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Parker 6250 User Manual

Servo controller
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6250 Servo Controller
User Guide
Compumotor Division
Parker Hannifin Corporation
p/n 88-013413-01B
October 18, 1993
Amended: June 8, 1998

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  • Page 1 6250 Servo Controller User Guide Compumotor Division Parker Hannifin Corporation p/n 88-013413-01B October 18, 1993 Amended: June 8, 1998...
  • Page 2 The information in this user guide, including any apparatus, methods, techniques, and concepts described herein, are the proprietary property of Parker Compumotor or its licensors, and may not be copied, disclosed, or used for any purpose not expressly authorized by the owner thereof.

  • Page 3: Table Of Contents

    Programmable Inputs & Outputs Connections................15 Trigger Input Connections....................16 RP240 Front Panel Connections.................... 17 Joystick and Analog Input Connections.................. 17 ANI Analog Input Connections (6250-ANI Option Only).............. 18 Extending 6250 System Cables .................... 19 Installation Verification ........................ 19 What's Next? ..........................21...
  • Page 4 Servo Tuning In a Hurry?............................ 23 Servo System Terminology ......................23 Servo Tuning Terminology....................23 Position Variable Terminology....................24 Servo Response Terminology ....................25 6000 Series Servo Commands ......................27 Servo Control Techniques........................ 28 Proportional Feedback Control (SGP)..................28 Integral Feedback Control (SGI).................... 29 Velocity Feedback Control (SGV) ..................

  • Page 5: Overview

    Contents of This User Guide Chapter Purpose Introduction Describes the 6250 and provides a brief account of its features. Getting Started Lists and describes the items you should have received with your 6250 shipment. A bench test procedure is provided to verify the system's basic functionality.

  • Page 6: Installation Process Overview

    After you successfully complete all procedures in Chapter 3, you will be ready to proceed to Chapter 4, Servo Tuning, to tune the drive and the 6250 for your application. The tuning procedures in Chapter 4 are based primarily on using the Servo Tuner option for Motion Architect.

  • Page 7: Introduction

    Using the 6000 Series Programming Language, you can program the 6250 via a PC or a dumb terminal. User programs are stored in the 6250's battery- backed RAM. The 6250 also provides operator interface capabilities when used with the Compumotor RP240 Front Panel.

  • Page 8: System Hardware Block Diagram

    ¥ 24 programmable outputs (Opto-22ª compatible) ¥ 2 auxiliary programmable outputs that can be configured for accurate output on position within ±1 count 6250-ANI Option offers two ±10V, 14-bit analog inputs (one per axis) with anti-aliasing filter. 6250 Servo Controller User Guide...

  • Page 9: Getting Started

    * The 6250-ANI is an optional version of the 6250 which provides two ±10V, 14-bit analog inputs. If you ordered a -ANI option, check the serial tag on the side of the 6250's chassis; it should say 6250-ANI. Pre-Wired Connections...

  • Page 10: Bench Test

    Full Duplex XON/XOFF: Enabled If your terminal is not capable of 9600 baud, use the 6250's auto-baud function to automatically set the 6250's baud rate equal to the terminal's baud rate. Refer to Optional DIP Switch Settings in Chapter 5 for instructions.

  • Page 11: Connect Power Cable

    Connect Power Cable The 6250 is shipped with an 8-foot power cable that is prewired and keyed. Attach the power cable to the 6250's connector as illustrated below. POWER WARNING 2 - A X I S S E R V O...

  • Page 13: Installation

    To help ensure personal safety and long life of system components, pay special attention to the following installation precautions. WARNING Always remove power to the 6250 before performing wiring installation or changing DIP switch settings. Heat & Humidity Operate the 6250 system at an ambient temperature between 32° and 122°F (0°...

  • Page 14: Airborne Contaminants

    (4 Plcs.) Panel Layout If you mount the 6250 in an enclosure with other equipment, be sure to maintain at least 2 inches of unrestricted air-flow space around the chassis. The maximum allowable ambient temperature directly below the 6250 is 122°F (50°C).

