User Manual - Tiny Controls
Contents
1. When JOG mode option is selected from the MAIN MENU the following screen appears JOG mode is used to position the table before entering in any mode This function can also be called in between program instructions programming mode Red and Green LED glows when the motor jogs Cont jog Table moves continuously with Cont speed until the time key is pressed This is handled by left right navigation keys Cont speed Jog speed can be changed by two ways 1 If Speed POT is set disabled in Setup menu press up down navigation keys to set the speed of continuous movement Range of Cont speed is from 1 99 Up key increases jog speed and down key decreases jog speed 2 If Speed POT has been enabled change the Cont speed by POT Up down navigation keys don t work in this condition 1 6 Move the table CCW CW by 0 1 degree for each press 2 7 the table CCW CW by 1 degree for each press 3 8 the table CCW CW by 10 degree for each press Note Cont speed is irrelevant of gear ratio Speed acceleration and Steps Rev Esc Return from current mode to the MAIN MENU If this command was called when a program 15 running pressing Esc key returns and resumes program where it was left I5 Cut to Length Mode When Cut to Length mode option is selected from MAIN MENU adjacent screen appears and shows the set value for CutIN SenselN and Dir This mode is used whenever it is req2. Its always possible STEPPER MOTOR CONTROLLER INDEXING CONTROLLER DOCUMENT OPERATION MANUAL DOCUMENT 7 DOCUMENT REV 2 0 PRODUCT INDEXING CONTROLLER STEPPER MOTOR CONTROLLER PRODUCT REV 2 0 CREATED OCTOBER 2013 UPDATED DEC 2014 Stepper Motor Controller THIS MANUAL CONTAINS INFORMATION FOR INSTALLING AND OPERATING THE FOLLOWING PRODUCT INDEXING CONTROLLER STEPPER MOTOR CONTROLLER TINY CONTROLS AND THE TINY CONTROLS COMPANY S LOGO ARE COPYRIGHTS OF TINY CONTROLS PVT LTD OTHER TRADEMARKS TRADE NAMES AND SERVICE MARKS OWNED OR REGISTERED BY ANY OTHER COMPANY AND USED IN THIS MANUAL ARE THE PROPERTY OF THEIR RESPECTIVE COMPANIES TINY CONTROLS PRIVATE LIMITED C 55 NISHAT PARK KAKROLA MOR NEW DELHI INDIA 110078 WEB http www tinycontrols com PHONE 91 991 119 3210 CONTENTS Item Page GENERAL DESCRIPTION 3 LOCATION OF COMPONENTS 4 TERMINALS 5 OPRATING THE INDEXING CONTROLLER 1 MAIN MENU SCREEN DIVISION MODE SCREEN DEGREE MODE SCREEN CONTINUOUS MODE SCREEN JOG MODE SCREEN CUT TO LENGTH SCREEN PROGRAM RUN MODE SCREEN PROGRAM EDIT MODE SCREEN SETUP SCREEN 1 6 EXAMPLE PROGRAMS 18 CONNECTION DIAGRAM 19 2 3 4 5 6 7 8 9 GENERAL DESCRIPTION Stepper Motor Controller or indexing controller is versatile single axis controller This controller is intended to control rotary tables but can also be used to perform many custom o
3. received WAIT_SENSE When this command is used then next command takes place after Sense input is received WAIT_ANY_KEY When this command is used next command takes place after ANY_KEY is pressed OUTLOW value This command is used to set the OUTPUT to low x is 1 to 4 The OUTPUT pin will be at low level or OV OUTHIGH value This command is used to set the OUTPUT to high x is 1 to 4 The OUTPUT pin will be at high level or 5V CONT START This command is used for continuous motion at set SPEED Pot input is ignored and the motor Accelerates at set Acc Value CONT STOP This command is used to stop continuous motion motor decelerates to step at current Acceleration value LOOPFOREVER This command is used for infinite loop SPEED value range is 0001 to 1200 RPM RPH This command is used to set the maximum speed which motor achieves while in operation ACCEL value range is 01 to 20 This command is used to set acceleration MOVETOMM value range is 00 00 to 99 99 This command is used when movement is required in absolute distance in mm MOVEBYMM value range is 00 00 to 99 99 This command is used when movement is required in relative distance in mm MOVETOCM value range is 00 00 to 99 99 This command is used when movement is required in absolute distance in cm MOVEBYCM value range is 00 00 to 99 99 This command is used when movement is required in relative distance in cm MOVETODEG value range
