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5K/10K Servo Creep Controller - Interactive Instruments, Inc.

1. Stop Transfers the controller to stroke control and halts the actuator at the current stroke feedback and the waveform generator output resets to zero The feedback display prompt changes from Run to Stop At this time the servo controller is halted until restarted any change in setpoint will not alter the actuator To resume control press and hold the key to restart the controller Constant Amp Waveform constant amplitude control can be enabled or disabled with this menu option When enabled the waveform amplitude and mean value are controlled more closely This option is typically used for fast cycle tests or if the specimen is very compliant This control will work with all cyclic waveforms not ramps Interactive Instruments 5K 10K Servo Creep Controller 26 View Max Min This menu item displays the maximum and minimum channel feedback results updated in real time Selecting this option prompts with the Select Channel menu Once the desired channel is selected the total overall and cycle maximum and minimum values are displayed The controller continuously updates these values 1000 times a second so even 1f the display is not fast enough to show the peak value this viewer will Pressing the down arrow will display the measured waveform amplitude max min and mean max min 2 value in real time Pressing the up arrow returns to displaying the max min values for the selected channel The Total max min values are r
2. Interactive Instruments 5K 10K Servo Creep Controller 35 Actuator Rate Select Actuator Rate from the Setup menu to display the information as shown below Enter Actuator Rate Def 20 08 in mn The current actuator rate is displayed as the default entry To select a new rate key in the desired rate and press the enter button To accept the default rate press without re entering the rate This is the maximum rate that the actuator controller will use in all modes The controller calculates how fast the actuator can move to minimize control error If the calculated rate is faster than the maximum rate the rate is clamped to the maximum rate The maximum actuator rate is stored in memory so the selected rate will be preserved until changed at a later time The rate can be programmed for slower actuator speeds to improve the accuracy and stability of the controller The rate can also be programmed faster to reduce control error faster The lowest actuator rate possible is 0 00001 in min Values less than that will be clamped to 0 00001 in min Note Faster actuator rates may be slightly faster than the programmed value due to the limited internal 100 ns timer resolution Slower actuator rates will match the requested rates more accurately while faster rates will be programmed to the next highest value Zero Channel Selecting this menu item will update the load stroke or auxiliary channel s offset so the current channel digital
3. Remember even of the load is programmed to control a low force the actuator is still capable of forces in excess of 10 000 Ibs so safety must be exercised at all times especially while working on or around the load frame Important Servo Maintenance Requirement Note A limitation of the Servo system is that when operating cyclic loads over 300 000 cycles the bearings need to be maintained on a regular bases When the actuator approaches 300 000 cycles it is very important to remove the system load and cycle the actuator over the entire 3 25 stroke range for several cycles to redistribute the grease It is also important to lubricate the system with the recommended grease as well The main bearing is not covered under the limited warranty agreement and would require the load frame be sent to Interactive Instruments for repair Bearing Grease The main thrust bearing must be lubricated periodically or the bearing will fail Attach a standard grease gun loaded with the recommended grease see below to the fitting on the motor thrust plate above the motor It is recommended to lubricate the bearing every half million to a million cycles by squeezing the grease gun handle 10 times Once the grease is injected it should be redistributed by moving the actuator over the full range of stroke The grease is a special lithium grease called Lithium Complex EP Grease and it can be purchased from Dieco www dieco us The actuator ball screw can be ins
4. Pressing a number on the keypad will display a prompt allowing the setpoint value to be reprogrammed Note The setpoint can t be changed if the actuator is stopped Restart the actuator by pressing the key and hold it for a second in the feedback display mode then set the new setpoint Interactive Instruments 5K 10K Servo Creep Controller 45 Network Interface WEB Server The servo controller has a built in computer with a network interface The computer contains a WEB server for the purpose remote monitoring of the current control and feedback parameters To access the WEB page identify the IP address of the servo controller using the View Config menu option under the Network Config menu Enter the IP address in the WEB browser URL address bar and press enter And the WEB page should display something similar to the following T Servo Controller C fi D 192 168 0 32 O Favs CJ Work 5 Purchase Home J BBB p eBay W Wikipedia D YouTube 7 Other bookmarks Servo Control 5 47 Servo10_103 Control Point 7000 0 lbs Setpoint 7000 0 Ibs Actuator State End Cycle Count Dx Load Stroke Aux Feedback 7001 1 lbs 0 00001 in 0 0000 Overall Max 7098 3 Ibs 0 00050 in 0 0000 Overall Min 5000 7 Ibs 0 00047 in 0 0000 Cycle Max 4999 8 Ibs 0 00001 in 0 0000 Cycle Min 4999 8 Ibs 0 00001 in 0 0000 Cycle Amplitude 0 0 Ibs 0 00000 in 0 0000 Cycle Mean 4999 8 Ibs
5. subtract up to 100 00 lbs from the current setpoint Interactive Instruments 5K 10K Servo Creep Controller 24 Waveform Type To specify a cyclic or ramp waveform use the following procedure Select Waveform Type from the Waveform menu Select which control channel waveform is to be modified Select Channel all Load 2 Stroke 3 Aux The next selection is the type of waveform Scroll through the list by using the up down arrows and press lt enter to select Waveform Type gt 1 Sine 2 Square 3 Triangle Depending on the selected waveform the display prompts for the required parameters The first line of each parameter prompt identifies the parameter to be entered The second line prompts with the default value To modify a parameter key in the new number on the keypad and press Pressing E will delete back one character then cancel the prompt once all characters have been removed The up arrow can be used for entering numbers in exponential format To enter 0 000012 type 1 2T 5 or 1 2e 5 Once the last parameter is entered all parameters are programmed at once for that specific control channel Pressing before entering the last parameter cancels all parameter entries The display then prompts for the Start Envelope Time which is the amount of time required to ramp to the final amplitude The time can be adjusted from 0 001 sec to 100 0 sec After entering a time the display prompts for the Reset Envelope Time as w
6. 0 00001 in 0 0000 Interactive Instruments Inc Designing products and providing full service manufacturing since 1993 web www interactiveinstruments com email info interactiveinstruments com phone 518 347 0955 USA The current default WEB page automatically refreshes every 5 seconds so the data is somewhat current To refresh more often press the WEB page refresh key FS on most browsers The WEB page can be easily customized or enhanced to suit personal requirements The WEB page layout and parameters can be customized using a simple HTML editor then saved in the controller s nonvolatile memory for future access Multiple WEB page can be stored and linked together for unlimited flexibility The default WEB page is named index html over writing it can replace the default WEB page with another You can store different HTML file names in the controller for various WEB pages For example an updated HTML document named test html can be accessed by trailing the IP address in the WEB browser with test html Interactive Instruments 5K 10K Servo Creep Controller 46 The various system parameters are updated to reflect the latest value every time the WEB page is refreshed Standard HTML documents can embed various system parameters any place in the document as needed as shown above in the default page The WEB server searches for special
7. 0 lbs and use 3500 as the new load range Be careful calibrating the loads in excess of the attached load cell The motor is capable of loads beyond the load cell but not continuously Once a range is entered the LCD will prompt if you would like to reset the limits and control stops to match the new range Select Yes by pressing 1 to match the limits to the new range You can select No by pressing 0 to maintain the original limits and control stops With the limits set to the channel range you don t have to remember to reprogram the limits to avoid unnecessary limit actions Note The load channel scale is a digital scaling factor and does not alter the analog calibration Modifying the channel scale without adjusting the analog calibration will effectively change the displayed values not the actual calibration of the machine For example assume the load frame is calibrated for the frames load cell 7500 lbs with the load channel scale also set for 7500 lbs Changing the load scale to 3750 lbs without adjusting the analog calibration and the unit will apply twice the commanded load This is because the calibrated 7500 lbs now is digitally scaled to represent 3750 lbs so each load display unit is actually 2 lbs Stroke The stroke scale is fixed internally and can t be increased or decreased The stroke channel is the only channel that scales the value when the units are modified This is because the stroke range is fixed and can t be mo
8. 44 The cycle counter is a 32 bit counter that is incremented after each waveform cycle is completed The cycle counter is capable of displaying up to 9999999 cycles After exceeding 9999999 it will divide the count by 1000 and place a K in the last location Exceeding 999999999 counts and the counter stops counting Feedback Display Keypad Holding the Waveform Generator Pressing the enter key under test will temporarily pause the waveform generator clock until the key is pressed a second time Display the Main Menu Pressing the E menu key while the feedback display is shown will continue to update the waveform monitor limits etc while navigating the menu This is to allow parameter changes such as actuator rate limit PID modifications etc during a test While in the menu pressing a second time will return back to display the feedback display Stopping the Controller Pressing the period key while displaying the feedback data or in the menu will stop the controller and suspend the waveform generator update The first line prompts with Stop to indicate the controller is disabled Pressing the period key a second time will restart the controller but not the waveform generator To restart the waveform generator go to the waveform menu and select Run Modifying the setpoint Press the Up or Down arrows while displaying the feedback data will jog the setpoint up or down Holding the up down arrows will slew the setpoint
9. 90735e 6 inches per pulse The fine position resolution allows for very precise load stroke and strain control A programmable timer is used to adjust the speed of the pulses to control the actuator between very slow rates to the maximum allowed system actuator rate Unlike a servo hydraulic system the servo electric system is able to control the maximum allowed actuator rate to suit test requirements Typical servo hydraulic systems are pre configured for one rate only fast or slow The servo controllers maximum actuator rate is a programmable limit that prevents the actuator from operating too fast Some tests such as high cycle fatigue test require very fast rates where control accuracy isn t as much an issue Long term creep strain tests sometimes require very slow actuator rates for smoother control and improved control accuracy The servo controller is able to fill both requirements with the same piece of equipment The typical actuator rate is set to a value that would be acceptable for most test conditions or about 20 inches per minute for moderate control response The waveform generator is then used to control the actuator load stroke or strain control The control error is calculated and the actuator rate is adjusted up to the maximum actuator rate to reduce the control error back to near zero Some test such as long term creep tests require precise control so a slower actuator rate is used instead of the typical 20 inch per minute rate As
10. Z CHAN OFFSET Set Offset z CHAN OFFSET Read Offset Display brief Help Note Parameters in parentheses are input parameters and parameters in square brackets are returned parameters Interactive Instruments 5K 10K Servo Creep Controller 59 When the servo controller is first powered up it is in manual control To place the unit in remote serial or network control mode the command C1 followed by a return CR can be sent to the controller to lock out the keypad The LCD prompts with an Asterisk in the upper left corner identifying the remote mode is now enabled To return back to manual control either press the E menu command on the keypad send the command CO CR or cycle the power switch on the servo controller When the controller is in remote mode the keypad commands are ignored Commands can be sent to program the controller in various modes without having to select them from the control panel menu For example to set the setpoint to 500 lbs send the command OO followed by a carriage return CR to select load control if not already in load control The response from the controller should be a CR to acknowledge the command Invalid commands are ignored by the controller A ZERO is often returned from bad parameters Then send F500 0 CR to program the setpoint to 500 Ibs To move the specimen actuator to a desired stroke of 250 inches send the command O1 CR to select stroke control followed by F 0 250 CR
11. and begin to make contact Thread the connector barrel until the connection is snug securing it into place As the barrel is tightened be sure to press in on the connector until it can t be pressed further and the barrel is tight The connector has an O ring seal to keep the connection clean so you will feel resistance before the connection is fully seated Interactive Instruments 5K 10K Servo Creep Controller 9 11 Connect the round end of the load cell cable into the load cell and rotate it until it is seated Then rotate the outer connector barrel to lock it in place Connect the other end of the load cell cable into the load cell port Port A on the bottom of the servo control panel Be sure to secure the cable to the control panel using the two screws on the connector shell The Cal button recessed can be pressed to verify the calibration of the load cell attached to port A See Port connection for more information about using shunt cal 12 Plug the power cord socket attached to the servo drive panel into the rear of the servo control panel The Servo controller gets its power from the servo drive panel so only one power cord is needed for the system 13 Attach the main power cord plug into a 110 volt or 220V if designated grounded wall outlet Avoid GFI ground fault interrupt protected outlets because the servos electrical noise on the ground line may falsely trip the breaker Interactive Instruments 5K 10K Servo Creep Controller 1
12. and continue running the waveform generator While in pause the motor controller will be active so any change in the control feedback will result in motion form the actuator Note this pause is not the same as the trapezoid hold status The trapezoid hold must continue to run the waveform timer to determine when to begin ramping Waveform pause can be used with the trapezoid temporarily suspending the trapezoids hold timer Restart Firmware X X0 to restart firmware warm boot X1 to reboot controller cold boot Read cycle count y Read the cycle count The cycle counter is a 32 bit counter counting up to 4 294 967 295 cycles before overflowing back to 0 To reset the counter you must reset the waveform timer to 0 Read Channel Offsets z Set Channel Offsets Z Reads and writes the offset of a channel Reading or setting the offset first requires the channel number 0 load 1 stroke 2 auxiliary Reading the channel offset returns the value that is currently added to the scaled channel data It is sometimes necessary to change the channels offset to better represent the actual measured results For example the load offset can be modified to remove the weight of a test grip or the stroke offset can be programmed to reposition the zero position The load and aux default zero offset is zero but stroke default is 1 6250 so position 0 is mid stroke 3 2500 inch 2 Help Displays a brief list of available commands Int
13. and ramp rate in control channel units sec The dual ramp requires the same as the single ramp but the type is 7 and the second ramp parameters end amplitude and rate follow after the first ramp parameters The trapezoid contains 7 parameters It requires the channel waveform type 8 the amplitude ramp rate and hold time in seconds followed by the second ramp rate and hold time The table below identifies the parameters for each type of waveform Waveform Type Par 2 Par 3 Par 4 Par 5 Par 6 Par 7 Sine 0 Amplitude Freq Square 1 Amplitude Freq Triangle 2 Amplitude Freq Haver Sine 3 Amplitude Freq Haver Square 4 Amplitude Freq Haver Triangle 5 Amplitude Freq Single Ramp 6 End Amplitude Rate Dual Ramp 7 End Amp 1 Rate 1 End Amp 2 Ramp 2 Trapezoid 8 Amplitude Rate 1 Hold 1 Rate 2 Hold 2 External 9 Amplitude Offset Programmable 10 Amplitude Freq Once the waveform parameters are programmed the waveform needs to be started with the waveform state control Q If the parameters waveform type frequency amplitude etc are reprogrammed while the waveform is running the new parameters take place immediately without resetting the waveform generator This is useful to modify the test frequency or ramp rate on the fly Use the j or J command to read or modify the Start Reset Envelope time for each channel For example to set the load waveform start time to 5 234 seconds enter the command J130 5 234 lt CR gt Ea
14. and the motor will move to this position within the limits of the unit Note No lt cr gt is needed after commands that don t need a subsequent parameter e g a d f H m o q s t T u v w y The lt CR gt is only needed to terminate numerical entries Interactive Instruments 5K 10K Servo Creep Controller 60 Sending Commands All commands begin immediately unless a number or a list of numbers are needed for the command For example to read the three feedback channels and the waveform time send the ASCII a command without a CR terminator All commands are case sensitive and can perform completely different operations depending on the case If a command requires a parameter the number is terminated with a carriage return OD hex to terminate numbers If a return is not sent the unit will wait until a non number is received It is important to send the commands and numbers as quickly as possible because some controller operations are suspended until the data is completely received While the controller is waiting for the complete command background operations such as display updates are temporarily suspended Once the command is completed normal operation resumes This is typically only a problem while manually entering commands with a terminal interface Using a computer to send and receive commands virtually eliminates the problem because commands can be entered instantaneously Information transmitted from the controlle
15. as possible The actual rate depends on the selected actuator rate The default setpoint is the current setpoint Pressing Enter or menu without entering a new value re selects the current setpoint The setpoint can be changed at any time even while a waveform is running Note The setpoint can t be changed if the actuator is stopped Restart the actuator by pressing and holding the key for a second while in the feedback display mode then set the new setpoint Interactive Instruments 5K 10K Servo Creep Controller 20 Waveform Each control channel has a programmable waveform generator with separate parameters providing a command signal to drive the servo system when that channel is in control Only one set of waveform parameters are enabled at a time allowing the load stroke or auxiliary to be controlled while monitoring the independent feedback channels The waveform parameters are saved in non volatile storage for each channel if the controller is powered down the parameters will be preserved so the same waveform can resume by just selecting the menu option Start from the waveform menu Internal waveforms fall into three groups bipolar waveforms comprising sine triangle and square unipolar waveforms comprising haversine havertriangle and haversquare and ramps which can be connected and repeated to form single ramps dual ramps and trapezoidal waveforms Note See the Important Servo Maintenance Requirement section above for
