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User Manual - Kollmorgen

1. Customer Support Danaher Motion is committed to quality customer service Our goal is to provide the customer with information and resources as soon as they are needed In order to serve in the most effective way please contact your local sales representative to answer all your product needs If you are unaware of your local sales representative please contact Danaher Motion Customer Support Visit our website often for MOTIONLINK software upgrades application notes and technical publications Danaher Motion Customer Support Continental US Customers 1 800 777 3786 International Customers 815 226 2222 Email customer service danahermotion com Website www danahermotion com 26 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Personality Module for CD LITE Personality Module for CD LITE The Personality Module is used to easily configure multiple CD Lite servo drives After one servo drive has been configured and tuned the parameters of that drive are uploaded into the module In order to configure additonal servo drives with the same parameters the module is plugged into those drives and the parameters downloaded into the drives The same parameters that are stored in an SSV file are stored in the Personality Module In addition when downloading the parameters CONFIG and SAVE commands are included Preparation The CD LITE should have firmware version 0 1 3 or higher Description and Opera
2. Hidden switch upload Download CDLite How To Order The Personality Module may be ordered by specifying its part number LE PRMDL 28 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Appendix A Appendix A The SERVOSTAR product family can be mated with a variety of motors Cable sets motor and feedback can be purchased directly from Kollmorgen which gives you a complete plug n play system However some users may find it necessary to manufacture their own cable sets This Appendix provides pinout information between the drive s power and feedback connections and the motor receptacles for most of Kollmorgen s motor products Motor Power Connections SERVOSTAR GOLDLINE B M EB amp XT SILVERLINE RBHR RBE H DRIVE CONNECTIONS B M EB XT WIRE Color Motor Wire Color Motor Wire Color Wire Color Motor Motor Winding to Receptacle Winding to Receptacle Winding to Receptacle Receptacle Receptacle Receptacle Receptacle AM Pin 3 Brown Pin3 Black Pini Red Red A8 PinB 4 Red Pin4 Red pi we White GND PinD 2 Green Yellow pi Green pi Green _ H LR RESOLVER Connection SERVOSTAR GOLDLINE B M EB XT RBHR C2 B M EB XT XT Wire Color en De Wire Color Wire Color 50X amp 70X 30X from resolver to Connector from resolver to motor receptacle motor receptacle Bi Fin B Pin E e E EE EE Pin 3 shield WEE Ping PinD
3. LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Appendix D Appendix D Motor Thermostat with CD LITE From version 0 1 8 CD Lite supports motor thermostat types PTC and NTC PIN C2 Feedback Connector Electrical drawing 13 Thermostat High MOT_TMP 25 Thermostat Low MOT_TMP THERMTYPE 0 for PTC When the PTC is more then 12 4 kQ the drive is in motor overtemperature fault state you will see H flashing in the seven segment display THERMTYPE 1 for NTC When the NTC is less then 0 5 kQ the drive is in motor overtemperature fault state Default THERMTYPE 0 SERVOSTAR CD LITE User Manual 37
4. ROM player Standard Video Adapter CGA MDA EGA MCGA VGA or SVGA Serial Port for communication link with SERVOSTAR CD Lite The serial communications port may be COM1 COM 2 COM3 or COM4 COM1 is the normal configuration COMI Address 3F8h Interrupt Request 4 COM 2 Address 2F8h Interrupt Request 3 COM3 Address 3E8h Interrupt Request 4 COM4 Address 2E8h Interrupt Request 3 gt gt gt gt SERVOSTAR CD LITE User Manual 5 System Startup Danaher Motion Kollmorgen Speciality Electronics RS 232A Protocol Settings Baud rate 9600 or 19200 Data bits 8 No parity Stop bit 1 DIP switch 6 determines the serial communication baud rate for either 9600 BPS or 19200 BPS z Oo es Communication The following chart shows the flow of data between the PC and the SERVOSTAR CD Lite When logic power is applied to the drive it loads the variable parameters stored in EEPROM into the dynamic RAM for fast and easy access You can read and write these variable parameters to and from the PC by one of several methods described in the INITIAL STARTUP section below USER SETTING VARIABLE FILE Feel 1 MOTDN LNK PC OR TERM NAL DUMP command LOAD command or Power up EEPROM variables SAVE command operating parameters M CRO PROCESSOR Memory Flow Chart The PC transmits serial data to the drive and stores it in dynamic RAM However any variable data changed from the PC is
5. actual motor velocity The command for the velocity loop can come from a direct user input OPMODE 1 The velocity loop is a digital sampling system operating at 4 kHz The difference between actual and desired velocity is filtered through a compensator algorithm and fed to the commutation loop The SERVOSTAR CD Lite Pseudo Derivative Feedback with Feed Forward PDFF 16 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Operation FeedFwd Gain VCMD rpm Current Controller Command command Filter Filter Integrator Integral Gain Proportional Gain V rpm Feedback Filter Torque Loop Most applications use the SERVOSTAR CD Lite in torque mode configuration The SERVOSTAR CD Lite has many internal variables that can be used to examine and dictate system operation Many of these variables and their locations in MOTIONLINK are presented graphically in the following discussions to help disclose meanings and relationships Analog Torque The SERVOSTAR CD Lite is most often configured to operate as an analog torque loop controller OPMODE 3 In this case the current loop receives its input from the analog to digital A D conversion system After conversion the input command signal is processed through an algorithm that adjusts the signal ANOFF1 ANDB ANZERO filters it ANLPFHZ and scales it SCALE before developing the current command The current or torque c
6. drive The drive s microprocessor monitors the current feedback signal and develops a RMS value of this signal for the purpose of providing a value that represents the current in the motor The system is similar to an I squared T accumulator Drive Foldback This Foldback algorithm monitors current feedback and if the feedback exceeds the continuous current rating of the drive motor combination ICONT decreases the system s current to the ICONT level For example under a step command input condition the Foldback algorithm allows maximum peak current IMAX output from the drive for V second After this the drive enters Foldback mode FOLD 1 and begins an exponentially Foldback to the system s continuous current It takes approximately six seconds for the exponential decay to drop from the system s peak current to its continuous level For drive currents that exceed ICONT but are below IMAX the system period before Foldback occurs is extended beyond two seconds Two seconds is the shortest time period that will elapse before the drive enters Foldback and only occurs when maximum peak current IMAX is drawn This Foldback feature is designed to protect the drive electronics not the motor The Configurable Output O1 pin 12 can be configured to indicate a drive Foldback condition Current Amp StartFoldback IMAX 2 EnFoldback EndFoldback ICONT 5 FOLDT 18 SERVOSTAR CD LITE User Manual Danaher Motio
7. lost when logic power is lost if it is not saved into non volatile EEPROM If you configure the same system on similar applications the variables can be saved on disk in an SSV file for convenient downloading into other drives 6 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup Installing MOTIONLINK Insert the CD ROM to load MOTIONLINK for Windows The CD ROM should AUTORUN If not select Start Run or browse your CD ROM drive Type D AUTORUN EXE and press the Enter key this assumes your CD player has a D letter designation Select a product and follow the instructions on the screen To run the program go to your Start Programs listing and select SERVOSTAR MOTIONLINK from the menu or click on the SERVOSTAR MOTIONLINK icon if loaded on the desktop Using MOTIONLINK MOTIONLINK gives you three methods to configure the drive The first uses a Startup Wizard and is the easiest and most highly recommended approach Its main purpose is for initial startups The second approach allows you to more indirectly perform the same configuration as the first using the Main MOTIONLINK screen This method is most convenient when corrections to an existing configuration are required The third method uses the Terminal Mode screen to directly set or monitor values for the same variables and commands that the other two methods configure through a more friendly user interface You can gain
