutation result. Six variations

of this scheme are available:
> First Index in Positive Direction
> First Index Next to Right Hard Stop
> First Index Next to Right Limit Switch
> First Index in Negative Direction
> First Index Next to Left Hard Stop
> First Index Next to Left Limit Switch
3. Other
> Powerup Position
> Hall Signals Transition
> Current Absolute Position

8.2.2 Advanced Parameters

Determines the initial value of the commutation phase, and, thereby, the
initial orientation of the current vector and the initial detent point.
Initial By properly setting this offset, you can avoid an initial jump in a system
Commutation with a predefined startup position. For other systems it can be used to
Offset determine a specific target position for the initial jump.
If no information is known about the relationship between the current
vector and the motor position, it should be set to 0 (the default).

Maximum Sets the maximum allowed distance for searching for targets (index or
Search limits). It is recommended to set the variable according to the operational
Distance distance.

Causes the system verify the encoder and motor variables during the
initial commutation process. If the variables seem to be configured wrong,
Verify Control
a general message will be displayed stating that improperly configured
and Feedback
variables are a possible reason for failure. Once corrected, you will be able
Parameters
to continue. In a case of more than 20% deviation between the defined
and measured pitch, the commutation process reports failure.

Display
Detailed
Displays commutation phase data (in electrical degrees).
Commutation
Results

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This option resolves a commutation loss due to improper incremental

Use Hall
encoder-to-motor rotation counts. When this option is selected, the
SIgnals for
commutation angle is adjusted at each hall transition. In between hall
Continuous
transitions, a sinusoidal commutation is calculated based on incremental
Commutation*
feedback.

Calculated Hall
Compensates for Improper hall alignment and optimizes torque/force
Alignment
production.
Offset*

Number of A word of caution: Deviation between defined and measured pitch does
Magnetic not necessarily indicate poor commutation quality. For example, incorrect
Pitches to definitions of feedback variables may be compensated for by high friction,
Measure thus the deviation may be low but the commutation will be poor.

*Only available when Hall Singals Transition is the selected option for "Retrieve
Commutation Phase at". This is the default condition if Hall sensors were selected.

8.2.3 Commutation Startup Program

Commutation Startup Program
The options that you have when setting the Commutation Startup program are illustrated in the
following diagram:

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Figure 7-1. Commutation Options

To set the Commutation Startup program:

1. Select one of the two Commutation Program options from the Commutation Program
dropdown list:
> Standard: Uses a built-in default commutation scheme that is incorporated in
Adjuster.
> User Defined: For selecting a commutation program that was previously saved in a
file (in this case you need to have prepared the Commutation Startup program
through Program Manager. A browser is displayed enabling you to search for and
load your program:

2. Select the required buffer for storing the Commutation Startup program from the Run in
Buffer dropdown list (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.
3. Set your preferences (see Preferences and Advanced Parameters), or click Default which
will enter default values in the preferences.
4. At this point you have two choices:

a. - causes the Adjuster

to automatically generate the Commutation program taking the Retrieve

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Commutation Phase at parameter as its starting point. It compiles the

program and runs it.

b. - causes the Adjuster

to generate the Commutation Startup program. You are prompted with:

The Buffer checkbox should be selected and the buffer number that
you entered in Step 2 should appear. If the program is to be
generated from a user file, select the File checkbox and click to
browse for the file. If you want to use automatic commutation,
select the Use Auto-commutation checkbox.

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.

Click Generate. In the Program Manager pod, note that program appears in the specified buffer,
and a notification that the program was successfully generated is displayed.
Click Start Startup Program to run the Commutation Startup program.
Observe the motion of the motor and the messages that appear in the Commutation Program
Output panel. If errors appear or the motor does not respond as it should, make adjustments to the
parameters and run again - refer to Troubleshooting Commutation.

8.2.4 Commutation Program Output Panel

Commutation Program Output Panel
There are two buttons associated with the Commutation Program Output panel:

> - clears the messages in panel.

> - enables you to save all the messages to a text file.

When you are done, click Next to go to the next Adjuster task.

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8.3 Troubleshooting Commutation

Troubleshooting Commutation
If the motor does not move during Start Commutation Program or Start 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 Start Commutation Program or Start Startup Program execution displays a message about wrong
motor variables, return to Components 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:
> The required Excitation Current is greater than the XRMS , XRMSD, or XRMSM value. If the
motor and drive rating allow it, try to increase the value.
> There is an obstacle in the path of the motion.
Another problem that can arise is the case where Verify Control & Feedback Parameters is not
selected in the Advanced Parameters. 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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9. Open Loop and Position Verification

This chapter covers Open Loop and Position verification procedures of the SPiiPlus MMI Application
Studio Adjuster Wizard Axis Setup and Tuning step of the Setup New System or Controller Task.

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

9.1 Open Loop Verification

The Open Loop Verification window enables you to check if the motor responds correctly to the
drive command, that is, the motor velocity should be in the same direction as drive command.

Enabling the motor may cause it to jump. To avoid personal injury or damage to the
equipment, check the following before enabling the motor:

> Ensure that nothing (people, cables, or other obstacles) is in the path of
the motor or objects connected to the motor.
> Ensure that the motor is securely anchored and that proper safety
barriers, stops, and limits are installed.

Be ready to engage the Emergency Stop switch.

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Values can be expressed either as:

> % - Percentages
> Amps - Amperes
which you select from the dropdown list.
The parameters on this window are:
> Drive Output Range - Percentage (or amperage) relative to the maximum voltage as
defined in Components - see Drive.
> DAC Offset - Offset to be added to the results of the current loop control. This value is
stored in the SLIOFFS variable.
The offset can be used to compensate for an active component of the motor load. For
example, in a vertical axis the weight of the carriage can be compensated.
1. Click Enable to enable the drive.
2. If an encoder is active in the system, click Zero to reset the encoder.

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3. Drag the Drive Output slider slowly to the right until the motor moves. If the motor does
not move (due to friction), increase the Drive Output Range (with the slider or by entering
a value) until the motor moves.

4. Verify that the velocity gauge indicator moves to the right (same direction you moved the
slider). If the velocity arrow moves in the opposite direction, select Invert Drive Command.

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. 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.

5. 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.

9.2 Position Verification

The Position Verification window is relevant only for open loop modes for step motors and enables
you to verify that the actual move corresponds to a commanded one, and make changes where
necessary.