  • Page 15: System Connections

    CAUTION Before connecting to your Motor/Drive system, be sure that power is not applied to the 6250. The 6250 provides a standard ±10V analog control signal for use with any servo drive.
  • Page 16 « CHZ– Z– CHAÐ « CHB+ CHBÐ CHZ+ NOTE: CHZÐ Apex Series CHA+ connected to 6250’s A– Apex Series CHA– connected to 6250’s A+ BD-E Drive 6250 BD-E Drive User I/O Connector DRIVE 1 ENCODER 1 SHLD BD-E Drive 6250 «...
  • Page 17 Drive’s pins 23 & 22 to CMD+ & CMD-. When in the Velocity Mode, connect pins 25 & 24 are CMD+ & CMD-. Connect the Drive’s A+ to the 6250’s A–. Connect the Drive’s A– to the 6250’s A+. Connect 6250 GND to 6250 COM.
  • Page 18 GND for +24V (X10 pin 16) GND ** (& Ext. Supply) NOTE: Connect SV A+ (called “A”) to 6250 A–. – Connect SV A– (called “A/”) to 6250 A+. External 24V Connect SV’s X10 pins 14 & 16 to an Power Supply external 24V power supply.

  • Page 19: End-Of-Travel Limit Connections

    If a runaway occurs (motor starts moving, usually at the fastest possible velocity, due to servo instability), the 6250 will shut down the drive if the maximum encoder position error (set with the SMPER command) is exceeded before an end-of-travel limit (either hardware of software) is encountered.

  • Page 20: Encoder Connections

    SHLD SHLD Note for Using Single-Ended Encoders If you are using a single-ended encoder leave the 6250's A-, B-, and Z- terminals not connected. Each axis has a 9-pin Phoenix connector for incremental encoder connections. Encoder The pin-out description for the connectors is provided below.

  • Page 21: Enable Input Connection

    Enable Input Connection (enable) input is located on the connector. The 6250 is shipped ENBL with wired to (see drawing) to allow motor motion. ENBL See the illustration above for an example connection using a normally-closed switch. Opening the switch sets the ±10V analog command output to zero volts and activates the shutdown outputs;...

  • Page 22: Trigger Input Connections

    The status of triggers A, B and C is represented respectively by bits 25 through 27 in the [IN], INFNC, INLVL, ONIN, and TIN commands. Using the WAIT command, the 6250 can be programmed to wait until one or more inputs switch to a desired state before executing the next command.

  • Page 23: Rp240 Front Panel Connections

    For the 6250 to recognize the RP240, the RP240 connection must be made prior to powering up (or resetting) the 6250. If you connect the RP240 to the 6250 before powering up the 6250, the 6250 will recognize the RP240 and send the *RP24¯ CONNECTED message to the RS-232C terminal.

  • Page 24: Ani Analog Input Connections (6250-Ani Option Only)

    Refer to the illustration above. When this input is not connected, the low velocity range is selected. The joystick release input allows you to indicate to the 6250 that you have Joystick Release Input finished using the joystick and program execution may continue with the next statement.

  • Page 25: Extending 6250 System Cables

    Cables foot cable. The maximum cable length between Compumotor encoders and the 6250 is 100 feet. If you wish to lengthen the encoder cable yourself, use 24 AWG wire. Encoder cables should be shielded with the shield connected (pin 1 on the connector).
  • Page 26 Set all the gains to zero by entering the following: SGP¯,¯, SGI¯,¯, SGV¯,¯, SGAF¯,¯, SGVF¯,¯ Enable the 6250 to send out the analog command by entering the DRIVE11 command. Set the DAC output limit to 10 volts by entering the DACLIM1¯,1¯ command.

  • Page 27: What's Next

    What's Next? At this point you should have successfully completed this chapter's mounting, connection, and test procedures for your 6250 system. The following steps are recommended to prepare you for applying the 6250 in your application. Step Couple the Load Couple the motor to the load, and couple the encoder to the motor (or load, as appropriate).

  • Page 29: Servo Tuning

    Compumotor 6250 Servo Controller. Servo Tuning Terminology The 6250 uses a digital control algorithm to control and maintain the position and velocity. The digital control algorithm consists of a set of numerical equations used to periodically (once every servo sampling period) calculate the value of the control signal output.

  • Page 30: Position Variable Terminology

    Drive Load Encoder The 6250 has the capability of providing a ±10V analog voltage output for commanding the motor's drive. After the digital control algorithm has calculated the digital control signal, this digital value is sent out from the DSP (digital signal processor) to the Digital-to-Analog converter (DAC). The DAC has an analog output range of -10V to +10V.