16. for a proper periodic calibration procedure but is useful for verifying between scheduled calibrations Note Do not press the shunt cal button while in load control or the controller will be fooled into thinking the load cell is loaded and the actuator will attempt to compensate Interactive Instruments 5K 10K Servo Creep Controller 54 Analog Output Each of the two amplifiers have analog outputs that can be monitored with external instruments such as oscilloscopes volt meters or analog acquiring systems The port A amplifier which is typically used for the load cell can be monitored with the BNC connector on the front of the servo control panel The Port B amplifier which is typically used for an extensometer can also be monitored with the BNC connector on the right STRAIN ENABLE SEC The analog outputs for port A and B represent the signal that the controller sees Each signal is a 10 volt magnitude representing the full analog range of the sensor If a 7500 lb load cell is attached to one of the ports then the scale factor of the voltage out would be 7500 lb 10 volts or 750 Ib per volt A 10K load frame would output 1000 lbs per volt Note The two analog output ports for load and auxiliary can be calibrated for better accuracy if necessary Both ports are currently calibrated so maximum load and maximum AUX output represents 10 volts out on the BNC connectors The potentiometers on the left side of the control panel can b
17. for the previous waveform cycle The peak monitor is useful to verify that controller performed as expected Read PID Parameters i Set PID Parameters I Read or set the PID parameters for a specific channel To read the PID parameters send the command followed by the channel number 0 load 1 stroke 2 auxiliary and a carriage return The controller will return with the Proportional Integral and Differential parameters To set the PID parameters send the command T followed by the channel number and the proportional differential and integral terms If the PID parameters are for the current control channel then they will be used immediately See the PID Parameters under Setup above for more information on adjusting the parameters Read system or channel value j Reads an internal value or servo drive parameter The table below represents the values that can be read using this command Note Multiple parameters can be accessed with a single command line by separating a list of parameters with commas terminating the last parameter with a carriage return For example to read parameter 1 2 and 3 control point amplitude setpoint enter the command j1 2 3 lt CR gt and the controller will return with the 3 values separated by tabs System Variables Index System Variable Control Point Waveform output setpoint Waveform output Setpoint Cycle Count PID Proportional Term PID Integral Term PID Differential T
18. frequency to 0 012 Hz send the command J222 0 012 The waveform controller will immediately adjust to the new frequency Note It is possible to modify the waveform parameters without disabling the generator be careful switching between cyclic and ramp type waveforms It is recommended the waveform generator is disabled before switching in and out of ramping functions or using the P command to properly initialize the entire waveform The Servo drive parameters can be modified at any time Refer to the Copley XPL 230 manual for a list of these parameters and the units associated with them To isolate the servo drive parameters from the system and channel parameters 1 1000 the servo drive parameters are numbered 1000 and up For example to modify the continuous current loop servo drive parameter to 10 00 amps send the command J1034 1000 lt cr gt The parameter modifications are only temporary Parameters are restored to the original value when the servo drive is powered down Not all servo drive parameters can be written too Refer to the XPL 230 manual for more information Note Be very careful when modifying some of the parameters because they can have a significant impact on control stability Interactive Instruments 5K 10K Servo Creep Controller 69 Read Max limit k Set Max limit K Read Min limit 14 Set Min limit L Reads and writes the maximum or minimum channel limit Reading or setting a limit first requires the c
19. in the Device text box and pressing enter As each device is linked the servo controller status and network information will appear below The servo status is updated regularly and should reflect the same information as the feedback display Note Be sure the servo controller is powered up and activated before attempting to communicate over the network After the servo controller is powered up it displays a message to initialize the actuator or stay put Select one of these options to activate the controller If the servo controller is not active it will ignore all network commands This is a safety feature to restrict remote access until the operator has confirmed the system is ready 1 servoUpdate lol System About Device ServoControl y Find Servo Status End 200 0 lbs Stroke 0 1245 in Load 16 9 lbs Aux 0 0000 Cycle 0 1 Network IP 192 168 0 33 MAC 0 D0 69 42 CD 99 Copyright c 2010 Interactive Instruments Inc servoUpdate Windows application Network Configuration Select the menu item Network from the System menu and the controller s network configuration will be displayed Feel free to change the servo devices name to something more appropriate avoid using spaces in the name You can use an underscore for a separator instead Select DHCP if your local server supports it the IP address will be automatically selected for you along with the subnet mask and default gateway You can
20. long term high cycle testing Constant Amplitude Control Constant amplitude control is available for trapezoid sine square triangle and the haver cycle and programmable waveforms The constant amplitude controller option can be enabled to greatly improves the actuators frequency response for multiple cycle testing This option can be turned on and off remotely or by the keypad When enabled the waveform generator monitors the previous cycle feedback peaks and the results control an outer loop adjusting the waveform amplitude to continuously adapt to the desired amplitude The constant amplitude control also monitors the feedback mean value and compares it to the desired mean and adjusts the setpoint to adapt to the desired mean for each cycle Neither of these controls modify the operators amplitude and setpoint values they are temporarily tweaked using internal variables Constant amplitude control only works for sine square triangle and haver and programmable waveforms which are primarily used for fast cycle control ramps are not impacted even when constant amplitude is enabled Enabling this feature allows the actuator frequency response to be pushed much farther Turning constant amplitude control off and after power up the waveform generator returns to the original control Effort was made to adapt the waveform output closely to the waveform parameters In some cases the constant amplitude control can go outside the bounds of the parame
21. modifying these terms because they can quickly cause the actuator control to become unstable Once all variables are entered they all become programmed at the same time after accepting the parameters by pressing 1 to confirm the change Pressing the menu key cancels the variable update The values are stored in memory so they don t require reprogramming after power up If the control mode is changed the proper PID parameters are automatically loaded Each of the PID parameters can be programmed from 0 off to 9999999 high gain To disable a parameter set the gain to 0 The Proportional factor cannot be removed entirely so its lowest value is 1 When adjusting start with small factor and increase them slowly until the proper control is obtained Be sure both steady state control and waveform control is stable with minimal error Each channel behaves differently so PID parameters will be different as well The best method for tuning a PID controller is to start with a low proportional gain with no integral and no differential gain Apply a square wave to the control channel and monitor the channel s analog output with an oscilloscope Slowly increase the proportional gain until the control overshoots slightly Then increase the differential gain to minimize the overshoot Once the waveform is clean and sharp try to increase the integral to improve the accuracy of a stable setpoint Too much gain will cause an unstable oscillation The
22. on Port A properly calibrated and balanced at 0 insert a paper clip into the hole located below the port A connector This will closes a switch placing a precision 59k resistor between the excitation voltage and the input The resistor will unbalance the load cell bridge simulating a load 3 Record the simulated load value displayed on the controller for future reference along with the digital load range and the load cell serial number Once the shunt cal load value is known the load cell can be checked for proper operation and calibration Verifying the load cell calibration 1 Power up the Servo controller and wait 15 minutes for the electronics and load cell temperature to stabilize 2 Verify the load is removed from the load cell and the digital offset is set to zero If the load cell does not read close to zero then adjust the load offset to balance the amplifier Also check the load range is programmed to the same value used to establish the shunt cal value 3 Press the shunt cal button with a paper clip and read the digital load on the controllers LCD If this value is the same as the value recorded earlier then the load cell calibration is verified Minor load cell calibration adjustments can be made using the shunt cal method by adjusting the load cell scale calibration in the connector Large discrepancies should be accommodated by performing a complete calibration procedure The shunt cal verify method is not a replacement
23. on up to 30 Hz It is also capable of controlling ramps from 10 units minute up to 10 units minute units are load stroke or strain depending on the control channel Although the waveform generator is capable of 30 Hz it is unlikely it will be able to reliably support that rate The waveform generator output is updated up to 1000 times a second and the waveform output is added to the current setpoint to generate the new control point which the controller will attempt to control The waveform generator is open loop so it can t guarantee the control error will be near zero that is up to the test conditions and the controller settings The actuator rate should be adjusted in conjunction with the waveform generator and control accuracy requirements Faster cyclic tests and ramps will require fast actuator rates while slower waveforms may require slow actuator rates As the waveform generator updates the control point the actuator controller will attempt minimize the error by moving the actuator rate slowly for small errors up to the maximum actuator rate for large errors This is why it may be important to consider the actuator rate for every test condition Envelope Control The waveform generator has the ability to slowly increase and decrease the waveform amplitude over a period of time Controlling the start and reset time is useful when applying high amplitude or high frequency waveforms Start and reset times can be programmed form 0 001 to 1
24. or below that pre load without unloading the specimen Note When the waveform generator output is added to the current setpoint The sign in the upper left corner of the feedback display signals that a waveform output is modifying the current setpoint When the sign is blank the waveform output is zero and not impacting the setpoint Waveform Envelope Start Control The startup can be controlled for cyclic waveforms to softly start a test A programmable timer can be set to quickly or slowly ramp the waveform amplitude up to maximum amplitude The timer can be adjusted from 1 ms up to 100 000 seconds before reaching full amplitude Each of the three internal waveform generators can be programmed to have different start ramp times Pausing the waveform will suspend the start envelope timer as well but restarting the waveform will restart the envelope timer to zero but start at the current amplitude If the amplitude of the waveform is modified the internal envelope start cycle will automatically reset to slowly increase or decrease to the new waveform amplitude Note The start envelope is only available for cyclic waveforms ramping functions are not impacted by the envelope control Waveform Envelope Reset Control The waveform reset can be controlled for cyclic waveforms to softly stop a test A programmable timer can be set to quickly or slowly ramp the waveform amplitude down to zero amplitude The timer can be adjusted from ms up
25. taken up with a 100 element bar graph that represents the absolute value of the load feedback signal The bar graph is automatically scaled to represent the current load feedback from 0 to the maximum load range The default represents load from 0 to 7500 lbs max Third Display Line Displays the feedback values of the stroke and load feedback channels The display units are also shown as well for each channel The load feedback represents the current load measured by the load cell The display values are filtered with the digital filter See Setup Channels for more information on configuring the load range offset filter and units The stroke feedback reflects the current actuator position relative to the stroke offset Since the stroke is calculated digitally based on the applied actuator position the resolution and accuracy is much better than using an analog displacement transducer See Setup Channels for more information on configuring the stroke units and offset Fourth display Line This line displays the optional auxiliary feedback value along with the waveform cycle counter The auxiliary channel is used to optionally display and record the results of an extensometer a second load cell LVDT or temperature sensor so the results can be read along with the load and stroke data If a signal is not attached to this port the range should be programmed to 0 to disable the port channel Interactive Instruments 5K 10K Servo Creep Controller
26. that wall socket is getting power Don t use GFI protected outlets or electrical noise from the servo drive may falsely trip the breaker e Controller may take up to 20 seconds to boot up from power up System Error is displayed e See that the controller cable is securely plugged into the control panel and the load frame e Check that the load cell is properly connected e Be sure the load stroke or auxiliary channels are not limited Actuator will not move e Check that the controller cable is plugged securely into the control panel and the servo drive e Be sure the 2 cables from the servo drive are plugged securely into the servo motor e Make sure that the load stroke or auxiliary is not out of range e Be sure the controller is not paused or disabled Press Enter or to release restart e Check to see if the servo motor is disabled If so press the Enable button on the control panel Has trouble controlling load e Slow the maximum actuator rate so it does not move for any little control error e Adjust the load filter to minimize noise e Retune the PID control parameters to stabilize the controller e Be sure the specimen is properly anchored e Check to see that the load cell cable is properly inserted at both ends Stroke Limit reached before the end of test e Reset the actuator to a higher position before starting a test e Make sure the control stops aren t set too close restricting stroke Actuator will not initialize e Check to see i
27. the waveform adjusts the control point the actuator ramp is clamped to prevent rapid actuator motion from disrupting the sensitive test environment Actuator rates as low as 0 00001 in min are possible for the finest actuator control so actuator adjustment will be dampened significantly Select an actuator rate that would be fast enough to maintain minimal control error A good tule is to use a rate at least twice the required rate to make sure the actuator can move fast enough to minimize control error Some experimentation may be necessary for load control applications to determine an acceptable actuator rate High cycle fatigue may require a faster rate than 20 in min Setting the actuator rate to 75 in min will greatly improve the cyclic frequency response at the expense of control accuracy The higher rates will permit speeds approaching servo hydraulic testers at a fraction of the system and maintenance cost Note Care must be taken when operating the load frame at high cyclic rates for long periods of time See the section Important Servo Maintenance Requirements above Interactive Instruments 5K 10K Servo Creep Controller 13 Waveform Generator The waveform generator can be programmed to manipulate the control point over a wide range of frequencies and amplitudes The waveform generator is capable of controlling the current control channels load stroke or strain The generator is capable of generating cyclic frequencies as low as 10 Hz
28. to 0 AN Resets the data acquisition storage index to 0 Read acquire index An Reads current acquire index Returns a number between 0 and 9999 to show the current number of data samples acquired Set the 3 acquired channel numbers AD Programs the 3 data channels which will be stored for each sample The channel numbers are the same as used by the j command Avoid using j commands that access the servo drive due to the time needed to access the data over the serial port Read the 3 acquired channel numbers Ad Reads back the 3 acquire channel numbers The values are same as used by the j command The default acquired channels are load stroke and AUX feedback which are represented by channels 100 200 and 300 Read Servo Status Read servo motor status and return 0 if the servo is enabled and operating no faults If a problem has been detected with the servo motor or drive the status will return 1 if the servo is disabled 2 if the servo drive has detected a fault and shut down 3 if the servo drive has an internal problem and 4 if the servo drive is undetected unplugged or powered down Read data a Read the load stroke auxiliary feedback and the waveform time in seconds since the waveform started The data is collected together as closely as possible so the data is not skewed Read Maximum Loop Control Error b Set Maximum Loop Control Error B Interactive Instru
29. values are evaluated and updated appropriately The feedback amplitude and mean value can be monitored in real time as well using the down arrow Pressing the up arrow will re display the max mins View Control View the current control value waveform setpoint along with the control feedback value and the current control error The bar graph on the top of the display represents the relative control error View Servo Stat View the Servos drive current drive temperature status and load These indicators are a good way of determining how hard the servo motor is working and whether the servo is being overstressed Setup Display the setup menu for configuring the system and channel setup parameters Network Config Displays a list of menu items to view and modify the current network configuration The network can be configured as a DHCP or Static network If your local network has a DHCP server the controller can request a valid IP address for your network A static IP address can be selected if DHCP is not available or if a static IP is desired If the servo controller is not plugged into a local network ignore this menu About Views the software version and copyright notice System Menu The controller firmware can be updated using a USB flash memory stick Other menu options are available to restart the control software or reboot the servo controller Interactive Instruments 5K 10K Servo Creep Controller 19 Mode Control The contro
30. 0 14 Inspect the load frame control panel servo drive panel and cables for shipping damage If any damage was caused in shipping please contact Interactive Instruments immediately Operating a damaged unit may result in additional damage or personal injury 15 Check all of the cables to make sure they are properly connected and secured Verify the servo driver com and safety cables go to the proper connectors to prevent damage to the driver 16 Check that the servo drive is enabled The enable button on the front servo control panel should be pushed in or the drive will not operate Any time someone works on the near the load frame while under power be sure to disable the servo drive to prevent unexpected motion 17 Verify the actuator is free of obstruction before applying power 18 Power up the unit by rotating the Main Switch on the servo driver panel to the On position The controllers operating system will require about 12 seconds to boot up in that time the LCD will display 2 black bars 19 As the unit is booting up the controller will access the DHCP server if available and automatically use the assigned network address If a DHCP server is not available a static address can be assigned 20 Note After powering down the controller be sure to wait 5 to 10 seconds before applying power again If the load feedback appears incorrect turn off the controller power wait 10 seconds and restore power Servo System Power Requi