To tune position verification:

1. Click Motion Manager Autoset. The Motion Manager panel is displayed.

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The Motion Type dropdown list gives you the option of defining the type of motion, the options
are:
> One Direction Repeated Move
> Back and Forth Move (Default)
Position is always measured between two points:
> Point A
> Point B
Point A is the start position and Point B is the end position. The motion is then measured
from Point A to Point B.

You can set these points by manually moving the motor to Point A and clicking ,
and repeating this for Point B.
You can change the sign of the value by clicking

The Dwell value is Dwell time between moves.

Feedback Position is the point where the feedback is to be measured. You can reset this position to
zero by
clicking
Position Error is a measure of the error in position.
The Motion Parameters that you can manipulate are:
> Velocity (VEL)
> Acceleration (ACC)
> Deceleration (DEC)
> Kill Deceleration (KDEC)
> Jerk (JERK)
To start the measurement:

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1. Click , this displays the Scope to measure position.

2. Click , this enables the motor of the axis you are working on.

3. Click , this starts the motion.

Visually check the motion. If there is a positional error, exit Adjuster and correct the value
in your program, then run Adjuster again.
4. Check the Scope display.
The ideal Scope display is a square wave indicating that the Position is well adjusted.

If the jitter is too extreme, adjust the parameters until the scope shows that the motion graph
closely matches the reference lines.

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10. Position and Velocity Loops

This chapter covers the Position and Velocity procedure of the SPiiPlus MMI Application Studio
Adjuster Wizard Axis Setup and Tuning step of the Setup New System or Controller Task.
The Position and Velocity Loops window enables you to tune the position and velocity loops in
order to optimize the servo system performance.

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.

The window has two modes:

> Velocity Loop - for tuning the velocity loop
> Position Loop - for tuning the position loop
You have to use both modes, one after the other, to completely tune the servo loops. In addition,
you make use of two tools:
> Scope, and
> Motion Manager
When you enter the Position and Velocity window, you:
1. Select mode from the Mode dropdown list.
2. Click to display the Motion Manager panel.
3. Click to display the Scope.
The MMI display should look as shown in Figure 9-1

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Figure 9-1. Velocity and Position Loop Adjustment - General Layout

10.1 Velocity Loop

The parameters associated with velocity in the Position and Velocity window in the Velocity Loop
mode are:
> Velocity Gain (SLVKP) - Proportional coefficient in velocity servo loop.
> Integrator Gain (SLVKI) - Integrator coefficient in velocity servo loop.
> Integrator Limit [%] (SLVLI) - Used to prevent the integrator from exceeding a certain
value.

The default value, 50%, is adequate for most systems.

> Low Pass Filter Bandwidth (SLVSOF) - Second order filter bandwidth.
> Integrator Bandwidth - Calculated by Adjuster, and is approximately equal to SLVI/20.5.

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You can change the values only of those parameters that are not greyed out.

The Motion Manager for Velocity Loop adjustments serves for controlling the motion in order to
observe it graphically in the Scope.

Figure 9-2. Velocity Loop Motion Manager Panel

The Motion Limited By dropdown list gives you the option of limiting the measurement to:
> Time Period - Typically used with rotary motion. Period sets the time intervals
> Between Two Points - Typically used with back-and-forth linear motion.
When you select this option, two more fields are displayed:
> Point A
> Point B
Point A is the start position and Point B is the end position. The motion is then measured from
Point A to Point B.

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Note You can set these points by manually moving the motor to Point A and clicking
, and repeating this for Point B. You can change the sign of the value by clicking
.

> Positive Direction Only - Motor moves in the positive direction only. Period sets the time
intervals.
> Negative Direction Only - Motor moves in the negative direction only. Period sets time
intervals.

The parameters that are available for changing depend on the type of controller and
motor.

Parameters that always appear are

> Velocity (% of Max) - which enables you to slow the motion by a certain percentage.
> Period - which enables you to define the period, in milliseconds.
Other parameters that may appear are: For PWM and Digital Current Control controllers, and an AC
Induction Motor motor:
> Field Constant (SLFIELD)
> Slip constant (SLSLIP)
If the Controller-Drive Interface is Analog (±10V) and a Nanomotion Piezoelectric motor:
> Dead Zone Minimum (SLDZMIN)
> Dead Zone Maximum (SLDZMAX)
> Zero Velocity Feedforward (SLZFF)
To start the measurement:
1. Set the parameters to the following initial values
> Low Pass Filter Bandwidth: 650Hz
> Integrator Gain: 0
> Velocity Gain: 100
> Integrator Limit: 50%
2. Make sure that the Velocity field is set to 10.

3. Click , this enables the motor of the axis you are working on.

4. Click ,this starts the motion.

5. Check the Scope display, the ideal display is a square wave as shown in Figure 9-3.

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Figure 9-3. Example Scope Display of Well Adjusted Velocity Loop

6. If the jitter is too extreme, adjust the parameters until the Scope shows that the motion
graph closely matches the reference lines.
> Double the Velocity Gain until the approximates a square with a small overshoot.
> Increase the Integrator Gain by hundreds, until you get a narrow overshoot of 10-20%
in the waveform.

It is recommended that the Integrator Bandwidth not exceed 50Hz. (Integrator

Gain)/20 = Integrator Bandwidth

10.2 Position Loop

Once you have adjusted the velocity loop, select Position Loop from the Mode dropdown list in the
Position and Velocity window.

The Velocity Loop Motion Manager panel is replaced by the Position Loop Motion
Manager panel and the Adjuster disables the motor.

The parameters associated with velocity on the Position and Velocity window in the Position Loop
mode are:
> Position Gain (SLPKP) - A proportional coefficient of the position.
> Position Bandwidth - Calculated by the Aduster Wizard, approximately equal to SLPKP/(2
x PI).
> Velocity Gain (SLVKP) - A proportional coefficient that is applied to the velocity
> Integrator Gain (SLVKI) - Integrator coefficient in position servo loop.
> Integrator Limit [%] (SLVI) - Used to prevent the integrator from exceeding a certain
value.

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The default value, 50%, is adequate for most systems.

> Low Pass Filter Bandwidth (SLVSOF) - Second order filter bandwidth.
> Integrator Bandwidth - Calculated by Adjuster approximately equal to SLVI/20.5.
> Acceleration Feed Forward (SLAFF) - Used for minimizing positional error during
acceleration/deceleration. It can be roughly calculated by (216 1E7 x EFAC/ACC)/0.1

You can change the values only of those parameters that are not greyed out.

