STACIS
Piezoelectric Active Vibration
Isolation System
2100
INSTALLATION &
OPERATION
MANUAL
TECHNICAL MANUFACTURING CORPORATION
15 CENTENNIAL DRIVE
PEABODY, MA 01960
USA
Tel: 978-532-6330 Fax: 978-531-8682
Website: www.techmfg.com
Document P/N 96-28765-01 Rev. N
STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
TABLE OF CONTENTS:
.......................................................................................................................1
1 Principle of Operation ............................................................................................ 5
2 General Information................................................................................................ 6
2.1 Introduction .....................................................................................................................................6
2.2 Product Selection............................................................................................................................ 6
2.3 General Specifications.................................................................................................................... 7
2.3.1 Performance ............................................................................................................................7
2.3.2 Physical Dimensions ............................................................................................................... 7
2.3.3 System Requirements ............................................................................................................. 7
2.3.4 Environmental.......................................................................................................................... 7
2.3.5 Floor Requirements ................................................................................................................. 7
2.3.6 Utility Requirements ................................................................................................................ 7
2.3.7 Terminology Defined ............................................................................................................... 8
3 Installation............................................................................................................... 9
3.1 Introduction .....................................................................................................................................9
3.2 Unpacking System.......................................................................................................................... 9
3.3 Floor Surface Requirements......................................................................................................... 10
3.4 Installation Spacer ........................................................................................................................11
3.5 Payload/STACIS Interface.......................................................................................................... 12
3.6 Earthquake Restraints ..................................................................................................................12
3.7 Isolator Orientation and Cable Connections................................................................................. 12
3.8 Detailed Mechanical Installation Steps (Pre-Power Up)............................................................... 14
3.9 Initial Power Up and Load Adjustment .........................................................................................15
4 System Initialization ............................................................................................. 19
4.1 Pre-Operational Self-Testing (POST)........................................................................................... 19
5 Menu Driven Functions ........................................................................................ 22
5.1 Menu Tree: ...................................................................................................................................22
5.2 Navigating the Menu Function Tree .............................................................................................22
5.3 Description of Menu Tree Functions............................................................................................. 26
5.3.1 Monitoring X, Y, or Z Signals................................................................................................. 26
5.3.2 Monitoring Isolator Loads ...................................................................................................... 26
5.3.3 Shaker Mode ......................................................................................................................... 26
5.3.4 System Diagnostics ............................................................................................................... 26
5.3.5 Adjust X/Y/Z Gains - Gain Adjustment .................................................................................. 27
5.3.6 Axis Enable/Disable .............................................................................................................. 27
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STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
5.3.7 Sat./Osc. (Saturation/Oscillation) Control ............................................................................. 28
5.3.8 LF/HF Alarms ........................................................................................................................ 29
5.3.9 Select Number of Isolators. ................................................................................................... 30
5.3.10 Set Powerup Test ..................................................................................................................31
5.3.11 Restore Defaults.................................................................................................................... 31
5.3.12 Save Parameters................................................................................................................... 31
6 Downloading New Software:................................................................................ 32
7 Appendix A: DC-2000 Controller Overview ....................................................... 35
7.1 Controller Performance Specifications ......................................................................................... 35
7.2 Controller Front Panel................................................................................................................... 35
7.3 Controller Back Panel ...................................................................................................................35
7.4 System Status LED and Alarm Relay........................................................................................... 36
7.5 The DI/O Interface ........................................................................................................................36
7.6 Connector Pinouts ........................................................................................................................37
8 Appendix B: Using TMC Analyzer to Collect and Upload Data......................... 42
List of Tables & Figures
Figure 1: Vertical and Horizontal Transmissibility for STACIS 2100..........................................................5
Figure 2: STACIS Isolator ............................................................................................................................9
Figure 3: STACIS 2100 Isolator Dimensions .............................................................................................10
Figure 4: Installation of STACIS on Uneven or Sloping Floor..................................................................11
Figure 5: Payload/STACIS Interface Configurations................................................................................ 12
Figure 6: Four Isolator System with Cables ...............................................................................................13
Figure 7: Three Isolator System with Cables .............................................................................................13
Figure 8: STACIS Base Pad ......................................................................................................................14
Figure 9: Wedgemount Access Hole .........................................................................................................18
Figure 10: Load Adjustment Tool............................................................................................................... 18
Figure 11: The Menu Keys......................................................................................................................... 22
Figure 12: Example of Using the Menu Keys............................................................................................. 23
Figure 13: Detailed Menu Structure for STACIS 2100.............................................................................. 24
Figure 14: DC-2000 Digital Controller – Front Panel .................................................................................35
Figure 15: DC-2000 Digital Controller – Rear Panel.................................................................................. 35
Figure 16: Digital Inputs and Outputs Schematic ...................................................................................... 37
Figure 17: AUX Power Connector – Pin Identification ...............................................................................39
Table 1: STACIS Standard Configurations ................................................................................................6
Table 2: Terminology Used in the Manual ...................................................................................................8
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Table 3: Typical Shipping Crate Contents ...................................................................................................9
Table 4: Load Sensor Calibration ..............................................................................................................17
Table 5: Alarm Conditions .......................................................................................................................... 30
Table 6: Digital Input/Output DB-37 Connector Pinout: .............................................................................37
Table 7: Analog Input/Output Channels 0-7 DB-37 Connector Pinout: .....................................................38
Table 8: Analog Input/Output Channels 8-15 DB-37 Connector Pinout: ...................................................38
Table 9: AUX. Power Interface Connector Pinout: ..................................................................................... 39
Table 10: COM1& COM2 Pinouts............................................................................................................... 40
Table 11: Summary of Serial Port Commands ...........................................................................................41
Symbols Used in this Manual
Symbol Purpose Symbol Purpose
Warning / Caution
Reminder
Important Information or
Notes
Warning:
No user-serviceable parts inside isolators or controller.
If the system fails to perform as specified, please contact TMC for
repair or service.
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STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
1 Principle of Operation
STACIS is a high-bandwidth, high-gain active vibration isolation system. It provides very high vibration
isolation performance without introducing a low-stiffness isolation system (such as traditional air
isolators). The high-stiffness “hard mount” feature of STACIS provides excellent position stability and
low susceptibility to external noise forces, giving facility engineers and researchers flexibility in locating
equipment in the manufacturing and laboratory area.
The STACIS system is based on a central controller with three or more individual isolators. Each
isolator contains three axes of active isolation (X, Y, and Z). When three or more isolators are combined,
the result is full six degree-of-freedom vibration isolation for the supported payload. Although at first
glance the system seems over-constrained, the patented topology of STACIS allows the isolators to act
independently of each other without conflict. Installation generally requires no special tuning, and once
installed the system is maintenance-free.
Each STACIS isolator contains a small “intermediate mass” supported in three axes by a set of five
piezoelectric (PZT) actuators. Three seismic sensors measure the translational motions of this mass.
This signal is filtered and fed back to the PZTs by a high voltage amplifier (HVA). A ~20Hz, highly
damped rubber isolator (also internal to the isolator) couples the intermediate mass to the supported
payload. The active feedback loop provides isolation between 0.6 and 150Hz, with a peak in isolation
around 10Hz. As the active isolation starts to reduce above 10Hz, the passive isolator takes over. An
example of the resulting vibration isolation performance is shown below1:
Figure 1: Vertical and Horizontal Transmissibility for STACIS
TMC’s DC-2000 Digital Controller is used to implement sophisticated non-linear feedback algorithms.
These ensure the isolation system performs well in extreme circumstances such as deep saturation and
1
The horizontal and vertical transmissibility was measured on a special shaker table with micron-level input. The isolated mass
was granite. Actual performance will vary depending on the nature of the floor and payload.
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2100
STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
marginally suitable installations. The result is a truly ‘plug-and-play’ system. The digital controller also
allows for monitoring the system over a standard RS-232 interface.
2 General Information
2.1 Introduction
STACIS 2100 typically consists of three, four, six or eight floor-mounted Isolators systems. The isolators
are made primarily of aluminum, weighing approximately 34 kg (75 lbs.) each. Each Isolator contains
electronics, vibration detection and correction devices, along with a passive isolator and an adjustable
wedgemount for load distribution. A digital Controller calculates vibration compensation signals for each
individual axis in each Isolator and provides communications and diagnostics.
2.2 Product Selection
TMC can provide on-site surveys to determine the suitability of STACIS for a particular installation. The
survey includes:
• Vibration measurements to determine if the proposed site’s floor noise is within the dynamic
capability of STACIS .
• Evaluation of the potential benefits derived from the installation of a STACIS system.
• The suitability of the floor for installation of STACIS (see following sections for details).
• The proper selection of the number and capacity of STACIS isolators.
• Whether the subject payload can be mounted directly on STACIS Isolators or if ‘risers’, bridge
plates, or other fixtures will be required.
The selection of the appropriate STACIS System is based largely on the load that each Isolator will be
required to support. When calculating this load, all supported weight (tool plus platform, etc.) must be
considered.