31. 00 000 seconds for each of the three independent waveform generators The envelope control is only available for cyclic bipolar and unipolar waveforms such as sine haversine etc Amplitude Envelope Start Envelope Reset Setpoint Envelope Waveform Control External Waveform Generator An external waveform can be used to control the load or stroke channel using an analog control signal The analog signal can be scaled to a desired range to best represent the analog control signal The control signal is received on the AUX channel analog input and scaled internally and added to the load or stroke channel For example you can program the controller to create a O to 2000 lb waveform with a O to 10 volt signal The analog voltage will modify the setpoint depending on the voltage on the AUX port This is useful if the test waveform can t be duplicated with the internal waveform generator Interactive Instruments 5K 10K Servo Creep Controller 14 Programmable Waveform Generator Custom waveforms can be downloaded into the controller to create a unique sequence of cyclic ramp segments Once loaded the waveforms amplitude and frequency can be further adjusted by the user interface for added flexibility Waveforms are programmed by loading a list of amplitude values and optional ramp segment times one segment per line From 1 to 1000 ramp segments can be programmed to perform smooth sequential list of ramps to emulate virtually any waveform U
32. 0K Servo Creep Controller 40 System Menu Various system level commands can be accessed to update the firmware via USB memory or reboot the firmware USB Update This menu item will allow you to update the system firmware without the use of the network It is much easier to update firmware using the network connection but sometimes it isn t practical in all situations Be sure the memory stick is properly formatted for Windows FAT32 or the servo controllers firmware will not recognize the firmware file Insert the memory stick in one of the two USB device ports on the bottom of the servo controller and select the USB Update menu option Scroll through the memory stick directory entries until the proper file is located and press Enter to select When the firmware is automatically read and loaded the controller software will then restart with the new firmware Verify the new firmware version number after restart using the About menu selection Note Not all flash memory sticks can be read by the servo controller If you have trouble locating a device that works we can repartition and format your memory device for you so it will work in both Windows and on the servo controller Lock Keypad Selecting this option will lock the keypad from accidental key entries Once the keypad is locked the display will return to the feedback display and ignore keys To unlock the keypad either power down the controller or press any key for about 3 s
33. 10K Servo Creep Controller 12 Servo Controller Overview The servo controller software is the front end program that contains the user interface to the actuator control and the waveform generator The actuator controls main job is to determine where the actuator should be positioned to maintain minimal control error while monitoring various system limits and conditions The actuator is controlled by sending digital position commands to a servo driver program which is responsible for controlling and monitoring the servo motor As the servo motor is repositioned the servo motor feedback is returned to the servo driver as a digital signal which updates the servo control program The digital position command and feedback allows for high speed positioning and reliable noise free response over a wide dynamic range Actuator Controller One of the requirements of the actuator controller is to be able to precisely position the actuator over a wide range of speeds The servo controller sends a constant stream of pulses to the servo drive to control the actuator position A separate line is used to control the direction of the motion so the actuator can be controlled up and down at a controlled rate Each controller pulse sent to the driver moves the actuator a fixed distance the smaller the distance the finer the control motion The servo driver is programmed to input 524 288 pulses for every inch of actuator travel so the effective positioning resolution is 1
34. CABLE INTO THE SERVO COMMUNICATIONS PORT also a DB9 OR THE SERVO DRIVER WILL BE DAMAGED 5 Plug a standard 9 pin cable into the Copley servo drive panel Right side of driver and the other end into the matching port on the bottom of the servo controller panel labeled SERVO COM This cable is used to communicate serially between the servo controller and drive Secure the ends of the cable with shell screws Be sure not to mistake the servo com cable for the safety cable both DB9 as noted in the previous step 6 In some installations it is helpful to install a grounding wire between the servo drive and the servo motor to reduce load feedback noise Attach a stranded wire or a grounding strap between the screw at the back of the servo drive panel to one of the screws on the servo motor case can lower the analog load cell noise 7 NOTE The servo drive may not operate properly if the cables are not fully seated and secured S If a network is available it is advised to plug a RJ45 Ethernet cable between the servo controller port bottom of controller panel and your local network switch or hub The network can be used to monitor the servo system and can be used to update the system firmware The servo controller can operate without the use of a local network 9 Plug the servo motor feedback cable high density DB26 into the rear of the servo driver port labeled J10 and secure the connector with the two screws Plug the other end of th
35. DUP iii 28 setup Channels tek a ie ae eh ee EE ari E 28 Reset Limit Trip Condition 29 Reset Control Loop Trip Condition 32 Actuator Rad oe 35 Zero Chanel E Bee E ek RRT 35 PID Parameters sia teases T TREE EE EREE E 36 Servo Paramotor bi 37 Select Baud Rate iii dci 37 Home Actua A a 38 Reset Sys STOKE eisereen Ee 38 Interactive Instruments 5K 10K Servo Creep Controller 4 SE eu 38 Network Comi id 39 Wiew ConliB cian boi et 39 NN O NO 39 ISI AMES AE A gece cuca ceevsaneyeodercesoutueh ins deed SE 39 ADO diaria 39 System MENU irnos rosa 40 USB Updat iii pi 40 Lock Keypad icici sii ds 40 Recall Confid Bhalla ee Ree ie aes Beles aie is 40 Store CONG css SA 41 Reset Conector 41 Reset Servo E EE 41 Restart Controle ternera 41 RED OO EE 41 VIEW AUS A 41 Lock Remote Kevin di AA lid 42 Feedback En spuere dd 43 Feedback Display Keypads aiaa A ape sont ENEE T EE EEEE 44 Network Interface se ereraa iia 45 WEBS oil 45 Network ACC S Sireen eih ES E ceden nent cece cde gasateds gege 46 ServoUpdate Windows Appltceanon noc nocn nero nora nono conos 47 Identifying Servo Controllers 47 Network Configuration 47 Firmware Update 47 ServoRemote Windows Application oooocnoccconnconocononononnnonncnononononnnnnnco noc nocn nono nccnnccnnonnos 48 IPhone A pp liCatiOM p ereen penneg o dees ares ip Nenes Enaou ieSe Sa i 49 Block Diari oia ito 49 Analog Port Connection pins 51 Shunt EC EE 53 Analog RU LEE 54 Servo En
36. Display Line The first character of the first line is a symbol that identifies the sign of the waveform generator output if active The symbol switches from to to a blank indicating the output of the waveform generator This is useful to see if the waveform generator is applying an output to the controller The label after the first character represents the current state of the actuator The table below identifies the label with the actuator status Actuator Status Indicator Run Waveform Generator is running Stop Actuator is stopped and held at the current position and the controller is disabled setpoint changes ignored Press the key to resume control Hold Waveform output is held at the current value but the controller is enabled Or the trapezoid is in the hold mode Pause Waveform output is currently paused by keypad Enter key Press Enter again to resume waveform updates End Waveform generator has completed its operation Off Actuator servo motor is powered off due to a limit action The number after the actuator status indicator is the current control point and units The control point is made up of the setpoint added to the waveform generator output As the waveform generator runs the control output updates in real time to reflect the new control point As the mode control changes from load to stroke or auxiliary the control units reflect the control channel Second Display Line The second line is entirely
37. Pad or iPod Touch For the application to work properly the servo controller must be connected and configured properly for your local network The iPhone iPod must also have access to the same network as well either with a VPN network connection or Wi Fi using a local Wi Fi access point It is helpful if both the servo controller and the iPhone are on the same subnet but it isn t necessary Download the application from iTunes application library by searching for Servo Remote and install it on your iPhone or iPod Run the application and the display will prompt with a list of accessible servo controller on your local subnet Spin the selector to the appropriate servo controller if more than one are identified and press Select To access a computer on a different subnet enter the controllers IP address in the IP text box and press Select The application will begin to communicate with the servo controller over the network and the controllers display information will be updated in real time Pressing keys on the keypad will send the commands to the controller and return the update LCD information similar to the Windows application Note The servo controller can be programmed to disable the remote keyboard if needed to restrict access While the remote keypad is disabled the LCD information can still be viewed but remote key entries are ignored To disable the remote keypad enter the System Menu and select Lock Remote Key Once dis
38. Read Channel Ranges oi 63 Set Channel Ranges Cf 5 63 Reset Fotal Max Min s A Son asis 63 GREAT 63 Read PID Parameters Oo 63 Set PID Parameters CHEF H cesscciccacedceevedeucd eecescverstecseaveeedenvendesedtevesentendasssverneentersedse 63 Read system or channel value Of 63 Write system and channel value OW 67 Read Max limit K o 04 0 24 Sarai ad 69 Set Max Wout KA sc ENEE a a 69 Read Man rer sts este lie i ee en Aili ee eet 69 Set Man dint LA it titi 69 Redd LED datt iia 69 Send Keypad character OM 69 Read port filter factors Ni c scscussieeseeceave seve ctesssceneesduacoensseceiosaons suecoodeeeaieoasawesia Sl son 69 Set port filter factors NIEH ni ia 69 Read Control Channel TO enee i ae ees Sah A Re A 69 Set Control Channel OP iii idad 69 Set Waveform Parameters D A AAA 70 Read Waveform Parameters pi 70 Set Waveform State QA e SES 71 Read Actuator State q ue Eed 71 Set Limit Action RF HF eta a Eege Hee Besse E 71 Read Limit Actron EN 3s ccseestuse Res rra ii SES 71 Read acttiator Tati Eegen te 72 Set actuator rate Mii iia ia 72 Reset Waveform timer CT 72 Read WavetOrm Det lin dt 72 Read Controller Status 0 72 Reset all action alarm flags NM 72 Firmware Version Wisin itn te ea hk ee ace ees 73 Read waveform pause Status Wi 73 Set waveform pause status OWN 73 Restart Firmware XH ore ern ereer andadas 73 Read cycle Count y s s s6 scssss
39. The Def value is the current actuator position relative to the upper position Note this number does not include the stroke offset it is the absolute distance from the highest actuator position If the system actuator position is reset while in stroke mode the actuator will be disabled to prevent the actuator from repositioning to the old stroke setpoint Reprogram the setpoint and restart the actuator by pressing the key Setpoint Slew The setpoint can be programmed to slowly slew to the desired setpoint over a programmable period of time Entering a time value in this menu prompt will slew setpoint adjustments from the current setpoint to the desired setpoint in the time entered For example if the Setpoint Slew timer is set to 5 seconds and the setpoint is currently at 1000 lbs setting the setpoint to 2000 Ibs will slew the setpoint from 1000 to 2000 lbs at 200 lbs per second reaching 2000 lbs in 5 seconds Selecting a 3000 lb setpoint would ramp the load at 100 lbs per second to reach the load in 5 seconds If the waveform is running at the time the entire waveform will slew referencing the ramping setpoint until the desired setpoint is reached The setpoint slew timer can be programmed from 0 001 sec to 100 000 sec All channels are programmed to use the same setpoint slew timer Interactive Instruments 5K 10K Servo Creep Controller 39 Network Config View and configure the local network configuration When selected disp
40. _ INTERACTIVE INSTR UMENTS 5K 10K Servo Creep Controller Instruction Manual Interactive Instruments 5K 10K Servo Creep Controller 2 Information in this document is subject to change without notice and does not represent a commitment on the part of Interactive Instruments Inc The software described in this document is furnished under license agreement or non disclosure agreement The software may be used or copied only in accordance with the terms of the agreement It is against the law to copy the software on any medium except as specifically allowed in the license or non disclosure agreement No part of this manual may be reproduced or transmitted in any form or by any means electronic or mechanical including photocopying and recording for any purpose without the express written permission of Interactive Instruments Inc O 2015 Interactive Instruments Inc All rights reserved Printed in the United States of America Companies names and dates used in examples herein are fictitious unless otherwise noted Printed October 20 2015 Interactive Instruments 5K 10K Servo Creep Controller 3 Table of Contents TIO EE 6 No AAA RO 6 Important Servo Maintenance Requirement oooccnnccnocnnonoconoconcnononononnnonnnnnn nono nnnnnnnn cnn co nono neon neon conocio nn nrnnnnnnnnns 6 Bearing Grease ui Bed ee EES 6 Installation and Setup ek DEE ee reck H Servo System Power Requirements 5
41. a similar waveform but programmed unipolar positive values only Notice each line has two values the first being the amplitude and the second separated by a comma is the time in seconds the generator takes to ramp to the value Even though example 2 amplitude is half of example 1 both waveforms will have the same amplitude since the values are normalized internally Example 3 shows how easy it is to create a simple triangle waveform With up to 1000 entries virtually any waveform can be customized Waveform Example 1 ustom Wave 1 ul o 8 e OrFWODOWM C 0 0 1 d 0 0 0 iS G N GOG OT a Waveform Example 2 tom Wave 2 G 0 0 Ee EA Hos OO o 6 8 e e e sto 1 1 9 2 0 1 0 0 Gol 1 2 0 1 0 0 DEI E EE O O T f r f r f r Waveform Example 3 Triangle Wave 1 0 1 20 Interactive Instruments 5K 10K Servo Creep Controller 16 Data Acquisition The controller has an internal data acquisition feature that will allow you to sample up to 3 internal system or channel parameters synchronously or asynchronously for up to 10 000 samples The data acquisition feature is only accessible with remote commands due to the amount of data involved The default data channels sampled are load stroke AUX feedback values but any 3 channel or system parameter can be programmed to be acquired Synchronous sampling is performed by programming the sample rate in samples per second Once set the sampling is
42. able siii A de a eE dea 55 OILO ELNO o 2 gunge EE dE E A eee ee ed es 56 Load cell cah raO ica cotta Eege EE Aerer 56 Axi ary Cal bration vato tii 56 Remote Commands tee dE NEES bossa cen tee vsedebecveves dee eevee 37 Sending COMME e 60 Set Servo Parameter SA Ji 60 Read Servo Parameter rel 60 Set the programmable waveform CDD 60 Read the programmable waveform Con 60 Set Acquisition Rate DACH ege EEN cvetacnsecassvnstgntaessasagavesvasdavssssbaseusvossoencveves 60 R ad Acquisition Rate AC reae inira eae n e e i 60 Sample one data sample set AA 60 Read Acquired Data A 61 Stop Data Acquisition CAS enee rer i es eiee sireno r Eti E rE E E EE iE eE asi 61 Clear Acquisition Memory AR 61 Start Data Acquisition Timer AM 61 Reset acquire index to 0 AN 61 Read acquire Index AD canvi ia sota ibn 61 Set the 3 acquired channel numbers ADH H 381 61 Read the 3 acquired channel numbers Ad 61 Read Servo Status ii c 61 Read data Mirta alli ts 61 Read Maximum Loop Control Error h 61 Interactive Instruments 5K 10K Servo Creep Controller 5 Set Maximum Loop Control Error B i 61 Enter Remote Control CH 62 Read waveform output value ol 62 Set waveform output value D ee ceeescceencecsseceeeeeceseceeeeecaeceeneecsaeceeeecsaeceeneessaeeeeees 62 Redd Wits Lettre ed i 62 Set Units EH H ccc cect kc EEN 62 Read Setpoint Ch E 62 Set Setpoint RE 62
43. abled the only way to re enable remote access is from the keypad on the servo controller 10 33 AM b iPod 2 46 PM Servo Remote T Servo Remote IP 192 168 0 11 192 168 0 35 Run 2482 6 1b Servo_193 _ Copyright 2012 Interactive Instruments Inc Interactive Instruments Inc Block Diagram The following is a block diagram of the basic internal structure of the Servo controller The control input selector selects the desired input to the system If the keypad is selected as the control then a keypad menu commands will control the unit Selecting Waveform Interactive Instruments 5K 10K Servo Creep Controller 50 allows the internal waveform generator to manipulate the control point Placing the unit in Remote Mode allows a computer to control the desired control point The feedback switch selects which parameter is controlled Selecting load as the feedback will place the unit in Load Control and adjust the motor to reduce the load error to zero Servo Control Block Diagram Interactive Instruments 5K 10K Servo Creep Controller 51 Analog Port Connection Two analog port connections are available on the bottom of the servo control panel to attach external sensors such as load or strain transducers Once attached the output of the transducer is amplified for monitoring feedback or possibly as a control channel The port A connector is typically used to interface with a load cell The controll
44. actory default settings power up the controller with the O key held down The LCD will prompt with a confirmation message Press to confirm or 0 to cancel LCD Menu options Press the El menu key to display the Main Menu Note When entering a parameter value with the keypad the button will first delete characters one at a time if one or more digits have been entered and then cancel the numeric entry if is pressed after all characters are deleted Pressing the key will also exit from the menus and return to the feedback display Main Menu all Mode Control 2 Setpoint 3 Waveform Pressing the UP Down arrows on the keypad will move the pointer through the list of menu options The list includes Mode Control Select between load stroke or aux control Setpoint Set the desired control setpoint Waveform Configure and control the waveform generator View Max Min View the Max and Min feedback values in real time View Control View the actuator control feedback and error View Servo Stat View the status of the servo motor Setup Configure the System and Channel parameters Network Config Configure and view Network configuration About View the Software Version System Menu System updates and management Note While the display is not showing the feedback screen and a key isn t pressed in 60 seconds the display automatically returns to the feedback screen Interactive Instruments 5K 10K Servo Creep Control
45. ally reset when condition is resolved 4 Currently at Min Stroke automatically reset when condition is resolved 5 Currently at Max Auxiliary automatically reset when condition is resolved 6 Currently at Min Auxiliary automatically reset when condition is resolved 7 Waveform Finishing 8 Keyboard Locked via key switch 9 Waveform pause Mode 10 Remote Control mode 37 Max load limit tripped 38 Min load limit tripped 39 Max stroke limit tripped 40 Min stroke limit tripped 41 Max auxiliary limit tripped 42 Min auxiliary limit tripped 43 Max load loop control error tripped 44 Max stroke loop control error tripped 45 Max auxiliary loop control error tripped 46 Max Loop Limit Tripped Reset all action alarm flags V Interactive Instruments 5K 10K Servo Creep Controller 73 The controller maintains the limit and loop error alarm status even after the error has been removed To reset all max min limit latches enter the command VO followed by a CR To reset all loop limit latches enter the command V1 followed by a return Firmware Version v Access the unit s firmware name and version number For example version 5 01 is returned as Servo 5 01 followed by the build time and date Read waveform pause status w Set waveform pause status W Read or set the waveform pause status Setting the pause status to will suspend the waveform timer placing the waveform on hold Setting the status to 0 will release the pause