The Motion Manager for Position Loop adjustments serves for controlling the position feedback in
order to observe it graphically in the Scope.

Figure 9-4. Position Loop Manager Panel

The Motion Type dropdown list gives you the option of defining the type of motion, the options
are:
> One Direction Repeated Move
> Back and Forth Move

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Position is always measured between two points:

> Point A
> Point B
> Point A is the start position and Point B is the end position. The motion is then measured
from Point A to Point B.

You can set these points by manually moving the motor to Point A and clicking ,
and repeating this for Point B. You can change the sign of the value by clicking .

The Dwell value is dwell time between moves.

Feedback Position is the point where the feedback is to be measured. You can reset this position
to zero by clicking.
Position Error is a measure of the error in position.
The Motion Parameters that you can manipulate are
> Velocity (VEL)
> Acceleration (ACC)
> Deceleration (DEC)
> Kill Deceleration (KDEC)
> Jerk (JERK)

The values that you put in for these parameters apply only for position loop
adjustment using this window. They are separate from the motion profile definitions
used by the controller during normal operation.

To start the measurement:

1. Click , this resets the Scope to measure the position loop variables: RVEL, FVEL,
and PE.

2. Click , this enables the motor of the axis you are working on.

3. Click ,this starts the motion.

4. Check the Scope, the ideal display is a square wave indicating that the Position Loop is well
adjusted.

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Figure 9-5. Example Scope Display of Well Adjusted Position Loop

5. If the jitter is too extreme, adjust the parameters until the Scope shows that the motion
graph closely matches the reference lines.
> Increase the Position Gain to minimize position error during acceleration and
deceleration.
> Increase the Acceleration Feedforward to minimize position error during acceleration

The theoretical Acceleration Feedforward can be calculated as follows.

For a linear motor:
SLAFF=215*2*104*M/(Kf*Kres*Ipeak)
Where:
M - Total moving mass [kg]
Kf - Motor force constant [N/A peak]
Kres - Encoder resolution [count/revolution]
Ipeak - Amplifier peak current [A sine peak]

For a rotary motor:

SLAFF=2π*2 15*2*107*J/(Kt*Kres*Ipeak)
Where:
J - Total moving inertia [kgm2]
Kt - Motor torque constant [Nm/A peak]
Kres - Encoder resolution [count/revolution]
Ipeak - Amplifier peak current [A sine peak]

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11. Save to Flash

The controller RAM is erased when the controller undergoes a hardware reset. A hardware reset
can be user initiated (HWRES command through the Communication Terminal) 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. The Save to Flash step, where it appears, enables you to save all the data generated by the
particular tool to the controller’s flash.

If you do not save the data to the controller’s flash, all of the data will be lost.

When you enter this step, the Save to Flash prompt is displayed.

1. Enter your user name in the User field.

2. Enter the application name in the Application field.
3. You can, if you desire, enter free text remarks in the Remarks field.
4. By default all data is selected. Select the data you want to load into the controller by
clicking (thereby deselecting) the checkbox of the data you do not want to be saved.
5. Click Save

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12. Sin-Cos Encoder Compensation

12. Sin-Cos Encoder Compensation

This chapter covers using the SPiiPlus MMI Application Studo Sin Cos Encoder Compensation tool.
The tool is used for adjusting SIN-COS encoders that are incorporated in the system.
The Sin Cos Encoder Compensation tool enables you to:
> Select axis for encoder measurements.
> Display a Sin-Cos Lissajous curve graph of the wave form.
> Read a controller’s gain, phase and offsets compensation parameters (SCGAIN, SCPHASE,
SCSOFFS, and SCCOFFS).
> Write new compensation parameters to the controller.
> Examine the compensation effect of each parameter.
The Sin Cos Encoder Compensation can do the following:
> Perform step-by-step calculations of the compensation parameters for Sin-Cos encoders
based on user input.
> Perform automatic calculations of the optimum compensation parameters set.

12.1 Activating Sin Cos Encoder Compensation

To activate the Sin Cos Encoder Compensation tool:

1. From the Toolbox click Diagnostics and Monitoring ( ) to display the

Diagnostics and Monitoring tools list.
2. Double-click Sin Cos Encoder Compensation. The Sin Cos Encoder Compensation window
is displayed:

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12.2 Sin Cos Encoder Compensation Window

The Sin Cos Encoder Compensation window consists of three sections (as shown above):
> Measurement Curve Display

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> Compensation Execution Panel

> Parameters Panel

12.2.1 Measurement Curve Display

The Measurement Curve is a Lissajous plot, an example of which is shown below, which displays the
curve of the results of the measurements performed by Sin Cos Encoder Compensation.

The Lissajous plot displays the aspect ratio of the phase shift between the input and output, with
an aspect ratio of 1 (perfect circle) corresponding to a phase shift of +90o as well as amplitude
differences (ellipse).

12.2.2 Compensation Execution Panel

The Sin Cos Encoder Compensation Execution panel:

serves for executing the Sin Cos Encoder Compensation calculation routines. The elements in this
panel are:
> Select Axis - used for selecting the axis from a dropdown list, the contents of which
depend on the type of controller. There is a LED associated with the selected axis that can
be:
> Grey - the axis is not enabled

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> Green - the axis is enabled.

If the axis is not enabled, you enable it by clicking the Enable button.

If you select an axis that is not connected to a Sin-Cos Encoder, it cannot be enabled.

Select the required axis from the dropdown list, for example:

> Compensation Status - this field displays messages associated with the Sin Cos Encoder
Compensation status. The messages that can be displayed are:
> Compensation Off - the Sin Cos Encoder Compensation has not been activated. (You
activate it by clicking the Run button).
> Compensation in Progress - the Sin Cos Encoder Compensation is performing its
measurements.
> Compensation Passed - the Sin Cos Encoder Compensation has completed its
measurements and the compensation is correct.
> Compensation Failed - the Sin Cos Encoder Compensation has completed its
measurements and the compensation is not correct.
> Compensation Cancelled - the Sin Cos Encoder Compensation has been stopped (when you
click the Stop button) before the measurements have been completed.
There is a LED associated with the status which can be:
> Grey - the Sin Cos Encoder Compensation has not been activated, or has completed its
measurements.
> Green/blinking - the Sin Cos Encoder Compensation has been activated and is working.
> Run/Stop button - activates or halts the Sin Cos Encoder Compensation measurements,
when clicked, the Run button changes to the Stop button for manually halting the
measurements in progress.
> ZoomIndicator - you have the following Zoom options:

When the display has been zoomed, the Zoom LED ( ) turns green.