STACIS 2100 isolators are available in three load ranges, designated by a “dash number” after the
primary part number (-01, -02, or –03). The (-01) load range is 400-1100 lbs., the (-02) is 900-2100 lbs.,
and the (-03) is 1900-4500 lbs. The table below provides a quick reference to total payload weights using
multiple isolators:
Table 1: STACIS
Reference Load Range per Isolator (operating) Min./Max Total Load (operating)
Standard Configurations
3x Isolator -01 400-1100 lbs. (182-500 kg) 1200-3300 lbs. (546-1500 kg)
3x Isolator -02 900-2100 lbs. (410-955 kg) 2700-6300 lbs. (1230-2865 kg)
3x Isolator -03 1900-4500 lbs. (864-2045 kg) 5700-13500 lbs. (2592-6135 kg)
4x Isolator -01 400-1100 lbs. (182-500 kg) 1600-4400 lbs. (728-2000 kg)
4x Isolator -02 900-2100 lbs. (410-955 kg) 3600-8400 lbs. (1640-3820 kg)
4x Isolator -03 1900-4500 lbs. (864-2045 kg) 7600-18000 lbs. (3456-8180 kg)
6x Isolator -03 1900-4500 lbs. (864-2045 kg) 11400-27000 lbs. (5184-12270 kg)
8x Isolator -03 1900-4500 lbs. (864-2045 kg) 15200-36000 lbs. (6912-16360 kg.)
Care must be used in selecting the system so that the maximum and minimum load for
each isolator is not exceeded. STACIS 2100 Systems with mixed isolator capacities are
also available. Contact your sales engineer or TMC for further information.
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2.3 General Specifications
2.3.1 Performance
Active Degrees of Freedom (system of 3+ isolators) ...................................................................................6
Active Bandwidth......................................................................................................................0.6 to 150 Hz
Transmissibility at Resonance ............................................................................................................... <1.1
Isolation above 2Hz.............................................................................................................................. >90%
Settling Time2 (10 lb. Step input) .....................................................................................................<300 ms
Dynamic Range........................................................................................................................... 60 dB Max.
Static Load Capacity/Isolator ........................................................................... 182-2045 kg (400-4500 lbs.)
Number of Isolators / system ......................................................................................................... 3 or more
Maximum Displacement ................................................................................15 µm peak-peak below 10 Hz
Maximum Static Load (non-operating)............................................................................2727 kg (6000 lbs.)
2.3.2 Physical Dimensions
DC-2000 Controller ...............................................482.6mm(19”)W x 368.3mm(14.5″)D x 44.5mm(1.75”)H
..........................................................(1 Standard RETMA unit w/rack mounting holes)
Isolator Size ..........................................300mm(11.75”)W x 320mm(12.5”)D x 277mm(10.9”)H (unloaded)
2.3.3 System Requirements
2.3.4 Environmental
(refer to EN 61010-1: 1993, EN 61010-1/A2: 1995):
For indoor use only, up to an elevation of........................................................................... 2,000m (6560ft.)
Maximum allowable operating temperature range:.............................................. 10°C to 32°C (50 to 90°F)
Maximum allowable storage temperature range:.............................................-40°C to 55°C (-40 to 130°F)
Maximum allowable humidity .................................................................. 53% up to 40°C, (20°C dew point)
Tolerance in mains supply voltage.......................................................................+/-10% of nominal voltage
Over voltage category ..................................................................................................................................2
Pollution degree (IEC 664) ...........................................................................................................................2
Controller ventilation requirements .................................. 25mm clearance on sides, 0mm top and bottom
2.3.5 Floor Requirements
Flatness....................................................................................... +/- 1.5 mm from perfect plane at isolators
Stiffness (low load isolators) .............................................................................4.4x107 N/m (250,000 lb./in)
Stiffness (medium load isolators).......................................................................6.2x107N/m (350,000 lb./in)
Stiffness (high load isolators)...............................................................................8x107 N/m (450,000 lb./in)
2.3.6 Utility Requirements
Mains Power Supply ...............................................................90 – 230VAC, 50 or 60 Hz, less than 400VA
Computer (optional) ........................................................... PC compatible w/ a 1:1, M-F, DB-9 serial cable
2
Settling time is defined as the time required for the oscillation amplitude to decrease by 90% from the initial peak amplitude
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2.3.7 Terminology Defined
Terms specific to the STACIS isolation system and its operation are listed below for your convenience.
Table 2: Terminology Used in the Manual
Term: Meaning:
STACIS
Isolator
Iso
Controller
Actuator
Fault
Active
Bandwidth
Flash Memory
Compensation
Resonant
Frequency
Geophone
POST
Wedgemount
From the word stasis meaning a stable state
A single load-bearing mount providing three axes of active vibration isolation,
connected to a central controller. Three or more isolators are required for a
complete isolation system.
Interchangeable abbreviation for the Isolator
The central control and power supply unit with a menu-driven interface
A piezoelectric ceramic device used as the actuator in STACIS isolators
A system condition which compromises the vibration isolation performance of
one or more STACIS isolators. Depending on the condition, the Controller
will generate a message on the LCD. The LED on the controller will turn
amber, a message may be sent over the serial port interface, and the axis
where the error was detected may be switched off.
Range of frequencies covered by the active vibration isolation. A passive
isolator built into STACIS provides isolation above the active bandwidth.
Nonvolatile memory in the controller. It contains the STACIS software and
user-set parameters, such as gains and other preferences.
An action by each Isolator to isolate/dampen vibrations that affect the payload
supported by STACIS
The frequency at which a system will oscillate at when given an impulse (such
as a jump on the floor). This may be electronic (from the servo), or a passive
structural resonance.
The vibration sensor used for active isolation in STACIS
Power On Self Test. A self test conducted every time the power to the
controller is turned on.
A machined low profile adjustable mount inside each isolator used to adjust the
load distribution between isolators in a system with at least 4 isolators.
Wedgemounts have limited travel and are not intended to be used to level the
platform and/or payload.
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STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
Isolator Part Number
Lift here (diagonal)
3 Installation
3.1 Introduction
STACIS 2100 systems are shipped FOB from Peabody, MA, in wooden crates measuring 1220 x 838 x
584mm (48” x 33” x 23”). The crates weigh 175kg (385 lbs.) for a 3-Isolator system, or 209kg (460 lb.) for
a 4-Isolator system. Six and eight isolator systems are shipped in two crates of the same size. The
crates have indicators to show if the crate was subjected to excessive shock, tilt or vibration during
shipment. Check the sensors, and inspect the crate for gross damage (punctures, etc.). DO NOT
remove the contents from the crate if the damage indicator is broken or if the crate or contents are
damaged. The carrier and TMC should be notified immediately, and a claim should be filed with the
carrier. The carrier is responsible for all shipping damages and all claims for damages must be made
against the carrier. Typical crate contents are:
Table 3: Typical Shipping Crate Contents
Quantity
3-Isolators
Quantity
4-Isolators
Description
1 1 Controller
3 4 Isolator
1 2 Main Double Cable
1 - Main Single Cable
3 4 Base Pad (Mylar sandwich)
1 1 AC Power Cord
1 1 STACIS Load Adjustment Tool
1 1 Software and User’s Manual (this document) on CD
3.2 Unpacking System
Remove the Isolators, Controller, and cables from the packing crate (see lifting note in figure 2 below).
Move all components to the installation site prior to performing the following steps.
Isolator Cable
Connect or (DB25)
Maximum Capacity
(1100, 21 00, or 4500 lb.)
Top (Load
Disk)
Shipping Latch
(each side)
and Serial Number
Isolator Number
(installation position)
HVA Cable
Connect or (DB9)
High Voltage
Amplifier (HVA)
HVA Power Lamp
Figure 2: STACIS Isolator
Page 9 of 43
Wedgemount
Access Hole
or from base
Base
STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
Isolators weigh 75 lbs. (34 k
g) each and require two persons to lift safely.
FRONT VIEW
SIDE VIEW
Connector
Connector
PLAN VIEW
Access point for
78 (20) 2 places
3.5 (89)
6.63”
(168)
Connector
Ø
1.86 (48)
•
•
Lift only by the four caps on the sides or the base.
•
Isolators must never be lifted by the load disk.
•
Failure to adhere to the cautions above will result in potentially permanent
damage to internal components.
0.
12.83 (329) typ.
1.05 (27),
2 places
internal leveling jack
11.00
(280) Ø
10.82
(275)
11.75
(300)
•
Dimensions shown in inches (mm).
•
The nominal unloaded height will be decreased
by the static deflection and creep in the internal
elastomer mount. The static deflection is
approximately 0.14” (3.5mm) at full load, and
the mount will creep 0.008” (200µm) in the first
100 hours, and an additional 0.002” (50µm)
after 1,000 to 10,000 hours.
12.50
(320)
Figure 3: STACIS 2100 Isolator Dimensions
3.3 Floor Surface Requirements
•
Please also refer to “Pre-Installation Manual” for detail of floor requirements and
riser installation.
•
Contact TMC for set-up training specific to your application.
