user`s manual
Contents
1. VACON DRIVEN BY DRIVES USER S MANUAL NX FREQUENCY CONVERTERS RESOLVER OPTION BOARD OPT BC 3 1 LED indicators INDEX Document code ud01039D Date 18 2 2011 1 R esolveroplion iboard OPTsSBUuuu uuu aaa 1 1 KASO LVA DASS iii 1 2 resolver 61672 6 0 1 121 1 reS i554 u lean cee un uD cea Rak SS alee aD aa as md Compatipleresoler DOS asia Anita te aa as 1 4 Resolver to digital Conversion DAGICS uni us die pas Ps GOMMECLORS ANC 1100 101 CIS u ni ha uuu Sum 2 A maaa PRI DO RIR PIA CESSA 2 1 nstalima the OPUON DONA ana aa 2 2 Stan Me Fes OVO RA rr LU a eae 2 3 Additional cabling instructions sq irei a a a a a 3 DIS mos S kane e SP VRCON 3 1 RESOLVER OPTION BOARD OPT BC The Resolver option board OPT BC provides the user with an interface to use resolvers as feedback device to Vacon NXP Drive The Interface provides speed and position data The OPT BC includes also encoder simulation output HTL level and secondary encoder input HTL levell 1 1 Resolver basics A resolver is a rotary transformer where the magnitude of the energy through the resolver windings varies sinusoidally as the shaft rotates A resolver contains one primary vvinding and two secondary vvindings the SIN and COS vvindings Primary winding is in the rotor of the resolver and secondary windings are in the stator Secondary vvindings are mechanically displaced 90 degrees2. N co LO M U kE DIAGNOSTICS 1 0 2 2 3 3 6 8 0 33 166 22 383 6 8 0 33 22 83 6 8 0 33 0 0 0 0 Oo 15 33 0 0 0 O 15 33 0 0 Oo 415 33 2 2 0 O Te 33 0 0 Oo Te 33 0 0 0 E 6 6______15 33 2 2 3 3 68 15 33 O 33 68 145 33 1 0 2 2 3 3 63 15 33 o A 22 33 68 15 33 I 22 33 68 1 _ 33 Table1 RIEXT values 24 hour service 358 0 40 8371 150 e Email vaconldvacon com VACON 17 OI N D O I 00 gl se O Ilo olilolol o VACON DRIVEN BY DRIVES Find your nearest Vacon office on the Internet at WWW Vacon com
3. AGNOSTICS jumper not installed 0 jumper installed resistor shorted JUMPERS X3 1 X3 2 X3 3 X3 4 X4 1 X4 2 X4 3 O O O O O O O O O O O O O O O O CO CO CO CO CO CO CO OCO CO CO O O QO O O O O O O O O O O O O O O O O O oo oo oo oo ooo O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O 24 hour service 358 0 40 8371 150 e Email vaconldvacon com VACON 15 Resistor values o NM 1m 11 o o 0 oo U 02 IS 65 D 00 O O1 CO O1 Sl a N O to ko O 19 IO O 10 5 10 O IOIO k 2 Co DO E a DIAGNOSTICS 16 0 VACON cO ge N 3 3 3 3 1 66 1 re N 0 co cO N pas A A A 2 2 3 3 0 6 8 1 66 0 22 8 24 46 8 8 6 6 25 1 25 66 6 26 1 26 66 6 6 21 21 16 6 6 8 6 8 6 8 28 3 28 96 29 96 J 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 34 66 1 66 35 35 66 33 1 66 36 2 36 3 36 86 3 3 37 86 3 96 38 0 38 96 39 0 39 8 40 16 pa cO 40 8 6 8 6 8 6 8 42 46 8 8 8 8 6 6 8 6 43 1 43 66 6 6 44 1 44 66 44 76 3 3 6 8 6 8 6 8 3 3 3 3 3 3 0 2 2 1 66 45 3 45 6 33 0 1 66 LO O N re N N re O N e LO M s 0 LL e N re N re O
4. der pulses or jitter to the pulse lengths Since the board supports large variation of resolvers the used resolver should always be verified before installation The option boards OPT BC OPT AK and OPT BE can only be used with Vacon NXP drives The option boards OPT BC and OPT AK can be connected to slot C The OPT BE board can be connected to slots B E C or D but sine cos signals can only be used in slot C If the OPT BE board is connected to slots B E or D the sine cos signals have to be disconnected using the jumpers see chapter Disconnect the drive from the mains before starting the installation Vacon NXP frequency converter Remove the cable cover Tel 358 01201 2121 e Fax 358 01201 2121 205 INSTRLLRTION VRCON 11 C Open the cover of the control unit Installthe option board in slot C on the control board of the frequency converter Make sure that the grounding plate fits tightly in the clamp Strip the cable at such distance from the terminal that you can fix it to the frame with the grounding clamp Note Vacon recommeds to use always shielded twisted pair cables with resolvers Use cables that are recommended for encoder and resolver feedback Do not mix singals in twisted pairs Exitation lt COS Always make earthing contact throughout the full circumference of the cable 360 Only remove the resolver cable s outer insulation where required The cable is weakened where the shield is re