46. also select a static IP address if necessary for force the controller to a specific fixed address Consult with your network administrator to see which would be more appropriate for you Firmware Update The Firmware menu item under the System menu will prompt for a properly formatted firmware file supplied by Interactive Instruments This file has an extension BIN and can contain various data files such as driver and controller firmware WEB pages system files etc The BIN file also contains information where the file should be placed in the controller s computer Once the proper BIN file is selected by the file dialog it will be sent over the network to the controller verified and then placed in the appropriate location The control firmware will then automatically restart with the new firmware The firmware will automatically configure itself to use the Copley servo driver or the Pac Sci servo driver depending on the hardware configuration of the controller Interactive Instruments 5K 10K Servo Creep Controller 48 ServoRemote Windows Application The servo controller also has a remote Windows Application that will allow an operator to remotely operate the controller over the network as though they are in front of the system Any keypad function can be remotely operated just as it is done on the keypad panel As the keys are pressed on the Windows app commands are sent to the controller and the LCD responds with the results Both the remote k
47. an be programmed from 1000 samples per second to 1e 300 samples per second Read Acquisition Rate Ac Read the current data acquisition rate The returned rate is the number of samples per second Sample one data sample set AA Sample one data sample set This command is useful to sample data asynchronously so data is collected based on an event instead of time Interactive Instruments 5K 10K Servo Creep Controller 61 Read Acquired Data Ar Read acquired data in the form of CHAN1 CHAN2 CHAN3 TIME where CHANI to 3 are the desired sample channels and TIME is the sample time stamp The default channels are LOAD STROKE AUX You can read N number of samples from to all 10 000 If you use 0 for the sample count all sampled data values are read back If the storage buffer isn t full it will read back only the stored values TIME is the floating point time in seconds with O referencing the start of the acquisition Note Each line of data sets is separated by a CR The last line in the data set is terminated with a CR LF Stop Data Acquisition AS Suspend data acquisition Sampling can be restarted at any time using the AM command Clear Acquisition Memory AR Clear Data acquisition memory and return the index to 0 Start Data Acquisition Timer AM Start timed data acquisition at the programmed data sample rate Keep sampling until stopped or buffer fills Up to 10 000 samples can be stored in memory Reset acquire index
48. ated by the waveform generator when the generator is operating This value is added to the setpoint internally to create the control point If the waveform is stopped the waveform output can be modified otherwise the output value is maintained by the waveform generator Read Units e Set Units E Read or set the channels units To read a channel units send the command e followed by the channel number 0 load 1 stroke 2 auxiliary The number returned represents the display units as shown in the table below To set the display units send the E command followed by the channel number then an index from the table below For example E0 2 will set the load channel units to kN Index Load Stroke Auxiliary 0 lb in 1 kp cm V 2 N in 3 kN cm 4 kg lb 5 kp 6 N 7 kN Note Changing the load or auxiliary display units will not automatically scale the data range to match the new units Be sure to modify the load or auxiliary range to reflect the proper unit scale Read Setpoint f Set Setpoint F Read or set the setpoint value The setpoint value is used as a base reference for the waveform generator The signal that comes from the waveform generator is added to the setpoint to derive the control point Interactive Instruments 5K 10K Servo Creep Controller 63 Read Channel Ranges g Set Channel Ranges G Reads and writes the range or the positive full scale value of a channel Reading or setting a range first req
49. ator rate is 75 0 inches per minute High performance brushless servo motor for rugged long term reliability Can be mounted in virtually any position Power requirements 110 Volts 5 amps peak 3 amps Nominal Load frame weight 182 lbs controller and drive weight 18 lbs Load frame height is only 32 inches Load resolution 0 2 Ibs Stroke resolution 0 000001907 inch Instrumentation Load is measured via mounted pancake load cell or external S beam load cell Rack mountable servo drive and servo controller 2 adjustable internal amplifiers with external ports for remote data logging Shunt calibration button is available for quick load cell verification Analog load and auxiliary is measured using a 16 bit analog to digital converter Programmable digital filter ranges from 0 625 Hz to 80 Hz Results are displayed in Metric or English or custom units Remote operation and data monitoring using integrated RS 232 serial port Ethernet control and WEB port monitoring Conirols Waveform generator supports sine square triangle and havercycle functions Cyclic rates from 10 Hz to 30 Hz conditions permitting Ramp generator supports single dual and trapezoid functions Ramp rates from 10 in min or 10 Ibs min or faster LCD panel constantly displays load stroke auxiliary data in real time Load control accuracy lt 0 05 full scale Stroke control accuracy lt 0 004 full scale Adjustable digital PID control algorithm precisely maintains control point M
50. aximum actuator response rate is adjustable from 0 00001 to 75 000 in min System parameters are stored in flash memory Programmable max min limits loop limits and control stops Software Analog data channels are scaled and offset to match any display units Fully programmable waveform and ramp controller Control loop error can be monitored for excessive values Programmable high and low limits with programmable actions Programmable Control Stops to restrict feedback conditions Overall and cycle peak monitors for each channel Graphical application interface LabVIEW Visual Basic etc via serial or network Interactive Instruments 5K 10K Servo Creep Controller 76 Electronics 200 MHz ARM9 Controller with TS Linux 2 4 26 Operating System 32M RAM 32M of Flash storage 1 10 100 Ethernet Port 2 USB 2 0 12 Mbit s max ports 16 key keypad for function selection and parameter entry Audio Beeper and LED to signal operation status 2 channel high speed 16 bit Analog to Digital converter RS 232 serial interface adjustable to 115200 baud 4 line by 20 character LCD panel Copley Xenus Plus XPL 230 40 Servo driver for smooth reliable control Digital servo feedback for accurate and reliable control Troubleshooting LCD does not display information e Check to see that the main power switch on the servo drive panel is on e Verify the power cord from the servo drive is plugged into the servo controller and the servo drive is plugged into an outlet e Verify
51. ch control channel maintains a separate start and reset time as well Note See the Important Servo Maintenance Requirement section above for cyclic testing Interactive Instruments 5K 10K Servo Creep Controller 71 Set Waveform State Q Read Actuator State q Set the waveform generator state or read the actuator state The table below identifies the actuator state with the state numbers The waveform state becomes negative when LED status indicator flashes eg if the actuator is running while the status LED blinks the state becomes 1 Actuator states read only 0 STOP Actuator Control stopped 1 RUN Waveform or ramp is running 2 HOLD1 First trapezoid hold state 3 END Waveform or ramp finished 4 OFF Actuator is powered off 5 RUN2 Second trapezoid or dual ramp ramp running state 6 HOLD2 Second trapezoid hold state Waveform states write only 0 START Start programmed waveform if on hold then release hold 1 HOLD Hold waveform timer restart using START state 2 FINISH If Cyclic or Trap Complete waveform and stop If Single or Dual Ramp Program setpoint to the current control point 3 RESET Reset waveform output to O and quickly returns to setpoint 4 STOP Stop waveform generator timer and transfer to stroke control Set Limit Action R Read Limit Action r Set and read the limit or loop limit action for each channel Reading or setting the action value requires the action type O limit Loop c
52. d Even if the drive is disabled the software keeps track of the actuator position Fault A Fault value is displayed if the servo drive recognizes a serious fault See Copley User Manual for more information The system must be powered down to reset a temporary drive fault Contact Interactive Instruments if the problem persists Unconfigured The Servo drive configuration has been unintentionally reset and is inoperable The servo drive must be reprogrammed to operate properly See Interactive Instruments for further details on programming the servo drive parameters Load Load reflects the load measured from the load cell which is the same value shown on the feedback display The load value doesn t come from the Servo driver but it is a useful parameter to monitor the servos torque while watching the servo status To exit the View Servo Stat menu press the ES menu Key Note If the display prompts with nan for any of the values it means the communication link between the servo drive and the controller is broken Check to see that the DB9 cable is in place and secured at both ends Interactive Instruments 5K 10K Servo Creep Controller 28 Setup The Setup menu selection is used to review and modify the channel and system configuration parameters View Setup View the various system and channel configuration settings Select between viewing the waveform channel configuration channel limits maximum loop error or system configuration set
53. d 9 See the table below to select the appropriate gain Voltage Range Range Resistor Voltage Range Range Resistor 10 0 V Open 0 10 V 505 Q 5 0 V 50 0K 0 05 V 251 Q 2 0 V 12 5K 0 02 V 100 Q 1 0 V 5 55K 0 01 V 50 0 Q 0 5 V 2 638K 0 2 V 1020 Q Other ranges can be selected using the equation below 50000 Range Resistor 10 0 RangeVolta ge 1 The ports analog offset zero control can be adjusting by setting the voltage on the offset input pin 2 Two pins are available that can be used to help set the offset voltage Pin 1 and 6 output 15V and 15V and can be used to trim the offset voltage using a trim pot With each end of the trim pot attached between 15V and 15V and the wiper attached to the offset pin the offset can be trimmed to suit most needs Large offsets may not be possible if the offset is significantly out of range Note The excitation voltage is available to power a full bridge sensor such as a load cell The excitation voltage is fixed at 10 volts and is able to deliver up to 75 ma If the excitation is not needed then this pin can be ignored Interactive Instruments 5K 10K Servo Creep Controller 53 Shunt Cal A shunt cal button is available to perform a quick verification of the load cell calibration attached to port A Establishing the shunt cal value 1 Calibrate the load cell See the Calibration procedure for more information 2 With the load cell
54. d amplitude instead of an end point is because the final control point is the endpoint plus the setpoint which makes it an amplitude Since the second point can be non zero it would be incorrect to call it an amplitude The first and second end amplitude values are completely independent of sign and or magnitude For example the first point can be a tension value while the second can be compression The first point can also be greater in amplitude than the second as well A typical use for a dual ramp is during a tensile test in which a different tensile rate is required once the plastic yield point of the specimen has been reached Once the dual ramp reaches the second end amplitude the ramp control point does not reset back to zero but holds the second end amplitude like the single ramp To return back to the setpoint as fast as the actuator allows use the waveform Reset function Select the finish command to set the setpoint to the current control point setpoint ramp control and the ramp control is set to zero This in effect establishes the end of the dual ramp as the start of a second ramp Note The direction of the ramps towards tension or compression are denoted by the sign of each amplitude Trapezoid A trapezoid waveform is made up from two segments each of which comprises a ramp followed by a hold time The first ramp slope amplitude and hold time and the second ramp slope and hold time all must be specified along with a se
55. d down arrows or type the parameter number on the keypad and press ENTER The parameter name is displayed on the second line The parameter ID is used for accessing the parameter remotely The R or the R W message identifies the parameter as read only or capable of read and write ENTER to Modify ID 45 R 1800 To modify a parameter press the key while displaying the proper parameter and the display will prompt for the modified value For example to modify parameter 34 Max Current type 34 followed by the key or use the up arrow until parameter 34 is displayed Then press the a key to modify the parameter The servo drive will only modify parameters that are valid modifiable variables since not all parameters can be written For example the velocity feedback can be read but not modified Select Baud Rate Select a BAUD rate that better matches the rate for the attached computer The factory default is 115200 which is fast enough for most applications and computers If your computer is not capable of operating at the faster rates select a slower BAUD rate Slower rates will significantly slow the data transfer rate into and out of the system Select Baud Rate 4 38400 5 57600 26 115200 Note All RS 232 communications are performed with no parity 1 stop bit and 8 data bits Interactive Instruments 5K 10K Servo Creep Controller 38 Home Actuator This performs the Home Actuator procedure similar to power
56. d load cell in series with the servos load cell and use the servos load frame to apply the load Once a calibration system is set up to control the load with a calibration load cell in series perform the following steps 1 Adjust the load filter as low as possible and slow the maximum actuator rate to maintain an accurate load control 2 Be sure the load cell is plugged securely into Port A connector on the servo controller and is screwed in place to make a good connection 3 Check that the servos load range is configured properly in the load configuration menu and the offset is set to zero 4 Allow time for the electronics and load cell to warm up and stabilize for approx 15 minutes 5 Set the load to zero using the calibration standard or disconnecting the load bar and adjust the servos offset zero trim pot O adjustment on the load cell connector for as close to zero as possible 6 Apply the maximum calibration load in tension using the calibration standard as the reference 7 Adjust the span trim pot S adjustment on the load cell connector so the LCD feedback matches the calibration standard load 8 Repeat with step 3 until the two load cells are close as possible Once you can verify that both ends of the scale agree with the calibration standard the system is properly calibrated Auxiliary Calibration The Auxiliary data port can be calibrated the same as shown in the load cell calibration with the exception it is p
57. dified If a higher stroke resolution is needed lt 0 00001 you can use an LVDT or linear potentiometer attached to the auxiliary channel Aux or strain The auxiliary range can be scaled to match the sensor attached to the unit Attaching an extensometer to the Aux channel will allow the controller to monitor strain as feedback and also control strain If a 20 percent extensometer is used change the auxiliary channel scale to 20 00 and the auxiliary strain will be displayed in percent The auxiliary can also represent in volts V load Ib kp N KN or stroke units in cm as well if the appropriate sensor is properly installed and calibrated in the Aux analog port Channel Offset Offsets can be added to the channel output to adjust the true output feedback value to a given load position or auxiliary feedback This value is digitally added to the channels feedback and remote output and does not impact the analog offset or the analog output signal Since the offset is added to the feedback the offset can be negative to removed or positive to add to the feedback signal The only way the analog offset can be adjusted is using the trim pots built into each port connector See Analog Output for more information Note If the offset is modified on the current control channel the actuator will be disabled to prevent the actuator from repositioning to the old setpoint Reprogram the setpoint and restart the actuator by pressing the key
58. e cable into the round mating connector with narrow pins on the servo motor This cable sends the rotational position feedback to the servo driver and to the servo controller You should not use any tools to tighten the connectors only tighten by hand Align the connector before tightening the connector housing Rotate the connector until it aligns with the motors mating connector Once the connector aligns it will drop in and begin to make contact Thread the connector barrel until the connection is snug securing it into place As the barrel 1s tightened be sure to press in on the connector until it can t be pressed further and the barrel is snug The connector has an O ring seal to keep the connection clean so you will feel some resistance before the connection is fully seated Note If the cable comes loose while the system is operating the system will produce unpredictable motion and possibly shut down so itis important that the cable is properly secured 10 Kc Plug the round servo motor power cable from the rear of the servo drive panel into the mating connector with thick pins on the servo motor It s important that the connector is fully seated or the system will not operate properly You should not use any tools to tighten the connectors only tighten by hand Align the connector before tightening the connector housing Rotate the connector until it aligns with the motors mating connector Once the connectors align they will drop in
59. e filter is set to 1Hz the incoming feedback will attenuate the signal 3db at 1Hz and 20db at 10Hz 40db at 100Hz etc EA gt gt Cuto ff fequency Slope 29 dBidecade Gain dB Passband Stopband 40 A L L 0 001 on o 1 10 100 1000 Angular fequency radis Display Units The load stroke or auxiliary units should represent the current range and calibration of the specific channel Selecting different display units will NOT automatically scale the calibration of the load or auxiliary channel See Channel Scale below to scale the load cell range to match the load units Stroke is a unique channel It does not rely on analog signal conditioning and is a fixed range therefore selecting between inches and centimeters will automatically scale the value to match the units Available display units for each channel Load Units lb kp N KN kg Stroke Units in cm Auxiliary Units V in cm lb kp N KN Interactive Instruments 5K 10K Servo Creep Controller 34 Channel Scale Load The load cell range arrives from the factory calibrated for 7500 lbs or 10 000 lbs for 10K load frames but other load cell ranges can be configured as well If the load cell calibration of 7500 is maintained then the load cell range can be set to 3402 0 kg 7500 lbs and the kg units can be used Another way to calibrate the load cell with metric units For example the load cell can be calibrated for 3500 kg or 7716
60. e used to adjust the span and offset for each port Interactive Instruments 5K 10K Servo Creep Controller 55 Servo Enable The red switch below the analog output ports enables the servo drive When the switch is pressed in the drive applies power to the servo motor and the actuator position can be controlled by the servo controller When the drive is disabled the servo motor current is removed so actuator can t move If a load is applied to the servo actuator when the drive is disabled the motor may backspin removing some or all of the load Even though the servo motor is disabled the servo controller still maintains the position of the actuator If the controller detects the servo drive is disabled or reports a fault the controller will prompt with a message after a few seconds similar to the message below Servo Disabled Press 1 to Ignore or 0 to Retry If the servo drive is re enabled the message will automatically be removed and actuator control will resume If the message doesn t clear when the drive is re enabled pressing 0 will attempt to enable the servo drive and resume actuator control Pressing 1 will ignore the servo status error until the controller recognizes the servo becomes enabled If the DB9 servo communication cable becomes disconnected from the drive it will prompt the message below after a few seconds Servo Disconnected Press 1 to Ignore or 0 to Retry Even though the cable is disconnected actuato