8. this example Configure the CD Lite to a Motor 1 Start MOTIONLINK by clicking on the icon SEAVOSTAR MOTIONLINK You will see the Startup screen below SSCS HAN MOA LIME Hom Betis Marian liom weer TELER verdere uf SEAS TAR Finse Aag Ete Gane Th wll bie gedig Pian fe AO HEG REG OOR EES BEE BESVIGTAR K fe miir and voed mechan Dick Har m tes kk Tof in gn n the Mes TONLE een De ices Veet Ties Hep Eed Select Start Verify that the drive information is correct Select OK Select Close From the new amplifier Startup window select Next For motor configuration Oy EE ay PD SERVOSTAR CD LITE User Manual 31 Appendix B Danaher Motion Kollmorgen Speciality Electronics 7 Select GOLDLINE XT MTX502A1 8 Select the TO Drive button to download the motor parameter to the Drive 9 Select Yes 10 Select Close to close the motor configuration window 11 From the new amplifier Startup window select Next for feedback configuration ERVUS LAH LIT CODER TYPE AND AE SOLUTION SELECTION alec the ronde Tyre using the conhok onthe Enc Tignes bab Zei Be Peskdon by Grieg a ah n thes 12 Select the encoder type and type the motor resolution in the resolution field you can manually rotate the shaft for confirmation 13 Select Close 14 From the new amplifier Startup window select Next For OPMODE configuration 32 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Specialit
9. 50 0ms Cho E 40mV 7 jul 2002 12 55 25 20 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Operation C3 E 10VDO 12 bit ANOFF1 SE ANDB ANLPFHZ ES ANZERO KVFR N 1000 ANINT z H 9 N Ee VD VE ka 1 CH1 0 Hee NEI wi KVI 1 LPF 1 icmp 3 Phase Scope ES VSCALE H VMAX pe J oO on LPF 1 LPF 2 Tourge CH2 S vospp VOMD _ 65 1537 LPF 2 Notch Loop Resonance i E VD is 1 when gt VD 000 A 10VDC o VF is 1 when gt VF 1000000 la Ic l ANOUT v LPF Loe Pass Filter 2 0 V velocity COMPFILT 1 1 current 2 VE velocity error LPF 1 Velocity 3 ICMD current command no D Le d dt on o Digital Output The digital output is a fix output where is ON during regular operation and of when the drive goes into Foldback mode in both operational mode velocity and torque Control Loops This section describes the servo control loops their characteristics and how to configure them Core Processors A 40 MHz embedded Controller and a 40 MHz DSP controller are the heart of the SERVOSTAR CD Lite They use its internal operating system to monitor inputs adjust outputs communicate serially maint
10. Danaher Motion Kollmorgen Speciality Electronics SERVOSTAR CD LITE User Manual SERVOSTAR Product Series M SS 008 0302 Firmware version 1 1 0 MOTIONLINK version 4 4 3 Ignite CD Lite version 1 0 5 Caution MOTIONLINK version 4 4 3 only works with Firmware version 1 1 0 and vice versa Record of Manual Revisions ISSUENO DATE BRIEF DESCRIPTION OF REVISION FIRMWARE 01 09 01 2001 Initial release 0 1 2 02 02 02 2003 Second edition updates for new firmware 1 1 0 VGA and PC AT are registered trademarks of International Business Machines Corporation Windows95 98 and Windows NT are registered trademarks of Microsoft Corporation EnDat is a registered trademark of Dr Johannes Heidenhain GmbH Kollmorgen GOLDLINE Kollmorgen SILVERLINE MOTIONEERING MOTIONLINK PLATINUM and SERVOSTAR are registered trademarks of Danaher Motion Kollmorgen Copyright Information Copyright 2001 2003 Danaher Motion Kollmorgen Speciality Electronics All rights reserved NOTICE Not for use or disclosure outside of Danaher Motion Kollmorgen Speciality Electronics except under written agreement All rights are reserved No part of this book shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no re
11. F MSPEED VEL_CONFIG_FAILED The velocity loop can t be 41 con figured with given parameters Ga celal IE power of 2 BURNIN ACTIVE Reguested function cannot 47 be executed during Burnin factory function BURNIN_NOT_ACTIVE Burnin factory function 48 cannot be stopped if it is not active NOT_AVAILABLE The requested variable value 51 is not available refer to the description of the variable in section to determine why SERVOSTAR CD LITE User Manual 21 Troubleshooting Danaher Motion Kollmorgen Speciality Electronics NO MESSAGE FAULTS Status Fatal ds Kaes SE iteady Display Fault Description irror pla lisplay ee 1 NoCompensation LTL 2 Invalid Velocity Com d d gt 6 1__ Failure while reading from the personality module Ir Hardware CW limit switchopen S gt L2 Hardware CCW limit switchopen J J L3 Hardware CW and CCW limit switches open _ Ir Ir A3__ Positive and negative analog supply fail I RAM failure during ini afo So d gt E E ET 8 Test LED pni E Ed Ee ed Fault Monitoring System The SERVOSTAR CD Lite s microprocessor is constantly monitoring the status of many different components In general all fault conditions are latched so you can readily determine the source of the problem When a fault is detected it is logged in the internal error log indicated in the stat
12. PinD Ping Yellow Pins Yelow Ra Pin 6 Shield a a Pin 14 Shield RE EE Pini3 PinT PinR Pin2 Yellow m pw Pn Pinu Pins Pin Yelow Ping Re TI Pin 12 Shield NN id SERVOSTAR CD LITE User Manual 29 Appendix A Danaher Motion Kollmorgen Speciality Electronics LE Encoder Connection SERVOSTAR GOLDLINE B M EB amp XT SILVERLINE RBE H al eee he Encoder Receptacle at Motor Receptacle Ee Dees Color a B M EB Series XT Series XT Series Jee IF NE Gei Pin 3 shied CO Pin 6 Shield CO EE EEN EEN EEN MEEN PRES Pns Pns PT Red Pa Red Pin Ping o PE pt Pini Brown Pini Goen O Pinio _ PnH Pan Pme Gay Pm Gwy Pan JL PnK TC PinK Pinis TI we mu T White Pin 12 Shield WEE Pinis Pint mit IC mg TI ve Pini Yelow Pin 14 Shield O EEN EEN EEN EE EEN Ee we OE AE es Bas N par N OR N Rd RR ER YE l Pp Pn 25 Panu Pnu Pin9 _ Yeow Pin Yew ___ Must be shorted to C 2 pin 18 for proper operation 30 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Appendix B Appendix B Setup Example The following example shows how to configure the CD LITE 3 AMP with GOLDLINE XT MTX 502A1 Once configured we will run it from MOTIONLINK in Torque Mode Remember Torque Mode doesn t need tuning Where in velocity mode you have to tune the PDFF VF VD and COMPFILTparameters not cover in
13. a more thorough understanding of the SERVOSTAR drive MOTIONLINK and its variable and command set by using the context sensitive Help F1 provided in MOTIONLINK When you begin the first screen you see is Startup Wizard This screen appears the first time and any time after should you choice not to deselect it MOTIONLINK is run on a PC It is designed to guide you through a step by step approach to configure a drive Click the START button on the first user screen and walk through the complete sequence of buttons provided to set the drive motor and application Opmode Tune Backup Go variable parameters Should you de activate this screen it can be reactivated by going to the Main MOTIONLINK screen pulling down the Configuration menu and selecting the New Drive 123 option Setting Drive Variable Parameters Click the Drive button This screen allows you to select a BUS value that corresponds to the incoming line voltage This selection actually determines the setting of the variable VBUS Also included is a realtime monitoring of the DIP switch on top of the drive so you can verify the proper setting for the drive address baud rate and various other parameters Click Exit to return to the Startup Wizard screen Setting Motor Variable Parameters Click the Motor button This screen allows you to access the MOTIONLINK motor database Select a motor family and then a model within that family Information will appear in the blan