1) STACIS 2100 should be installed on a concrete floor and not on a raised computer floor. If the
concrete floor is flat within .02” (.5 mm) over the area of the isolator and level so that each
isolator location is at the same height within .12” (3 mm), the isolators can be installed directly
on the floor. The isolator base contacting the floor has an area of 64 in² (.04 m²). If the floor is
not flat and level, and at the same height within .12” (3 mm), steel plates 13” x 13” x 0.5” thick
(330 x 330 x 12 mm thick) should be grouted to the concrete floor level within 0.010”/ft. (.8
mm/m) and the same elevation within .06” (1.5 mm). See Appendix A in Pre-Installation
Manual for detailed information on measuring the floor flatness, grouting, waffle floors, and
vibration measurements. If isolators will be installed on risers for increased elevation, see also
appendix B in Pre-Installation Manual as the floor flatness and level requirements are nullified
in this case. Remove any burrs or high points on the surfaces where the STACIS isolators will
be placed.
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G
rout or epoxy, typical ½” thick
Uneven/sloping floor
2) STACIS should only be installed on floors having a minimum stiffness (in all axes) as specified
here. Risers and stands can be used under STACIS isolators, providing the stand-to-isolator
interface also meets the same stiffness requirement.
Isolator Load Minimum Interface Stiffness
Low load (-01) 250,000 lbs/in. (44 x 106 N/m)
Medium load (-02) 350,000 lbs/in (62 x 106 N/m)
High load (-03) 450,000 lbs/in (80 x 106 N/m)
3) STACIS has a maximum displacement of 480 µ” (12 µm) peak-peak or ± 240 µ” (6 µm) at
frequencies below 10 Hz. At frequencies above 10 Hz, the maximum displacement decreases
as the frequency increases.
4) The maximum peak-peak broadband displacement of the floor in each axis under all conditions
(vibration plus displacements due to walking, etc.) must be less than 480 µ” (12 µm). If the floor
exceeds 480 µ” (12 µm) of displacement, one or more channels of the STACIS isolators may
overload and isolation may be briefly lost. If it is known, or suspected, that the floor exceeds
the maximum displacement, consult with TMC.
A maximum floor displacement of 400 µ” (10 µm) is recommended to provide a
safety factor due to the fact that walking frequently produces non symmetrical
displacements which can exceed the displacement in only the + or - direction
even though the peak to peak displacement may be within the limit.
3.4 Installation Spacer
If steel plates as noted above will be used, fabricate a temporary wooden spacer for each Isolator with
dimensions of 150x150x290mm (4”x4”x 12.25”). If base plates will not be used, or if risers will be used to
increase the operating height of STACIS, calculate the correct height for the spacer blocks. These blocks
will support the payload (or platform) and provide a 0.25” clearance above the isolators to avoid shocking
the isolator and to also while minimize excessive wedge loading; both of which can lead to overloading
and damage of the isolator (see installation steps in section 3.8).
Mechanical jacks with an adequate load capacity can be used in place of the spacers, providing the jacks
do not leak or drift downward under load. Professional rigging is required in most cases.
Four spacers need to be used to support
the platform during installation. These can
be wood or hydraulic jacks
Payload interface plate
Steel plates grouted to the floor to
form a level and coplanar mounting
surface for the isolators
Figure 4: Installation of STACIS
on Uneven or Sloping Floor.
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STACIS 2100 WITH 3
ISOLATED
•
If using non-adjustable spacers, a bottle jack or jack stand is needed to slightly offload and remove the spacers.
•
Professional rigging is recommended
3.5 Payload/STACIS
Interface
In some instances, the payload can be installed directly on the top surface of the Isolators. This is
determined during the vibration survey and engineering analysis discussed in 2.2, or through information
supplied to TMC. If the payload has more than four points of support, or if the support points do not
completely cover the top surface of each Isolator, an interface plate will be needed. Some suggested
configurations are shown in Figure 5.
CRADLE
BASE
ISOLATED
ISOLATED
MACHINE
INSTALLATION OF
MACHINE DIRECTLY
ON STACIS 2100
WITH 4 ISOLATORS
Figure 5: Payload/STACIS
MACHINE
INSTALLATION OF
MACHINE AND BASE ON
STACIS 2100 WITH
4 ISOLATORS
ISOLATED
MACHINE
LOW HEIGHT
INSTALLATION USING
CRADLE BASE AND
STACIS 2100
Interface Configurations
MACHINE
RAISED
FLOOR
BASE
SMALL MACHINE
AND BASE ON
ISOLATORS
3.6 Earthquake Restraints
In certain areas of the world that are prone to earthquakes, the STACIS system can be provided with the
necessary restraints to minimize or prevent damage to the system and its payload. Contact TMC for
details.
3.7 Isolator Orientation and Cable Connections
STACIS 2100 can also be used as a platform for producing controlled vibration (a shaking platform). For
this function to work properly, the isolators need to be installed in a specific orientation with respect to
each other. This is shown for three and four isolator systems below:
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Iso
#3
Iso
#2
Iso
#1
Iso
#4
Controller
Controller
Iso
#1
Iso
#2
Iso
#3
DC-2000
Double Cable
Front (Connector Access)
shown with arrows
Figure 6: Four Isolator System with Cables
Double Cable
Front (Connector Access)
DC-2000
shown with arrows
Single Cable
Figure 7: Three Isolator System with Cables
•
In STACIS systems built prior to December 2005, the combination of a “Y” cable
and two (2) “single” cables are used instead of a “double” cable. For a 3-isolator
system, the “Y” cable for isolators #1 & #2 connects into the controller’s Analog
Input/Output Channels 0-7 connector.
•
If the system will not be used as a shaker, the isolators may be placed in any
location and orientation that provides the best loading. Contact TMC for a setup
drawing specific to your application.
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Ensure the pickup point of the wooden spacer or jack is 5mm higher than the
top
3.8 Detailed Mechanical Installation Steps (Pre-Power Up)
•
If risers or baseplates will be used, they must be installed with grout a minimum of 12
hours prior to operating the STACIS system. See “Pre-Installation Manual and
Checklist”.
•
Prior to starting the mechanical installation, the installer must confirm the load that
each isolator will be required to support. This can be calculated using the weight of
the payload, its center of gravity (CG), the weight of the platform and the number of
isolators.
•
The installer must ensure that the isolator capacities are properly matched with their
installation locations.
1) Position the STACIS base pads (see figure below) on the riser, baseplate, or floor where the isolators
will be located. Place the isolators on the base pads according to the orientation shown in the figures
above.
Figure 8: STACIS Base Pad
The base pads consist of a soft compound sandwiched between two sheets of Mylar. They
conform to the gap between the bottom of the isolator and the riser, baseplate, or the floor
and thus provide a very solid mechanical point of contact. The base pads are an important
component in the successful installation of the system.
2) Release the Shipping Latches (see Figure 2). This is very important!!! Do not use excessive force
to release latches. If latches are very tight they can be released after isolator is loaded.
3) Place a wooden spacer or jack on the floor next to each isolator to support the payload prior to
lowering it directly onto the isolators (see Section 3.4).
surface of the nearest isolator.
4) Verify that the entire top surface of each Isolator will be in contact with the payload when it is lowered
onto the isolators. Adjust the position of the isolators as necessary.
5) Use the jacks to support the payload within 5mm of the top of the isolators, but not contacting. Recheck the alignment to confirm that the payload will fully cover the top surface of each isolator, and then
lower the payload the final 5mm.
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If using wooden blocks,
•
place a bottle jack between two isolators, centered under one end of the platform,
•
raise the platform slightly, just enough to remove the spacer blocks,
•
then slowly lower the jack in a very controlled manner until this end of the payload is resting on the
nearest isolators.
•
Repeat for the other end.
The 5mm gap prevents excessive wedge loads from being applied to the isolators.
•
Use care to avoid shocking and/or overloading the Isolators. The Isolators can
be damaged if exposed to a load or force (load plus shock) greater than 6000 lbs
(2727 kg).
•
When moving or replacing an isolator, lifting one corner of the payload will
transfer up to 50% of the total weight to the diagonally opposite isolator,
potentially damaging its piezo ceramic stacks. Therefore, always locate the jack
midway between the Isolators on one side rather than just one corner, especially
if the total weight exceeds 10,000 lbs. (4545 kg).
6) Relieve any side-load on the Isolators by slightly raising the payload/plate over each Isolator with a
hydraulic jack thus allowing the Isolator to center itself and then slowly lower the plate on the Isolator.
The high-frequency passive mount in STACIS will cause the isolator height to creep
downward over time. The initial loading will deflect the isolators by up to 0.125” (4 mm).
Within the first week, the isolators may creep down an additional 0.04” to 0.12” (1-3 mm)
depending on the load. The system can be operated during this time; however, the level
of the system may change.
The isolators are equipped with a built-in wedgemount. The wedgemounts provide a
mean to redistribute the loading between the isolators. They are not, however,
intended to be used to level the payload. The stroke of the wedgemounts is very
limited.
The wedgemounts may be used on rare occasions for very small changes to the
payload’s level; however, care must be used to keep the isolator loading adequately
distributed. Adjustments to the payload’s level should be done with shims placed
between the isolators and the supported payload. The use of the wedgemounts for load
distribution is described below.