4. is 000 0 to 999 9 This command is used when movement is required in absolute degree MOVEBYDEG value range is 000 0 to 999 9 This command is used when movement is required in relative degree SETDIV value range is 0001 to 9999 This command is used to set division MOVETODIV value range is 0001 to 9999 This command is used when movement is required in absolute division MOVEBYDIV value range is 0001 to 9999 This command is used when movement is required in relative division WAIT_SEC value range is 000 1 to 999 9 This command is used to generate delay between two commands Setting WAIT SEC 1 gives the delay of 1 second LOOPFOR value range is 0001 to 9999 This command is used for looping and must be ended with LOOPEND LOOPEND This command is used to end loop instruction and every loop LOOPFOR or LOOPFOREVER must be ended with LOOPEND SKIPSENSE This command is used to skip a segment of instructions in program When sense input pin is set low SKIPSENSE 0 executes and SKIPSENSE 1 is skipped When sense input pin is set high SKIPSENSE 1 executes and SKIPSENSE 0 is skipped SKIPEND This command is used to determine the length of program segment until where the SKIPSENSE is to be executed RUNCOUNT This command is used to determine how many times a program or a section of programs has been executed Run count gets reset when controller enters in program edit mode Editing the Program 1 Enter in program edit
5. motor is running CutMM IN CutMM IN is input length which is always less than mark length It ranges from 1 to 9999 MM represents motion in mm and IN represents motion in inches SenseMM IN SenseMM IN is the sensing zone length in mm for mark sensor The mark sensor is sensed in this range Dir This parameter is used to set direction CW clockwise and CCW counter clockwise Key Pulse The Next Move can be initiated by giving pulse to the INPUT pin or pressing any navigation key OK Press OK key to enter in edit mode to change the parameters on this screen Esc Press Esc to exit from current menu to main menu In this mode if value of sense mm is 0 then the sense input is ignored and controller works in Move by MM mode else it scans sense pin and works in Cut to Length mode 6 Program Run Mode Press key 6 to enter in program run menu from main menu A provision for four programs is provided in Stepper motor controller The program can be a maximum length of 170 instructions and can be edited in program edit mode Use key 1 4 to select the required program Press Esc key to exit from program run menu If there is no program loaded in flash a message INVALID PROGRAM appears Enter in set up mode and select yes for factory reset It loads four default programs in flash After the user selects a program the adjacent screen appears It shows current position and speed of motion for
6. program selected Whenever controller waits for any input it is displayed by a wait message At time activity takes place red LED glows OUTPUTS 1234 show the state of output pins 1234 1 shows the high state at the output pin whereas 0 shows the low state at the pin See the terminals section for output pins 1 4 Run count shows how many times program a section of program has been completed If a user has inserted the run count command in the program then only the increment in run count is shown else run count remains 00000 The adjacent message appears along with run count when the complete program is executed Press Esc key to exit to main menu All the commands that can be used in programs are discussed in Program edit menu 7 Program Edit LIST OF COMMANDS CCW When this command is set the motion takes place in anticlockwise direc tion CW When this command is set the motion takes place in clockwise direction HOME This command is used for home purpose Before using this command direction must be set JOG This command 15 used for initial setting of table position using jog mode NOP This command is used for no operation It can be used to temporarily remove an instruction by replacing it with a NOP END This command is used to end program and every program must have END command at very last WAIT_PULSE When this command is used then next command takes place after Pulse input is
7. ae 24 5 653 6 5 6 5 0 0 0 00 0 0 aC Ji Emergency
