System Maintenance and Care

Regular maintenance is essential for keeping your RTMC130 Motion Control System operating reliably and accurately. This guide outlines the recommended procedures for calibration, hardware care, and troubleshooting to maximize the lifespan and performance of your equipment.

Regular Calibration Procedures

Precise calibration is critical for maintaining accurate motion control. Different axis types require specific calibration procedures.

Linear Axis Calibration

For track, lift, and other linear motion axes:

1. Establish Reference Point:
   • Move the axis to a known physical reference point (often a hard stop or limit switch)
   • Use the SET HOME button on the jogbox with the axis number
   • Or use the zh command: zh 1 (for axis 1)
2. Measure and Verify Scale:
   • Move the axis a precise distance (e.g., 12 inches) using a measuring tape or caliper
   • Check that the displayed position value matches the physical distance moved
   • If incorrect, adjust the scaling factor in AxisSetup → Scale
3. Verify Multiple Points:
   • Test movement at 25%, 50%, and 75% of the axis travel range
   • Ensure position values remain accurate throughout the range
   • Adjust as needed for any non-linearity in the system

Rotary Axis Calibration

For pan, tilt, and other rotational axes:

1. Establish Zero Position:
   • Set axis to a known reference angle (e.g., level or perpendicular to ground)
   • Use a digital level or protractor to verify the angle
   • Zero the axis at this position using SET HOME
2. Verify Angular Measurement:
   • Rotate the axis a precise amount (e.g., exactly 90°)
   • Confirm the displayed value matches the physical rotation
   • Adjust scaling factor if positions don't match
3. Check for Backlash:
   • Test approaching a position from both directions
   • Measure any discrepancy (backlash)
   • Adjust the Backlash parameter in AxisSetup if needed

Focus and Zoom Calibration

For lens control axes:

1. Set End Points:
   • Move to minimum focus/zoom position, verify sharp focus on near object
   • Record this position as the "near" end point
   • Move to maximum focus/zoom position, verify sharp focus on far object
   • Record this position as the "far" end point
2. Create Calibration Table:
   • Use the MakeTable function (accessed via UtilFiles menu)
   • Set up reference distances and corresponding motor positions
   • For zoom, record focal length values at various positions
3. Verify Mid-Points:
   • Test several intermediate positions to ensure smooth, accurate transitions
   • Fine-tune calibration table as needed

Long-Term Hardware Care

Proper maintenance of hardware components extends the life of your system and ensures consistent performance.

RTMC Card Maintenance

• Dust Removal:
  • Power down the computer completely
  • Use compressed air (low pressure) to remove dust from the RTMC card
  • Pay special attention to cooling vents and chip heatsinks
  • Avoid touching electronic components directly
• Connection Inspection:
  • Check that the card is firmly seated in its ISA slot
  • Inspect the edge connector for corrosion or damage
  • If corrosion is present, clean with isopropyl alcohol and a soft brush
• External Connector Care:
  • Inspect DB25 and DB37 connectors for bent pins or damage
  • Check that all screws are properly tightened
  • Apply contact cleaner spray if intermittent connections occur

Jogbox Maintenance

• Button and Knob Care:
  • Clean buttons with a soft, slightly damp cloth
  • For sticky buttons, use compressed air around the button edges
  • Apply small amount of contact cleaner if buttons remain unresponsive
• Cable Maintenance:
  • Inspect the full length of the jogbox cable for cuts or damage
  • Check strain relief at both ends of the cable
  • Avoid sharp bends or kinks in the cable
  • Replace the entire cable if intermittent connections occur
• LCD Display Care:
  • Clean with a microfiber cloth specifically for displays
  • Never use alcohol or ammonia-based cleaners on the LCD
  • If display shows dead pixels or dim areas, the LCD may need replacement

Motor System Maintenance

• Stepper Motor Care:
  • Keep motors clean and free of debris
  • Listen for unusual noises during operation (grinding, clicking)
  • Check for excessive heat during extended operation
  • Avoid exposing motors to water, dust, or extreme temperatures
• Driver Unit Maintenance:
  • Ensure adequate ventilation around driver units
  • Check that all DIP switch settings remain secure
  • Verify that power supply voltage remains stable under load
  • Keep driver units in a clean, dry environment
• Wiring and Connection Care:
  • Inspect all cable connections for secure termination
  • Check for frayed wires or damaged insulation
  • Ensure proper strain relief at connection points
  • Label all cables to prevent mis-connection during maintenance

Mechanical System Maintenance

• Rail and Linear System Care:
  • Clean rails regularly with a lint-free cloth
  • Apply appropriate lubricant as specified by the manufacturer
  • Remove built-up debris from bearings and guides
  • Check for smooth operation throughout the range of motion
• Gearbox and Transmission Care:
  • Check for gear backlash and adjust if necessary
  • Inspect gear teeth for wear or damage
  • Maintain proper lubrication according to manufacturer specifications
  • Listen for unusual sounds during operation
• Belt and Pulley Maintenance:
  • Check belt tension regularly
  • Inspect belts for cracks, fraying, or glazing
  • Verify pulley alignment
  • Replace belts showing signs of wear before they fail

Preventative Maintenance Schedule

Following a regular maintenance schedule helps prevent issues before they occur and ensures consistent system performance.