7) Confirm that the shipping latches on either side of the isolators (quantity 2 per isolator) have been
disengaged.
3.9 Initial Power Up and Load Adjustment
For four (4) STACIS
isolator systems, the loading of the isolators must be adjusted using the internal
wedgemounts [after the installation of the payload] to achieve a distribution within the nominal load range
for all isolators To aid with the load redistribution, each isolator has an electronic displacement sensor
that measures the deflection of the STACIS’ internal high-frequency passive mount. The output of the
sensor can be displayed on the digital controller’s LCD. The sensor readings relate to the load exerted
on the isolators according to Table 4 below.
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•
The sensor reading is not related to the overall height of the isolator.
•
Adjusting the wedgemount in one isolator will affect the displayed value by altering the
load on all isolators, as in redistribution of the load.
•
The reading of the load sensors is not intended for precise measurement. It is simply
an effective method for providing information about the relative load distribution
between the isolators.
For three (3) isolator STACIS
systems, the wedgemounts cannot be used to adjust loading of the
isolators. Follow the steps below to monitor isolator loading. If the isolators are not properly loaded, their
installation location must be changed until each isolator is within its proper load range.
8) Connect the Main Cables between the Controller and Isolators as illustrated in Figure 6 and Figure 7.
•
The main cable connectors are labeled at both ends to indicate controller and
isolators connection points.
•
At the isolator end, the cable forks, with one connector going to the top of the
isolator (DB25), and a second (DB9) going to the High Voltage Amplifier (HVA).
•
Do not connect the cable to the high voltage amplifier in the base of the
isolator at this time. These cables (which power the active isolation) should only
be connected after the load adjustment procedure is complete.
•
Any excess length of the cables could be coiled.
9) Connect the Controller’s AC Power Cord to an appropriate AC power source (110-230 VAC).
10) Switch the Controller’s Main Power ON (rocker switch on the left of the front panel). Note: The LCD
backlight and System Status LED will light.
11) The system will perform an automatic Power-On Self Test (POST). The LED will turn amber and the
following message will display on the LCD:
S T A C I S 2 1 0 0
P o w e r - U p S e l f T e s t
This test will last approximately 60 seconds.
At this point of the installation, the POST will find that all axes are “out of range”. This is
because the HVA cables are not connected. This is normal.
Throughout the test, the controller’s LCD will show error messages like:
1 Z a x i s N o t O p t i m i z
d G = - 7 0 . 5 d B d P = - 4 5 º
Upon completion of the test, the System Status LED will turn green and the LCD will show a message
indicating the “not optimized” condition for the last axis tested.
12) Press the switch PREVIOUS on the controller’s front panel repeatedly until the following message is
seen on the LCD:
T M C S T A C I S 2 1 0 0
p n 9 5 - 2 8 7 5 6 - 0 1 R e v #
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13) Press the “+” switch repeatedly until the following message is seen:
+ / - S e l e c t s F u n c t i o n :
M o n i t o r L o a d S e n s o r s
14) Hit the “SELECT” switch. The following LCD screen will be shown:
The controller should have been configured at the factory to the correct number of
isolators (2, 3 or 4). If not, (typically when the controller is shipped as a replacement)
the display may not show the correct number of readings. If this is the case, refer to the
Menu Driven Functions in the Section 5 for instructions on how to configure the
controller for the correct number of isolators.
The displacement (deflection), in mm, displayed for each isolator is proportional to the load compression
of the isolator’s internal high-frequency elastomer mount. The table shows the corresponding load range
in lbs or kg based on range of deflection.
LOW LOAD (-01) ISO. MED. LOAD (-02) ISO. HIGH LOAD (-03) ISO.
LOAD lbs. (kg) DEFLECTION (mm) DEFLECTION (mm) DEFLECTION (mm)
400-600 (180-270) 2.2-2.8 * *
600-900 (270-410) 2.8-3.6 * *
900-1100 (410-500) 3.6-4.5 2.2-2.5 *
1100-1500 (500-680) 2.5-3.5 *
1500-2100 (680-955) 3.5-4.5 *
1900-2100 (865-955) 2.2-2.5
2100-2500 (955-1135) 2.5-3.0
2500-3200 (1135-1455) 3.0-3.3
3200-3800 (1455-1730) 3.3-3.8
3800-4500 (1730-2045) 3.8-4.5
•
Readings less than 2.2 mm may be an indication of an under-loaded isolator, whereas
readings greater than 4.5 may be an indication of an over-loaded isolator.
•
For proper loading, each isolator should have between 2.2 and 4.5mm deflection. If an
isolator is loaded outside of this range, follow the instructions in the following section to
re-distribute the load. If all isolators are out of this range, please contact TMC.
15) Isolator Load Re-Distribution Using the Internal Wedgemount
For a 3-isolator system, if the isolators are not properly loaded, their installation location
must be changed until each isolator is within the proper load range specified above. The
loading of the isolators should not be adjusted using the internal wedgemount.
If proper loading cannot be achieved, a different load capacity isolator may need to be
purchased to correct the problem.
I s o 1 : 2 . 6 I s o 2 : 2 . 8 m m
I s o 3 : 2 . 7 I s o 4 : 2 . 4 m m
Table 4: Load Sensor Calibration
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When performing the load adjustment procedure, the cable to the HVA connector
(bottom of the Isolator) must be disconnected.
The following procedure applies only to a 4-isolator system.
A tool is provided for adjusting the loading of the isolators using the wedgemounts. The tool is a 7/16
(11.1 mm) hex rod 5.75” (146 mm) long. There is an oval hole on the side of the top cover of the isolator
where the tool can be inserted to engage the wedgemount. There are three notches on the rod to
indicate the position (height) of the wedgemount. When the tool is fully inserted into the wedgemount, the
position of the notches relative to the outer surface of the isolator indicates the height as follows:
Figure 9: Wedgemount Access Hole
Figure 10: Load Adjustment Tool
Tool Notch Location Relative to
Isolator Outer Surface
Inner notch is flush fully down (minimum usable height)
Center notch is flush mid height position
Outer notch is flush fully up (maximum usable height)
Wedgemount Position
To adjust the load on the isolators, proceed as follows:
A) Confirm that all of the wedgemounts are at their mid height position.
B) Depending on the displacement reading (refer to the previous section on displaying the reading on
the controller LCD), increase the loading of the isolators by turning the tool clockwise (the
displacement value increases)) or decrease the loading by turning the tool counterclockwise (the
displacement value decreases) until all isolators are loaded within the proper displacement range for
the weight of the supported payload
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Prior to initial power
-
up, confirm the room environment is within a tempe
rature
Mechanical Installation is complete.
•
Ensure the difference in the displacement readings is kept to a minimum. For
example, on a symmetric payload supported by 4 isolators, the isolators along one
diagonal should not be loaded more than those on the opposite diagonal.
•
Adjusting the wedgemount on one isolator will change the load on all isolators.
•
If adequate adjustment cannot be achieved with the wedgemount, aluminum or
stainless steel shims, maximum one (1) per isolator, of approximately 10” x 10”
(254mm x 254mm) square should be added between the top of the isolator and the
interface plate/payload for the isolators with the less than desired loading.
•
Similarly, if the platform is not level as desired, shims must be used to change the
level. Measure the height of the platform at the corners to calculate the height
difference at each isolator. Compensate for the height difference by adding shims
on top of each isolator accordingly. This can be accomplished by slightly jacking
up one end of the platform to add shims to two isolators at a time. When complete,
allow 20-40 minutes for the internal elastomer mounts to settle before rechecking the level. Use 10” x 10” (254mm x 254mm) square shims, maximum one
per isolator
16) After the loads are correctly set, turn the controller power OFF, and connect the high voltage
amplifier (HVA) power connectors to the bottom of the isolators.
4 System Initialization
range of 10 °C to 32 °C (50 °F to 90 °F) and the dew point (humidity) is less than
20 °C (68 °F). Allow the STACIS
condensation which could damage the actuators.
4.1 Pre-Operational Self-Testing (POST)
After switching the controller power to ON, the controller will start its boot sequence; the system status
LED will light up red momentarily, then flash green for a few seconds. The controller will then perform a
number of internal self-tests to confirm system performance. The tests last approximately 60 seconds.
This includes a ~25 second warm-up time for stabilizing the analog filters and preamplifiers. Immediately
on power up, the following display will be shown:
T M C S T A C I S 2 1 0 0
P o w e r - U p S e l f T e s t
The system status LED will then change to steady amber as the unit goes through the POST. The
system is not ready for operation until the self-test is successfully completed.
The beginning of the system diagnostics (servo-loop) tests is indicated by the following message:
T e s t i n P r o g r e s s
System to stabilize in temperature to prevent
1 Z a x i s
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During
the power-up self test
, isolation, alarms and some control functions are disabled. A test is run
for each axis sequentially. The gain and phase of each channel is measured at a single frequency, to
confirm proper actuator and sensor function. The difference between the measured value and a
reference value is displayed on the LCD as:
@ 5 H z 1 Z a x i s :
d G = 2 . 5 d B d P = 5 º
The values for the last axis checked are displayed until the measurement for the next axis is completed.