61. econds The keypad will remain unlocked until it is locked again using the same menu option This option is restored to unlock on powerup Recall Config Recall from storage a previously stored configuration file Configuration files contain all of the parameters preserved in storage that are restored after power up such as the actuator rate PID parameters feedback channel range offsets waveform settings etc except the actuator position The current actuator position is preserved and is not restored The current control channel is not changed as well because the control channel is not preserved in the configuration file since the controller always restores to stroke control from power up Each file is stored to a file name configN txt where N can be any number so you can theoretically store thousands of unique configurations This is useful to store various configurations for fast slow test scenarios special waveform configurations limit setups etc Interactive Instruments 5K 10K Servo Creep Controller 41 Store Config Selecting this option will store the current controller configurations into a file named configN txt where N is any number The parameter file can be recalled another time to restore PID parameters channel limits waveform settings etc The actuator position is not restored even though it is saved in the configuration file Reset Config Reset the current configuration to the factory defaults It would be a go
62. ed entirely if an action isn t set Control stops don t have associated actions they are always active and never require a reset The only way a control stop can be ignored is to move them to the range limits of the feedback channel Once a control stop is exceeded the display will flash an error on the second line of the feedback display until the appropriate feedback is between the max and min stops For example the display below over the load feedback bargraph identifies a stroke stop while in load control Notice the message also identifies the maximum stop limit with the sign End 19 2 1b Stroke Stop 0 12345 in 15 3 lb 0 00000 DA Interactive Instruments 5K 10K Servo Creep Controller 31 Max Loop Limit Change the maximum allowed control loop error and action for a desired channel When a channel is in control an error is calculated desired command measured feedback and the maximum error or loop error can be tested to be sure the feedback is in an acceptable range Detecting an excessive loop error is useful to help determine if the current control loop is controllable Excessive loop errors are typically due to a measurable change in the compliance of the specimen As a specimen yields or breaks it may be helpful to stop or reset the waveform generator to halt the test and possibly prepare for another specimen Each channel maintains its own maximum loop limit value and associated action but the channel in cont
63. ell This is the time it takes to ramp from the current amplitude down to 0 when the Waveform Reset command is issued The last display shows the summary of the selected waveform and parameters Once the waveform parameters are entered the waveform must be started before it begins to operate Interactive Instruments 5K 10K Servo Creep Controller 25 Start After programming the waveform generator for the current control channel the waveform can be started For cyclic waveforms the waveform ramps from zero to the chosen amplitude If the setpoint is programmed to be a value other than zero the waveform starts at the setpoint and adds the waveform amplitude to the setpoint When the output of the waveform generator is negative the control point setpoint waveform output can track below the setpoint Once started the cycle counter waveform timer and the total max min values for all channels are reset If a Start Envelope time value is programmed for the selected channel the waveform amplitude will ramp from 0 to the desired amplitude over the time period The first line of the feedback display prompts with Run while the function generator is running The symbol in the upper left corner identifies the status of the current waveform output A or identifies the sign of the controlling waveform output value A blank not or identifies the waveform output as zero so the control point is the same as the setpoint Ho
64. er reads port A to measure and scale the system load The port B connector is typically used to measure the specimen strain but can be used to measure almost any type of differential voltage or bridge sensor Virtually any type of sensor can be attached with the use of an external signal conditioning amplifier The pins are arranged so common 3 8 25 turn trim pots can be easily attached to the DB9 port using solder or crimp connectors minimizing discrete wiring as shown below Note Select a value of R1 that gives an acceptable range of gain for the particular sensor For a typical 2 to 3 mv volt bridge you can use a 200 ohm trim pot 200 or 500 Ohm m Range J3 G ne x S Lo po E RNG 101 GREEN to TN 101 WHITE 8 IN EN 3 EX Ex1 BLACK dd EX Elo OFF 1 6 4 Fe AS OFF3 x Ta offset Ly DBOM O af 2 Analog Port A and B Calibration and Sensor Interface Note Port A and B are electrically identical Port A is used primarily for the load cell while port B can be used for strain feedback or strain control DIOJN Wl oalyAywolm 1 1 1 l 1 f Analog Port A and B Pinout Interactive Instruments 5K 10K Servo Creep Controller 52 The input to the port is made between pin 8 and pin 4 The default amplifier gain is 10 0 volts full scale The gain of the amplifier depends on the value of the resistor between pin 5 and 9 To increase the amplifier gain add resistance between pin 5 an
65. eractive Instruments 5K 10K Servo Creep Controller 74 Error Conditions While returning the actuator to home if the controller detects a servo error the display will prompt with the error and the LED will blink rapidly The following descriptions explain each error condition Servo Not Found If the servo drive is not connected to the servo controller or the servo drive isn t powered up and running the controller will display this message Servo Error n If the servo drive returns an error n this message is displayed along with the error number Please refer to the Copley manual for more information on the error Interactive Instruments 5K 10K Servo Creep Controller 75 Servo Specification 5K Load Frame Maximum peak actuator load 7500 tension 2000 Ibs compression Maximum continuous actuator load is 5500 lbs tension Maximum actuator stroke range is 3 25 inches Maximum actuator rate is 75 0 inches per minute High performance brushless servo motor for rugged long term reliability Can be mounted in virtually any position Power requirements 110 Volts 5 amps peak 1 5 amps Nominal Load frame weight 152 lbs controller and drive weight 18 lbs Load frame height is only 28 inches Load resolution 0 1 Ibs Stroke resolution 0 0000015625 inch 10K Load Frame Max peak actuator load 10 000 tension 2000 lbs compression Maximum continuous actuator load is 10 000 lbs tension Maximum actuator stroke range is 3 25 inches Maximum actu
66. erm Du E L H ra GC Interactive Instruments 5K 10K Servo Creep Controller 64 7 Control Channel 8 Current Waveform Type 9 Actuator W aveform State 0 Stop 1 Run1 2 Hold1 3 End 4 0ff 5 Run2 6 Hold2 10 Maximum Actuator rate 11 Waveform Time seconds 12 System status Bits 13 Waveform Paused State 14 PID output value 15 Control error 16 Current Actuator Rate stroke units minute 17 Limit Tripped Status 18 Limit Tripped Action 19 Limit Tripped Time relative to waveform time 20 Network Type 0 DHCP 1 Static 21 Load Bar 0 to 100 22 Run Time seconds since controller started 23 Setpoint Slew Time seconds 24 Total System Stroke 25 Total System Time 26 Total System Cycles 27 Resettable Stroke 28 Resettable Time 29 Resettable Cycles 30 Waveform State 0 Stop 1 Run 2 Hold 3 Finishing 4 End 31 Actuator State 0 Stop 1 Active 2 Off 3 Fault 32 Constant Amplitude Control 0 Disable 1 Enable 33 Waveform in cycle time seconds 34 CA Setpoint Adjustment 35 CA Amplitude Adjustment Channel Variables x 1 for load 2 for stroke or 3 for auxiliary channel Index Channel Variable x 00 Channel Feedback filtered x 01 Channel Range x 02 Channel Offset x 03 Filter factor x 04 Units x 05 Overall Maximum x 06 Overall Minimum x 07 Cycle Maximum x 08 Cycle Minimum x 09 Cycle Amplitude x 10 Cycle Mean value x ll Max Limit x 12 Min Limit x 13 Limit error Action x 14 Current loo
67. eset when a waveform is first started Pressing the enter key while viewing the Max Mins will reset the total peaks as well Peak Detector The controller continuously monitors the load stroke and auxiliary feedback values 1000 times a second Any time a value exceeds the currently stored value the new value is recorded in its place Cycle peaks are maintained on a cycle by cycle bases Once a cycle completes determined by the waveform generator the current cycle peak results are saved and the current peak detector is reset to the current feedback values This method requires two sets of registers The first set used to establish the current cycle peaks and the second is used to display the previous cycle peak results once the cycle is complete To exit press the E menu key View Control The controller s main responsibility is to minimize the error between the control value and the selected control channels measured feedback The View Control menu selection displays the control point value setpoint waveform amplitude along with the feedback value The difference represents the control error The smaller the error the better the controller is at positioning the actuator The control error is displayed on the bottom line The top line of the display is a bar graph representing the absolute value of the control error The default bar graph scale is 1 10 or every horizontal pixel feedback display 10 Pressing the O to 9 keys re
68. eypad and the panels keypad can be manipulated at the same time pressing a key on the control panel will update both the LCD and any remote panel monitoring the servo system on the network One application can monitor multiple systems just like the servoUpdate Windows app Pressing the Find button will attempt to identify any and all systems on the local networks subnet If the system is not on the local subnet enter the IP address manually and press Find to connect Use the standard IP address format with decimal point separators eg 192 168 0 100 Communicating over a slow network connection it may be necessary to slow the display update rate to 2 updates sec Select the Slow rate from the menu Display Rate at the top of the application Faster display rate is also available for local networks for 10 updates per second The medium display rate is about 4 updates per second With the Windows app as the primary application you can use your computer keyboard to enter the keypad commands remotely as long as the Windows app keyboard is not focused on the devices hostname text field If it is press the Tab key to move to another area of the app The 0 to 9 keys and the decimal point minus Up Down and Enter can be entered directly The other keys are mapped as shown below Computer Keyboard Windows App Operation Home Menu Display controller menu Backspace Clear Remove entered characters F2 Waveform Access the waveform menu F3 Ac
69. f the servo motor is disabled If so press the Enable button on the control panel e See that the controller DB9 and DB26 cables are securely attached to both the controller and servo drive Keypad is not accepting keys e The remote mode may be programmed to prevent keypad modifications See the remote C command for more information e Check to see if the Keypad is locked Press and hold any key for 3 seconds to unlock Interactive Instruments 5K 10K Servo Creep Controller 71 Limited Warranty Interactive Instruments Inc warrants the Servo Controller and Load Frame against defects in material and workmanship for a period of one year from receipt by the end user If Interactive Instruments Inc receives notice of such defects during the warranty period Interactive Instruments will either at its option repair or replace products which prove to be defective Should Interactive Instruments be unable to repair or replace the product within a reasonable amount of time customer s alternative exclusive remedy shall be a refund of the purchased price upon return of the product If this product was purchased as part of a system in a coordinated shipment or as a system add on it is warranted against defects in material and workmanship during the same period as the system Exclusions The above warranty shall not apply to defects resulting from Improper or inadequate maintenance by customer customer supplied software or interfacing unaut
70. feedback display and remote value is zero independent of the previous offset value The LCD will prompt with the new offset programmed for the selected channel This menu item does not affect the analog output Note If the offset is modified on the current control channel the actuator will be disabled to prevent the actuator from repositioning to the old setpoint Reprogram the setpoint and restart the actuator by pressing the key Interactive Instruments 5K 10K Servo Creep Controller 36 PID Parameters The PID parameters are used to control the motion of the actuator The three parameters can be modified for the load stroke and auxiliary channels to improve the response time and minimize control error for each control mode The default PID parameters were originally selected to work over a wide range of conditions Sometimes it becomes necessary to modify these parameters to improve the controller s response characteristics for a specific test Each of the PID parameters are used to scale the results of control calculations and affect the control behavior Selecting this menu option prompts the operator for the appropriate control channel that is to be modified Each channel has a separate array of scale factors so the control channel can be changed without having to re enter the PID parameters Once the channel is selected then the display prompts for the Proportional Integral and Differential scaling factors sequentially Be careful in
71. hannel to remove noise Be careful about over filtering the data because it can also remove useful information from the data Adjusting the channel filters do not affect the analog voltage output only the digital values Filter Values with associated filter frequency 0 None 5 5 Hz 1 80 Hz 6 2 5 Hz 2 40 Hz 7 1 25 Hz 3 20 Hz 8 0 625 Hz 4 10 Hz Note Since the stroke channel is created digitally this channel should not require filtering Read Control Channel 0 Set Control Channel O Read or set the current control channel 0 Load 1 Stroke 2 Auxiliary When a transfer takes place the new control feedback value is used as the new setpoint for minimal movement of the actuator Interactive Instruments 5K 10K Servo Creep Controller 70 Set Waveform Parameters P Read Waveform Parameters p Set and read the waveform parameters The number of parameters depends on the type of waveform Cyclic waveforms require 4 parameters The first parameter is the channel number since each channel maintains its own waveform generator parameters The second parameter contains the type of waveform 0 to 5 for the 6 cyclic waveform types See the table below for the types of waveforms The third and fourth parameters contain the amplitude in control channel units and frequency in Hz of the waveform Ramps require the same channel number and wave type 6 and the end amplitude in control channel units
72. hannel number 0 load 1 stroke 2 auxiliary followed by the max or min parameter Reading the command returns the Max or Min limit for the selected channel Be sure to set the appropriate limit action to enable the limit See set limit action R for more information The limits protect not only the current control channel limits but the indirect channels as well The limits are saved in nonvolatile storage so be sure to reset them back to the default after modifying them Read LCD data m Reads the 4 lines of the LCD with a carriage return terminating each line for a total of 84 characters 21 per line Send Keypad character M Send a single keypad character to the controller simulating a key being pressed on the keypad Valid ASCII characters are 0 to 9 decimal point and dash Letters are used for the other keys so A is used for enter B for menu C for up arrow and D for down arrow This command in conjunction with the Read LCD data command allows remote access to the controller over a network link Read port filter factors n Set port filter factors N Reads and writes the filter value of a channel Reading or setting a filter value first requires the channel number 0 load 2 Auxiliary Reading the channel range returns a number representing the current filter value Writing the channels filter will program a digital filter for the desired channel At times it is useful to filter the data from a c
73. hannel number 0 load 1 stroke 2 auxiliary Reading the action returns the value shown below To set the action send the corresponding value after the action value and channel number The actions are stored in battery backed memory Action Type Description 0 Limit The following action is used if the channels limit is exceeded 1 Loop Error The following action is used if the loop error is exceeded Once an action is tripped the action is automatically reset to ignore Limit Action Description 0 Ignore Ignore Limit 1 Reset Waveform Reset Waveform Generator 2 Unload Switch to load control and control to a programmed load 3 Xfer and Hold Switch to the limited channel program the setpoint to the limit 4 Stop Switch to stroke control and hold current position 5 Actuator Off Servo Drive is powered off Loop Error Action Description 0 Ignore Ignore Loop Error 1 Hold Waveform Hold Waveform Generator 2 Finish Waveform Finish Waveform Generator 3 Reset Waveform Reset Waveform Generator 4 Unload Switch to load control and control to a programmed load 5 Stop Switch to stroke control and hold current position Interactive Instruments 5K 10K Servo Creep Controller 72 6 Actuator Off Servo Drive is powered off Note The unload action requires an extra parameter which is the load setpoint value When setting this action remember to add the load value as the last parameter Reading the unload action returns the
74. horized modification or misuse operation outside of the environmental specifications for the product or improper site preparation and maintenance NOTE The main thrust bearing is NOT covered under the limited warranty agreement
75. ily be overwritten or deleted causing the controller to fail Corrupted controllers may need to be sent to the factory for repairs Network Access The controller can be controlled and monitored over the network as well The controller monitors port 50000 to allow the remote commands to be sent to the controller and the results returned as well remotely More than one computer can access the port at the same time See the list of remote commands below for more information Interactive Instruments 5K 10K Servo Creep Controller 47 ServoUpdate Windows Application The servo controller comes with a Windows application that makes it easy to identify various servo controllers on a local network update the network configurations remotely and even update the controller firmware over a network The servoUpdate application can automatically locate all controllers on a local network subnet and communicate with controllers on a different subnet as well If the controller is addressable over the Internet it is also possible to monitor a servo controller from anywhere Identifying Servo Controllers When the Windows application is started it send a command over the local subnet to find any controller and identify itself to the Windows application Multiple controllers can respond and the device drop down list will identify them individually Controllers beyond the local subnet can be accessed as well one at a time by manually entering the controllers IP address