8. e is a instruction for the same purpose The above message appears when key 8 is pressed See connection diagram for home switch connection Example program Example program 1 To move a disk 36 with soeed 400 RPM acceleration 1 at every pulse input endlessly Assuming TSTEP 087 stepper driver which is 10 micro step drive takes 2000 pulses for one revolution Also rotating disk is directly mounted on the motor shaft so gear ratio is 1 Set these parameters in SETUP menu by pressing the key 9 from home menu gear ratio as 1 and Steps Rev revolution is 2000 Save changes and exit to home screen by pressing ok Now go to Program Edit Mode to edit the instructions for the Program ACCEL SPEED 0400 DIR CW LOOPFOREVER WAIT PULSE MOVEBYDEG 036 0 LOOPEND END oave the Program and exit to home screen by pressing OK key The program can be run from main menu selecting Program Run Mode Note In setup menu the boot mode can change to Program Run Mode so program is executed from next time every time the controller is switched on Connection diagram Line 90 250V neutral AC Earth Earth e O oko S zt _ TEE i oko _1 o o c9 oe 6 wn E BE 5 ome 2 120 o 0 on OHO 29 5 I C6 UNSIIRIRZI
9. for step rev is 200 to 9999 Step MM This parameter sets Steps or pulses required for 1MM of linear motion Range for step rev is 0000 01 to 9999 99 Pulse width This parameter sets width of step pulse driven to the motor The range for step pulse width is 2us to 8us It can be changed by the left right navigation keys not by numeric keys Direction This parameter sets direction CW clockwise and CCW anticlockwise for all modes except the continuous mode However direction can be changed using left right navigation keys after entering in modes Speed POT This parameter enables or disables the use of pot in continuous mode By default pot is set disabled Accel This parameter sets Acceleration Range for acceleration is 01 to 20 Speed This parameter sets Max Speed in RPM RPH It is the maximum speed motor achieves And the range for Max Speed is 1 to 1200 Backlash Backlash is any non movement that occurs during axis reversals For example if X axis is commanded to move 1 cm in a direction and immediately after it is commanded to move 1 cm in the reverse direction the backlash exists them it does not immediately start reverse movement and motion departure is not precisely 1 cm Backlash compensation backlash feature simply allows the user to add the additional amount of backlash in same units for axis reversal For example for move by degree backlash compensation is in degrees and for move by mm backlash co
10. in both cases Dir This parameter set direction CW clockwise and CCW counterclockwise This parameter set in continuous mode doesn t affect the direction set in Setup mode However if direction is changed in Setup mode then direction in continuous mode also changes Input shows the movement when an input is received at pulse pin or sense pin on the basis of mode set in Action parameter Use up navigation key for next mode and down navigation key for previous mode Red LED glows at the time of activity and green LED glows when any key is pressed long Action This parameter is used for setting Action Action has 7 modes These modes are described below one by one Mode 0 When pulse is given at pulse input pin the motor rotates in the direction set and stops on receiving the pulse on sense input pin Mode 1 In mode 1 motor rotates in direction set as far as the input signal is received at pulse input pin And motor rotates in opposite direction if the signal is received at the sense input pin However if the input signal is applied to both the input pin then no activity takes place 2 In 2 as far as the input signal is received at pulse input the motor continues to rotate in direction set However if an input signal is received at pulse input pin and also on sense input pin motor begins to rotate in opposite direction Mode_3 In mode_3 when a pulse is received at input pin motor begins to r
11. menu as shown in the adjacent screen to edit the exising program 2 Select any program from the four programs by pressing respective numeric key and enter 3 The screen adjacent shows a window of 3 lines of program along with a cursor gt 4 Lines begin with the current line number followed by the command and its value The cursor shows current line while next to the cursor current line number is displayed In above figure cursor is currently on line number 1 Command instruction can be changed by pressing left right navigation keys and values can be entered by number keys 0 9 Use up down navigation keys to change the line Press Ok key to modify program after making all changes Press Esc key to discard the modifications made and retain to previous settings on exiting from program edit menu Setup Menu When setup option is selected from MAIN MENU the adjacent screen appears A provision for two profiles is given in Stepper motor controller in which the user can save two different setup menus User needs to input the profile number in setup menu when it is required to be used Use navigation keys and numeric keys to change menu settings Save the modifications by pressing OK key or discard by Esc key Gear ratio This parameter sets gearing ratio The range for gear ratio is 001 0 to 999 9 Step rev This parameter sets Steps or pulses required for a single revolution of motor shaft Range