14. able input to get power to the motor The drive enable logic is based on the following variable switches and flags ACTIVE This is the overall readiness flag indicating the enable disable state of the drive If high 1 the drive is enabled and power is being applied to motor The following equation must hold true for ACTIVE to go high ACTIVE READY AND REMOTE where READY DRIVEOK AND SWEN READY Flag that indicates the drive is free of faults and ready to hardware enable DRIVEOK Switch indicates the status of the drive faults SWEN Switch indicates the status of the software enable EN or DIS REMOTE Switch indicates the status of the hardware Remote Enable line on the C3 connector fault status software enable drive ready 1 no faults 0 disable 1 no faults 1 enable READY REMOTE ACTIVE drive ready hardware enable power to the motor H Om If the drive will not enable check the state of the switches and flags by clicking the Status button in the upper right hand corner of the Main MOTIONLINK screen If using a terminal you can query the drive for the value stored in the STATUS variable The Status Display indicates an enabled drive when the decimal point is illuminated solid 10 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup Feedback The SERVOSTAR provides a motor position output to you in the form of quadrature encoder signals elimina
15. ables memory RAM Random Access Memory and the program memory EPROM Electrically Programmable Read Only Memory are tested If a RAM fault is detected an T is displayed and the drive is halted If an EPROM fault is detected a c is displayed and the drive is halted The user configuration non volatile memory EEPROM Electrically Erasable Programmable Read Only Memory is also checked for integrity upon power up Any discrepancy in this data is noted with an e in the status display After power up is successfully completed any subsequent fault in the operation of the EEPROM is noted with an F in the status display WatchDogs The SERVOSTAR incorporates a watchdog system to maintain software operation integrity Failure of the watchdog mechanism displays three bars on the status display and causes the drive to halt This normally indicates serious problems Please contact Danaher Motion Customer Support SERVOSTAR CD LITE User Manual 23 Troubleshooting Danaher Motion Kollmorgen Speciality Electronics Firmware Upgrades From time to time Danaher Motion adds features to its products that expand their overall capabilities Features added to the SERVOSTAR CD Lite can be easily implemented at the customer s site This is accomplished by downloading new firmware via the drive s serial port directly from a host computer When ordering a firmware upgrade you receive the following files Lccd xxx emb firmware cod
16. ailure o Over voltage Excessive _omm rate P Over current Power stage surge current rl Resolver line break resolver Break in resolver input lines detected 12 RDC error resolver Resolver to digital error EE EE s2 mr ME N EE AE SU 7 r4 A B line break encoder Break in encoder A B input S lines detected r6 Ilegal halls encoder Ilegal hall combination 4 6 detected cane Kee Ee eg Fee N Erala x 4 1 4 2 4 4 c Under voltage Bus voltage is too low Motor over temperature Motor overload caused overheating Al Positive analog supply fail Failure in 12V supply T A2 Negative analog supply fail J D e EEPROM checksum fail EEPROM checksum F Foldback System in FoldBack mode 12 The Over Current fault can only be cleared by cycling power The other faults can be cleared by toggling the Enable 20 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Troubleshooting NON FATAL ERROR CODES Status Error Message Possible Cause Fatal Non Fatal Error Display NO ERROR No error was recorded E EG UNKNOWN COMMAND ___ Undefinedcommand 2 checksum ackmode 2 DRIVE_ACTIVE Drive needs to be inactive 23 for the requested command or variable VALUE OUT OF RANGE Variable value out of range 25 EE BEE syntax error INOT_PROGRAMMABLE Variable is read only 36 current loop design failure MENCOF
17. ain servo control and monitor faults The flash memory firmware that controls the core processor and gives the SERVOSTAR CD Lite its operating characteristics is saved in EPROM The version number of the firmware can be read using the VER command When calling Danaher Motion Customer Support be sure to have the firmware version number readily available The most recent version of firmware is available for purchase and is easily field upgradable through a PC It can be obtained by contacting a Danaher Motion sales representative or by contacting the Danaher Motion Customer Support SERVOSTAR CD LITE User Manual 15 System Operation Danaher Motion Kollmorgen Speciality Electronics Servo Loop Description The SERVOSTAR CD Lite provides high performance motor control by controlling up to three distinct closed loop systems within the DSP the current commutation velocity Current Loop Since current and torque are proportional in a Permanent Magnet PM motor the current loop is often referred to as the torque loop The function of the current loop is to regulate motor current as directed by a Current command signal The current command signal from the microprocessor can either come from a direct user input OPMODE 3 or from the output of the velocity loop There are actually three current loops one for each motor phase Each current loop receives its own command input from the commutation loop The SERVOSTAR CD Lite uses a fully digital pol
18. alent Output EEO signals depends on the type of motor feedback device SERVOSTAR CD LITE User Manual 15 System Startup Danaher Motion Kollmorgen Speciality Electronics Resolver Systems The output signal is developed through the R D hardware circuitry for minimal phase lag and has a maximum frequency determined by the motor speed and R D limits It provides a configurable ENCOUT resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft The placement of the index pulse INDEXPOS can be varied on resolver systems within 360 electrical degrees of the feedback signal For single speed resolvers this means you can vary the position of this signal over one mechanical revolution For multi speed resolvers the mechanical position variation is determined by the pole pair count of the resolver e g three speed resolver gives mechanical variation of the pulse within 1 3 of a revolution Encoder Systems The output signal is the actual encoder feedback signal that is pre configured MENCRES in the drive s motor parameters It can be scaled down by multiples of two ENCOUTO 1 2 4 8 16 and has a maximum frequency limit of 3 MHz 16 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Operation System Operation The SERVOSTAR CD Lite has a seven segment indicator Status Display that indicates four types of states Power up Steady State Flashing State Momentar
19. ands are grouped alphabetically for easy look up and are found at the end of this manual Be sure you review this information before you begin Initial Startup Most drives are shipped from the factory already configured for a particular motor You can verify this by applying logic power and monitoring the Status Display A factory configured drive goes through a power up sequence flashing all segments of the display before settling out to a number indicating the mode of operation If the drive is not configured with a particular motor the display will flash a minus sign indicating that you must enter drive motor and application variable parameters The remainder of this section describes the process of setting up a non configured drive Caution must be taken when applying power to the drive It is factory configured to enable upon application of power Verify that the hardware Remote Enable REMOTE enable switch is disabled Upon powering up the SERVOSTAR performs a series of self tests If the Status Display illuminates a solid number then no errors were found and the EEPROM has loaded its variable parameters or loaded with default values in case of invalid EEPROM data into RAM The Remote Enable switch on the I O connector C3 may now be energized thus enabling the servo loops SERVOSTAR CD LITE User Manual 9 System Startup Danaher Motion Kollmorgen Speciality Electronics Enabling the System 24 volts must be present at the C3 en
20. as speed and torque optimization through commutation angle advancing of the drive s output current waveform with respect to the motor s back EMF waveform Firmware and serial number information VER MOTOR via terminal CD Lite versus CD gt oes gt gt gt Power board Logic power generated from line SERVOSTAR CD without Top switch Power board Logic power supplied from external 24 VDC Same as SERVOSTAR CD Digital board Current Card Board CCB instead of UCB C1 Serial Communication is R 232 only support for personality module C2 Feedback Incremental Encoder A B Z Hall A B Hall Halls only sine wave or SIX step Resolver only w Logic power supplied from external 24 VDC C3 Analog input fault output I O Analog output C4 Same as SERVOSTAR CD C7 Not available C8 Not available Configuration DIP switch settings CD LITE defines the RS 232 baud rate hold switch drive enable and disable EN DIS and changes to Ember Mode MOTIONLINK Same as SERVOSTAR CD except to Record application SERVOSTAR CD LITE User Manual 3 Product Description Danaher Motion Kollmorgen Speciality Electronics Part Number Description The SERVOSTAR CD Lite serial and model numbers are Month Manufactured Year Manufactured Manufacturing F acility Unit Manufactured Feedback Power Options E Encoder 250 Logic power generated from line R Resolver 260 Logic power suppli