After completion of all tests, the LED will turn green, and the LCD will display either:
S T A C I S 2 1 0 0
p n 9 5 - 2 8 7 5 6 - 0 1 R e v #
3 Y a x i s N o t O p t i m i z
d G = - 7 0 . 5 d B d P = - 4 5 º
If the gain and phase of each axis are within the default
values. This screen is called the “title screen”.
Message similar to the one at left if one or more
values are detected to be out of optimal range of the
reference value during the gain/phase
measurements; only the last axis detected to be out
of range will remain on the display. This is called a
“not optimized” message.
Not Optimized Message During POST
Possible situations which may cause this malfunction include:
1. Installations with excessive floor noise level - vibration sensors saturate
due to the combination of high sensor gains and running of the self-test
with servo feedback loop OFF i.e. “open loop”.
To verify if this is the case, connect an oscilloscope to the BNC
connector “ANALOG OUTPUT” on the controller’s front panel and then
monitor vibration sensors’ readings during the pre-operational self-test
(POST) [restart the POST by switching the Controller OFF and then ON]
to determine if the signal is “clipping” at +10 V or -10 . If signal clipping is
happening, the pre-operational self-test should be disabled; use menu
option Set Powerup Test (see
Description of Menu Tree Functions
section).
2. HVAs are not properly connected to the isolators.
3. Cables are not properly connected.
4. System is simply not functioning correctly. If this is the case, contact
TMC Service.
Report all “Not Optimized” messages to TMC.
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If the title screen does not appear after completion of the POST and there is
no error message displayed on the LCD, or if the status LED remains
amber/orange, shut the controller OFF and then turn it back ON after
approximately 10 secs to repeat the power up sequence. If system still does
not function correctly, contact TMC service.
If at any time during operation the system becomes unstable, proceed to
section 6.4 for instructions on control loop gains adjustment using the menu
Adjust X/Y/Z Gains
When the title screen appears, the isolation system is fully enabled, including
access to all functions. Normal operation will start.
Optional configurations are described in the following sections.
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5 Menu Driven Functions
The
primary functions that control
panel menu system. These include required parameters (such as the number of isolators), and optional
parameters (such as COM port function).
5.1 Menu Tree:
On power up the controller LCD displays a message like “TMC STACIS 2100” “pn 95-28576-01 r #”;
pressing any one of the menu key leads to the first main menu option; pressing PREVIOUS repeatedly
from any menu tree level returns to the default display.
The Menu Tree is described below on a graphical map (Figure 13). The DC-2000 controller’s primary
functions are listed on the left. In general, press SELECT to move to the right on the map or press (+) to
move up the map or (-) to move down the map.
Detailed descriptions of the controller’s functions follow the graphical map.
5.2 Navigating the Menu Function Tree
As discussed above, navigation through the menu tree is accomplished by using the “Menu Keys” (Figure
11 below). Figure 12 illustrates how to navigate the menu tree. This is an example – the actual
messages might differ depending on the revision of the software installed in your system.
the behavior of STACIS are accessed through the controller’s front-
The top level (default display upon power-up) shows the product name, and the firmware revision
number. Press any key to navigate to the main options menu level to access the primary functions. From
this level,
Press Select key to move one level down the tree; thus,
selecting the currently displayed option.
Press Previous key to move one level up the tree; i.e. return
to last menu level visited.
Use the (+) and (-) keys to select between the different options
at a given menu level, to change a parameter’s value (such as
Figure 11: The Menu Keys
Moving down the tree always leads to the first option at the next new level. Moving up the tree goes back
to the last menu option visited.
Try it out. Rest assured that the controller cannot be damaged simply from navigating the menu tree
and/or making changes to operating parameters. Parameter values will not be permanently changed
unless saved using the Save Parameters menu option. Even after saving changes to operating
parameters, the controller can be returned to the “factory default” settings through the Restore Defaults
menu option.
adjusting a gain up or down), or to select a different Degree of
Freedom or axis.
After configuring the system to your liking, always go to
the Save Parameters menu option to permanently store
the settings. Settings are not saved automatically.
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...
Menu:
SELECT
Menu:
SELECT
Menu:
SELECT
...
...
Menu:
SELECT
Menu:
SELECT
...
...
Menu:
SELECT
...
PREV .
TMC STACIS 2100
pn 95-28756-01 R.##
Menu:
PREVIOUS
Any Key
-/+ Selects Function
Monitor X/Y/Z Signal
Menu:
Menu:
Menu:
PREV IOUS
PREV IOUS
PREV IOUS
Cursor:
(+)
-/+ Selects Function
Monitor Load Sensors
Cursor:
(+)
-/+ Selects Function
Shaker mode
Cursor:
(+)
-/+ Selects Function
System Diagnostics
Cursor:
Cursor:
Cursor:
(-)
Menu:
PREVIOUS
(-)
Menu:
PREV IOUS
-/+ Select Direction
Shaking Vertical
Cursor:
(+)
Cursor:
(-)
-/+ Select Direction
Shaking 0°
Cursor:
(+)
Cursor:
Cursor:
(-)
(-)
(-)
-/+ Select Direction
Shaking 45°
Cursor:
(+)
Menu:
PREVIOUS
Cursor:
(+), (+)...
Cursor:
(-), (-)...
Menu:
Menu:
PREV IOUS
-/+ Selects Function
PREVIOUS
LF/HF Alarms
Menu:
-/+ → Disable/Enable
Menu:
SEL.
(-)
LF Alarms Enabled
Cursor:
-/+ → Disable/Enable
LF Alarms Enabled
(+)
Cursor:
-/+ → Disable/Enable
LF Alarms Disabled
(-)
Menu:
PREV IOUS
Cursor:
(+), (+)...
-/+ Selects Function
Cursor:
(-), (-)...
-/+ → LF/HF SELECT
→ Set LF Alarm
Cursor:
Menu:
PREV IOUS
Cursor:
(+)
Save Parameters
Cursor:
(+) disabled
Figure 12: Example of Using the Menu Keys
Page 23 of 43
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TMC STACIS 2100
pn 95-28756-01 r #
-/+ Selects Function
Monitor X/Y/Z Signal
-/+ Selects Function:
Monitor Load Sensors
-/+ Selects Function
Shaker Mode
-/+ Selects Function
System Diagnostics
-/+ Selects Axis
BNC Output: 1Z axis
Iso1:2.6 Iso2:2.8mm
Iso3:2.7 Iso4:2.4mm
-/+ Select Direction
Shaking Vertical
-/+ → Mode SELECT → Run
Manual LTF Meas.
-/+ → Mode SELECT → Run
Auto LTF Meas.
-/+ Selects Axis
BNC Output: 1Z axis
-/+ Selects Axis
BNC Output: 1Z axis
BNC Output: 1Z axis
Test in Progress
-/+ Selects Function
Adjust X/Y/Z Gains
-/+ Selects Function
Axis Enable/Disable
Cont'd... next page
Figure 13: Detailed Menu Structure for STACIS 2100
-/+ → Mode SELECT → Run
Upload Data to PC
-/+ → Axis SELECT → Adj
Set 1Z axis gain
-/+ → Axis SEL → On/Off
1Z axis ENABLED
Page 24 of 43
@5 Hz 1Z axis
dG = 2.5dB dG = 5°
Run PC Program
TMC Analyzer
-/+ → Adjusts Gain
1Z axis Gain = 5.0
STACIS 2100 Piezoelectric Isolation System - Installation & Operation Manual P/N 96-28765-01
-/+ Selects Function
LF/HF Alarms
-/+ Selects Function
Sat./Osc. Control
+/- Selects Function
Set # of Isolators
-/+ Selects Function
Set Powerup test
-/+ → LF/HF SELECT → Set
LF Alarm
-/+→LF/HF SELECT→Set
HF Alarm
-/+ → Func. SELECT → Set
Saturation Control
-/+ → Func. SELECT → Set
Oscillation Control
Hit SELECT to Change
Now 4 Isolator Cfg.
-/+ Func. Select → Set
Disable/Enable
-/+ → Disable/Enable
LF Alarms Enabled
-/+ → Disable/Enable
HF Alarms Enabled
-/+ → Disable/Enable
Saturation Cont. On
-/+ → Disable/Enable
Oscillation Cont. On
-/+ Adjust
4 Isolator Cfg
-/+ Disable/Enable
Powerup Test Enabled
-/+ Selects Function
Restore Defaults
-/+ Selects Function
Save Parameters
Are you sure?
SELECT Continues
Are you sure?
SELECT Continues
Figure 13: Detailed Menu Continued
Defaults Restored
PREVIOUS to Continue
#s Saved to FLASH
PREVIOUS to Continue
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5.3 Description of Menu Tree Functions
The following sections describe the function of the different options shown above.
5.3.1 Monitoring X, Y, or Z Signals
This menu option allows the monitoring of the control signal sent to the HVAs for the three control axes
(X, Y and Z) for each of the isolators. The signal can be seen on the BNC Output located on the
controller’s front panel. The signal is proportional to the vibration motion being cancelled by the system.