12. mpensation is in mm Home Speed This parameter sets Max Home Speed this is the maximum speed motor achieves while home And the range for Max Home Speed is 1 to 1200 Home Input This decides whether the home search input is to be low or high Boot Mode This parameter sets the Boot up mode for the controller It can be set to any mode listed in the MAIN MENU For example if it is set to PgmRun mode the controller bypasses the Main Menu screen and directly starts in RUN mode NOTE In cases where the boot mode is set to Program mode and the program has some infinite loop or some error the boot mode can be reset to default home screen To reset switch off the controller and hold 0 Zero key while switching on the controller Default Program Default program sets which program is to be run after booting if boot mode selected in program run mode Splash Screen This parameter turns Off On initial splash screen One use of making splash screen off can be fast boot up time Homing on Boot This parameter if set yes enables homing after booting Factory Reset This parameter reset all parameters to Factory Defaults It can be used If you want to start over and it also loads a SAMPLE program erasing any user program stored at EEPROM memory Homing feature is available on key 8 users press key 8 motor moves in opposite direction to the direction set in setup menu and searches for home sensor input In program mode ther
13. n ground For NPN type proximity OV Common ground Connect to STEPPER DRIVER e g TSTEP 087 10 11 12 13 14 15 16 17 18 19 20 21 4 23 opeed Connect to center of POT for speed input in continuous mode STEP STEP PULSE OUTPUT Connect to STEPPER DRIVER eq TSTEP 087 DIR DIRECTION OUTPUT Connect to STEPPER DRIVER eq TSTEP 087 Actvty ACTIVITY OUTPUT Goes low while motor is moving Ack ACKNOWLEDGE OUTPUT Active low pulse after every move completion OUTPUT General purpose output pin OUTPUT General purpose output pin OUTPUTS General purpose output pin OUTPUTA General purpose output pin 0 V Ground Pulse Connect output of NO NPN type proximity switch sense Connect output of NO NPN type proximity switch Home Connect output of NO NPN type proximity switch Com In Common for above 3 inputs can be supplied external 12 volt or jumped from 12v output from the controller 12V OUTPUT For NPN type proximity OPERATING THE INDEXING CONTROLLER MAIN MENU When the power is applied to the board first a solash screen appears and then Home screen appears All options are available on this screen The user can return to home screen from any menu item by repeatedly pressing Esc key Press the number corresponding to the function you want to use Division Mode Degree Mode Continuous Mode Jog Mode Cut to Length Mode Program Run Mode Program Edit Mode Set
14. n here It cannot be set by the operator Key Pulse The Next Move next division move for Division mode can be initiated by giving pulse to the INPUT pin or pressing right navigation key Use left navigation key to move the motor in opposite direction OK Press OK key to enter in edit mode This allows the user to change the parameters on this screen Esc Press Esc to exit from current menu to main menu Speed is dependent on gear ratio and steps rev There is no accumulation of error in Division when the resultant motor steps are a fractional number The error is compensated spread over the entire revolution so that after x number of moves the table reaches exactly the same potion where it started if direction is not changed 2 Degree Mode When DEGREE mode option is selected from the MAIN MENU the following screen appears This mode is used whenever a movement is required in degrees On each pulse or key press motor moves by set degrees Red LED glows when the motor runs the set degrees For example if the set value for move degree is 090 0 then on each pulse it moves 90 degrees And one revolution i e 360 degree is completed in 4 key or pulse input MoveDeg This parameter sets value to move in degrees it can be set from 0 1 degree to 999 9 degrees The required value of gear ratio steps rev soeed and acceleration and required direction can be set in SETUP mode In order to refer to the SETUP m