21. at produced by the power supply Bus Under Voltage An under voltage condition shuts down the drive and displays an u in the status display This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply 22 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Troubleshooting PowerStage Fault OverCurrent Hardware circuitry monitors load short circuit transistor failure and instantaneous OverCurrent In general toggling the Remote Enable cannot reset a power stage fault Power must be cycled A flashing P in the status display indicates this condition Low voltage power supply faults Out of tolerance values on the 12 VDC analog supplies will cause an A to be displayed and disable the drive OverSpeed fault Software continuously monitors the actual feedback speed If the motor speed exceeds the VOSPD limit a J is displayed and the drive is disabled This normally occurs when there is an improperly tuned system and the load overshoots its commanded speed No compensator In case the SERVOSTAR cannot design a compensator after a RSTVAR command CLREEPROM or any change in the motor or drive parameters a flashing minus sign is displayed and causes the drive to disable This display normally indicates the drive does not have a compensation file loaded Memory reliability During the initialization process upon power up the runtime vari
22. aving Variables Parameters to SSV file Restoring Factory Variable Parameters Restoring Custom Variable Parameters Main MOTIONLINK Screen This screen appears the when you exit out of the MOTIONLINK Startup Wizard screen All the screens mentioned in the method above can be accessed from this screen and should be used to make corrections in the current system configuration Setting Drive Variable Parameters From the Configure menu click the Drive option The same screen appears as described in the Startup Wizard screen section Click Exit to return to Main MOTIONLINK screen Setting Motor Variable Parameters Selecting the Motor option under the Configure menu you can obtain the same parameter screen found in the Startup Wizard screen Click Exit to return to Main MOTIONLINK screen Customizing to Application By dropping down the Operational Mode listing you can select the mode of loop control desired velocity torque Clicking the Tune button you can select the system bandwidth the type of loop control and the filtering necessary for the application These are the same parameter screens found in the Startup Wizard screen Click Exit to return to Main MOTIONLINK Screen Saving Variable Parameters to EEPROM At the top of this screen you can click the button labeled RAM E to save the modified variables from RAM to EEPROM Saving Variable Parameters to SSV file Occasionally you may desire to backup the variable paramet
23. dback and motor cables in the same conduit Danaher Motion Kollmorgen has tested cable lengths up to 75 ft 22 9 m without degradation of performance However performance may vary depending on motor and resolver type Tests were performed with standard Danaher Motion Kollmorgen cable and its low impedance and Danaher Motion Kollmorgen GOLDLINE motor resolver Please consult the factory for cable and resolver impedance specifications when long cable runs above 250 ft 76 m are desired Danaher Motion Kollmorgen recommends twisted shielded pair for feedback cables da SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup Resolution and Accuracy The SERVOSTAR calculates motor velocity as the derivative of position change in position over time With its patented technique all readings are extended to a resolution of 16 bit For velocity feedback calculations the drive converts the resolver input to 18 bits of resolution giving smooth motor velocity control The digital resolution RDRES of the Resolver to Digital Converter system is determined automatically according to the application velocity limit VLIM The following is a summary of the SERVOSTAR s resolution capabilities VLIM RPM RDRES Encoder Eqv Output C4 gt 6100 4096 4096 quad counts 1500 to 6100 16384 16384 quad counts lt 1500 65536 65536 quad counts R D Converter Specifications System accuracy using resolver fee
24. dback is effected by several components The following table gives information on the inaccuracy that each of these components contribute to the total accuracy of a standard SERVOSTAR system Components ArcMinutes R D Converter 4 Resolver mechanics rotational 8 Resolver mounting on motor shaft 2 Inter LSB digital dither over the least significant bit 5 Total Worse case 19 Resolver Accuracy Specifications Halls Only Halls only with sinus commutation According to halls the drive creates the sine wave for the commutation which is updated every halls switch Hall only with six step commutation Electrical Degree HA HB HC Current from phase to phase for clockwise direction Disconnect Phase 0 60 100 AtoB C 60 120 101 CtoB A 120 180 001 CtoA B 180 240 O11 BtoA C 240 300 010 BtoC A 300 360 110 AtoC B Encoder Equivalent Output The SERVOSTAR provides a motor position output to you in the form of quadrature encoder signals eliminating the need for an additional position feedback device The outputs are differential line drivers There is an associated DC common output C4 pin 3 which can connect to your port to keep common mode noise and voltage spikes minimized for device protection Because there are normally differences of potential between your controller and the drive connection is recommended if ground loops occur disconnect and retest The source of the Encoder Equiv
25. e xxx describe the firm ware version Ember txt firmware upgrade utility Cdlignit exe windows application to download the firmware code Ig bat for user how want to ember in DOS Mode Ignite exe for user how want to ember in DOS Mode Upgrade Procedure in windows operation system 1 Turn off the CD LITE 2 Change the DIP switches 8 and 10 to 1 you can find them on top of the CD LITE 3 Turn ON the CD LITE Make sure that the seven segment Led on the CD LITE changes to E Ember 4 With explorer activate Cdlignit exe the following dialog box appears Ignite CD Lite 1 0 5 Com Port e C Com This program will update your ServoStar firmware om To do this take the following steps Com2 1 Power off the Drive C Coma 2 Set DIP swithes 8 and 10 to UP c 3 Power ON the Drive and verify that the letter E is shown Com4 on the seven segment display xi Baud Hate Fiename t i SC O W OC 9600 fiom e C 38400 ceo ase 1 Advanced Exit 5 Select the Com Port 6 Select Baud Rate default 115200 7 Select Advanced the dialog box Advanced options appears 24 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Troubleshooting Advanced options EN Files to download File Name File Path Leed_110 emb I X eng LCCD FIRMWARE Delete Cancel 8 Select Lccd_xxx emb and select OK 9 From the windo
26. e placement current loop with high bandwidth and a current loop sampling rate of 16 kHz 62 5 us All coefficients of the current loop are digitally calculated inside the drive for a given set of motor and drive characteristics The current loop also includes adaptive gain terms to compensate for some non linear effects The current loop incorporates electrical isolation for protection from the high voltage BUS These current loops also convert the output voltage to a Pulse Width Modulated PWM signal providing the highest efficiency possible The PWM center frequency can be 8 or 16 kHz according to the drive size Commutation Loop This loop converts a single phase current command signal into a three phase position modulated sine wave input to the current loops The SERVOSTAR CD Lite has a patented sinusoidal wave form generator that uses a technique called Torque Angle Advance to get top performance out of its motors The waveform generator is part of the microprocessor and is updated at a 16 kHz rate This provides hi fidelity sinewave commutation at both low and high velocities The sinewave output must be aligned to the back EMF characteristics of the motor This is why resolver or encoder alignment to the motor is critical Velocity Loop The purpose of the velocity loop is to regulate motor speed Like the current and the commutation loops the velocity loop is fully digital and uses the resolver or the encoder feedback signals to calculate