If little or no signal is present on an axis relative to the other system’ axes, this may be an indication of a
damaged vibration sensor. If the signal is too large, it may be an indication that an actuator is damaged
or the floor displacement is too high and the system gains need to be lowered. The Monitor Sig. on BNC
function is used primarily for troubleshooting and monitoring the system’s performance. The output is
immediate when the user selects the axis to monitor.
5.3.2 Monitoring Isolator Loads
As described in the earlier
Installation
section of the manual, this function is used to monitor the loading
of the isolators. It shows the nominal deflection of the internal elastomer mount inside each STACIS
isolator.
5.3.3 Shaker Mode
With this function, STACIS can be used as a dynamic shaker for vibration testing of equipment. The
shaker function operates in “open loop” mode and can be set for the vertical axis, every 45 degree axis in
the horizontal plane, X Twist (rotation), Y Twist or Z Twist.
“Open Loop” mode disables the vibration isolation function, and uses a signal applied to the controller’s
front-panel BNC Input directly to the PZT stacks in the STACIS isolators. The resulting displacement of
the payload is proportional to the input at frequencies below 10Hz, but it rolls off quickly at high
frequencies. This mode applies the largest signals to the payload, and
Shaker Mode is ideal for two-channel vibration transfer measurements, etc.
When using the STACIS system as a shaker, the actuators and/or sensors can
saturate depending on the mode, frequency, and amplitude of input signal. If saturation
occurs, the resultant payload motion will no longer be proportional to the input. TMC
recommends that a reference sensor (such as an accelerometer) is always used to
confirm that the payload motion is correct.
5.3.4 System Diagnostics
This function is a test mode, used only for troubleshooting. It allows the user to test and collect data for
each of the system’s servo loops individually.
In
Manual Mode
, the user is able to inject a known signal into a particular axis (1X through 4Z) through
the controller BNC Input using a signal generator. The controller processes the signal and output a
response through the BNC Output. The signal can be monitored with an oscilloscope.
In
Automatic Mode
, the same checks performed during the power-up sequence are reproduced on the
user selected axis. The response signal can be monitored by connecting an oscilloscope to the
controller’s BNC Output.
The
Upload Data to PC
option allows the user to collect, save and recall data representing the
structural “signature” of the entire assembly (i.e. customer supporting frame, payload and TMC’s isolation
Page 26 of 43
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system) using the TMC PC based application
instructions on running the analyzer software
TMC Analyzer
.
.
See Appendix C for detailed
5.3.5 Adjust X/Y/Z Gains - Gain Adjustment
All control gains of the
STACIS isolation systems have been set at the factory to provide optimal
performance in all typical installations. However, in some installations (installations on weak floors, for
example), it may be necessary to adjust the control gain of one or more axes to improve system stability.
Optimal adjustment of the gains requires training and experience. Though the system
cannot be damaged,
always contact TMC prior to adjusting the gains
. The
STACIS isolation system is designed with two advanced features (Oscillation Control
and Saturation Control) which virtually eliminate the need for end-user gain adjustment.
Gains must never be increased above the 0 dB level.
handle gains above this level. Too high a gain may result in oscillation and saturation.
The system is not designed to
The procedure for adjusting the system’s control gains is as follows.
a. Plug an oscilloscope to the controller’s BNC Output to monitor the system’s signal.
b. Select the axis for which the gain needs to be adjusted.
c. Adjust the gain as appropriate, using
Note: each click of the key alters the gain by 1 dB
(+)
key to increase (but not above 0 dB) or
(-)
key to decrease.
•
If the system goes into high-frequency oscillation (making an audible ‘chirp’ sound),
the gain should be reduced until the oscillation is eliminated.
•
If the low-frequency drift of the control signal exceeds +/- 0.5 volts under ‘normal’
circumstances (a quiet room environment, and no storms outside), the gain should
also be reduced until this behavior goes away.
To keep the new gains permanently, save them in the controller’s non-volatile (FLASH)
memory (explained later in this section)
5.3.6 Axis Enable/Disable
This is the menu option for individually activating or deactivating the control servo loop for each active
axis. This menu is a powerful diagnostic tool that can be used to identify sources of system’s instability.
The
BNC output
identify unstable axis is the following:
•
Disable all axes – set each axis as
is automatically set to the axis displayed on the LCD. The standard procedure is to
Disabled.
•
Enable them by adding (set to
the system stability for approximately 15-30 seconds. In this matter, systematically find the axis,
which by
Enabling or Disabling
Enabled
) one axis at the time. After each axis is enabled, monitor
create or eliminate instability.
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•
Adjust (reduce) the servo loop gain for the identified axis by three (3) dB, i.e. 3 clicks of the (-)
menu key, through the
Adjust X/Y/Z Gains
menu discussed above, and then re-assess the
performance of the system.
•
Continue to check one axis at a time to screen for any other underperforming axis by repeating the
above procedure until all instability problems are eliminated.
•
The setting for an individual axis is preserved once saved in NVRAM. Thus, a
disabled axis will remain disabled until the user re-enables it.
•
Even with a disabled axis, all testing (data collection, etc.) will be unaffected for the
axis.
5.3.7 Sat./Osc. (Saturation/Oscillation) Control
This is the menu option for enabling or disabling saturation and/or oscillation control. The Saturation
Control and Oscillation Control features are advanced, non-linear, and adaptive control algorithms. They
allow the system to operate trouble-free for extended period of time under adverse conditions (periods of
high seismic noise or large payload disturbances).
TMC strongly recommends that these functions remain enabled during system operation.
They may be disabled
diagnostic is completed.
only for diagnostic purposes
and reset to “
enabled
” once the
Saturation Control
monitors when the signal to an HVA is in danger of saturating the actuator. To
prevent saturation, the controller automatically reduces the gain in the affected channel. Although this
preventive action also reduces the vibration isolation, it prevents a hard saturation in the servo, which can
result in unwanted impulses sent to the payload. In our experience, this is much less disruptive for most
applications. If Saturation Control reduces the gain by more than 20dB, a warning is sent over the COM
port (if enabled). If this occurs, check and remove the source of excessive external disturbance.
Oscillation Control
is a very advanced feature which monitors for oscillations in the control loops. If
oscillation is detected, this feature modifies the control system filters in an attempt to stabilize the
STACIS® system.
An oscillation is a consistent and high-amplitude frequency in the feedback signal. The frequency is
identified, and a filter is added to make the system more stable at that frequency. Oscillation Control
will continue to increase the aggressiveness of this filter, until the oscillation goes away. If too large a
correction was necessary to the control filters, an Alarm is triggered, and the channel is disabled.
•
Filtering is limited by the need for isolation. The aggressiveness of the filter is
increased through a series of 6 steps. Each increase causes a reduction in lowfrequency isolation. Beyond the 6 steps of adjustment, the loss in low-frequency
isolation is too great and the system will prompt for user intervention.
•
Oscillation control filters are not stored in FLASH memory; if the controller power
is turned OFF, the filters will all be reset to zero. If oscillation reoccurs, the filters
will re-adjust.
Both Saturation Control and Oscillation Control are applied to a single axis at a time. Gain reduction in
one axis usually causes minimal changes in the system’s overall isolation performance.
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It is stro
ngly recommended that the Alarms
stay
enabled.
5.3.8
LF/HF Alarms
This is the menu option for enabling or disabling the alarms for Oscillation Control and Saturation Control.
These two features monitor the operation of the STACIS system for oscillation and saturation,
respectively (see Oscillation Control and Saturation Control sections above). Whenever oscillation or
saturation is detected, the controller automatically attempts to correct the problem. If the automatic
adjustment fails, an “Alarm” (if enabled) condition is indicated by:
- a message on the LCD showing the axis and type of alarm.
to clear it from the LCD, press the
Previous
key;
Note:
To acknowledge the message and
- the System Status LED turns from green to flashing amber;
- Alarm Relay by triggers (see Table 3).
In addition, the affected axis is disabled to prevent damage to the actuator.
Two types of alarm condition may occur: an “LF” (Low-Frequency) Alarm or an “HF” (High-Frequency)
Alarm.
Low-Frequency Alarms happen when the control signal to an actuator exceeds a specified value for an
extended period of time. If Saturation Control is enabled
(strongly recommended default)
, the system
gains are automatically adjusted to prevent saturation of the actuator from ever developing. Therefore, if
Saturation Control is enabled, LF Alarms will never be triggered. If Saturation Control reduces the gain
by large amounts, a warning can be sent over the controller’s COM port interface (if enabled).
High-frequency Alarms happen when the system detects an oscillation. The system monitors the period
and amplitude of the signals to the HVAs. If the system oscillates - signal with a regular period and high
amplitude detected - for longer than a specified time period, then an Alarm is triggered, and the channel is
disabled.
Disabling them could
cause permanent damage to the actuators from uncontrolled oscillation. The option to
turn the alarms off is mainly a diagnostic tool.