Symptom-Based Mechanical Troubleshooting

This section helps identify and resolve common mechanical issues based on observed symptoms.

Axis Movement Issues

Position Accuracy Issues

Testing and Validation Procedures

Regular testing helps ensure your system continues to operate within specified parameters. These validation procedures should be performed periodically.

Axis Accuracy Validation Test

1. Set Up Test Points:
   • Create a test move with precisely spaced keyframes (e.g., every 2 inches or 10 degrees)
   • Save this as a dedicated test file (e.g., AXISTEST.MOV)
2. Physical Measurement Setup:
   • For linear axes: Use a digital caliper or measuring tape with 1/32" or 1mm resolution
   • For rotary axes: Use a digital protractor or level with 0.1° resolution
   • Position measurement tool to read actual position at each point
3. Run Validation Test:
   • Step through test points one-by-one
   • At each point, record the displayed position and the measured position
   • Calculate deviation at each point
   • Document maximum and average error for the axis
4. Interpretation:
   • Linear axes should maintain accuracy within ±0.5mm (±0.020")
   • Rotary axes should maintain accuracy within ±0.1°
   • If errors exceed these values, recalibration is needed

Repeatability Test

1. Setup:
   • Create a simple test move with two extreme positions
   • Install a dial indicator to measure actual position at test point
2. Execute Test:
   • Move to Position A and zero the dial indicator
   • Move to Position B and then back to Position A
   • Note any deviation on the dial indicator
   • Repeat this cycle 5-10 times
3. Evaluation:
   • Calculate maximum deviation across all cycles
   • Linear axes should repeat within ±0.025mm (±0.001")
   • Rotary axes should repeat within ±0.05°
   • If repeatability is poor, check for mechanical issues

System Performance Test

This test verifies the system's ability to maintain accuracy under dynamic conditions:

1. Create Test Move:
   • Design a complex multi-axis move using all relevant axes
   • Include various speeds, accelerations, and direction changes
   • Total duration should be 1-2 minutes
2. Execute Multiple Passes:
   • Run the move 3-5 times consecutively
   • Observe operation throughout each pass
   • Note any unusual sounds, vibrations, or hesitations
3. Final Position Check:
   • Mark or measure the exact final position after first pass
   • Compare final position after each subsequent pass
   • Any deviation indicates cumulative errors

Component Replacement Guidelines

When components need replacement, following these guidelines ensures proper installation and system integration.

RTMC Card Replacement

1. Preparation:
   • Back up all system files and configurations
   • Document current jumper and DIP switch settings
   • Power down system and disconnect all peripherals
2. Removal:
   • Remove system cover according to computer manual
   • Disconnect cables from old RTMC card
   • Remove mounting screw and gently extract card from ISA slot
   • Place old card in anti-static bag
3. Installation:
   • Configure new card with same jumper/DIP switch settings
   • Insert card firmly into same ISA slot
   • Secure with mounting screw
   • Reconnect all cables in original configuration
4. Testing:
   • Run RTMC diagnostic software to verify card function
   • Run dr (Diagnostic Report) command
   • Test each motor output individually
   • Verify all axes operate correctly

Motor Driver Replacement

1. Preparation:
   • Document all driver settings (current, microstepping, etc.)
   • Take photos of wiring connections
   • Turn off power to driver
2. Removal:
   • Label all wires before disconnecting
   • Disconnect power cables first, then signal cables
   • Remove mounting hardware and extract driver
3. Installation:
   • Mount new driver securely in same position
   • Configure DIP switches/jumpers to match old settings
   • Connect signal cables, then power cables
   • Double-check all connections before powering on
4. Configuration and Testing:
   • Adjust current limiting to match motor specification
   • Set microstepping to match system configuration
   • Test motor at slow speed before running at full speed
   • Verify smooth operation throughout range of motion

Stepper Motor Replacement

1. Selection Criteria:
   • Match or exceed torque rating of original motor
   • Ensure compatible mounting pattern and shaft size
   • Verify electrical specifications (voltage, current, etc.)
   • Confirm step angle (typically 1.8° or 0.9° per full step)
2. Installation:
   • Align shaft carefully with coupling or pulley
   • Use thread locker on mounting screws
   • Ensure proper wire connection sequence (refer to motor datasheet)
   • Verify shaft rotates freely before powering system
3. Calibration:
   • Re-calibrate the axis completely
   • Adjust scaling factor if step angle differs from original motor
   • Test motor through full range of motion at various speeds

Storage Recommendations When Not In Use

Proper storage helps maintain system integrity during periods of inactivity.