15. ode press 9 after exiting from degree mode menu Change the speed after changing gear ratio and steps rev in SETUP mode Status Current degree is shown here It cannot be set by operator Key Pulse The Next Move next degree move for Degree mode can be initiated by giving pulse to the INPUT pin or pressing right navigation key Use left navigation key to move the motor in opposite direction OK Press OK key to enter in edit mode This allows the user to change the parameters on this screen Esc Press Esc to exit from current menu to main menu Speed is dependent on the gear ratio and steps rev and it changes in accordance to these values set in Setup menu There is no accumulation of error in Degree mode whenever the resultant motor steps are a fractional number 3 Continuous Mode When CONTINUOUS mode option is selected from the MAIN MENU adjacent screen appears and shows set value of Speed in RPM RPH Direction and Action On each pulse input or key press the motor starts or stops Red LED glows when the motor runs Speed This parameter sets velocity that the motor achieves The range of velocity is from 1 to 1200 its max value depends on Gear ratio and the steps rev If Speed POT input is enabled in Setup menu speed parameter is set from analog input and cannot be edited using keys We can set speed manually as well as by the POT attached However gear ratio and steps rev affect speed
16. or 5 V POT connections Display 20x4 LINES alphanumeric Max Operating Temperature 55 deg C LOCATION OF COMPONENTS Major components of the Indexing Controller c 2 5 o The description of these components is as following 1 NUMERIC KEYS 0 9 Numeric keys are used for entering the numeric values in edit mode In some modes these serve alternate functions 2 NAVIGATION KEYS PANEL UP DOWN RIGHT LEFT In edit mode these keys are used to navigate the cursor In some modes these serve alternate functions 3 amp Esc Press OK to enter in edit mode In edit mode pressing OK key saves the modified values in EEPROM Press Esc to back out of menus mode Pressing Esc repeatedly returns the control to the main menu 4 LCD DISPLAY 20x4 This LCD indicates all the information related to MENUS or MODES 5 LEDs RED LED indicates the activity and GREEN LED indicates long key press TERMINALS REMOVABLE BLOCK TERMINALS PIN NUMBER OON DOU EB 24 90V to 260V 50Hz 60Hz Live Handle with care 90V to 260V AC 50Hz 60Hz Neutral Handle with care Earth To Earth Main line Handle with care OV Common ground Connect to POT 5 OUTPUT For POT connection 12V OUTPUT For NPN type proximity sensors Emgcy EMERGENCY INPUT Connect output of N O NPN type proximity switch OV Commo
17. perations In circular motion i e division or degree mode there is no accumulation of error i e the error is distributed in whole motion if the programmed motion cannot be achieved exactly due to odd gear ratio of other setting lt can work either in simple indexing modes like dividing mode degree mode and cut to length or fully programmable with I O mode In programmable mode the program can be a maximum length of 170 instructions As NESTED LOOPS are also supported the actual program is capable of performing a variety of complex operations The following commands are supported see Program edit section for more details Motion setup CCW CW SPEED ACC SETDIV MOTION COMMANDS MOVETODEG MOVEBYDEG MOVETODIV MOVEBYDIV MOVE TO MM MOVE BY MM MOVE TO CM MOVE BY CM CONT START CONT STOP CHECK INPUTS WAIT P WAIT S WAIT FOR PULSE INPUT WAIT FOR SENSE INPUT CHECK KEYPAD WAIT ANY KEY CHANGE OuTPUTS OUTLOW x OUTHIGH x RECURSION LOOPFOR LOOPFOREVER LOOPEND DwtELL WAIT SEC SKIP PROGRAM SKIP SENSE SKIP END COUNT CHECK RUN COUNT OTHER NOP END HOME JOG SPECIFICATION FEATURES Supply Voltage 90V to 250V AC 50Hz 60Hz Max Pulse Rate 40 KHz Overall Size 165mm x 102mm x 76 mm Mounting Panel mount 155mmx92mm Inputs 4 NPN Proxy Pulse Sense Home and Emergency input Outputs 2 for motor STEP and DIR Activity Acknowledge 4 General purpose 12 V for NPN proximity type sens