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ERROR
INDICATIONS
FAULT DETECTED
PROBABLE CAUSE
RECOMMENDATION-
TROUBLESHOOTING
LF ALARM
Required stroke of isolation system
exceeds the dynamic range of the
actuators.
•
The SYSTEM STATUS LED turns
to amber.
•
A message similar to the following
is displayed on the LCD:
A l a r m : L o w F r e q O s c
I s o l a t o r # 3 A x i s Y
•
Alarm Relay is triggered
Repeated low frequency instability.
Actuator dynamic range is exceeded.
Control signal is over a preset
threshold (near saturation) for more
then 60% of any given 60 second
period.
Heavy mechanical disturbances
applied to the floor near the STACIS
installation.
Heavy mechanical disturbances
applied directly to the payload (moving
stage problems, maintenance work,
etc.).
Load adjustment for one or more of the
isolators is incorrect.
Soft floor causing the isolator to tilt
(horizontal channels only)
One or more isolators have failed.
Check the operation of the system located on the payload for malfunction.
Verify that the reported isolator rests solidly on the floor/surface without any
rocking. Replace the base pad with a new one as necessary.
Check all isolators for proper loading and adjust loading as necessary.
Reduce loop gain by 3dB (3 clicks of (-) menu key) for the channel shown in the
alarm message.
If none of the above helps, contact TMC for assistance.
High Frequency Oscillation
•
The SYSTEM STATUS LED
turns to amber.
•
A message similar to the
following is displayed on the
LCD:
A l a r m : H i g h F r e q O s c
I s o l a t o r # 3 A x i s Y
•
Alarm Relay is triggered
Constant instability at a frequency
between 10 Hz and 150 Hz.
Actuators generate a drumming
sound.
A channel oscillates for more then
360 consecutive cycles at a constant
frequency.
Floor is soft and does not meet the
installation requirements.
Load for one or more isolators is
incorrect.
Gain for an isolator is too high in one
or more axes, making servo loop
unstable.
One or more actuators has failed
HF ALARM
5.3.9 Select Number of Isolators.
The DC-2000 controller can be configured to control 2, 3, or 4 isolators. When purchased as part of a
STACIS system, i.e. isolators and controller, the correct number of isolators is pre-configured at TMC
before to shipment. This function makes it possible to update the number of isolators in the event of a
change in the installation, e.g. an isolator is added or removed due to changes in the weight of the
payload, etc. The number of isolators may also need to be re-configured when the “Restore Defaults”
option is used, or the controller software is updated.
Table 5: Alarm Conditions
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The system may not function properly, or may incorrectly indicate an ALAR
M
5.3.10 Set Powerup Test
Menu option for enabling or disabling the automatic execution of the Power Up Self Test. The self test at
power up consists of running “open loop” gain and phase measurements for each axis.
If the power up self test is run in a “noisy” environment, e.g. high level base vibration, the
measured signal could be compromised and produce faulty results. To avoid such
situations, the power-up [self] test should be disabled.
5.3.11 Restore Defaults
This function makes it possible to restore all parameters to the factory default settings. This includes
ALL
settings which can be changed through the menu system, such as control gains, number of isolators, etc.
condition
after using this command, especially in cases where there was a significant
difference between the installed system configuration and the factory default configuration.
One example is the case where the number of isolators defined in the controller’s software
no longer matches the actual number of installed isolators
•
The factory default configuration will not automatically be saved into the controller’s
non-volatile memory.
•
To keep the factory default configuration, save them using the
Save Parameters
function.
•
To go back to the last saved system configuration, i.e. to not keep default
configuration, simply turn off controller and then reboot.
5.3.12 Save Parameters
This function permanently saves all of the currently active settings in the controller to non-volatile
memory. It should be used only confirming that the settings are proper for the system, and functioning
correctly. All saved parameters are retained even after the controller is power cycled OFF and ON.
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Step 5
, a
Step
4
Step 5
,
6 Downloading New Software:
New system operating software can be downloaded by connecting the controller to a computer
via the serial ports (COM1 or COM2). The software package shipped with the system includes
a program called SerialLoader.exe to facilitate the downloading process.
Downloading new software will reset all parameters to the factory defaults.
Follow the instructions below to install new software.
1. Connect the controller to a computer using a serial communication cable.
A DB-9 Male to DB-9 Female “one-to-one” serial cable is needed. For computers with
only USB ports, a commercially available USB-to-RS232 (to COM) exchanger is
required.
2. Load the provided software package to the computer.
3. Launch the SerialLoader.exe program.
After the program opens, a dialog box similar to the one below will display.
4. From the dialog box, select the PC serial port that is connected to the controller.
b & c
5. Click on Select File. A standard Microsoft Windows file dialog box will display.
a. Locate and select the new system profile .hex file to load.
b. The file selected will be displayed in the Filename field, and the Auto Download and
Manual Download buttons will turn from gray to solid.
c. Confirm the file loaded is correct (computer location and name).
6. The new software will be downloaded using the Manual Download method.
Click the Manual Download button. The following screen will then display:
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Download
Download
7. Turn the controller power OFF, and then back ON after 10 seconds. The System Status
LED on the Controller’s front panel will be “red”, and then turn “green” and start to blink.
Click the OK button above or press the Enter key on the computer keyboard immediately
after the status LED starts blinking “green”.
The LED on the Controller’s front panel will turn “amber” and start blinking rapidly,
indicating that the download is in progress. The Serial Loader window will now indicate the
progress of the download in the Status window.
Progress
8. After the download is complete, the Status box will indicate the total bytes transmitted, and
the time required in seconds. ‘Successful’ means the downloaded .HEX file passes the
checksum test, and is written to flash (non-volatile) memory.
Result
After the download is complete, the LED will turn “green”, and the controller will automatically
reboot, and the new software will start to run.
•
New software download resets all system parameters to the factory default settings.
Therefore, the system must be re-configured for the specific application/installation.
Parameters such as number of isolators, control gains, etc. typically require
adjustments; refer to the
Description of Menu Tree Functions
section for instructions.
•
After configuring the system, permanently save the parameters in memory using the
“Save Parameters” menu option.
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Failed Downloads:
On rare occasions, a software download will fail the checksum and the new software will NOT
be written to flash. If download fails,
Manually shut the power OFF and then back ON to reboot the old version of the
application software.
Repeat the downloading process described above.
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1 2 3 4 5 6 7 8
10 11 12 13 14 15 16 17 18
7 Appendix A: DC-2000 Controller Overview
7.1 Controller Performance Specifications
Analog Inputs ...................................................................16 x16 bit / 96dB Dynamic Range, ±10V full scale
Analog Input Protection ....................................................................................................................±15 Volts
Analog Outputs ...............................................................16 x 14 bit / 84dB Dynamic Range, ±10V full scale
Analog Output Protection ............................................................................. indefinite short circuit protection
Digital Input Current Rating ......................................................................................... 2mA min / 30mA max.
Digital Output Current Rating ........................................................................................................30mA max.
Digital I/O Protection .................................................................full optical isolation (see
DI/O Isolated Supply ...................................................................................... 5VDC, 300mA max. (1.5 Watt)
COM Ports.................................................................... 9600 Baud, 8 data, 1 stop, no parity, no flow control
DSP Engine.................................................................................................................. TMC320C32 / 60MHz
Sampling Rate....................................................................................... 5KHz (Max. Transport Delay 0.6ms)
Power Consumption ...............................................................................................................................200W
7.2 Controller Front Panel
Figure 14: DC-2000 Digital Controller – Front Panel
The DI/O Interface
)
Ref. # Name Description
1 Main Power AC Power ON/OFF rocker switch.
2 COM 1 Serial RS232 interface port; used to establish a communication channel to
3 Analog Input BNC connector for injecting external analog signals (analyzer, etc) into
4 Analog Output BNC connector for monitoring the control signal from a selected axis.
5 Menu Control
6 LCD Main display used for navigating the menu system and communicating
7 Master Reset Used to force a hardware reset; same as power cycling.
8 System Status Tricolor system status LED (green - normal, red - alarm, amber - warning).
7.3 Controller Back Panel
Figure 15: DC-2000 Digital Controller – Rear Panel
a personal computer; pinout information follows.
selected isolator axes.
Four switches: SELECT, PREVIOUS, +,and -.
information and instructions to the user.
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Ref. # Name Description
10 Alarm Relay, AUX Power
Interface
11 Main Analog I/O Connector,
Channels 0-7
12 Main Analog I/O Connector,
Channels 8-15
13 Digital Input/Output Optional digital I/O connector; pinout information follows.
14 CE Label Marking to indicate compliance to CE requirement.
15 Cable Restraint Loop power cord through the restraint to provide strain relief
16 COM 2 Second RS232 interface port
17 Ground External grounding lug.
18 AC Power Entry Module Standard IEC power cord connection point.
”Dry contact” alarm relay, Auxiliary power source; used in
special applications; pinout information follows.
Cable connection point to isolation system using channels 0-7
as designated.
Cable connection point to isolation system using channels 815 as designated.
7.4 System Status LED and Alarm Relay
Possible system status LED indications:
Green LED - indicates normal operation. Alarm relay (see Table 10 above) is enabled,
indicating that Alarm is OFF – normal operation condition.