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> Zoom In - Hold Shift key and place the mouse cursor in the Scope display in area you
want to zoom into. Click the Left mouse button to display the Zoom icon. When the
icon appears, click the Left mouse button. Without releasing the Shift key, each time
you click the Left mouse button, you increase the zoomed display.
> Zoom In Area - While holding the Shift key, press the Left mouse button and drag to
mark the area you want to zoom, then release the mouse button.
> Zoom Out - While holding the Shift key, place the mouse cursor in the zoomed area
and click the Right mouse button. Without releasing the Shift key, each time you click
the Right mouse button, you zoom out one level.
> Move Graph - Hold Ctrl key and Left mouse button - a hand is displayed. Drag the
graph to where you want.
> Undo - To undo all zooms, press Shift + Backspace keys. (You can also undo the zoom
by clicking the Zoom LED ).

12.2.3 Parameters Panel

You use the Parameter panel to set up parameters and display options you want. The panel has
three tabs:
> Advanced
> Cursors
> Statistics

12.2.3.1 Advanced Tab

The Measurement tab is used for defining the required input measurement parameters and to
control the output results.

The panel is divided into two sections:

> Compensation Criteria
This section displays the target criteria used by the Sin Cos Encoder Compensation when
making the calculations and current values of calculated parameters along with a set of
LEDs. If the current value of any parameter is equal to or less than the target value, the

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associated LED is Green (otherwise it is Red if the value fails, or Grey if the parameter is not
relevant).
The criteria are:
> Iterations - the number of iterations that the Sin Cos Encoder Compensation is to
perform during the measurements.
> Asymmetries - Max(dx,dy) - Min(dx,dy), where dx is Xfinal point - Xstart point, and dy is
Y final point - Y start point. If this is zero, the graph is a perfect circle.
> Shift X - the offset on the X axis
> Shift Y - the offset on the Y axis
> Slope - dy/dx, where dx is Xfinal point - Xstart point, and dy is Y final point - Y start point.
You can make changes to the values of the Target fields when fine-tuning the compensation.

Clicking Default sets default values of the target calculated parameters.

> Parameters
This section lists the ACSPL+ variables that are connected with managing Sin-Cos encoders.
These are:
> SCGAIN - Modify the amplitude of the COS signal, to compensate amplitude difference
between the SIN/COS signals
> SCPHASE - Modify the phase of the COS signal, to compensate phase difference
between the SIN/COS signals (phase should be 90 degrees)
> SCSOFFS - Compensating SIN signal offset
> SCCOFFS - Compensating COS signal offset
> SLEBIASA - Defines a Sin-Cos encoder’s hardware compensation for the Sine offset
> SLEBIASB - Defines a Sin-Cos encoder’s hardware compensation for the Cos

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SCGAIN, SCPHASE, SCSOFFS, and SCCOFFS are all software-based variables.

The SLEBIASA and SLEBIASB variables, on the other hand, are hardware-based.
Hardware compensation has some advantages over software compensation:
possibility to get analog signals out of saturation, and making hardware based features
like PEG more accurate.
In principle these variables have similar functionality as SCSOFFS and SCCOFFS; however,
they are only supported by the following controller models:
> SPiiPlusNT-HP/LD (compensation diapason ± 350 mV)
> SPiiPlusDC-HP/LD (compensation diapason ± 350 mV)
> SPiiPlus-UDMpc (compensation diapason ± 625 mV)
> PiiPlus-CMnt-2 (compensation diapason ± 750 mV)

If the controller model supports it, Sin Cos Encoder Compensation first calculates the
software compensation variables, and then writes the final values to the hardware
variables (and resets the software ones).

You have the option of changing the values by inputting new values in the appropriate fields.
Details of these variables are provided in the SPiiPlus Command & Variable Reference Guide.
There are three action buttons associated with this section:

Sin Cos Encoder Compensation reads the current variable values from the
controller.

Sin Cos Encoder Compensation writes the variable values into the controller.

Sin Cos Encoder Compensation sets the default values into the controller.

12.2.3.2 Cursors Tab

The Cursors tab enables you to mark points on the display where you are interested in seeing
exactly what the values at the points are.

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There are two cursors, X1 and X2, for delimiting the Cos voltage values, and two cursors, Y1 and Y2,
for delimiting the Sin voltage. As the Sin Cos Encoder Compensation performs its routines, the
values at the cursor settings are displayed in the field below the graph. For setting the cursors see
SPiiPlus MMI Application Studio User Guide.

12.2.3.3 Statistics Tab

For each run, the Sin Cos Encoder Compensation builds a statistics table consisting of compensation
calculation measurements in the Statistics tab:

The rows are color-coded, Green for those values that passed the compensation measurements,
and Red for those that failed.
At the bottom of the table the Sin Cos Encoder Compensation adds a line containing the average
values of the variables. There is a separate line for each axis that was checked.
Right-clicking on any row displays a menu with the following options:

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> Set Parameters - selecting this option causes the Sin Cos Encoder Compensation to use
these variable values for purposes of making the measurement.
> Save to Flash - selecting this option causes Sin Cos Encoder Compensation to save the
values to the controller’s flash memory.
> Delete - selecting this option deletes the row from the Statistics.
> Clear All - selecting this option removes all the values from the Statistics.

12.2.4 Running Sin Cos Encoder Compensation

To perform automatic encoder compensation:
1. From the Execution pane select axis from the Axis dropdown list.
2. Click Enable
3. Click Run

If the motor associated with the encoder is a brushless motor, it has to be commutated
before encoder compensation. In the event that it has not been commutated, the
following is displayed:

The easiest way to commutate the motor at this point is to enter the COMMUT
command via the Communication Terminal, for example:

Then click Run again.

4. If the compensation is successful, go to the Advanced Tab of the Parameter Selection

panel and save the values to the controller’s flash memory by clicking Set in Parameters.

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Once you have completed the Sin-Cos compensation, return to theVerification Task of
the Adjuster Wizard.

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13. 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).

Figure 12-1. Homing

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.
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.

Version 2.60 has a set of predefined homing methods. You can also define a homing
method as well. The homing methods obey the DS402 standard.
For details, see SPiiPlus ADK Suite v2.60 Release Notes.

