Aerotech UNIDEX 100/U100i single axis motion controller

Power on test: Do not connect the motor first, check 5V, LED, communication SETUP； Connect the motor for low-speed testing of phase, feedback direction, limit, and return to zero; Finally, load and check the current, temperature, and tracking error.

If the original device uses U100 integrated driver, replacing it with U100i and external amplifier requires redesigning the cabinet and wiring. If the original device uses U100i, replacing it with U100 can simplify the wiring, but it is necessary to confirm the driving current and motor type. Regardless of the replacement, PGM, DEF, MAC, CAM, and parameter files should be backed up, and the Flash ROM archive settings should be recorded.

Common faults and troubleshooting

The system is completely not powered on: Check the AC line fuse F2, U100 may have blown due to a serious malfunction. Before replacement, all electrical connections must be checked and the power supply disconnected. If the fan is running but the system is not powered on, check the 5V fuse F3, unplug the P2-30 external load, and eliminate overload.

System not powered on or abnormal: may be due to new software or memory damage. Perform SETUP: Short circuit P2-19 and P2-16. If P2-20 is not connected to an external power source, short circuit P2-20 and P2-30 again. After powering on for 5 seconds, power off and remove the jumper. Check if JP 2 is in position 2-3.

Unable to store or download program: Execute SETUP and clear memory. Check for battery failure, U100 battery is used to maintain RAM.

RS-232 no communication: Confirm that the control board jumper is RS-232-C; Check baud rate, data bits, stop bits, parity check; Confirm that com_100.exe is using the correct COM port. If using RS-422-A, it is necessary to confirm the factory configuration and chip installation.

Motor without torque or shaking: Check the JP16/JP17 motor type jumper; Check the motor fuse; Brushless motor inspection PRM: 239 commutation type and Hall wiring; Check the encoder connection and phase; Check if the feedback source parameters have selected the wrong port. When the DC has a brush speed loop, check if JP8 is between 2-3 and verify the polarity of the speedometer.

Overload LED on: RMS current limit PRM: 217 exceeded. Raise PRM: 217 to the rated value of the motor, if it still exceeds, the motor capacity will be insufficient. Position errors, speed, and acceleration traps can also trigger overload.

Control fault LED on: Check if the fault mask configuration matches the actual system, including limit polarity, feedback source, and RMS current limit. REG: 302 and REG: 317 can help locate.

Limit false alarm: Check PRM: 317 reverse mask. The low effective hardware limit should set bits 8 and 9 to 1, and the high effective limit to 0. The software limit is set by PRM: 129 and PRM: 130.

Encoder count not working: Confirm that the encoder is not being used for both position and velocity feedback simultaneously; If the counter has been used for servo feedback, it cannot be used to capture or trigger outputs. Check if the LOAD input is pulled down to avoid damaging the servo loop.

Shunt Active LED on: The regenerative energy is too high. Check the Shunt fuse F4 and adjust R2 to make Shunt conductive when the bus voltage is about 15% higher than the normal value. U100i needs to refer to the amplifier manual.

In terms of maintenance, the chassis, cooling vents, cables, and connectors should be checked monthly. Turn off the power during cleaning, use a dry soft cloth, and if necessary, slightly wet water or isopropanol. Do not allow liquids to enter the connector. Internal high voltage may still exist after a power outage, and maintenance must be carried out by qualified personnel. Before long-term shutdown, backup parameters and programs, and record jumper and fuse configurations.

FAQ

What is the difference between U100 and U100i?

U100 includes a control board, driver, and power supply, which can directly drive the motor; The U100i only has a control board and requires an external BA series or third-party amplifier.

What motors does UNIDEX 100 support?

Supports stepper motors, DC brushed motors, and AC brushless motors, but the factory configuration of one controller is fixed to one type.

How to enter SETUP to restore default parameters?

Short circuit P2-19 and P2-16, and if necessary, short circuit P2-20 and P2-30. After powering on for about 5 seconds, turn off the power and remove the jumper.

How to switch between RS-232 and IEEE-488?

PRM: 019=1 is RS-232, PRM: 019=2 is IEEE-488. After switching, the controller needs to be reset.

What about the electric scooter?

Check the encoder phase, speedometer polarity, JP8 configuration, feedback source parameters, and commutation settings. Disconnect the motor first and test the feedback direction at low speed.

Can we directly replace other brands of motion controllers?

It cannot be judged solely based on size and current. It is necessary to verify the motor type, feedback, and communication I/O、 Expand options, parameters, and fuse configurations.