  • Page 31: Servo Response Terminology

    Setpoint Profile Complete Commanded Position Distance ( D ) Constant Acceleration Deceleration Velocity Time The other type of time-varying position information is the actual position; Actual Position that is, the actual position of the motor/load measured with the encoder. Since this is the position achieved when the motor responds to the commanded position, we call the overall picture of the actual position over time the position response (see further discussion under Servo Response Terminology).
  • Page 32 A typical stable position response plot in preset mode (MC¯) is shown below. Settling Time Target Zone Mode Settling Band Setpoint Setpoint Commanded Overshoot Steady State Position Position Error Actual Position Rise Time Transient Steady State Time 6250 Servo Controller User Guide...

  • Page 33: 6000 Series Servo Commands

    Sets the maximum allowable error between the commanded position and the actual SMPER position as indicated by the encoder. If the error exceeds this limit, the 6250 shuts down the motor drive with the Shutdown output. You can enable the ERROR command to continually check for this error condition, and when it occurs to branch to a programmed response defined in the ERRORP program.

  • Page 34: Servo Control Techniques

    To ensure that you are tuning your servo system properly, you should understand the tuning techniques described in this section. The 6250 employs a PIV&F servo control algorithm. The control techniques available in this system are as follows: P..Proportional Feedback (controlled with the SGP command) I ..

  • Page 35: Integral Feedback Control (Sgi)

    Integral Feedback Control (SGI) Using integral feedback control, the value of the control signal is integrated at a rate proportional to the encoder position error. The rate of integration is set by the Servo Gain Integral (SGI) command. The primary function of the integral control is to overcome friction and/or gravity and to reject disturbances so that steady state position error can be minimized or eliminated.

  • Page 36: Velocity Feedback Control (Sgv)

    Consequently, because the control signal is now proportional to the acceleration of the commanded position, the 6250 essentially anticipates the velocity of the commanded position and initiates a control signal ahead of time to more closely follow (track) the commanded position.

  • Page 37: Tuning Setup Procedure

    DRIVE¯¯ command. If your motor drive does not have a shutdown input, use a manual emergency stop switch to shutdown the drive's power supply. You can also use the E N BL input to disable the 6250's analog output signal.
  • Page 38 Step 2. If the noise level is still unacceptable, consult the noise suppression techniques described in Appendix A. The purpose of this step is to ensure that a positive voltage on the 6250's S t e p 7...

  • Page 39: Drive Tuning Procedure (Velocity Drives Only)

    20 rps/V, then the drive will reach the maximum velocity (116.67 rps) when the 6250's command output is only 5.833V. This means the full range of ±10V is not fully usable. To use the full range of ±10V, the gain factor has to be adjusted to 11.667 rps/V.

  • Page 40: Controller Tuning Procedure

    Commanded Velocity Actual Velocity Time Proceed to the Controller Tuning Procedure section to tune the 6250. S t e p 4 Motion Architect Automatic Gain Selection Feature The drive scale factor and step response information gathered in the latest Drive Tuner module session can be used in the Controller Tuner module to automatically select gains that should greatly shorten the iterative nature of the controller tuning process.
  • Page 41 In addition to computing the 6250's control signal, the DSP also computes the commanded position trajectory. When the servo sampling frequency is increased, the motion trajectory update rate has to be decreased, and vice versa.
  • Page 42 Select and use Time Graph 2 as the vertical axis and as the horizontal axis. (Make Actual Position Time sure both are enabled to be displayed.) Click Graph 1 Graph 2 6250 Servo Controller User Guide...
  • Page 43 S t e p 4 Optimize the Proportional (SGP) and Velocity (SGV) gains ( see illustration for tuning process ): If you are not using Motion Architect: Enter the following commands to create a step input profile (use a comma in the first data field when tuning axis 2—e.g., D,5¯...
  • Page 44 START Increase SGP UNTIL Decrease SGV Increase SGV UNTIL UNTIL Decrease SGV UNTIL STOP Decrease SGP UNTIL Increase SGV UNTIL Decrease SGV UNTIL 6250 Servo Controller User Guide...
  • Page 45 Lower the integral gain (SGI) value to reduce the overshoot. Check whether the 6250's analog output saturates the ±10V limit; you can do this by either using Motion Architect's data gathering feature (in the...

  • Page 46: Tuning Scenario

    Tuning Scenario The following tuning scenario presents an actual example of tuning Compumotor 6250 Servo Controller with a Digiplan UD Drive system with a brushed motor and unknown load inertia. The UD Drive operates in velocity mode; therefore, the 6250's analog control signal output is a velocity command to the UD.
  • Page 47 S t e p 2 With SGP equal to 15, the response became slightly underdamped (see plot). Therefore, we should introduce the velocity feedback gain (SGV) to damp SGP = 15 out the oscillation. S t e p 3 With SGV equal to 2, the response turn out fairly well damped (see plot).