13.1 Homing Program Using Limit Switches

The following program is an example of a homing procedure for the 0 axis that is equipped with a
DC brush motor and limit switches.

! The program executes the following sequence:

! - Move to the left limit switch.

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! - 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 (in this case: 0).
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

13.2 Homing Program Using Hard Stops

The following program is an example for a homing procedure of the 0 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 (in this case: 0).
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.

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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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14. Protecting Application

14. Protecting Application

Up to this point, the controller has been in the 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.
The controller can be in one of two modes:
> Protected Mode - certain restrictions are placed on the programs in the controller’s
Program buffers. Usually this mode is used to ensure that the programs cannot be edited.
> Not Protected Mode - no restrictions are placed on the Program buffers.
The Protection Wizard is used for setting and unsetting the Protection Mode of the controller. It
leads you through the performance of the following tasks:
> Define Protection
> Update Protection
> Remove Protection
> View Protection

14.1 Starting Protection Wizard

1. From the Toolbox click Application Development ( )

to display the Application Development tools.
2. Click Protection Wizard in the Application Development list of tools.

You can also activate the Protection Wizard using the right-click Add Component
option of the Workspace Tree.

The Protection Wizard Task window is displayed in the workspace.

3. Select the task you want to perform by clicking the appropriate button and then click Next.

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If the controller is in the Not Protected mode, the only task available is Define
Protection.

If the controller is in the Protected mode, the tasks available are: Update Protection,
Remove Protection, and View Protection Status.

14.2 Define Protection

The Define Protection task enables you to put the controller into the Protected Mode and to set
certain restrictions on the programs stored in the controller’s buffers.
To define Protection:

This task, and this task only, is available if the controller is in the Not Protected mode.

1. Since this is the only task available, click Next. The Set Protection Level window is
displayed.

There are three tasks that can be performed from the Select Protection Level window:
> Application Protection
You perform this task to set the program in the specified buffers to Read Only, that is, it
can be viewed but cannot be modified.
> Intellectual Property Protection
You perform this task to set the program in the specified buffers such that its contents
cannot be modified and cannot be seen.
> Custom Protection
There are three tasks that can be performed from the Custom Protection window:

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> You can set the program in the specified buffers such that its contents cannot be
modified and/or cannot be seen.
> You can set specified variables to Read Only, that is, it can be viewed but cannot be
modified.
> You allow the system to be reconfigured.

14.2.1 Setting Application Protection

1. To set Application Protection, select the button next to Application Protection. Then click
Next. The Buffers Protection task is displayed.

By selecting the Prevent from editing checkbox you set the program in the buffer to
Read Only, that is, it can be viewed but cannot be modified.

2. Click Next. The Preview Changes window is displayed:

3. Check that the proper Protections are set. If they are, select Accept. Click Next. The Set
Password window is displayed.

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4. If you want to set a user password to prevent unauthorized personnel from removing
Protection, type it into the Enter password and Confirm password fields.

A password is not required.

5. Click Next. The controller is rebooted. Wait for the notification of a successful restart.

The controller must be restarted, otherwise the protected programs can become
corrupted.

6. Click OK.
The Report window is displayed.

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7. To save the report click Save report. The browser window is displayed:

8. Select a directory and enter a filename. Click Save.

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The file extension for all reports is .log.

9. To print the report click Print report.

10. Click Finish to exit the Protection Wizard.

14.2.2 Setting Intellectual Property Protection

1. To set Intellectual Property Protection, select the button next to Intellectual Property
Protection. Then click Next. The Buffers Protection task is displayed.

By selecting the Prevent from editing and viewing checkbox, you set the program in
the specified buffers such that its contents cannot be modified and cannot be seen.

2. Click Next to preview changes and follow step 3 through step 10 in Setting Application
Protection to complete setting protection and to exit the Protection Wizard.

14.2.3 Setting Custom Protection

14.2.3.1 Custom buffer protection
1. To set Custom Protection, select the button next to Custom Protection. Then click Next.
The Buffers Protection task is displayed.

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By selecting the Custom Protection checkbox, you set the program in the specified
buffers such that its contents cannot be modified and/or cannot be seen.

2. Click Next. The Variables Protection Task is displayed.

14.2.3.2 Custom variable protection

You can click to sort the variables by groups, or to sort alphabetically.

1. Select the appropriate Read only box to prevent the variables from being edited.
You can either set all the variables in a group by selecting the Read only box, or expand
the groups by clicking the tree expansion button: and marking individual variables for
read only.

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2. Click Next. The Advanced Protection Task is displayed.

14.2.3.3 Advanced protection options

1. To allow system configuration, select the checkbox.

2. Click Next to preview changes and follow step 3 through step 10 in Setting Application
Protection to complete setting protection and to exit the Protection Wizard.

14.2.4 Update Protection

The Update Protection task enables you to make changes in Protection settings.

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This task is available only if the controller is in the Protected mode.

To update Protection data:

1. Select Update Protection in the Select a Task window.

2. Click Next. The Set Protection Level window is displayed.

3. You have the option of changing the Protection by selecting the appropriate buttons:
> To change Application Protection settings, select the button next to Application
Protection. Then click Next and follow the procedure described in Setting Application
Protection.

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> To change Intellectual Property Protection settings, select the button next to Intellectual
Property Protection. Then click Next and follow the procedure described in Setting
Intellectual Property Protection.
> To change Custom Protection settings, select the button next toCustom Protection. Then
click Next and follow the procedure described in Setting Custom Protection.

In the selected protection task, you enable protection or cancel an existing Protection
by clicking the selected checkbox ( ) to toggle it on or off.

14.2.5 Remove Protection

The Remove Protection task enables you to disable the Protection mode.

This task is available only if the controller is in the Protected mode.

To remove Protection:
1. Select Remove Projection in the Select a Task window.

The password field appears next to the task heading when you select this task.

2. Type in the password, if needed, and click Next. The following notification appears:

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3. Click Yes. The controller reboots.

4. Wait for the appearance of a successful restart message:

5. Click OK. The Report window is displayed:

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6. To save the report click Save report. The browser window is displayed:

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Select a directory and enter a filename. Click Save.

The file extension for all reports is .log.

7. To print the report click Print log.

8. Click Finish to exit the Protection Wizard.

14.2.6 View Protection

The View Protection task enables you to view the Protection mode settings of the controller.