76. lays the menu below Network 1 View Config 2 Type 3 IP View Config Selecting menu item 1 will display the current network parameters which include the Host Name Network type DHCP or Static IP current IP Subnet Mask and the gateway Use the Down arrow to display the gateway address Type Menu item 2 allows you to modify the network type between DHCP and Static IP DHCP is the preferred type if your network supports it A DHCP network will program the appropriate network parameters automatically If the local network doesn t support DHCP the parameters can be entered manually The default factory setting has DHCP selected so most users only have to plug the network cable into the Ethernet jack to establish connection You can use the View Config menu item to see what the assigned IP address is if DHCP is available IP Subnet Mask Gateway Menu items 3 through 5 are available to modify the static IP address subnet mask and gateway address if DHCP is not available or a static IP address is required Consult with your network administrator for information on network configuration The only parameter that can t be modified using the keypad is the host name because it requires a full keyboard to enter The host name can be modified using the supplied Windows application along with the other network related parameters About Displays the current software version number along with the copyright notice Interactive Instruments 5K 1
77. ld Hold the waveform generator at the current control point The feedback display prompt changes from Run to Pause Select Start from the Waveform menu to restart the waveform without resetting the time cycle count or total max min s Holding a waveform during a start or reset envelope will also suspend the respective envelope timer as well Releasing the hold by selecting Start or Reset will also restart the envelope timer so the cycle time will require the full time but from the current amplitude Note Pressing the enter key while displaying the feedback display will also pause the function generator displaying Pause Pressing a second time restarts the generator Finish For a cyclic waveform complete the current cycle then hold at the setpoint in the current control mode For a ramp function the ramping is halted and the setpoint is set to the current control point amplitude setpoint The actuator will move at the fastest rate allowed See Actuator Rate command Once the waveform stops the feedback display prompt changes from Run to End Reset to Setpt For a cyclic waveform ramp to the setpoint from the current waveform value at the maximum actuator rate see Actuator Rate command For cyclic waveforms if the Reset Envelope time value is set the waveform amplitude will reduce to zero over the programmed time period Once the reset cycle is complete the feedback display prompt changes from Run to End
78. ler 18 Mode Control is used to select which channel load stroke or auxiliary is in control Two options are available when transferring control to another channel Option 1 is to automatically set the setpoint to the measured feedback of the selected control channel Immediate or option 2 is to go to a programmed setpoint immediately after the transfer 1s complete Go To Setpoint is used to program the current setpoint value or reference point all waveforms are applied to If the waveform is not active the actuator controls to the programmed setpoint Waveform selects the waveform generator configuration and control options menu Configurations include selecting the waveform type such as sine square triangle haversine haversquare havertriangle single ramp dual ramp and trapezoid along with the required parameters An external waveform is also available using the AUX analog input channel The waveform control options are available to start hold finish reset and stop the waveform generator Each control channel maintains separate set of waveform parameters so the parameters don t require reprogramming if the mode control is changed back and forth Waveform commands are also preserved after power up View Max Min View a channels maximum and minimum feedback values in real time The display will indicate the overall max and min values since the waveform was started along with the max and min values for the previous waveform cycle The
79. les are only 6 foot long so be sure the controller is close to the servo drive panel Install the load frame firmly to a stationary platform The actuator is capable of rapid motion so be sure the load frame is securely mounted before operating Check to make sure the two servo motor connectors are easily accessible If the servo load frame is mounted horizontally be sure to support the weight of the load frame The top mounting ring has 3 mounting holes that are 0 531 equally spaced on a 7 5 diameter bolt circle The load cell has a 1 14 UNS thread interface Note When threading into the load cell be sure to stop at least Y inch before hitting the bottom to prevent interference between the load cell and the frame Interactive Instruments 5K 10K Servo Creep Controller 8 3 Plug the 26 pin high density controller cable connector into the bottom of servo control panel labeled SERVO and plug the other end into the mating connectors located on the Copley servo drive J8 The 26 pin cable is used to exchange high speed digital position commands between the servo controller and drive Secure the ends of the cable with shell screws 4 Plug a standard 9 pin cable into the Copley servo drive port J5 and the other end into the male 9 pin port on the servo controller panel labeled SERVO SAFETY This cable is used to supply power to the servo driver as well as enable the driver Secure the ends of the cable with shell screws DO NOT PLUG THE SAFETY
80. ller can be programmed to control load stroke or auxiliary analog sensor To change from the current control mode into a new control mode select the Mode Control menu item The display will prompt with a list of control channels Select one of the channels by entering 1 2 or 3 to select Load Stroke or Aux The display then prompts with options on how the control change will take place For Aux control be sure an appropriate sensor is installed in the Aux analog port and is properly scaled and calibrated Immediate The first option Immediate will quickly transfer control to the new channel and set the current setpoint to the control channel feedback value As long as the new feedback channel is stable the transition should have minimal effect on the actuator position Go To The second option Go To allows a new setpoint to be programmed immediately after the transfer of control is performed This is an efficient method of switching control and programming the new setpoint in one operation For example while in stroke control you can switch to load control at 100 lbs by selecting Go To 100 lbs Setpoint Programs the setpoint to a new value The setpoint is the mean value of the of the maximum and minimum excursions of the controlling waveform On normal cyclic waveforms sine square triangle 1t is the center point which the waveform swings On haver waveforms it is the starting and end point All setpoint transitions are made as quickly
81. ller will stop the actuator during the control restart and transition to stroke control after the restart Note It is not recommended to have a specimen in the actuator during restart unpredictable results may occur Reboot The controller computer can be rebooted to resolve unforeseen controller or computer problems This process may take 10 to 20 seconds to complete Note It is not recommended to have a specimen in the actuator during reboot unpredictable results may occur View Status The servo controller preserves several long term system status variables which can be useful to determine how long and active a particular load frame has been operating This information can be useful for preventative maintenance and as general system usage information The controller maintains the total non resettable system stroke total cycles and total time in operation even after powering down since the machine was manufactured A user resettable set of parameters is also available which maintains the same parameters but may be reset any time by the operator These variables are also preserved after powerdown The stroke value is stored as inches of actuator travel reflecting how far the actuator has moved up and down over time The cycles value is a total count of the waveform generator output which reflects approximately the number of cycles on the main bearing Interactive Instruments 5K 10K Servo Creep Controller 42 over time The time interval
82. load as a second parameter Read actuator rate s Set actuator rate S Read and set the maximum allowed actuator rate in inches per minute or centimeters per minute The new rate will be stored in nonvolatile storage To set the actuator rate to 15 2 in min send the command S15 2 followed by a carriage return Rates that exceed the limits of the unit will be limited to the valid range The fastest recommended rate is 75 0 in minute and the slowest is 0 00001 in minute Note the actual rate may be slightly faster due to rounding with the internal 100 ns timer resolution Reset Waveform timer T Read Waveform timer t Read or reset the waveform and ramp timer to see how long the waveform has been running When the waveform is started the waveform time is automatically set to 0 Pausing the waveform will temporarily stop the waveform timer as well Resetting the waveform timer will also reset the waveform cycles to zero Read Controller status u Read the state of the controller The returned status is a single number in HEX format representing which controller status bits are set and reset The table below identifies the status bit to the internal control mode Bit Status 0 Limit Tripped Set 1f any max min limit or any loop error is tripped 1 Currently at Max Load automatically reset when condition is resolved 2 Currently at Min Load automatically reset when condition is resolved 3 Currently at Max Stroke automatic
83. lugged into Port B connector and the reference depends on the type of sensor used Interactive Instruments 5K 10K Servo Creep Controller 57 Remote Commands Remote commands serial or network can be sent to the unit to control the basic operation of the unit and collect data in real time Using a basic set of commands the servo controller can be programmed with the use of a computer to perform various operations The default serial configuration for the Controller is 115200 baud 8 data bits 1 stop bit and no parity Note Commands are case sensitive they behave differently if they are upper or lower case Below is a list of the remote commands along with a brief description of the command AC RATE Set acquisition rate samples second Ac RATE Read acquisition rate AS Disable data acquisition AA Make one sample Ar SAMPLES Read acquired data samples to read 0 for all AR Clear acquisition memory AM Start automatic acquisition AN Reset acquire index to 0 An Read current acquire index AD CHAN1 CHAN2 CHAN3 Set 3 channel numbers to acquire Ad CHAN1 CHAN2 CHANJ3 Read the 3 acquire channels S Set Servo Parameter s Read Servo Parameter D Set LCD Value Types d Read LCD Value Types P Download Programmable Waveform p Read Programmable Waveform E Read servo status a LOAD STROKE AUXILIARY TIME Read load stroke auxiliary waveform time B CHAN MAX Set max loop error b CHAN MAX Read max loop error C ON Se
84. ments 5K 10K Servo Creep Controller 62 Reads and writes the maximum loop control error for a specific control channel Reading or setting a max error first requires the channel number 0 load 1 stroke 2 auxiliary followed by the max parameter Reading the command returns the Max error for the selected channel Be sure to set the appropriate loop error action to enable the limit See set limit action R for more information The max loop limit protects only the current control Each channel has its own programmed loop limit and each is saved in nonvolatile storage but the current control channel is only channel that is monitored Enter Remote Control C Once the servo controller has been powered up the unit can then be placed in remote control by sending it the C1 CR command The LCD will display an asterisk in the upper left corner in place of the waveform sign status to show the unit is being controlled remotely Once in the remote command mode the commands come directly from the serial port or the network not from the keypad To exit the remote command mode either press the Menu button on the control panel send a CO CR command or powering down the control panel If the controller is not placed in remote mode the keypad can modify system parameters at the same time Read waveform output value d Set waveform output value D Read or set the current internal waveform generator output value This value is typically upd
85. nnel and begin controlling to the or limit to remove the error condition Stop Any feedback values beyond the max or min limits place the controller in stroke control and halts the actuator at the current stroke feedback and the waveform generator output resets to zero The feedback display prompt changes from Run to Stop At this time the servo controller is halted until restarted any change in setpoint will not alter the actuator To resume control press and hold the key to restart the controller Actuator Off The controller will send a command to the servo drive to disable the actuator servo power The servo motor will be disabled from any motion until re enabled Note When a limit action is activated the LCD prompts as shown below for example Stroke Limit Trip Stop Actuator 0 12345 in 15 3 lb 0 00000 DA The first line of the display identifies the limit that was tripped in this case the stroke limit and the second line displays the action taken The action takes place immediately and the programmed action for the offending channel is automatically reset to the Ignore action This allows the controller to perform the action without potentially loop cycling between multiple limits The error message will continue to display on the top two limes until the limit is acknowledged by resetting the message Reset Limit Trip Condition To reset the action select the menu item Limit Selection from the main me
86. nu Setup Setup Channels menu The software will automatically recognizes a limit was tripped and prompt with the message Reset all Limits Confirming the reset with a 1 will clear both max and min limit trip conditions for all channels Canceling the request will not reset the limit trip condition so the limits can be reset individually or reset at a later time Note Be sure any tripped limits actions are reactivated prior to restarting a test Once a limit is tripped the action is reset to ignore Interactive Instruments 5K 10K Servo Creep Controller 30 Control Stops Control stops can be set to prevent further actuator motion from encroaching beyond the programmed control stop settings Each feedback channel has a set of control stops that are programmed by default to the maximum range of each feedback channel Tighter stops can be set by decreasing the control stops to restrict control and or feedback from exceeding its programmed stop The current control channel will be restricted to values between the maximum and minimum stop Feedback channels that reach one or more of the programmed stops will restrict motion of the control channel as well although control can be issued to move away from the control stop Control stops behave differently than limits A stop will always restrict actuator motion when a stop is reached or exceeded but limits will execute a programmed action to resolve the limit limits can be ignor
87. od idea to home the actuator to make sure the stored home position is accurate Once the factory configuration is restored the controller software will restart to properly restore the parameters If the servo controller is configured to use the Copley driver the firmware will ask if the load frame is 10K capable of 10 000 lbs If so answer 1 for yes so the configuration will be initialized for the 10K load frame parameters Answering No will initialize the parameters for a 5K load frame The Copley driver is only compatible with the AKM72K 5K and AKM74L 10K servo motors with digital BiSS feedback The Copley driver is not compatible with the AKM72K 5K motor with a analog resolver feedback Reset Servo Err If the servo drive enters an error condition fault 1t will disable power from the drive to prevent further motion of the actuator You can view the error condition that caused the fault by using the View Servo Stat menu option To restore power and control to the servo drive you can issue a software reset to the servo drive with this menu option Care must be taken to address the original error condition because after the drive is reset it will resume previous operation Restart Control This menu item will restart the firmware without having to reboot the controller Restarting the firmware is always much faster than rebooting At times it may be necessary to restart the controller firmware to perform diagnostics The contro
88. ompt changes from Run to Stop At this time the servo controller is halted until restarted any change in setpoint will not alter the actuator To resume control press and hold the key to restart the controller Actuator Off The controller will send a command to the servo drive to disable the actuator power The servo motor will be disabled from any motion until re enabled Interactive Instruments 5K 10K Servo Creep Controller 32 Note When a loop limit action has tripped the LCD prompts as shown below Control Loop Trip Reset Waveform 0 19456 in 215 3 1b 0 00000 123 The first line of the display identifies the control loop has exceeded its limit and the second line displays the action taken The action takes place immediately and the programmed action for the offending channel is automatically reset to the Ignore action The display will continue to indicate the loop trip until the limit is reset The reset command is located in the Loop Limit Selection menu Reset Control Loop Trip Condition To reset the loop trip action select the menu item Max Loop Limit from the main menu Setup Setup Channels menu The software will automatically recognizes the control loop was tripped and prompt with the message Reset all Limits Confirming the reset with a 1 will clear the loop trip conditions for all channels Canceling the request will not reset the control loop trip condition so the loop
89. on be sure the test are is free of test specimens or the specimen may be damaged Actuator Initialization Pressing displays a confirmation prompt below Pressing a second time and the actuator moves down to locate the bottom position This is done by slowly moving the actuator and waiting for the servo motor to stop at the bottom most position Once the actuator stops moving it assumes it is the lowest possible position If an object blocks the actuator from moving the home position may be incorrect and it is best to relocate the proper end position Ready to Home Press 1 to Confirm or 0 to Cancel Note It is preferred to locate the home location after power up but if a specimen is already mounted then it is better to assume the current position If the actual and stored position is off by more than 1 4 the actuator can bottom out internally causing the servo to stall and release the load While the controller is active or in control the status LED on the control panel will blink to indicate possible servo activity The same LED will indicate an error condition by flashing at a faster rate and will be on steady if the actuator is stopped Note The servo controller will ignore serial and network commands until the controller is active LED blinks continuously This is a safety feature to prevent automated programs from taking control of the actuator so the operator is in complete control after power up Interactive Instruments 5K
90. ontrol waveform is very flexible and can be used to control the load or stroke setpoint The analog signal is input on the AUX channel DB9 connector on the bottom of the servo controller on pin 4 with ground on pin 8 See Analog Port Connection for more information Note The AUX port defaults to a 10 volt input if the range resistor is open circuit To fine tune the analog input signal you may want to use a range resistor so you can calibrate the analog signal See the section Analog Port Connection for more information on selecting an appropriate ranging resistor An offset can be programmed into the AUX signal as well Program the offset using the AUX channel offset command under the Setup Setup Channels Channel Offset menu item Any changes to the AUX input channel such as digital filtering will impact the External Control feature Even though the AUX channel is used to adjust the setpoint the control channel load or stroke identifies which set of PID parameters are active When you are done with the external control feature set the AUX range to 0 in the Setup Channel menu This disables the AUX channel and allows more time for the main application Note The resolution of the AUX channel doesn t have to match the load or stroke channel scaling is performed internally You can program an external control range of 100 lbs while the load range is set for 7500 lbs The analog input will be able to add or