Short-Term Storage (1-3 Months)

• Mechanical Components:
  • Position axes in mid-range (not at extreme limits)
  • Relieve tension on belts if possible
  • Cover system with dust cover
  • Store in a climate-controlled environment
• Electronic Components:
  • Turn off power but leave system assembled
  • Ensure storage location has low humidity
  • Consider running system briefly every 2-4 weeks
• Software:
  • Create full system backup before storage
  • Leave computer with DOS boot disk ready

Long-Term Storage (3+ Months)

• Mechanical System Preparation:
  • Apply rust preventative to any exposed metal surfaces
  • Loosen or remove belts to prevent permanent stretching
  • Cover system with breathable material (not plastic)
  • Consider vacuum-sealed bags with desiccant for sensitive parts
• Electronic Storage:
  • Remove RTMC card from computer and store in anti-static bag
  • Store jogbox with cable loosely coiled (not tightly wound)
  • Consider removing batteries from any peripheral devices
  • Store in temperature and humidity-controlled environment
• Documentation:
  • Create complete system documentation including:
  • Current hardware configuration
  • Cable routing diagram
  • Calibration data and settings
  • Known issues or workarounds
  • Store documentation with system

Recommissioning After Storage

1. Inspection:
   • Check mechanical components for corrosion or damage
   • Inspect all cables for cuts, cracks, or rodent damage
   • Verify all connections are intact and not corroded
2. Mechanical Preparation:
   • Re-install belts with proper tension
   • Lubricate all moving parts according to specifications
   • Manually move all axes to ensure free movement
3. System Startup:
   • Reinstall RTMC card if removed
   • Perform power-on tests incrementally
   • Run full calibration procedure
   • Test with simple movements before complex operations

Software Backups and Configuration Management

Maintaining proper software backups ensures quick recovery from data loss or system failure.

Backup Strategy

• System Software Backup:
  • Create complete disk image of system drive using disk imaging software
  • Store backup on multiple media types (floppy disks, ZIP drives, external HD)
  • Label with OS version, RTMC software version, and date
• Configuration Files:
  • Back up all .SET and .ENV files
  • Document DIP switch and jumper settings
  • Create backup copy of RTMC130.LIB
• Project Backup:
  • Create separate backups for each project
  • Include all .MOV files and related configuration files
  • Document project-specific settings and configurations

Recovery Procedures

1. Software Crash Recovery:
   • Use the rq (Reload Quit) command to recover lost data
   • If unsuccessful, reload latest backup files
   • Re-enter any changes made since last backup
2. Complete System Restoration:
   • Boot from DOS system disk
   • Restore system disk image if available
   • Reinstall RTMC software if necessary
   • Restore configuration files from backup
   • Restore project files from separate backup
   • Perform system verification tests

File System Maintenance for Optimal Performance

MS-DOS systems require regular file maintenance to ensure reliable operation.

Disk Organization

• Directory Structure:
  • Keep moves organized by project in separate directories
  • Maintain clean root directory for system files
  • Use consistent naming conventions
• Recommended Folder Structure:

  C:\RTMC48\          - Main program directory
  C:\RTMC48\MOVES\    - General moves directory
  C:\RTMC48\SETUP\    - Setup and configuration files
  C:\RTMC48\BACKUP\   - Backup files
  C:\RTMC48\PROJ\     - Project-specific directories

Regular Maintenance Tasks

• Disk Cleanup:
  • Delete temporary files (*.TMP) when no longer needed
  • Archive old project files to backup media
  • Maintain at least 10MB free disk space at all times
• Disk Defragmentation:
  • Run DOS DEFRAG utility monthly
  • Perform before important projects
  • Defragment after deleting large numbers of files
• File Integrity Check:
  • Run CHKDSK periodically to check for disk errors
  • Repair any file allocation errors immediately
  • Consider running SCANDISK for more thorough checks

Performance Optimization

• CONFIG.SYS Optimization:
  • Maximize available conventional memory
  • Set FILES=40 and BUFFERS=30 for optimal performance
  • Avoid loading unnecessary device drivers
• DOS Performance:
  • Use SMARTDRV or similar disk caching utility
  • Set LASTDRIVE=Z to maximize available drive letters
  • Consider creating a minimal boot configuration for RTMC130 use