This task is available only if the controller is in the Protected mode.

To view the Protection mode settings:

1. Select View Projection in the Select a Task window.

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2. Click Next. The Buffers Protection task is displayed.

3. Click Next. The Variables Protection is displayed.

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You can view the settings of the individual variables by clicking the tree
expansion button: of the groups.

4. Click Next. The Advanced Protection is displayed.

5. Click Finish to exit the Protection Wizard.

14.2.7 Entering Incorrect Password

If the password that you enter is incorrect, the Protection Wizard displays the following message:

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1. Acknowledge the message by clicking Continue. The wizard informs you of the Protection
task that has failed, for example:

2. Your options are:

> Click Back to return to the window with the password field and enter the correct
password, or
> Click Finish to exit the wizard.

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Appendix A. Working with a Gantry Axis

Appendix A. Working with a Gantry Axis

A.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.
Figure 14-1 illustrates a typical gantry system with two motors (X1, X2) that move a single axis (X):

Figure 14-1. Typical Gantry

A.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 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 Figure 14-2). 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 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:

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Figure 14-2. 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.

A.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 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.

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A.3.1 Gantry Setup and Configuration

1. SPiiPlus MMI Application Studio > Toolbox > Setup > Adjuster: Set the safety
parameters for the master (limits, current values, position error etc). Copy the
configuration to the identical slaved axis – see Axis Architecture.
2. SPiiPlus MMI Application Studio > Toolbox > Setup > Adjuster >Commutation: make
commutation separately for each (if DC brushless motor is being used) - see Commutation.
3. SPiiPlus MMI Application Studio > Toolbox . Setup > Adjuster > Open loop verification:
make verification in open loop separately for each motor - see Open Loop and Position
Verification.
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

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)

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SLAFF(S_AXIS)=SLAFF(M_AXIS)
EFAC(S_AXIS)=EFAC(M_AXIS)

!------ 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 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 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.

A.3.2 Commutation and Homing

Load the following program to a buffer and run it:

!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)

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!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

!------------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

A.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. Enablecommands should always be declared for both axes, for example:

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ENABLE (M_AXIS); ENABLE (S_AXIS)

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Appendix B. Dual Loop Control

Appendix B. Dual Loop Control

Dual Loop control is commonly used when there is poor stiffness between the motor and the load
(for example, in belt-driven systems as shown in Figure 15-1). 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.

Figure 15-1. Dual Loop System

The Dual Loop tuning process described in this chapter is compatible with NT Firmware
version 2.1 or higher.

Normally the SPiiPlus MMI Application Studio Adjuster Wizard is used for fine-tuning control loops;
however, the current version does not support Dual Loop control. This chapter provides a work-
around procedure for setting up Dual Loop control.

B.1 Dual Loop Basics

Dual Loop control of an axis in NT products is more flexible compared to previous ACS Motion
Control products. The user can assign feedbacks from various channels or from an analog input to
the axis, with the constraint that the axis and channels must relate to the same Servo Processor.
In Dual Loop the control of the axis is based on at least two feedback sources:
> Load position feedback - used as input for the Position Loop.
> Motor position feedback - used as input for the Velocity Loop and for the motor’s
Commutation as well.
Figure 15-2 a simplified block diagram of Dual Loop control.

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Appendix B. Dual Loop Control

Figure 15-2. Controller in Dual Loop Block Diagram

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B.2 ACSPL+ Variables

The following ACSPL+ variables are involved in Dual Loop control:

B.2.1 MFLAGS
MFLAGS is an integer array, with one element for each axis in the system, each element of which
contains a set of bits used for configuring the motor.
In order to set the system for Dual Loop control, bit 20 (#DUALLOOP) of MFLAGS has to be set to 1
for the relevant axis, for example, MFLAGS(0).#DUALLOOP = 1, sets axes 0 to Dual Loop control, that
is, the Bi-Quad filter is moved from the Velocity Loop to the Position Loop.

B.2.2 SLVRAT
SLVRAT is a real array, with one element for each axis in the system, and is used for defining the
gear ratio between the Position Loop feedback and the Velocity Loop feedback:

B.2.3 SLVKP
SLVKP is a real array, with one element for each axis in the system, and is used for providing a
proportional coefficient that is applied to the velocity of the specified axis.

B.2.4 XVEL
XVEL is a real array, with one element for each axis in the system, and is used for defining the
maximum allowed velocity for the axis. XVEL affects the effective value of the Velocity Loop
proportional gain SLVKP differently:
In Dual Loop, the effective value is given by:

If then the effective gain is decreased according to the latter formula.

Otherwise the effective gain is increased.

B.2.5 EFAC
EFAC is a real array, with one element for each axis in the system, and is used for defining a factor
between the raw feedback in encoder counts and the FPOS value calculated by the controller.
Its format is:
EFAC(axis_index) = value
Where value ranges between 1-15 to 1+15 (the default value is 1).

B.2.6 FACC
FACC is a real array, with one element for each axis in the system, and is used for defining the
feedback acceleration value of the axis.

B.2.7 Routing Variables

The following are used for routing a feedback to a desired axis.

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When using these variables the feedback sensors must relate to the same Servo
Processor.

B.2.7.1 SLPROUT
SLPROUT is a real array, with one element for each axis in the system, and is used for setting the
feedback routing of the position for the specified axis.
Its format is:
SLPROUT(axis_index) = value
Where value specifies the feedback source and can be one of those given in Table 16-1.
Table 16-1. SLPROUT Values

Value FPOS

0 According to E_TYPE position

001 From channel 0 Quadrature position or Absolute Encoder position

002 From channel 0 SINCOS positon

003 From channel 0 HSSI position

101 From channel 1 Quadrature position or Absolute Encoder position

102 From channel 1 SINCOS position

103 From channel 1 HSSI position

201 From channel 2 Quadrature position or Absolute Encoder position

202 From channel 2 SINCOS position

203 From channel 2 HSSI position

301 From channel 3 Quadrature position or Absolute Encoder position

302 From channel 3 SINCOS position

303 From channel 3 HSSI position

X04 Rout from analog input X (where X can be 01 or 02)

The controller supports a standard control loop configuration where the 0 feedback position FPOS
(0) is obtained from the 0 encoder, FPOS(1) from the 1 encoder, etc.
SLPROUT ≠ .0 indicates FPOS is from an alternative sensor, for example, if SLPROUT(0) is 0104, FPOS
is obtained from an analog input 0 rather than from the encoder. In this case, the feedback source

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could be a potentiometer or any other device that produces analog voltage proportional to the
motor position.
The meaning of the routing value depends on the axis and the controller model. For example, a
value of 1 specified for the 0 or 2 axis selects the 0 encoder, the same value for the 1 or 2 axis
selects the 1 encoder.