91. p error x 15 Loop error Action x 16 Limit error unload value x17 Loop error unload value x 18 PID proportional gain constant x 19 PID Integral constant x 20 PID Differential constant x 21 Waveform Amplitude x 22 Waveform Frequency Interactive Instruments 5K 10K Servo Creep Controller 65 x 23 Waveform Ramp Endpoint 1 x 24 Waveform Ramp Endpoint 2 x 25 Waveform Ramp Rate 1 x 26 Waveform Ramp Rate 2 x 27 Waveform Trapezoid Hold time 1 x 28 Waveform Trapezoid Hold time 2 x 29 Waveform Type x 30 Waveform Envelope Start Time seconds x31 Waveform Envelope Reset Time seconds x 32 Currently at Max Limit x 33 Currently at Min Limit x 34 Currently at loop Limit x 35 Max Limit Tripped x 36 Min Limit Tripped x 37 Loop Error Tripped x 38 Control Stop Max x 39 Control Stop Min x 40 Channel Control Point zero if not control channel For example to read the load feedback send the command j100 The controller will return with the current load feedback value Note Some variables can be read using direct commands but variables such as cycle amplitude and mean can only be read using this command System strings can also be accessed as well Strings are variables that don t fit into a numerical value such as the products name IP address etc A list of variables can be accessed using the list of variables below Index String Variable 400 Product Name and firmware Version 401 Setpoint with units 402 Load with
92. parameter definitions are as follows Proportional The Proportional value scales the proportional error This error is calculated by taking the difference between the current and desired setpoint The proportional value is responsible for most of the error correction Many controls require only the proportional term Integral The integral value scales the accumulated or integral error This error is calculated by accumulating the proportional errors over time The purpose of this term is to be more aggressive in the control output the longer the error persists Differential The differential value scales the rate of change of or the differential error This error is calculated by measuring how fast the error is changing and to slow the control down if the change in error is too rapid This term is useful in minimizing setpoint overshoot and allowing a larger proportional value Interactive Instruments 5K 10K Servo Creep Controller 37 Servo Parameters The Servo Parameter menu option enables the viewing and modification of the Copley servo drive parameters Please refer to the Copley XPL 230 servo drive manual for details about the parameters and their effects Be careful when modifying servo tuning parameters because they can cause uncontrollable actuator activity The parameter modifications are only temporary and are restored back to the original settings when powered down To scroll through the list of parameters alphabetically use the up an
93. pected by pulling down the bellows near the load cell to expose the screw assembly Add the same lithium bearing grease to the ball screw to keep it lubricated and re attach the bellows to keep dirt and debris from contaminating the screw Interactive Instruments 5K 10K Servo Creep Controller Installation and Setup On the bottom of the Servo controller panel you will find several connectors as shown below Follow the steps below to prepare the system before powering up the load frame 1 2 AUX SERVO SERVO SAFETY E a E NETWORK SERVO COM Bottom of Servo Controller Panel cre End 5 AL E k nie E Ieieilre E eE wel H fei Lo a Ciel O Te fo bead E nue sit E E S oy sz 00 1 Rear of Copley Xenus Plus XPL 230 Servo Drive Mount the servo drive panel with the red yellow power switch and the servo control panel with keypad into a 19 rack It is preferable for the servo drive to be mounted close to the bottom of the rack keeping the servo drive as cool as possible so heat from panels below it don t increase the ambient heat of the drive The two servo motor cables will also have to reach the load frame so placing the panel close to the ground is usually the best position The servo control panel should be placed at or below eye level to make it easy to read the LCD and press the keys on the keypad The interconnecting cab
94. performed automatically until the sampling is suspended or the acquisition memory fills Sampling rates can be programmed from as fast as 1000 samples per second to as slow as 1e 300 samples per second Asynchronous sampling is performed by sending a sample command to the controller whenever data is to be sampled Once the data is collected or even as data is being collected the data samples can read from memory You can read from 1 to all 10 000 data sample sets using remote commands Note At times the controller is too busy to acquire a data sample when sampling at rates over 200 samples per second Missing data samples will be replaced by duplicating the following data sample The time stamp will reflect the missing entry by indicating duplicate time stamps Interactive Instruments 5K 10K Servo Creep Controller 17 Guide to the Servo Controller Before starting a test e Verify that the load frame controller and servo drive are properly setup see Installation and Setup e Power up the controller by switching the power switch located on the Servo drive panel e Wait 10 to 15 seconds for the controller to boot up and begin displaying information on the LCD e Press the enter or E menu key to locate the home switch or stay The LCD will prompt with the feedback display Resetting the Controller The controller stores some of the control parameters in nonvolatile memory To reset all control parameters and actuator position back to the f
95. pped the limit condition is latched and the display will reflect the error until reset Reset the limit state by selecting the Reset Limit menu item in the Limit Selection menu or remotely with the V command Note Modifying a Max or Min limit with a limit action already enabled will be ignored if the limit will cause an immediate trip Enabling a limit action that would cause an immediate limit trip will also be ignored The list of limit action items are as follows Ignore Any error for the specified channel will be ignored and no action will be taken Note This does not exclude an over range of the load or stroke channel If the load A D value exceeds 100 8 of the programmed range the controller automatically suppresses control in that direction If the stroke exceeds the limit of the machine control is also suppressed in that direction Reset Waveform Any feedback values beyond the max or min limits will automatically reset the waveform generator See Waveform Reset for more information Unload Any feedback values beyond the max or min limits and the controller is placed into load control and the control point is set to a programmed value The Interactive Instruments 5K 10K Servo Creep Controller 29 programmed unload value can be set to any load value within the limits of the controller Xfer and Hold Any feedback values beyond the max or min limits and the controller will transfer to the offending cha
96. quency is automatically set to accommodate the total of all segment times This value can be overridden by programming another frequency the controller then scales each time entry to arrive at the to the new frequency Reloading the original waveform from a file will restore the time segments to the original values and the original frequency Interactive Instruments 5K 10K Servo Creep Controller 15 Programmable Waveform File Format The waveform file is an editable format that can be created using Notebook or any ASCII text editor The file name must end in WAV and can have from 1 to 1000 line entries one for each ramp segment Each segment should be terminated with a carriage return The first line is special and can contain a descriptive name of the waveform such as LoadProfile 2 or Log Sweep 2X The optional waveform name will be automatically truncated to 20 characters to fit on the display The name should begin with a letter to prevent it from getting confused with a waveform value If the waveform name is not available the USB file name will be used instead The name is displayed whenever the programmable waveform type is viewed The examples below represent two different types of waveforms Example 1 is a 14 segment bipolar waveform both values with constant segment times Since the amplitudes don t have time durations associated with the segments the time is based on the waveforms cycle frequency Example 2 is
97. r motion can continue as normal Reconnect the DB9 cable and the message will automatically be removed If the message doesn t clear when the drive is re enabled pressing 0 will re attempt communications Pressing 1 will ignore the servo status error until the controller recognizes the servo becomes enabled Note When you are working on the system and your hands are near the actuator it is highly recommended to turn off the system power to prevent the actuator from moving If the controllers power must be left on then you must disable the actuator by pressing in on the enable switch to toggle the driver off preventing unexpected actuator motion Verify the servo is disabled by observing the blinking green light on the rear of the servo drive Interactive Instruments 5K 10K Servo Creep Controller 56 Calibration Load cell calibration Load calibration is accomplished by adjusting the load range and offset trim pots on the load cell connector plugged into the side of the load frame Before calibrating the load cell a second load cell and external amplifier is needed as a reference One of two methods can be used to perform the calibration 1 With the Servo system properly warmed up 15 minutes Remove the load cell from the Servo and install it in another load controlling system that is considered a calibration standard The load cell must still be attached to the servos internal load cell amplifier 2 Add a calibration standard load cell an
98. r will not hold up the background updates because the serial transmitter is performed in the background To send a list of parameters each parameter is separated by a comma For example to program the load PID parameters the following command can be sent 10 100 1 200 followed by a return to terminate the last number This will program the load PID controller parameters with P 100 I 1 D 200 Set Servo Parameter S Send servo parameter to Copley servo drive The first value is the integer register number from Copley documentation and the second value is the value to be written to the register See the Copley documentation for more information Read Servo Parameter s Read the servo drive parameter from the Copley servo drive See the Copley documentation for more information Set the programmable waveform P Send programmable waveform values to the controller The first line is an optional waveform name terminated by a carriage return Following lines are of the form X Y where X is the waveform amplitude 1 0 and Y is the ramp duration in seconds You can set 1 to 1000 entries one per line and the final entry is terminated with a blank line Similar to USB waveforms the time value isn t required if all the segments are of the same length of time Read the programmable waveform p Read the programmable waveform generator name and values Set Acquisition Rate AC Set the data acquisition rate The rate c
99. reflects the approximate number of hours the servo motor in operation while moving or stationary Note Non cyclic waveform cycles are not recorded in the cycle counts Each parameter is useful and reflects the general usage activity of the frame The total actuator displacement is useful to determine the activity of the actuator screw while the cycles is useful to determine the relative activity of the main bearing Time is a good indicator how long the servo motor has been powered up Since this information is periodically saved to file 10 minutes while under motion to 1 hr stopped some information may be lost if the system is powered off without going through a reboot cycle but the data loss should be minimal New units will have the Reset date set when the unit was purchased and should be maintained for the life of the controller If the firmware is updated with this feature for the first time the Reset date will have to be entered by the operator for the first and only time as noted below When the control software is run for the first time the Set value is initially set to until the set date is programmed by the operator When the operator views the status parameters for the first time the software prompts for the current month day and year so this information can be used as a reminder when the total status was initially set Selecting the View Status menu will display the resettable parameters as sown below These
100. rements The servo controller and load frame doesn t require a lot of power to operate Below is a table of approximate required power for a 110 volt 60 Hz system As you can see a relatively small uninterruptible power supply UPS could relatively easily supply power to one or more units maintaining a controllable load throughout a power outage 10K Load Frame Load Power 0 lbs 35 watt 1000 lbs 50 watt 2000 lbs 65 watt 3000 lbs 80 watt 4000 lbs 110 watt 5000 lbs 130 watt 6000 lbs 180 watt 7000 lbs 210 watt 8000 lbs 260 watt 9000 Ibs 330 watt 10 000 lbs 400 watt Types of UPS systems There are generally two types of UPS units online and offline The less expensive offline UPS will work but some power line disturbances pass through to the UPS disrupting the controller More expensive Online UPS is a better choice for critical applications when you can t afford to lose load control Interactive Instruments 5K 10K Servo Creep Controller 11 Power up If the controller diagnostics pass all internal tests the LCD will then prompt Power Up OK Initialize Actuator Press 1 to Home or 0 to Stay Press the 1 key on the front of the control panel to locate the home switch or press O to maintain the same actuator position Since the actuator position is stored in memory the actual position may be different than the stored position if the actuator moves while powered down Note Before the actuator moves to locate the home positi
101. rol is the only channel monitored Since each channel can have a different loop limit and action the control channel can change from stroke to load and auxiliary without needing to reprogram the loop limit When the current loop limit exceeds the programmed maximum loop limit an action can takes place as shown below After the action is selected the action is forced to Ignore Be sure to re enable an action after an action trips When the servo controller is powered up and before the actuator is sent to home all loop error actions will be automatically set to Ignore Be sure to reprogram the actions back to the desired action before continuing Ignore Any error for the specified channel will be ignored and no action will be taken Hold Waveform The waveform is held at the current value Select Waveform start to continue See Waveform Hold for more information Finish Waveform The waveform will proceed until finished and then end See Waveform Finish for more information Reset Waveform The waveform will be reset See Waveform Reset for more information Unload The controller is placed in load control and the control point is set to a programmed value The programmed unload value can be set to any load value within the limits of the controller Stop Transfers the controller to stroke control and halts the actuator at the current stroke feedback and the waveform generator output resets to zero The feedback display pr
102. scale the bar graph from 1 1 key 0 to 1 1000 key 9 Select a range that displays a reasonably scaled bar graph To exit press the E menu key The compliance of the specimen and the speed of the loading significantly affect the size of the control error As the compliance reduces and loading speed increases the controller has a difficult time reducing the control error This is why it is sometimes necessary to reprogram the control parameters for varying specimens and test condition To minimize the control error try adjusting the maximum actuator rate and or the PID parameters These two items significantly change how the controller reacts to the control error No one setting can be used for all test conditions but typically one set of parameters can in general be used for a wide range of conditions Interactive Instruments 5K 10K Servo Creep Controller 27 View Servo Stat The servo drive has limitations that must be monitored to prevent it from becoming overheated and reduce system performance or disable the servo entirely The View Servo Stat Menu item is a good tool for monitoring the status of the servo motor and the system Below is an example of the View Servo Stat menu option 23 425 39 32 C Enabled 3525 1 Lbs The display prompts with 4 important servo parameters as discussed below Current The current is displayed in percentage of the drives capacity The motor and drive is capable of 100 current for short periods of
103. sesestsscess sets sasestsaveshcedacnsscdsaty sega dacs sees deoesscodasssastssvvasostanecostes 73 Read Channel Offsets CG 73 Set Channel Offsets CGZ31 EE O AR S ER EE 73 Help OT 73 Error Conditions sser r aa E he ee ee nies 74 Servo e EE 75 Troubleshooting mts dd COET NETKO dee 76 Limited Wald ir E E E E en ene AE cap E E ee A debut 77 Interactive Instruments 5K 10K Servo Creep Controller 6 Introduction The 5K 10K Servo Creep Controller is capable of continuous or cyclic loads up to 5 000 or 10 000 lbs depending on the servo load frame The unit is capable of maintaining constant load conditions for days months and even years with minimal maintenance requirements The Servo system is also capable of sustained cyclic motion as well Cyclic motion is programmable from as low as 10 300 Hz up to 10 Hz and beyond under limited test conditions The higher the test frequency runs the shorter the actuator stroke due to the servos limited actuator rate Optimal cyclic control rate is typically less than 5 Hz Safety Information The Servo is capable automatically moving the actuator with very high forces very quickly It is important to observe and follow all safety information in this manual While working on the servo load frame is important to disable the servo controller by powering down the system and prevent other operators from intentionally or unintentionally powering up the system while someone is working on or around the load frame
104. sing Excel or other spreadsheet programs complex waveforms can be created and exported to a text file rather easily The structure of the waveform file is very simple and easy to create Each line represents a waveform segment and contains an amplitude value which is typically of the range 1 0 to 1 0 but can be any value The amplitude values are used to control the overall shape of the waveform Once a waveform is loaded the controller automatically normalizes the amplitude values so the waveforms true amplitude is controlled by the waveform generators amplitude The waveform amplitude value is multiplied by half the waveform generator amplitude to create the waveform generator output for the specific control channel A stored waveform can be reused for stroke or load control since each channel can has a different waveform generator amplitude Once a waveform is downloaded it is available for any control channel just by selecting the programmable waveform Each waveform segment text line can also have an optional time value in seconds separated by a comma The time controls how long it would take to ramp from the previous segment value to the current value A time of 0 5 would generate a ramp that transitions to the new amplitude in 1 2 second while a value of 2 0 would perform the ramp in 2 seconds The time value allows for long constant hold times or fast ramp segments if needed If the time entry is zero or not included on the segment line the d
105. sisccssc ccssbssesostcssnsssssssasestosvesscedscnsscbogeeat qe dacssosassonss TS SEERE E ea UPER ES SSE 10 Types OL UPS SYSTEMS cto iii iia das aii 10 PO WOE Up eich Sod lidia 11 Activator Initially zations TA 11 Servo Controller OVErvaew icerisine ros a EErEE e sseeetbe asap cnet EEr esoe E E E EEEE iras 12 Actuator Controller iii 12 Wavetorm Generatora A AA das 13 Envelope Control ii 13 External Waveform Generator ccci c ccsissessessssesscesssnsvesostescdesstnscsesspesscodbessdesssesssgvesnecoeess 13 Programmable Waveform Generator 14 Programmable Waveform File Format 15 Data ACGuisition et ote 16 Guide to the Servo Controller sesiis essesi roere rA ten EENS 17 Berore Startins di 17 Resetting the Controller cocinas coccion indiana EES De ENEE ENEE 17 LCD Menu Ops A 17 Mode Eontrol in 19 ru EE EE 19 Eo Ke EE 19 A a ia R TA T nell nase ite NE 19 KE EE 20 Constant Amplitude Control cui rl ta a 20 Cyclic Waveforms otra e 21 Waveform Envelope Start Control 21 Waveform Envelope Reset Control 21 Ramping Waveforms muerde latest 22 Waveform EE 24 e TEE 25 Hold ascii ios aos 25 Le E 25 Reset to Sepia it 25 MU e id da io hae os 25 Constant Amp iicioiconiolocicinse cogi sees sssssasestsavessceducnsvebsseeat ea EEES EKOE ESE a SEERE EERE IPERE SISET 25 View Max MUM cortita a a a e ei ea 26 Peaks Detector geen ee E E EAE AE E R Ale 26 View Control naenin E E E nro 26 KAS E EE 27 KEE 28 WAS WISE