27. ed from external 24 VDC Current Rating 03 3 Amp Continuous 9 Amp Peak 06 6 Amp Continuous 18 Amp Peak 09 10 Amp Continuous 20 Amp Peak Resolver configuration could be ordered only with Logic power supplied from external 24 VDC 4 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup System Startup Application Load For system startup you need a PC with MOTIONLINK for windows LE CD LITE drive brush less motor and your application connected to the motor With MOTIONLINK you can initialize and configure you drive to your application After that you will connect the drive to your servo controller You can communicate with the SERVOSTAR CD Lite through the serial port Since MOTIONLINK is designed to guide you through the operation process of the drive the MOTIONLINK discussion in this section covers only general steps of use A dumb terminal can also be used to communicate to the drive You may find this method of communication very awkward until a certain level of familiarity with the drive s operation is achieved MOTIONLINK also provides a terminal emulation feature that contains many useful editing tools for this type of communication Computer Requirements MOTIONLINK requires an IBM PC or compatible computer with the following features IBM compatible Pentium or higher computer 16 M RAM Windows 95 Windows98 WindowsNT 4 0 with Service Pack 3 Windows 2000 CD
28. er time Operating modes enable internal sinusoidal from a 10 VDC command The documentation provided for the SERVOSTAR CD Lite includes this document the SERVOSTAR CD Lite Quick Start manual and the SERVOST ART CD Lite Variable and Command Reference These are provided to assist you in installation and use of the SERVOSTAR CD Lite product Product Features The SERVOSTAR CD Lite includes a vast array of features Its various control techniques interfaces and user tools give the customer a fully compatible amplifier to meet most motion control applications The user features are Main Features Digital current loop Velocity loop mode Available in 3 6 or 10 amp continuous current Self protecting power stage Encoder feedback PWM switching frequency up to 16 kHz Supports Danaher Motion Kollmorgen s wide range of motor solutions Optional 24 VDC logic input supply to separate from main supply Easy tuning and setup using MOTIONLINK for Windows Easy initialization utilizing a Personality Module tt gt gt Oo gt gt OO Robust Design Fully isolated electronics Fault Protection against output phase to phase short circuit over voltage under voltage over current over temperature motor and drive feedback loss Current foldback 12t provides protection against over heating drive Can be optionally used with Danaher Motion Kollmorgen s Regeneration Resistor SERVOSTAR CD LITE User Manual 1 Product De
29. ers from one drive for use in another To do this you must pull down the Edit menu and select Backup Variables request the information from the drive Receive button into the editor and save Save button the contents in a SSV format to a specified disk location 8 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup Restoring Factory Variable Parameters To restore the original factory variable parameters pull down the Configure menu select Motor and select the motor family and motor model Click the To Drive button to send the variable parameters to RAM and the RAM E SAVE button to save to EEPROM Restoring Custom Variable Parameters This process assumes that you saved the custom variable parameters to a SSV file as described above To restore the custom parameters pull down the Edit menu select Backup Variables and click on Open Highlight the custom SSV file to import variable parameters into editor Click Xmit to send variable parameters to drive Terminal Mode Use the MOTIONLINK Terminal Mode or any other dumb host to directly monitor or modify the variable set and command the drive This approach should only be taken when a PC with a Windows operating system is not available and or you are well versed with the variable and command set Each variable and command are referenced for its syntax and parameter definition The variables and comm
30. es direct manipulation of velocity loop gain parameters Monitoring and Troubleshooting Tools Control loop monitoring via terminal o Current torque I IA IC ICMD IMAX ICONT DICONT DIPEAK o Speed V VCMD VE Dual state digital output O1 can be used to communicate occurrences of foldback Software status switch indicator provided for Configurable Inputs IN Analog output to monitor Current Velocity V VE LICMD SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Product Description Fault and Safety Detection Watchdog faults Speed and current protection VOSPD VLIM ILIM Fatal and non fatal error coding with text explanation to the host FLTHIST FLTCLR Also includes a run time counter TRUN that records the time the error occurred Configurable drive thermal protection through the foldback feature FOLD FOLDMODE It sets the maximum time limit the drive can provide peak current 3 1 to the motor Hardware position limit switch detection INx where x is 1 or 2 Configurable fault relay output RELAY RELA YMODE Active enable indicator through the Status Display decimal ACTIVE DRIVEOK SWEN READY REMOTE General Many enabling and disabling features K REMOTE EN DIS Flash firmware memory for easy field upgrade installation Danaher Motion Kollmorgen s patented Torque Angle Control for buried magnet motor designs MTANGLC MTANGLP MVANGLF MVANGLH defined
31. g is achieved can vary the performance Error Codes In most cases the SERVOSTAR CD Lite communicates error codes with a text message via the serial port to the host Some error codes are also transmitted to the status display The same message is saved in the EEPROM under an error history log FLTHIST ERR so that nothing is lost when power is removed Not all errors reflect a message back to the host In these cases the no message errors communicate only to the status display The response of the SERVOSTAR CD Lite to an error depends on the error s severity There are three levels of severity 1 Warnings simply called errors are not considered faults and do not disable operation 2 Non fatal errors or simply faults that disable the drive and indicate a fault status 3 Fatal errors or fatal faults that disable almost all drive functions including communications command DIS or K followed by the EN command or toggling the Remote Enable line The drive is automatically disabled at the occurrence of a fault Executing a drive disable A REMOTE resets the fault latch If the fault condition is no longer present re enables the system SERVOSTAR CD LITE User Manual 19 Troubleshooting Danaher Motion Kollmorgen Speciality Electronics FATAL FAULTS ERROR CODES Status Error Message Possible Cause Fatal Non Fatal Error Display Notat f t Power stage over temperature Overload fan malfunction power stage f
32. he motor data sheet PolePitch mm Vmax Max linear Speed mm sec BEMFI Linear Back EMP Vpeak m sec L L Motor poles usually it is 2 Resolution uM micron before quad Calculate CD Lite parameters MENCTYPE according to the feedback type MSPEED Vmax x 60 PolePitch RPM MENCRES PolePitch Resolution Motor Rev MENCOFF 0 if MENTYPE 6 VLIM Vilim x 60 PolePitch RPM VOSPD Vlospd x 60 PolePitch RPM VSCALE Vlscale x 60 PolePitch RPM Oo oe OO OH Os Lite Variable and Command Reference RPM MKT BEMFI x PolePitch 60 x 16 54 10 3Nm RMS AMP MPHASE please check hall table and compare halls phasing VMAX is automatically calculated after execute the command CONFIG for further information see CD One Pitch lt PFB 4 X MENCRES 65536 RRD 360 Electrical degree Halls HA HB HC no p oo p ot t 1 1 10 MENCOFF Z index pulse 0 0 SERVOSTAR CD LITE User Manual Appendix C 35 Appendix C Danaher Motion Kollmorgen Speciality Electronics 0 to 60 Degree HA 1 HB 0 and HC 0 MPITCH 2 x Pole one electrical cycle mm Temp Sensor Ee X mee Ke Feedback Motors phases To Lx C2 Resolution micron PFB MPITCH MENCRES x 4 MPITCH Resolution 36 SERVOSTAR CD