For the values of the E_TYPE variable see the SPiiPlus Command & Variable Reference
Guide.

B.2.7.2 SLVROUT
SLVROUT is a real array, with one element for each axis in the system, and is used for setting the
feedback routing of the velocity for the specified axis.
Its format is:
SLVROUT(axis_index) = value
Where value specifies the feedback source that is routed to the FPOS variable and can be one of
those in Table Table 16-2.
Table 16-2. SLVROUT Values

Value FPOS

0 According to E_TYPE velocity

001 From channel 0 Quadrature velocity or Absolute Encoder velocity

002 From channel 0 SINCOS velocity

003 From channel 0 HSSI velocity

101 From channel 1 Quadrature velocity or Absolute Encoder velocity

102 From channel 1 SINCOS velocity

103 From channel 1 HSSI velocity

201 From channel 2 Quadrature velocity or Absolute Encoder velocity

202 From channel 2 SINCOS velocity

203 From channel 2 HSSI velocity

301 From channel 3 Quadrature velocity or Absolute Encoder velocity

302 From channel 3 SINCOS velocity

303 From channel 3 HSSI velocity

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Value FPOS

X04 Rout from analog input X (where X can be 01 or 02)

For the values of the E_TYPE variable see the SPiiPlus Command & Variable Reference
Guide.

B.2.7.3 SLCROUT
SLCROUT is an integer array, with one element for each axis in the system, and is used for setting
the feedback routing of the velocity commutation for the specified axis.
Its format is:
SLCROUT(axis_index) = value
Where value specifies the feedback source that is routed to the FACC variable and can be one of
those in Table Table 16-3.
Table 16-3. SLCROUT Values

Value FPOS

0 According to E_TYPE velocity

001 From channel 0 Quadrature velocity or Absolute Encoder velocity

002 From channel 0 SINCOS velocity

003 From channel 0 HSSI velocity

101 From channel 1 Quadrature velocity or Absolute Encoder velocity

102 From channel 1 SINCOS velocity

103 From channel 1 HSSI velocity

201 From channel 2 Quadrature velocity or Absolute Encoder velocity

202 From channel 2 SINCOS velocity

203 From channel 2 HSSI velocity

301 From channel 3 Quadrature velocity or Absolute Encoder velocity

302 From channel 3 SINCOS velocity

303 From channel 3 HSSI velocity

X04 Rout from analog input X (where X can be 01 or 02)

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For the values of the E_TYPE variable see the SPiiPlus Command & Variable Reference
Guide.

B.2.8 Configuring Dual Loop Control Procedure

This procedure is divided into two parts:
> AXIS Setup
Where AXIS is the axis of the drive to which the motor is physically connected.
> LOAD Setup
Where LOAD denotes the load feedback channel.
In general, the axis can be different from the motor feedback channel; however, this procedure
assumes that the motor feedback is connected to the axis of the drive. Further it is assumed that
the load’s user units are employed with both feedback sensors, rather than counts. In this way, the
Dual Loop setup is easier since fewer changes are needed (scaling gains, axis limits, and the like).
For purpose of illustrating the procedure, the following was used:
> Linear stage drive with a lead screw:
A linear encoder for stage position, rotary encoder for motor velocity and commutation.
> User units: mm.
> The motor is connected to axis ‘0’.
> The motor feedback, connected to axis ‘0’, is a rotary Quadrature encoder, with 2000
[lines/revolution].
> The load feedback, connected to axis ‘1’, is a linear Quadrature encoder with 12500
[lines/mm].
> Both include an internal multiplier of 4.
> The lead screw pitch: 1[ inch/revolution]= 25.4[mm/revolution]

B.2.8.1 AXIS Setup

For setting up the AXIS we employ the SPiiPlus MMI Application Studio Adjuster Wizard. The reason
for this is that while the Adjuster Wizard cannot be used for Dual Loop control, it can easily be used
for calculating the parameter values for a Single Loop thereby saving the user some time.
1. In the Adjuster Wizard Select Task, select the Axis.
2. Then for the task select Setup New System or Controller.
Click Next.
3. Fill in the details in the Initialization window, and click Next.
4. In the Axis Architecture: Axis Structure window setup AXIS as a single loop axis with the
motor’s feedback; the feedback topology should be Single, on motor. Choosing User
Units Applied To Load. This is recommended for working in the same units with both
feedbacks.
5. Proceed until the Axis Setup and Tuning step and skip Position and Velocity Loops tuning.

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6. Save to Flash and exit Adjuster Wizard.

7. Calculate the user units for EFAC(AXIS).
User units applied to EFAC(AXIS), which defines the ratio between the motor feedback counts and
the load user units, can be calculated as follows:

For example, for a linear motor with a feedback resolution of 500[lines/mm] and an internal
multiplier of 4, if the desired user units are [mm]:

For a rotary motor connected to a ball screw:

> Feedback resolution: 2000 lines/rotation
> Gear ratio: 1 motor rotation = motion of load
> Multiplier: 4
> .Required user unit: .m (micron)

B.2.8.2 LOAD Setup

Using the value for EFAC(AXIS) calculated in AXIS Setup, we now calculate the user units parameter
for EFAC(LOAD).
The load feedback setup requires just setting EFAC(LOAD) and verifying that the load feedback
functions as expected. (If the load feedback does not change, use the command FCLEAR LOAD to
reset the load feedback).
We will be making use of the SPiiPlus MMI Application Studio FRF Analyzer. In particular, we will be
making use of an improvement made to the FRF Analyzer in version 2.10:
In the Design mode, the FRF Analyzer simulates changes in the Position Loop servo parameter
SLPKP and the Position Loop Bi-Quad filter parameters. A separate Position Loop measurement is
required in Dual Loop systems.
1. In the SPiiPlus MMI Application Studio Communication Terminal enter the
command:MFLAGS(AXIS).20=1 (this sets AXIS to Dual Control).
2. Open the SPiiPlus MMI Application Studio FRF Analyzer (for details of using the FRF
Analyzer see the SPiiPlus MMI Application Studio User Guide):

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3. Set the FRF Analyzer to the Design Mode.