  • Page 48: Target Zone (Move Completion Criteria)

    SGP = 70 SGV = 2.52 Target Zone (Move Completion Criteria) Under default operation (Target Zone Mode not enabled), the 6250's move completion criteria is simply derived from Commanded the move trajectory. The 6250 considers Move is actually...

  • Page 49: Target Zone Mode

    (that is, within the distance zone defined by STRGTD and less than or equal to the velocity defined by STRGTV). If the motor does not settle into the target zone before the timeout period set with the STRGTT command, the 6250 detects a timeout error (see illustration below).

  • Page 51: Hardware Reference

    (general specifications, I/O circuit drawings and pin outs, and DIP switch settings). General Specifications The following table contains general specifications for the 6250. I/O pin outs and circuit drawings and optional DIP switch settings are provided later in this chapter.

  • Page 52: I/O Pin Outs & Circuit Drawings

    Shutdown relay output to drives that require a closed contact to disable the drive(see circuit drawing below). The shutdown relay is active (disabling the drive) when no power is applied to the 6250. When the 6250 is powered up, the shutdown relay remains active until you issue the DRIVE11 command.

  • Page 53: Encoder Connectors (For Use With Incremental Encoders Only)

    Encoder Connectors (For Use With Incremental Encoders Only) The following table lists the pin outs for the 6250's three 9-pin screw terminal connectors. The internal encoder input circuit is shown below. ENCODER In/Out Name Compumotor E Series Description Schematic Encoder Cable Colors...

  • Page 54: Auxiliary (Aux) Connector

    Shield —Internally connected to chassis ground (earth) — SHLD Ground ISO GND Joystick Connector Pin outs for the 6250's Joystick 25-pin D connector are listed below. The following illustration shows the internal input circuits. In/Out Name Description Analog Channel 1 8-bit, analog input for joystick control of axis.

  • Page 55: Rp240 Connector

    +5VDC power output Optional DIP Switch Settings The 6250 is equipped with a four-position DIP switch package you can use to select the 6250's device address (necessary only for daisy-chaining multiple 6250s with one RS-232C circuit), and to use the 6250's auto baud rate feature.
  • Page 56 The 6250 should send a message to the terminal confirming the baud rate (i.e., *9600). You should now be communicat- ing to the 6250 via the terminal. If no baud rate messages is received, verify steps 1 through 3 and repeat step 4.

  • Page 57: Troubleshooting

    If you are having difficulty isolating a problem be sure to document all occurrences of the problem along with as much specific information, such as time of occurrence, 6250 status, and anything else that was happening when the problem occurred.

  • Page 58: Reducing Electrical Noise

    Start from the top of the list of remedies and use the suggested procedures to isolate the problem. Refer to other sections of the manual for more information on 6250 set up, system connections, and feature implementation. You may also need to refer to the 6000 Series Software Reference Guide.

  • Page 59: Rs-232C Troubleshooting

    Verify that the computer/terminal and 6250 are configured to the same baud rate, number of data bits, number of stop bits, and parity. If your terminal is not capable of 9600 baud, you can use the 6250's auto-baud function to automatically set the 6250's baud rate equal to the terminal's baud rate.

  • Page 60: Returning The System

    Returning the System If you must return your 6250 system to affect repairs or upgrades, use the following steps: Get the serial number and the model number of the defective unit, and a purchase order number to cover repair costs in the event the unit is determined by the manufacturers to be out of warranty.

  • Page 61: Appendix A: Reducing Electrical Noise

    DC common tied to Earth (AC The following electrical devices are notorious for power ground). As a rule, it is preferable to have the 6250 generating unwanted electrical noise conditions: signal ground or DC common floating with respect to Earth.
  • Page 62 Earth through the drive, and on to Earth Filter the power line. Use common RF filters, and use at the computer. From there, the loop returns to the 6250 an isolation transformer for worst case. system through RS-232C signal ground. If a voltage...

  • Page 63: Index

    17, 18 disturbance rejection 28 problems 53 assumptions drive pull-up 48 skills required to use the 6250 i connections 46 pull up to +5V 3 auto baud feature 49 on/off status LEDs 5 triggers 48 auto-baud 4, 53...
  • Page 64 24 servo control methods/types 28 open-loop operation 31 sampling frequency 35 servo sample rate 18 servo sampling frequency 35 servo sampling period 23 servo tuning (see tuning) 23 setpoint 24 6250 Servo Controller User Guide...

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