Yellow/Amber LED - indicates system is or has moved outside of the normal operation
Go/No-Go window as a result of external disturbance, system’s instability, etc. In this case,
the Alarm relay is disabled, indicating an Alarm condition.
Immediately after power up, the LED will turn red, then flash green for a 5 seconds. The
period, when the LED flashes green, is when new software can be downloaded using the
‘manual’ download option. Alarm relay is disabled, indicating Power-up condition.
The function of the LED and Alarm Relay can be customized for application-specific
requirements.
7.5 The DI/O Interface
This connector located on the rear the controller provides access to 16 digital inputs and 16
digital outputs. Both inputs and outputs are isolated with optical couplers.
Figure 16 below shows a schematic diagram of the controller internal wiring. Connections
available to the user are shown on the right (Rear Panel Access).
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Figure 16: Digital Inputs and Outputs Schematic
• The (+5Volts) and (GND) on the DB-37 connector are configured with jumpers and are
connected to an isolated power supply (300mA, 1.5W), internal to the controller.
• The jumpers are set as shown above by default, but can be changed before shipping
upon request. The jumpers are internal to the controller and must be changed at
the factory, or by authorized TMC personnel only
• All of the LED (+) terminals are connected to a common +5 volt bus through 1.5 KOhm
resistors.
• All of the open collector emitters are connected to a common ground bus.
• Current-limiting 100 Ohm resistors are used to protect the output transistors.
• Both +5V and GND are available on the DB-37 connector.
7.6 Connector Pinouts
The following tables show the pinouts for each of the connectors on the back of the DC-2000:
Digital Input/Output Connector
Table 6: Digital Input/Output DB-37 Connector Pinout:
Pin # Function Pin # Function Pin # Function Pin # Function
1 D in 0 11 +5 VDC 21 D in 9 31 D out 1
2 D in 1 12 D out 8 22 D in 10 32 D out 2
3 D in 2 13 D out 9 23 D in 11 33 D out 3
4 D in 3 14 D out 10 24 D in 12 34 D out 4
5 D in 4 15 D out 11 25 D in 13 35 D out 5
6 D in 5 16 D out 12 26 D in 14 36 D out 6
7 D in 6 17 D out 13 27 D in 15 37 D out 7
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Pin # Function Pin # Function Pin # Function Pin # Function
8 D in 7 18 D out 14 28 GND - 9 N. C. 19 D out 15 29 +5 VDC - -
10 GND. 20 D in 8 30 D out 0 - -
•
‘N.C.’ means ‘no connection’.
•
The +5 VDC and GND connections shown in this table are configured as shown in the
previous section. They are connected to an isolated power supply (300mA, 1.5W).
Analog Input/Output Connectors
•
For both Analog I/O connectors, the GND and power connections are non-isolated.
•
The ‘+V Aux’ pins are connected to a dedicated power supply for powering systems
external to the digital controller.
Table 7: Analog Input/Output Channels 0-7 DB-37 Connector Pinout:
Pin # Function Pin # Function Pin # Function Pin # Function
1 A Out 0 11 A In 6 21 A Out 3 31 GND
2 A Out 2 12 GND 22 GND 32 +15 VDC
3 GND 13 GND 23 A Out 5 33 -15 VDC
4 A Out 4 14 GND 24 A Out 7 34 GND
5 A Out 6 15 GND 25 GND 35 GND
6 GND 16 +48V 26 A In 1 36 GND
7 A In 0 17 +48V 27 A In 3 37 GND
8 A In 2 18 +48V 28 GND - 9 GND 19 +48V 29 A In 5 - -
10 A In 4 20 A Out 1 30 A in 7 - -
Table 8: Analog Input/Output Channels 8-15 DB-37 Connector Pinout:
Pin # Function Pin # Function Pin # Function Pin # Function
1 A Out 8 11 A In 14 21 A Out 11 31 GND
2 A Out 10 12 GND 22 GND 32 +15 VDC
3 GND 13 GND 23 A Out 13 33 -15 VDC
4 A Out 12 14 GND 24 A Out 15 34 GND
5 A Out 14 15 GND 25 GND 35 GND
6 GND 16 +V Aux 26 A In 9 36 GND
7 A In 8 17 +V Aux 27 A In 11 37 GND
8 A In 10 18 +V Aux 28 GND - 9 GND 19 +V Aux 29 A In 13 - -
10 A In 12 20 A Out 9 30 A in 15 - -
•
Analog input 15 is connected to the controller’s front-panel BNC input.
•
Analog output 15 is connected to the controller’s front-panel BNC output.
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AUX. Power Interface
This connector located in the rear of the controller can be utilized as an auxiliary power source
or a “dry contact” alarm relay.
Table 9: AUX. Power Interface Connector Pinout:
Pin # Function
1 + 48V
2 GND
3 COM (Alarm Relay 2)
4 NC (Alarm Relay 2)
5 NO (Alarm Relay 2)
6 GND
7 NC/+48V (Alarm Relay 1)
8 NO/+48V (Alarm Relay 1)
9 GND
*** N.C. means no connection ***
Figure 17: AUX Power Connector – Pin Identification
#1
Serial Ports (COM1 and COM2)
#2
#8
#9
The serial ports provide a communication interface between the DC-2000 controller and a host
computer or other machines. The controller and computer must be connected using a DB9
serial cable or
ports only.
a commercially available USB-to-RS232 (to COM) exchanger for computer with USB
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The serial port follows the RS-232 standard and has the following properties:
Table 10: COM1& COM2 Pinouts
PIN Number Function Pin Number Function
1 N.C. 6 N.C.
2 TXD2 7 CTS2
3 RXD2 8 RTS2
4 N.C. 9 N.C.
5 GND
*** N.C. means no connection ***
Serial Port Commands & Status Byte
The commands structure for communication is a single character terminated with a carriage return. When
a command is issued, the system echoes back its current status in the form of a status byte, terminated
by a
<CR>, e.g.
Number: p <CR>
combined 8 bit value of two ASCII format bytes, followed by the a carriage return (
command is issued, the system echoes back “Unknown Command”.
serial port commands.
x00<CR>… xFF<CR>, or echoes back a string, also called
”, indicating the command typed. The status byte is reported over the serial port as a
Status Byte
<CR>)
, like “
Part
. If an unknown
The table below lists typical
Contact TMC for more information.
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Table 11: Summary of Serial Port Commands
s <CR>
p <CR>
w <CR>
u <CR>
r <CR>
‘Read Status” - Returns status byte, this is a null command; it does not affect any
changes to system operating parameters.
“Part Number” - sends the TMC system software part number and revision to the front
panel LCD. It also echoes the P/N to the serial port if the port is used.
“Print System Status” - sends to PC the string of current status of all of alarms, warnings,
feedback settings, etc.
“System Self-test result” - sends to PC the string of measured value, compared with
default value for each active servo loop.
“
Reset” - System Reset; restores parameters to values saved in flash memory
(NVRAM), and then initiates startup sequence. Returns status byte showing
current mode.
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to stop
8 Appendix B: Using TMC Analyzer to Collect and Upload Data
If not already installed on your computer, install the
TMC Analyzer
application by running the
Setup.exe file from the “TMC_Analyzer 1.xx install” folder. Contact TMC Service for a copy of
the application, if necessary.
Follow the procedure below:
A. Connect a DB9 serial cable between the computer and the COM 1 port located on the controller’s
front panel.
B. Set the controller LCD menu to
Analyzer
(see illustration below).
Press the
PREVIOUS
message is seen on the LCD:
System Diagnostics Upload Data to PC
Run PC Program TMC
switch on the controller’s front panel repeatedly until the following
T M C S T A C I S 2 1 0 0
p n 9 5 - 2 8 7 5 6 - 0 1 R e v #
Press the “+” switch repeatedly until the LCD shows:
+ / - S e l e c t s F u n c t io n :
S y s t e m D i a g n o s t i c s
Press the “
SELECT
” switch, and then press the “+” switch repeatedly until the LCD shows:
- / + M o d e S E L E C T R u n
U p l o a d D a t a t o P C
Press the “
SELECT
” switch. The LCD will now show:
R u n P C P r o g r a m
T M C A n a l y z e r
C. Launch the TMC analyzer application Analyzer.exe. A screen similar to the one below will display.
Step D
Step E
Step F
Step G
Click on
Note:
Stop test
at any time
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D. Select communication port for RS232 interface (same port as in step A above).
E. Select axis (1, 2, 3, and 4 in H (horizontal) or Z (vertical)). Numbers (1,2, etc.) correspond to the
isolator position.
F. Click on
Start test
•
•
•
•
.
The controller LCD will display
“## axis / Test in Progress
The gain-phase profile will plot on a log graph starting with the higher frequencies.
The complete test takes approximately 3 minutes.
Click on
Stop test
to stop at any time.
G. Click on
Save Test File
and then save test data for each axis as a
H. After collecting the transfer function for all axes, exit from
and close TMC Analyzer program.
I. E-mail test data files to TMC for review.
”.
CSV
file.
Upload Data to PC
controller LCD menu
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