33. ial receiver is applied to a precise 12 bit Analog to Digital A D conversion system The A D conversion system is read by the microprocessor 250us for the velocity loop mode and every 62 5us for the torque current loop mode of operation Encoder based units have the additional benefit of a Dual Gain ANDG input When enabled the system uses two 14 bit A D inputs to read the user supplied analog signal One input is a direct reading of the 10V signal while the other incorporates a 2x gain term When the input voltage is less than 4V the 2x channel is used to determine the user s input voltage This extends the resolution to a 15 bit equivalent Above 4V the system uses the straight 14 bit conversion Special software algorithms are used to minimize cross over distortion and add 0 25 V hysterisis Analog systems often require scaling and offset bias The SERVOSTAR CD Lite adds an analog offset ANOFF1 variable to this reading performs an analog deadband ANDB adjustment and scales it through velocity loop input scaling VSCALE or torque loop input scaling ISCALE before passing the data to the selected control loop The analog input ANIN1 variable indicates the analog reading after the offset ANOFF1 and the deadband ANDB adjustments but before the loop scaling The ANIN1 variable range is 22500 counts or mV The SERVOSTAR CD Lite also has an automatic analog input zeroing function Invoking the ANZERO command while the drive
34. is enabled or disabled samples motor velocity over a 32 ms period and updates ANOFF 1 accordingly to cancel out analog input offset This command uses an internal offset mechanism that has finer resolution than ANOFF1 is capable of providing 18 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Operation Remote Enable Input REMOTE The opto isolated Remote Enable input REMOTE provides a hardware drive enable switch This 12 24 VDC input disables or enables the power stage output to the motor The signal must be customer supplied to get the drive to enable in combination with other parameters ACTIVE and operate Tapping the signal off the logic supply C5 is not recommended The toggling of this switch also initiates an attempt to recover from a fault condition Fault Output Relay RELAY RELAYMODE The SERVOSTAR CD Lite provides a drive ready drive up output in the form of a relay RELAY output The relay RELAY output is controlled by the SERVOSTAR CD Lite s microprocessor There is a software switch RELA YMODE that configures the relay RELAY output to act as a Drive Ready or Drive Up indicator If RELAYMODE 0 the relay is closed when the drive is error free and ready to run This is a Drive Ready configuration If RELAYMODE 1 the relay is closed only when the drive is enabled This is a Drive Up configuration ACTIVE equals 1 If RELAYMODE 2 is not avalib
35. k parameter fields on the right Click on the To Drive button beneath the fields to send the variable parameters to the drive Click Exit to return to the Startup Wizard screen For you that has a configured drive a From Drive button is provided to retrieve the motor data already in the drive Retrieving this data will not erase it from the drive SERVOSTAR CD LITE User Manual 7 System Startup Danaher Motion Kollmorgen Speciality Electronics If the motor cannot be found in the database click on you Define tab Contact Danaher Motion Customer Support for detailed instructions Customizing to Application Click the Opmode button in the Startup Wizard screen to select the mode of loop control desired velocity or torque Click Exit to return to the Startup Wizard screen Click on the Tune button in the Startup Wizard screen to set the system bandwidth the type of loop control and the filtering necessary for the application Caution should be used when executing the AutoTune feature Some applications are not A capable of handling the vibration caused as the shaft senses its load If this is in question manually tune the drive Also when the load inertia is very large and the selected bandwidth is high this feature may fail to perform Setup Complete Click EXIT to go to the Main MOTIONLINK screen For explanation on these functions refer to the Main MOTIONLINK screen Saving Variables Parameters to EEPROM S
36. le with CD LITE If RELAYMODE 3 the relay is open when no faults are latch and closed when the drive detects a fault Limit switches The SERVOSTAR CD Lite provides two limit switches only in Velocity mode one for CW direction of the shaft and one for CCW direction of the shaft To enable limit switch mode LIMIDIS should be zero Operational mode for both sides Operational mode for Type both sides Motor rotate CW Motor rotate CCW CWLIM R 0 1 0 CCWLIM R 0 0 1 IN IN 123 R 110 010 100 CW Switch H W Close Open Close CCW Switch H W Close Close Open 7 Segment H W X L1 L2 display Drive status X Disable Disable SERVOSTAR CD LITE User Manual 19 System Operation Danaher Motion Kollmorgen Speciality Electronics Configurable Analog output ANOUT The 10 V 8 bit analog output ANOUT is used as a monitoring tool only The setting of this variable allows you to measure the Velocity velocity error current command and current feedback This enables you to tune the CD LITE This pin must be referenced to DC common pin 4 Example using ANOUT and scope Before tuning CH1 PIN 2 and 3 of C3 ACMD 350 rpm 200 ms CH2 PIN 13 and 4 of C3 ANOUT 0 V Tek Ris 1 00kS s 71 Acas F chi 200V EE 200V EMSOOMS CRF OMV 7 jul 2002 12 48 53 After tuning Tek Run 1 00kS s Sample chi 2 00V iD 2 00 V amp M
37. n Kollmorgen Speciality Electronics Troubleshooting Troubleshooting The MOTIONLINK package comes with a comprehensive monitoring and troubleshooting help set For troubleshooting the drive it provides a Status screen click on Status button in the upper right hand corner of Main MOTIONLINK screen The Status screen allows you to check the drive enable switches the status display LED fault status with complete error history and mode settings for several of the drive s protection features If using the terminal mode you can simply check the contents stored in the FLTHIST variable An additional help provided by MOTIONLINK is the I O screen click on I O button on the side of the Main MOTIONLINK screen The I O screen gives you the ability to check the status of the hardware position limit switches the motor thermostat and the encoder equivalent output It also allows you to set up the I O on the C3 connector for a variety of troubleshooting and monitoring approaches For monitoring system performance MOTIONLINK comes with a variety of monitoring tools You can monitor a variety of variables from the Monitor screen click Monitor button at the top of the Main MOTIONLINK screen to compare up to three variables against themselves at one time The Tune and Record screen allows you to evaluate the system s actual performance against a predefined command profile Also from this screen adjusting the gains until optimum followin
38. nstuseseseasseseas 11 xal SOMO and ACCULACY EES 12 Resolver iese ee 13 1 L SE Cable Lengths VALL LL LL LL LL LL LL LL LL LL LL LL LL LL he LL LL LL LL LL ES OE EE EE EE EE 18 Analog EL EEN 18s Remote Enable Input REMOTES ME EN RE OE EE RR OE ER EE 19 Fault Output Relay RELAY RELAYMODE Limit switches Configurable Analog output ANOU ee ee ves ese Ee ees pa nee Ee DAE oe onde Ee ee eke RA 20 EE A BEE EEGEN 15 ii ee eee SERVOSTAR CD LITE User Manual i Table of Contents Danaher Motion Kollmorgen Speciality Electronics Servo Loop Descriptor EE 16 Current ER EE N EE EE OE RE E EE 16 E EE 16 EER ceca EE 16 Torque LOOP ee Analog WOR UG E 17 Current Yi AU EE ER N N IE EE EE 17 FIRMWARE UPGRADES Ee 24 NEE 24 CUSTOMER SUPPORT EE EE 2 DESCRIPTION legs SOMER AE EK EE EE ER EE OE EE IG 27 Error ee a A ES 27 EE 28 ii SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Product Description Product Description The SERVOSTAR CD Lite is a new economic addition to the SERVOSTAR family Designed primarily for current loop applications this amplifier provides high performance with fully digital current and velocity loop control Digital control brings with it all the advantages of ease of use eliminating the need adjusting potentiometers Since the control loop parameters are stored digitally there is no drift in performance ov