4. Tune the Velocity Loop of the desired axis as in Single Loop. Note that the Bi-Quad filter in
the Velocity Loop is disabled, as this filter has been moved to the Position Loop in Dual
Loop mode (by the MFLAGS setting).

Velocity Loop tuning will not require changing if the same load user units are used.

5. Disable the axis. Set , using the feedbacks and gear

parameters. SLVRAT can be calculated as follows:

For example:

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6. Set the axis’ encoder factor as the encoder factor of the load feedback:EFAC(AXIS) = EFAC
(LOAD)

It is recommended initializing FPOS(AXIS) and verifing that the new movement range
does not reach the hard stop.

For example: EFACNEW(0) = EFAC(1) = 0.00002

7. To verify the value of SLVRAT, follow these steps (if manually moving the motor is
possible):
> Zero both feedback positions.
> Disable the axis.
> Manually move the axis to an arbitrary position.

> Calculate . This value should be close to the value calculated in Step 4.
8. Route the load feedback as the position feedback of the desired axis, by changing
SLPROUT(AXIS) as shown SLPROUT Values.
For example, we want to route the load’s Quadrature encoder from channel 1 to axis 0, so
according to the table: SLPROUT(0) = 101.
9. If you need to read the motor feedback, it can be assigned to another axis, say Load, using
SLPROUT as above.

If XVEL was originally set according to the Load units, no further change is needed
after step 6. Otherwise, XVEL should be changed according to SLVRAT before tuning
the Velocity Loop, to maintain the Velocity Loop tuning.

10. Using the FRF Analyzer tune the Position Loop of the system in Dual Loop. Measure the
Position Loop FRF separately in order to apply the Bi-Quad Filter, if needed.
Typical configurations of the Bi-Quad filter in the Position Loop are Notch filter or Lead filter which
adds phase to the Open Loop FRF, allowing improved bandwidth and stability margins. See BI-Quad
Filter for a detailed explanation regarding the Bi-Quad filter tuning.
For verification, you may measure the Velocity Loop FRF separately. It should resemble the
previous measurement of step 3.

When tuning the Position Loop, in order to produce a proper measurement and avoid
system damage, remember to change the excitation level, since the excitation is a
velocity command (% of XVEL), rather than current.

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11. From this point, the Load Feedback is used for the Position Loop and the Motor Feedback
is used for Commutation and the Velocity Loop.
Since the same load user units are used, XVEL(0) should not be changed and no further tuning is
needed for the Velocity Loop:

As can be seen, the raw value of remains the same after routing the load feedback
to the Position Loop, so no further change in the Velocity Loop tuning is needed.
In the Position Loop tuning, the Bi-Quad was configured as a Notch filter and allowed the
proportional gain to be further increased.

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Appendix C. Working with Dynamic Braking

Appendix C. Working with Dynamic Braking

C.1 About Dynamic Braking
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 17-1.

Figure 17-1. 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.

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:
SPiiPlus MMI Application Studio > Toolbox > Diagnostics and Monitoring > Scope

C.2 Dynamic Brake - Safety Verification

C.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.

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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)

where:

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

[m/s] - is the maximal linear velocity of the motor

is the phase impedance (the sum of a phase resistance and phase

reactance)

For a rotary motor:

(2)

where:

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

[rad/s] - is the maximal angular velocity of the motor

is the phase impedance (the sum of a phase resistance and phase

reactance)

The inductor reactance X, [rad/sec] is:

(3)

where:

is the phase inductance

f, [1/s] - is the frequency of the AC flowing through the

circuit. f can be found from motor velocity as:

for the linear motor, where Pitch is 180 electrical

degrees.

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for the rotary motor, where NP is the number of poles.

The linear motor impedance is found from:

(4)

The rotary impedance can be found from:

(5)

Therefore, equation (1) can be represented as:

(6)

Equation (2) can be respresented as:

(7)

IN addition you should verify that the drive can still withstand the heat dissipation.
Assum 2V drop on each transistor, the maximum allowed power dissipation on one transistor is:

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:

> In the case of a DC motor:

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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.

C.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.

C.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:
> For a DC brushless motor:

> For a DC motor:

where KT is motor torque/ force constant.

C.2.4 Dynamic Brake - Verification Example

C.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 17-1.
Table 17-1. 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

Kinetic energy (in Joule) is:

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This is lower than the permitted 6 x 20 = 120 J of the drive.

Impedance is

maximum current during braking process is (in A):

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

It is also lower than the 18.4A current of the motor, so the motor can easily withstand the current
and resulting heat dissipation.
The braking torque will be (in N):

C.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 17-2.
Table 17-2. Three-Phase Motor Specifications - Rotary Motor

Specifications Unit Value Note

Rotor moment of inertia Kg x m2 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

Kinetic energy is (in Joule):

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This is lower than the 6 x 20 = 120 J of the drive.

Impedance is

Maximum current during the braking process is:

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

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

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 x 1000 x 250 x 256 = 96 x 106 [counts/sec]

C.2.5 Dynamic Brake Operation Procedure

Before operating the Dynamic Brake, verify that no damage will happen due to the
dynamic Brake.

You define the Dynamic Brake (VELBRK) value in the SPiiPlus MMI Application Studio Adjuster
Wizard (see About the Adjuster Wizard. VELBRK is one of the Miscellaneous Definitions task:

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1. Select the Use Dynamic Brake checkbox.

2. Enter a value for the Dynamic Brake in the Threshold Velocity (VELBRK) field:

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

3. Click Next to continue with the Adjuster Wizard.

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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Appendix D. ASDF Measuring Motion Performance

Appendix D. ASDF Measuring Motion Performance

D.1 Measuring Settling Time
1. Define the target position by assigning values to SETTLE and TARGRAD variables, see
Motion Completion.
2. Open SPiiPlus MMI Application Studio > Toolbox > Diagnostics and Monitoring > Scope.
Figure 18-1Figure 18-1 depicts a Scope configured to measure settling time for a
nanomotion piezoceramic motor.

Figure 18-1. Measuring Settling Time (Piezoceramic Motor Example)

Figure 18-1Figure 18-1 is taken from the old version of the SPiiPlus MMI. The operations
in this procedure are valid for the new version details of which can be found in the
SPiiPlus MMI Application Studio User Guide.

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.

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Appendix D. ASDF Measuring Motion Performance

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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