AACC MECHATRONICS CLEARPATH SERVO SETUP

Step 1: Autotune the ClearPath Motor

Autotune is a feature that optimizes the motor’s behavior by performing controlled

movements. The system automatically adjusts settings like acceleration, deceleration,
and torque to ensure smooth, precise, and stable operation.

Specifications for Autotune:

● Acceleration: 10

● Torque: 5% of the motor’s maximum torque

● Maximum Velocity: 50 RPM

● Rotation: Unlimited

● Shaft Movement: Rotates freely in both directions

What to Expect:

● The process will take approximately 10 minutes to complete.

● The motor will perform a series of test rotations and movements during this time.

Steps to Perform Autotune:

1. Open the ClearPath MSP software.

2. Navigate to the Autotune feature under the Motor Setup tab.

3. Ensure the shaft can rotate freely without obstruction.

4. Enter the specifications listed above into the Autotune settings.

5. Click Start to begin the Autotune process.

6. Wait for the process to complete while monitoring the on-screen progress bar.

Completion:

Once the process finishes, the motor will be tuned and ready for use. Verify the settings
and proceed to the next step in your setup.
STEP 2: Controlling the Servo: Two Methods

After setting up and autotuning the ClearPath servo, you can control it using two methods:

1. Override Inputs (Software Control)

2. External Control Using the CLICK PLC

Method 1: Override Inputs (RAMP UP/DOWN to Selected Velocity)

The first method involves controlling the servo directly through the ClearPath MSP
software.

Setup Parameters:

● Torque Limit: 5%

● Acceleration: 10 RPM/s

Steps:

1. Open the ClearPath MSP software.

2. Navigate to the RAMP UP/DOWN to Selected Velocity tab.

3. Set the Torque Limit to 5% and the Acceleration to 10 RPM/s.

4. Use the Override Inputs in the software to control the motor:

o A = Off, B = Off → Motor will run at 0 RPM (stopped).

o A = On, B = Off → Motor will ramp to 10 RPM.

o A = Off, B = On → Motor will ramp to 20 RPM.

o A = On, B = On → Motor will ramp to 50 RPM.

Key Notes:

● Override Inputs allow you to test and control the motor behavior safely from the
software.

● Monitor torque and velocity feedback to ensure smooth operation.

Method 2: External Control Using the CLICK PLC

The second method involves wiring the servo to a CLICK PLC for external control and
programming the desired logic.

Wiring Instructions:

1. Ground Connections:

o Connect the following wires to 0V (Ground):

▪ Red (HLFB-)

▪ Yellow (Input B-)

▪ Brown (Input A-)

▪ Orange (Enable-)

2. Signal Connections:

o Use the following wires for signals:

▪ Green (HLFB+)

▪ Black (Input B+)

▪ White (Input A+)

▪ Blue (Enable+)

3. Connect to the CLICK PLC:

o Assign PLC outputs to the servo's input signals:

▪ Enable+ (Blue)

▪ Input A+ (White)

▪ Input B+ ( Black)

Programming the PLC:

1. Configure the PLC outputs to control the signals as follows:

o A = Off, B = Off → Motor runs at 0 RPM.

o A = On, B = Off → Motor ramps to 10 RPM.

o A = Off, B = On → Motor ramps to 20 RPM.

 o A = On, B = On → Motor ramps to 50 RPM.

2. Write a ladder logic program to toggle these outputs based on your desired control
logic.

Testing the System:

1. Power on the system and run the PLC program.

2. Verify that the motor operates at the correct velocities based on the input signals
from the PLC.

Important Notes for Both Methods

● Always double-check wiring and settings before powering the system.

● Monitor torque and velocity feedback during testing to ensure proper operation.

● Use Override Inputs for initial testing and the CLICK PLC for integration into your
system.
Step 4: Setting Operational Mode and Homing the Servo

1. Set the Operational Mode:

1. Open the ClearPath MSP software and navigate to MODE-POSITION.

2. Select 4 Positions (Home to Hard Stop) under the "Move to Absolute Position"
section.

3. Click OK to confirm your choice.

2. Configure Homing Setup:

1. Go to the Homing Setup menu.

2. Choose Shaft Angle Homing under the "Homing Mode" section.

3. Manually or programmatically move the servo shaft to the desired home position.

4. Click Set Home Angle to save this as the home position.

5. Adjust additional homing parameters:

o Homing Occurs: Select either "Upon first Enable after power-up" or "Upon
every Enable."

o Homing Direction: Choose CCW (Counter-clockwise) or CW (Clockwise).

o Homing Move Settings:

▪ Speed: Set to 10 RPM.

▪ Accel/Decel: Set to 10 RPM/s.

o Torque Limit: Set to 5% for the homing process.

6. Once the homing setup is complete, verify the system returns to the set home
position accurately.

Step 5: Setting Positions and Practicing with Override Inputs

After homing is set up, define the four user-defined positions and practice controlling them
with override inputs.

User-Defined Positions (4 Positions):

 ● Position the servo to the desired locations for each input state and link them to the
following overrides:

o A = Off, B = Off → 0 (e.g., Home Position)

o A = On, B = Off → 200

o A = Off, B = On → 400

o A = On, B = On → 600

Practice with Override Inputs:

1. Use the Override Inputs in the software to test movement between the four defined
positions:

o Toggle inputs A and B to move to different positions.

o Verify the servo moves smoothly to each location.

2. Adjust and fine-tune the positions if necessary using the software.

Step 6: Connecting to the CLICK PLC

Once the positions and movements are tested using override inputs, integrate the system
with the CLICK PLC for external control.

Wiring Setup:

● Follow the wiring instructions outlined previously:

o Ground Connections: Connect Red, Yellow, Brown, and Orange to 0V

(Ground).

o Signal Connections: Connect Green, Black, White, and Blue to PLC

outputs.

● Assign PLC outputs to control the following:

o Enable (Blue)

o Input A (White)

o Input B (Black)

Programming the PLC:

 1. Use the ladder logic to control the servo's positions:

o A = Off, B = Off → Move to Position 1.

o A = On, B = Off → Move to Position 2.

o A = Off, B = On → Move to Position 3.

o A = On, B = On → Move to Position 4.

2. Test the program to ensure proper transitions between positions.

Final Notes:

● Operational Mode: Always set this first before homing and defining positions.

● Homing Setup: Verify the home position is accurate before proceeding to the next
steps.

● Testing: Test thoroughly with override inputs before connecting to the PLC for
external control.
Final Summary

Throughout this process, we’ve covered the complete setup, configuration, and control of
the ClearPath servo motor, giving a comprehensive understanding of its functionality. We
began by using the Autotune feature to optimize the motor's performance for smooth and
precise operation. Following that, we explored two methods of control: software-based
override inputs and external control using a CLICK PLC, gaining hands-on experience
with both approaches.

We then delved into operational modes, particularly absolute positioning, allowing the
servo to move to multiple user-defined positions based on input signals. To enable this, we
used the Shaft Angle Homing method, a straightforward approach to set the home
position without the need for physical stops or switches. We tested these positions using
the override inputs, reinforcing the importance of precise configuration and verification.

Finally, we integrated the servo with a CLICK PLC, wiring and programming it to replicate
the same control logic externally. This gave us a real-world application of servo control in
automated systems. By completing these steps, we’ve developed a solid foundation in
setting up, configuring, and utilizing the ClearPath servo for a variety of motion control
tasks, bridging the gap between software tools and hardware implementation. This
knowledge is a critical stepping stone for applying servo control in complex automation
and mechatronics systems.