39. ommand is checked against the peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and fed to the three phase current loop regulator which calculates a current error This error is fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC BUS Module 325 VDC bus typical to supply the required current to the motor windings The actual motor current is updated and the process begins again Current Sampling The current loop receives corrective feedback from the current sampling circuitry The current sensors use closed loop hall sampling techniques in all units The current sample is used by the current loops to regulate the current in each of the three motor phases Two phases A and C of the current signal are sampled by the microprocessor at a 16 kHz rate The momentary A phase current and C phase current are monitored by examining the IA and IC variables respectively The microprocessor calculates the equivalent absolute current which can be monitored as I This value can be averaged for 2 4 8 16 32 or 64 samples SERVOSTAR CD LITE User Manual 17 System Operation Danaher Motion Kollmorgen Speciality Electronics Foldback The SERVOSTAR CD Lite offers two types of FoldBack protection for both the motor and the
40. ource the encoder is no longer than 50 ft 15 m Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder Please consider this carefully when designing the system An option that would allow the use of longer lengths implements a separate supply located at the motor to source the encoder Quadrature signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths Resolution and Accuracy A SERVOSTAR encoder based system typically exhibits minimal inaccuracies outside of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used 12 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics System Startup One mechanical Rev PFB 4 X MENCRES 0 PRD 65536 Electrical degree 101 011 110 Halls EE EE Ed y ff ITT TT ee ee ee oT TT 100 001 010 MENCOFF Z index pulse Number of electrical degree MPOLES 2 MENCRES resolution of the motor encoder PPR 360 360 360 360 Incremental Encoder A B Z Halls e The Drive according to the hall section start commutates e The Drive set the electrical angle after first hall switch e The Drive re set the electrical angle after first Index pulse switch e From now on the Drive calculates
41. rent modes of operation It is factory configured in OPMODE 1 Analog Velocity Controller but may be reconfigured by the user Not all commands and variables are active or meaningful in every OPMODE OPMODE 1 Analog Velocity Controller The SERVOSTAR CD Lite is configured as a velocity loop controller and is controlled via a 10V analog input signal The commanded velocity is proportional to the input voltage OPMODE 3 Analog Torque Current Controller The SERVOSTAR CD Lite is configured as a torque loop controller and is controlled via a 10 V analog input signal The commanded current is proportional to the input voltage System I O This section discussions the I O features of the C3 connector except for the Thermostat input on C2 see appendix Electrical specifications are in the Quick Start Guide Analog Input ANIN1 The velocity or torque loop can receive its command from an analog voltage source and is selectable through the OPMODE variable The analog input to the SERVOSTAR CD Lite is differential This means that the signals received at the two inputs are subtracted from each other to create a difference that is used to command the rest of the system This type of input has a high degree of noise immunity and in many cases will allow for ground isolation between systems This analog input also has a low pass filter ANLPFHZ to prevent high frequency noise from entering the system The input voltage from the different
42. scription Danaher Motion Kollmorgen Speciality Electronics FeedBack Devices et os Incremental Encoder A B Z with HED Hall Effect Device Incremental Encoder A B with HED Hall Effect Device HED Hall Effect Device sine wave or six step Resolver only w Logic power supplied from external 24 VDC Amplifier Configuration Use MOTIONLINK to configure the amplifier Use the Personality Module to quickly and easily configure additional amplifiers MOTIONLINK Software Environment gt Oo gt OO Os MOTIONLINK version from 4 3 Easy setup commanding and monitoring technigues Setup wizard to assist users in fast easy setup Contains an extensive database for many of Kollmorgen s motor series A Backup screen that provides automatic loading of system parameters Realtime measuring of many system parameters Status screen indicating system operation and fault error checking Extensive On line Help file F1 designed to assist the user in MOTIONLINK s intuitive nature A set of limit folders allowing you to manipulate the velocity current and filtering limits from one screen An Input Output I O screen for easy manipulation of the I O thermostat options encoder output and hardware position limits capabilities A Feedback Device screen that provides realtime pictorial positioning information It also includes a Resolver Zeroing routine and an encoder initialization screen A Control Loop screen that provid
43. sponsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Danaher Motion Kollmorgen Speciality Electronics that is furnished for customer use ONLY No other uses are authorized without written permission of Danaher Motion Kollmorgen Speciality Electronics Information in this document is subject to change without notice and does not represent a commitment on the part of Danaher Motion Kollmorgen Speciality Electronics Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues Danaher Motion Kollmorgen Speciality Electronics Table of Contents Table of Contents I FeedBack Deieeg kt ee ee ee annann nnana nkka ee ee ee ee ee 21 Amplifier EE 2 MOTIONLINK Software Emfroen 2 I 1 I I 1 i SYSTEM START UP shite aaah i ai oe i ies ee E BEER 5 RS 232A PROTOCOL SETTINGS sssscsscossvescessssssuesussnsecvessecnsssasesnenosensecnssseenussaseanenvestesensesuenersasenncnvessesensenes 6 SEENEN 6 INSTALLING MOTIONLINK EE H USING I TEE TEE 7 Startup UE EE 7 Main MOTIONLINK Screen 8 KSE 9 dea EN E RE RE 9 ENABLING THE SYSTEM N NG ie OND EE IG EE OG EN N 10 EE 11 Incremental Encoder vsccccccsvsvsvevevsvsvscsvsvevscsssevsvsvsvsvsvsvssssssssasusuevesesesesasavavavssssssssssssvsvsessssssavi
44. the electrical angle according to A B counter A B Halls e The Drive according to the hall section start commutates e The Drive set the electrical angle after first hall switch e From now on the Drive calculates the electrical angle according to A B counter Resolver The SERVOSTAR uses either single two poles or multi speed multiple poles resolver feedback to monitor the motor shaft position A resolver can be thought of as a transformer whose output is unique for any given shaft position an absolute position feedback The transformer is driven with a sinewave reference signal Two AC signals are returned from the resolver into the Sine and Cosine inputs All three of these sinewave signals are low level and susceptible to noise SERVOSTAR CD LITE User Manual 13 System Startup Danaher Motion Kollmorgen Speciality Electronics One mechanical Rev PFB 4X 4096 16384 lt a PRD 65536 Electrical degree 360 360 360 360 Number of electrical degree MPOLES 2 MENCRES is fix to 4096 Resolver feed back The Drive obtains its absolute position from the ATAN of the sin and cos of the Resolver Specifications Type Control Transmitter Max DC Resistance 120 Ohms stator S5mA ACRMS Output Voltage To Drive 2 VAC Cable Lengths It is important to use properly shielded cable and to keep it away from other noise radiating devices and cables It is not recommended to run the fee
45. ting the need for an additional position feedback device The outputs are differential line drivers There is an associated DC common output C4 pin 3 which can connect to your port to keep common mode noise and voltage spikes minimized for device protection Because there are normally differences of potential between your controller and the drive connection is recommended if ground loops occur disconnect and retest The source of the Encoder Equivalent Output EEO signals depends on the type of motor feedback device This section describes the various feedback types and how they function beginning with firmware version 0 1 8 Type MENCTYPE Comments Incremental A B Z Halls 0 Incremental A B H 6 Resolver NA Halls only w sinus commutation 5 Defined in MOTIONLINK Hall only w six step commutation 10 Defined by setting DIP switch 2 to ON Incremental Encoder The output signal is the actual encoder feedback signal that is pre configured MENCRES in the drive s motor parameters It can be scaled down by multiples of two ENCOUTO 1 2 4 8 16 and has a maximum frequency limit of 3 MHz The SERVOSTAR can use encoder feedback to monitor the motor shaft position As opposed to a resolver which is an absolute position feedback device the encoder is an incremental device that indicates changes in position The encoder resolution of the SERVOSTAR and therefore the drive s encoder equivalent o