18. uired to cut a particular length of material Red LED glows when motor runs User can cut material in the units of mm as well as inches Move to Unit parameter using left right navigation keys and select MM using up down navigation keys If motion of motor is required in mm and then set values for Cut sense and direction parameters For example in bag making machine mark is available to cut sheet but sometimes distance between marks are not equal Say if mark to mark length is 100mm then it may differ in the range of 97mm to 103mm In this case we put distance of CutMM with 97mm and remaining 6mm is filled in SenseMM and CutMM value is always less than mark length When input signal activates it moves till CutMM and after that SenseMM signal activates In this process it is expected that mark sensor should activate in the span of 97mm to 103mm If it activates between 97mm to 103mm motor stops and cut is executed And if sensor fails to activate in the span of 97mm to 103mm for any reason motor stops at 103mm and cut is executed But this is not proper cut If it happens three times consecutively mark error is declared Press key 1 in Cut to length mode to see the mark error number After three consecutive mark errors a message appears Press any key to exit from this error screen However if user wants to reset the mark error number in between the cut to length execution the user has to give a pulse on Sense input while the
19. un in direction set However motor rotates in opposite direction as far as the input signal is applied to sense input The motor stops when the input pulse is received on pulse input pin Mode_4 In mode_4 when an input pulse is received at pulse input pin motor begins to rotate in direction set and stops when pulse 15 applied at the same pin If the motor is rotating on applying the pulse at pulse input pin and meanwhile an input pulse is applied at sense input pin the motor starts rotating in opposite direction However when an input pulse is received at sense input pin motor starts rotating in opposite direction and stops when the pulse is applied on the same pin Mode 5 In mode 5 when the right navigation key is pressed motor rotates in direction set until the key is pressed And when left navigation key is pressed motor rotates in opposite direction until the key is pressed Green LED glows on long pressing the keys Mode 6 In mode 6 motor rotates in direction set when the right navigation key is pressed However motor rotates in opposite direction when the left navigation key is pressed The motor stops when either right or left navigation key is pressed OK Press OK key to enter in edit mode This allows the user to change the parameters on this screen Esc Press Esc to exit from current menu to main menu f user wants to use pot for speed control then enable the Speed POT in setup menu 4
20. up Menu OU 5 WN Hm NOTE There is homing feature available on key 8 If user presses key 8 on home screen motor moves in opposite direction to the direction set in setup menu and searches for home sensor input In program edit mode there is a home instruction for the same purpose NOTE Anytime if Emergency input is received motion is halted and current operation even program run mode is aborted A message of emergency is displayed Press any key to make the control return to HOME screen NOTE HOME Screen can be bypassed by setting the Boot mode in Setup menu This is useful if you want the controller to start in a particular mode By setting boot mode to Program Run mode the controller starts executing Program without any input from user 1 Division Mode When Division mode option is selected from MAIN MENU the following screen appears This mode divides one revolution in predefined number of parts For example if the divide by is num x then one complete revolution is completed by x number of key press or pulse inputs Red LED glows when the motor runs Divide By This parameter sets the value for dividing circle into number of parts in the range of 0002 to 9999 The required value of gear ratio steps rev speed and acceleration and required direction can be set in the SETUP mode Change the speed after changing gear ratio and steps rev in SETUP mode Status Current division number is show
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