106. t Reset Remote control mode C ON Read Remote control mode D AMP Set waveform output d AMP Read waveform output E CHAN U Set Units e CHAN U Read Units F SET Set Setpoint f SET Read Setpoint G CHAN RNG Set Channel Range g CHAN RNG Read Channel Range H Reset Total peaks h CHAN TMX TMN CMX CMN _ Read Total and Cycle peaks I CHAN P 1 D Set PID parameters i CHAN P L D Read PID parameters jN Read system or channel value n IN Set waveform value n K CHAN MAX Set Max Limit k CHAN MAX Read Max limit L CHAN MIN Set Min Limit CHAN MIN Read Min limit M KEY Send a keypad value to the controller m Read the 4 LCD lines N CHAN FLT Set Channel Filter n CHAN FLT Read Channel Filter Interactive Instruments 5K 10K Servo Creep Controller 58 O CHAN Set Control Channel o CHAN Read Control Channel P CHAN W P1 P2 P3 P4 P5 Set Waveform Parameters p CHAN W P1 P2 P3 P4 P5 Read Waveform Parameters Q STATE Set Waveform State q STATE Read Actuator State R TYPE CHAN ACT Set Limit or Loop Action r TYPE CHAN ACT Read Limit or Loop Action s RATE Read actuator rate S RATE Set actuator Rate T Reset waveform time to 0 t TIME Read waveform time u BITS Read status bits in HEX format v VER Read software version V type Reset limit or loop limit tripped status flags W HOLD Set Waveform Hold state w HOLD Read Waveform Hold state X REBOOT Restart Reboot Firmware y CYCL Read cycle counter
107. tags with the format NNN and replaces the string with the appropriate system or channel value including appropriate units by the number NNN Using the braces instead of will replace the string with the same value without units The system variables 0 to 999 can be found in the remote command j list see Read System or Channel Value below For example to display the current cycle count in an HTML document the text string 3 will be replaced automatically by the current cycle count value Download the default HTML document from the controller to get an example how the various HTML documents are tagged To access the controllers default WEB page use any FTP client program and connect using the controllers IP address Log into the controllers FTP server using root as the username no password is needed Browse to the root www directory to find the default index html document Download it to a local computer and view the document in an HTML editor to see the various tags Any HTML document placed in the www directory can be accessed with a WEB browser even if it doesn t contain system variable tags Try to keep custom WEB pages as small as possible with minimal graphics so the WEB updates don t impact the servo controllers update speed The WEB server is shared by the servo controller so high cyclic updates will be impacted by the large WEB updates Note Be careful when accessing data using FTP data files can eas
108. ter The table below represents the values that can be written using this command System Variables Index Variable Waveform Generator Output Setpoint Cycle Counter Current PID Proportional Value Current PID Integral Value Current PID Differential Value Control Channel Current waveform type Actuator State 10 Actuator Rate 13 Waveform Pause 23 Setpoint Slew Time seconds 36 Constant Amplitude Control 0 Disable 1 Enable VD GO A Ch LN P L HA ra Channel Variables x 1 for load 2 for stroke or 3 for auxiliary channel Index Variable x 01 Range x 02 Offset x 03 Filter x 04 Units x ll Max limit x 12 Min limit x 13 Limit action x 14 Max Loop limit x 15 Loop limit action x 16 Limit unload value x17 Loop error unload value x 18 Channel PID Proportional x 19 Channel PID Integral x 20 Channel PID Differential x 38 Control Stop Maximum x 39 Control Stop Minimum Interactive Instruments 5K 10K Servo Creep Controller 68 Waveform Channel Variables x 1 for load 2 for stroke or 3 for auxiliary channel Index Variable x 21 Waveform Amplitude x 22 Waveform Frequency x 23 Waveform Ramp Endpoint 1 x 24 Waveform Ramp Endpoint 2 x 25 Waveform Ramp Rate 1 x 26 Waveform Ramp Rate 2 x 27 Waveform Trapezoid Hold time 1 x 28 Waveform Trapezoid Hold time 2 x 29 Waveform Type x 30 Waveform Envelope Start Time seconds x31 Waveform Envelope Reset Time seconds For example to modify the stroke waveform
109. ters but this was typically when the waveform parameters amplitude setpoint wave type etc are adjusted dramatically manually by the operator In most cases the constant amplitude control does a very good job of matching the waveform parameters as long as they are within the servos performance range Note To minimize the constant amplitude control adjustment errors while significantly modifying the waveform parameters it may be better to temporarily disable the feature change the parameters and wait an appropriate amount of time to stabilize control then re enable Interactive Instruments 5K 10K Servo Creep Controller 21 Cyclic Waveforms Bipolar Bipolar waveforms are cyclic waveforms that start at a setpoint proceed to a peak amplitude positive or negative reverse direction pass through the setpoint to the opposite peak amplitude and then return to the setpoint When selecting bipolar waveforms you must specify the set point amplitude frequency and the starting direction amplitude sign of the waveform Unipolar Unipolar waveforms have the same shape as bipolar waveforms but are offset by the cyclic mean value form the setpoint The cyclic mean is the mean level of the peak to peak amplitude This means that the waveform excursions take place entirely above or below the setpoint This feature is useful when you wish to start your test with a pre load on your specimen then have the specimen load cycling take place entirely above
110. time Continuous current should be kept below 50 to keep the servo from overheating and loosing torque The higher the current the higher the drive temperature and the lower the maximum motor torque If the motor can t supply enough torque the drive will automatically shut down the motor To restore the power to the driver you must cycle the power on the entire system or reset the servo driver error using the System menu Reset Servo Err menu option Temp The temperature is a measured at the servo drives heat sink The higher the temperature the lower the maximum drive capability As the drives temperature climbs 40 C above ambient the motor torque linearly degrades so that 50 C the servo driver is 2 3 the capacity when the drive is at 40 C If the temperature is consistently high be sure the motor isn t over stressed with continuously high loads and verify that the drive fan is not blocked If the load frames main bearing is damaged causing an increased load to the motor it can also cause the drive temperature to increase Monitoring the heat sink temperature is a good indication of the condition of the bearing Status The status line displays the general status of the servo drive Enabled The drive is operating and the motor is under power Disabled The drive is disabled and the motor is not under power The drive can become disabled if the front panel switch is not engaged pressed in or if the servo controller cable is unplugge
111. tings Setup Channels Modify the desired channel parameters The menu prompts with a list of channel configurations The list includes Limit Selection Max Loop Error Digital Filter Display Units Channel Scale and Channel Offset Limit Selection Change the desired channels maximum limit minimum limit and action The channel limits can be used to prevent the actuator from extending beyond a programmed limit whether the channel is the current control channel or not When a limit is tripped an action command can be programmed to perform an operation when a limit is reached or exceeded Each feedback channel can have different set of programmed limits and limit actions For example if the controller is in load control and a stroke limit is reached the stroke action is performed and the controller is placed in the stroke limit mode until reset In the same example if a load limit is tripped while in load control the load limit action is performed When the servo controller is powered up and before the actuator is sent to home all limit actions will be automatically set to Ignore Be sure to reprogram the actions back to the desired action before continuing Note Max Min Limits and a loop limits are monitored separately and each feedback channel can have separate actions although each channels min and max limit share the same action A limit is considered enabled when an action other than ignore is selected Once a limit is tri
112. to 100 000 seconds before reaching zero amplitude Each of the three waveform generators can be programmed to have different reset ramp times Pausing the waveform will suspend the reset envelope timer as well but restarting the waveform will restart the envelope timer to zero but start at the current amplitude The reset envelope is only available for cyclic waveforms ramping functions are not impacted by the envelope control Once a waveform is finished resetting the waveform will be placed in End mode Interactive Instruments 5K 10K Servo Creep Controller 22 Ramping Waveforms Single Ramp Ramp waveforms are linear functions which have a ramp rate and an end amplitude The reason it is called an end amplitude instead of an endpoint is because the final control point is the programmed endpoint plus the setpoint which makes it an end amplitude Single ramps do not automatically return to the setpoint To return back to the setpoint as fast as the actuator allows use the waveform Reset function Select the finish command to set the setpoint to the current control point setpoint ramp control and the ramp control is set to zero This in effect establishes the end of the first ramp as the start of a second ramp Note The direction of the ramp towards tension or compression is denoted by the sign of the amplitude Dual Ramp A dual ramp is a conjunction of two ramps of differing slope and end amplitudes The reason it is called an en
113. tpoint value Since the trapezoid waveform is offset by the setpoint the trapezoid starts from the setpoint and ramps to the amplitude plus the setpoint and begins the first hold The second segment ramps back to the setpoint for the second hold Note The direction of the trapezoid towards tension or compression is denoted by the sign of the amplitude Interactive Instruments 5K 10K Servo Creep Controller 23 External Control An external waveform can be controlled using the analog voltage on the AUX input channel Selecting the External Control waveform will prompt for the maximum range of the AUX waveform control For example to program a 0 to 10 volt signal for 0 to 2000 lbs program the External Range to 2000 This range will be programmed into the AUX channel range so the AUX feedback will be used as the external waveform value The AUX channel will be read 1000 samples per second and the value will be used as the waveform value to be added to the current setpoint Since the external control signal is a waveform command it is added to the current setpoint so if you would like the AUX channel to control the load exactly make sure the setpoint is set to zero so the waveform output is the same as the control point Be sure to start the waveform to enable the external waveform control You can also pause the waveform by pressing the On the keypad which will suspend the waveform update and maintain the last value The External C
114. trip can be reset individually or reset at a later time Note Be sure any control loop actions are reactivated prior to restarting a test Interactive Instruments 5K 10K Servo Creep Controller 33 Digital Filter A low pass digital filter can also be programmed to filter out analog noise Setting a high filter value 80 Hz allows the controller to report fast changes to the feedback channels but the digital feedback reflects more analog noise High level of electrical noise can impact the peak detectors and possibly record and trip a false peak at times Lowering the filter value 5 Hz or lower reduces the noise and increase the feedback resolution but the feedback can be slow to the control response The controller uses the filtered feedback values for display purposes and for recording peak values The servo controller uses pre filtered feedback values for control purposes so the digital filter will not impact control characteristics This allows the use of maximum filtering without having to worry about inducing control oscillation Note The digital filter is a simulated single pole filter so the filter frequency is attenuated by 3db at the selected frequency For example setting the filter to 1 Hz will reduce a 1 Hz feedback waveform by 3 decibels or reduce the amplitude by a factor of SQRT 2 2 or about 70 which is actually half the energy Higher frequencies will be attenuated at 20db per frequency decade power of 10 For example if th
115. tuator Access the actuator menu F4 Control Toggle between load and stroke control F5 Channels Setup channel menu F6 System System menu F7 Limits Limit menu F8 Feedback View feedback display F9 Max Min View current control channel Max Min 0 00002 in 7000 7 1b 0 0000 0 INTERACTIVE INSTRUMENTS Menu ol gene Waveform Actuator Control Setup Channel System Display Servo System Feedback Max Min Servo10_103 Remote Keypad Interface Application Note Be careful when operating the servo load frame remotely if an operator is making changes locally they can be seriously hurt if the controller behaves unexpectedly Interactive Instruments 5K 10K Servo Creep Controller 49 Note You can dedicate an icon to the Windows desktop to one specific servo controller This can be done by changing the properties of the Windows application or shortcut icon Right click on the icon and select properties Next to the application target ServoRemote exe enter the IP address of the servo controller For example C AppPath ServoRemote exe 192 168 123 200 If the servo controller is available it will be the default controller for the app on startup Press Find to find the other controllers on the same subnet iPhone Application A free application is also available through Apple iTunes store which will allow you to remote operate the servo controller from your iPhone i
116. uires the channel number 0 load 1 stroke 2 auxiliary Reading the channel range returns the maximum value allowed by the channel Writing the channels range will program the data channels maximum value Adjusting the channel ranges does not affect the analog voltage output only the digital scaling factor Note Since the stroke channel is fixed digitally stroke range is not adjustable Reset Total Max Min s H Read Max Min s h Reset the total peak readings to the current feedback value or read the total and cycle peak readings for the specified channel The controller continuously monitors the filtered load stroke and filtered auxiliary feedback values 1000 times a second Any time a value exceeds the currently stored value the new value is recorded in its place Cycle peaks are maintained on a cycle by cycle bases Once a cycle completes determined by the waveform generator the current cycle peak results are saved and the current peak detector is reset to the current feedback values This method requires two sets of registers The first set used to establish the current cycle peaks and the second is used to display the previous cycle peak results once the cycle is complete To read the current peaks send the command hn where n is the desired feedback channel The controller responds with 4 numbers The first two are the overall max and min values since the waveform was started or the H command was sent The second two are the peaks
117. units 403 Stroke with units 404 Aux with units 405 Load Units 406 Stroke Units 407 Aux Units 408 Control Channel 409 Network IP Address 410 Network MAC address 411 Network Subnet Mask 412 Network Gateway Address 413 Network host name 414 Last Limit Trip 415 Last Limit Action 416 Actuator State 417 Setpoint Other internal system variables can be accessed as well for diagnostics 500 899 The Copley Servo drive parameters can be read using this command Servo parameters can be accessed at any time Refer to the Copley XPL 230 manual for a list of these parameters and the units associated with them To isolate the servo drive parameters from the system and channel parameters the servo drive parameters are numbered 1000 and up For example to access the temperature parameter XPL 230 drive parameter 32 Interactive Instruments 5K 10K Servo Creep Controller 66 issue the command j1032 lt CR gt and the servos heat sink temperature in degrees C will be returned These commands will require serial communication with the servo drive so they may be slow to respond to numerous commands Note Ifa parameter can t be accessed because it is an invalid ID or the servo drive serial cable is disconnected the software will return nan for not a number Interactive Instruments 5K 10K Servo Creep Controller 67 Write system and channel value J Writes to a selected system or channel internal values and servo drive parame
118. up After selecting this menu item the software will request 1 to confirm operation Reset Sys Stroke If the actuator position becomes out of sync with the display values this feature will enable the operator to program the controller s stroke position to match the actuator The preferred method is to re initialize the actuator by disconnecting the specimen cycling the controller s power Sometimes it isn t possible to re initialize the system due to test setup so we included an option to manually configure the actuators position relative to the frame Care should be taken when programming the position because the actuator has no way of properly verifying its position unless it locates the home switch upon power up Programming the position with an incorrect value may cause the actuator to run out of room on one end and possibly overdrive the actuator at the other end Neither cases will harm the actuator the only problem may be that system will lose power and release the load The actuators position is programmed by measuring the distance between the top of the actuator and the highest possible actuator position and entering this value For example if the actuator is about 3 4 from the upper position then program 0 75 into the system stroke and the actuator will now know it is 3 4 from the upper end not including for the stroke offset Select Reset Sys Stroke from the setup menu displays the following Enter Position Def 2 5000
119. uration is automatically set based on the current waveform frequency and the number of segments in the file For example loading a 10 segment waveform with the waveform frequency set to 0 125 hz will program each segment time to 0 8 seconds 1 0 0 125 10 0 8 sec so the waveform cycles every 8 seconds Simple waveforms can be loaded by using a file of amplitude values one entry per line and the servo controller calculates each segment time automatically This way complex waveforms can be easily loaded by using a simple list of amplitudes Waveforms are loaded using USB flash memory drives The waveforms are stored in a text file with the extension WAV and are loaded into the controller when Programmable Wave is choosen and the waveform file is selected The waveform file should be saved to a USB flash drive then plugged into one of the two USB connectors on the bottom of the servo controller Once a waveform file is loaded into the controller the USB flash is no longer needed and can be safely removed Any further changes to the waveform are performed on the locally controller copy Note You can use a standard USB extension cable to extend the USB port to a more convenient position Multiple waveforms can be stored on the USB device at one time the waveform menu interface will display a list of WAV waveform entries for you to select between When a waveform is loaded which is found to have programmed segment times the waveform fre
120. values can be reset to 0 by pressing the period key Resettable with Stroke 1 2 Cycles 13 Time 0 5 hr To view the non resettable values press the down arrow and to return to the resettable values press the up arrow Note the display also prompts with the Set value which should represent the day the total parameters were zeroed for the first time Set 5 24 2012 Stroke 8743 9 Cycles 1543 Time 196 6 hr Press the Menu key to return to the run time display Lock Remote Key Selecting this option will lock all remote keypad entries preventing remote applications from controlling the servo controller Remote applications can still monitor the status of the controllers display in real time but any key commands are ignored To reactivate the remote keypad access reselect Lock Remote Key option and remote keys are accepted Note This option is restored to unlock on power up Interactive Instruments 5K 10K Servo Creep Controller 43 Feedback Display The feedback display contains the typical information an operator would like to view while the controller is in operation It provides the current setpoint value and units actuator and waveform generator status waveform output sign feedback output values for load stroke and auxiliary along with the current cycle count The display also graphically displays the load cell feedback in the form of a bar graph for a quick visual feedback of the load frame loading condition First

5K/10K Servo Creep Controller - Interactive Instruments, Inc.

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