46. tion The Personality Module has a female D 9 connector to plug into the serial connector C1 on the front panel of the CD Lite The Personality Module has two switches and one green LED on it A recessed switch is used for UPLOADING parameters from the drive into the Personality Module The tip of a pen or some similar instrument is needed to access the switch The switch needs to be pressed for a minimum of 2 seconds in order to activate the upload procedure During the upload the display will show 3 bars flashing first the lower then the middle and then the upper An easy access switch is used for DOWNLOADING parameters from the Personality Module to the drive Pushing this button downloads the values from the Personality Module to the drive During the download the CD Lite display shows 3 bars flashing first the upper then the middle and then the lower This action takes a few seconds The Green LED is lit to indicate that the system is powered on Error Display If an error occurs during DOWNLOAD from the Personality Module the display on the 7 segment flashes 7 e If an error occurs during UPLOAD to the Personality Module the display on the 7 segment flashes 6 SERVOSTAR CD LITE User Manual 27 Personality Module for CD LITE Danaher Motion Kollmorgen Speciality Electronics Schematic The following diagram describes the PRMDL schematically easy switch download D 9 plugs into Upload Drive C1 Port 4
47. us display enunciated over the serial port and in most conditions causes a drive disable Many faults can be reset by toggling the hardware remote enable REMOTE input The following is a list of the more frequent faults the drive detects in the unit hardware and operating system Motor OverTemperature The Motor s External Thermostat input is monitored for an open circuit condition The user can define using THERMODE what happens under this fault condition The worst case event is a power stage disable when an H appears in the status display and the fault relay contacts RELAY are open Drive OverTemperature The internal heatsink temperature is monitored for an unsafe condition This condition causes a t to be displayed and disables the drive The drive will eventually cool enough to allow reset of this condition RMS OverCurrent FoldBack The FoldBack detection system can clamp the available output current This is not a true fault condition but may cause undesired performance due to the command current being limited below what is required to achieve the desired performance This condition is indicated with a flashing F in the status display and can be detected by monitoring the FOLD switch variable Bus OverVoltage An over voltage condition shuts down the drive and displays a lower case o in the status display This fault occurs mostly during regen operation where the BUS is raised to higher values than th
48. utput is fixed because it is a hardware characteristic of the encoder device The encoder interface includes three groups of wires l A B and complements lines make up the encoder quadrature signals The signals are received differentially through line receivers before being passed through a wire break detection circuit 2 The narrow Index pulse normally appears once per revolution and indicates a known physical position of the shaft This pulse is received differentially through a line receiver before being passed through a wire break detection circuit This signal is hardware capturable 3 Hall signals provide information representing the approximate absolute location of the motor shaft From this information the motor can sinusoidally commutate forward until the index signal is detected at which time true position is known These signals are isolated by an opto coupler and can be differential or open collector type signals SERVOSTAR CD LITE User Manual 11 System Startup Danaher Motion Kollmorgen Speciality Electronics Specifications Required Signals Types A B with or without Index pulse A B Index with or without Hall Channels Halls may be integral or discrete Halls Differential or Open Collector System Voltage 5 VDC Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels legal Hall Code Detection Cable Lengths The recommended cable length when using the SERVOSTAR to s
49. w Ignite CD Lite Select the Start Button to start download the new firmware from PC to the CD LITE wait until you get the message download successful i Ignite CD Lite 1 0 5 lel sl Com Port e e e C Comt This program will update your ServoStar firmware om To do this take the following steps Com2 1 Power off the Drive C Coma 2 Set DIP swithes 8 and 10 to UP c 3 Power ON the Drive and verify that the letter E is shown Com4 on the seven segment display xi p Baud Rate File name eng LCCD FIRMWARE SVERSIONSY1104P1108L C 9600 C 19209 Download successful 115200 38400 AE E Advanced Exit 10 Select Exit and turn Off the CD Lite 11 Change the DIP switches 8 and 10 to 0 back to normal operating mode 12 Make sure you have the correct firmware From terminal type the VER command SERVOSTAR MOTIONLINK Terminal File Edit Settings Communications Data Help 3 0 Amp tinuous 9 0 Amp peak rating Firnw d 1 0 Runtim SERVOSTAR CD LITE User Manual 25 Troubleshooting Danaher Motion Kollmorgen Speciality Electronics or From MOTIONLINK Basic Drive Setup Lg S Be To obtain the latest firmware version or receive additional help contact the Danaher Motion Customer Support Communication Error EN x Error Timeout expired Check yours settings If you get and your setting is correct Please recycle the Power of the Drive and Restart the Ignite Application
50. y Electronics Appendix B 15 For Operation mode select Analog Torque 16 Select Close 17 From the new amplifier Startup window select Next for backup motor parameter to a file 18 When the Next button changes to Finish select Go 19 The main window of MOTIONLINK appears 20 Select Analog Input GE RYDSTAR MOTIOMLIKE Command bom SERVOSTAR CD LITE User Manual 33 Appendix B Danaher Motion Kollmorgen Speciality Electronics 21 Select Zero Input 22 Select OK for ANZERO procedure 23 Change the Hardware enable input so pin 8 in C3 connector is 24 Return where pin 7 is the 24 source If you are not sure go to the terminal window and type REMOTE REMOTE should be 1 SERVOSTAR MOTIONLINK Terminal File Edit Settings Communications Data Help gt REMOTE 24 Change axis state from Disable to Enable Axis C Disable Enable 25 You can see that the seven segment of the CD Lite is now 3 Now you are about to move the motor shaft Type 300 in the Analog Offset Analog Difset Im molts ANDFF 10000 10000 26 To stop the motor select Zero Input Now you can operate the system with your analog input 300 mVolts 0 3 Volts 34 SERVOSTAR CD LITE User Manual Danaher Motion Kollmorgen Speciality Electronics Appendix C Linear Motor with CD LITE The CD LITE maintains only rotary variables To use a linear motor you should convert the linear parameters to rotary values from t
51. y State The decimal point directly relates to the global drive enable Status Display Drive State Display Appearance Momentarily illuminates all display segments forming an 8 and the decimal point Steady State Displays the operational mode OPMODE of the drive 1 or 3 No Faults OPMODE 1 is Velocity mode PDFF velocity controller OPMODE 3 is Current mode Current loop parameters Flashing State Used to indicate an abnormal operating state If the position hold feature is active the OPMODE number will flash at a 1 Hz rate If a fault was detected a flashing code will be displayed to identify the fault Some codes consist of a sequence of two or more digits see Troubleshooting section In general these faults will cause a latched disable sometimes controllable through software switches To clear fault toggle remote enable except for OverCurrent If the encoder initialization function ENCSTART is active the OPMODE number will flash at a 3 Hz rate Momentary Fault Displays a character momentarily for 500 ms before returning to the steady state You can reset the timer C Communications Error F Drive is in FoldBack mode Flashing Drive enabled power to the motor but a motor safety feature has been disabled for example LIMDIS 1 SERVOSTAR CD LITE User Manual 17 System Operation Danaher Motion Kollmorgen Speciality Electronics Operational Modes The SERVOSTAR CD Lite has the ability to assume diffe

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