5. esolver output voltage is usually told in the resolver specifications If the specifications do not mention the output voltage it can be calculated with the formula Output Voltage Input Voltage Transformation Ratio The resolver output voltage must be between 1 7Vrms 5 0Vrms From 1 Vrms to 2 6Vrms 9 95 9579 From 2 7Vrms to 5Vrms Oo o Tel 358 01201 2121 e Fax 358 01201 2121 205 VRCON 7 1 5 2 X16 and X3 X4 Excitation Voltage Control The Resolver board s Excitation voltage is configured with these jumpers The Excitation source acts as a constant current source VRef TS Excitation voltage is calculated as follows Vref Exciting voltage of resolver Input Voltage lref Exciting current of resolver Zro input Impedance of resolver Note that this value is not the same if the excitation frequency Is different than in the resolver specs Nominal Zro is usually presented in form R JX Vrso Output V of RSO terminal 0 7 Vrms Rf 56 000 ohm Fnom Nominal Excitation Freq resolver Spec Fex Excitation Freq of the R D converter 10 20 kHz Ri 180 000 or 400 000 ohm jumper Riext 1 to 63 7 jumpers 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 8 VR CON Step 1 Calculate the Input impedance of the resolver If the nominal excitation frequency for the resolver is equal to Fex then Zro is the same as in the resolver specification and this step can be om
6. from each other The primary winding is excited by an AC voltage called the reference voltage Vr The induced voltages in the SIN and COS VVindings are equal to the value of the Reference Voltage multiplied by the SIN or COS of the angle of the input shaft from a fixed zero point R1 th SIN 0 4 R2 Rotary 4 Transformer SIN S2 Resolver signals Why resolvers When a Motion control application exists in a hot humid dusty oily or mechanically demanding environment a resolver based system is the preferred choice 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 4 VR CON 1 2 Resolver board features Excitation Frequency 10 20 kHz Transformation Ratio The output voltage of the resolver has to be 1 8 to 5 Vrms 12 Bit 2 LSB 4 LSB C Encoder Simulation Output A B Z max pulse frequency 150kHz Secondary Encoder input HTL level A B Z 1 3 Compatible resolver types Output voltage 1 7 9 0Vrms Number of poles 2 4 6 20 Option board software V5 or later System software version V182 or later Note If the number of poles of the resolver is not 2 then the resolver can only work with a motor that has the same number of poles e g a 6 pole resolver with a 6 pole motor 1 4 Resolver to digital conversion basics The OPT BC board sends the Exitation signal to the resolver and resolver sends sin and cos signals back to the board In the OPT BC board these p
7. index 7 3 1 7 3 1 1 Invert direction dz Reading rate 7 3 1 3 Exciting freq 10 20 012 7 3 1 4 Resolution bits 10 12 bits PAG S Resolver Poles 7 3 1 6 Enc 2 Pulse Rev 7 3 2 3 Simulated pulses rev is calculated on the basis of resolution bits R and resolver poles The formula used is Simulated Pulses rev 2 Resolver poles 8 Example Resolution bits 12 Resolver poles 2 Simulated Pulses rev 2 2 8 Simulated Pulses rev 1024 Lower resolution is used in high speed applications 60 000 240 000 rpm J In 10bit mode the resolver sends 256 pulses revolution and in 12 bit mode 1024 pulses revolution The absolute position value from the resolver is mapped to Anin 3 8 3 5 the slot of the option board The absolute position value is from O to 4095 2 12 4096 Resolver Frequency is mapped to Anln 3 1 and Resolver speed is mapped to Anln 3 2 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 14 VR CON DIAGNOSTICS 3 1 LED indicators There are two LED indicators in the option board Yellovv LED The Processor LED The status of the processor Option board not activated Blinking Run State Red LED The R D converter LED The status of the R D converter Fault conditions Abnormal sensor Error Abnormal R D conversion Only way to reset the red LED is to recalculate jumper settings and do a power up cycle Tel 358 01201 2121 e Fax 358 01201 2121 205 DI
8. itted Otherwise 2 IF X New Zro R r t Fnom Step 2 Calculate the Riext value 56 000 4180000 07 Riext Vref OR 300000 zro Riext Vref Step 3 Get the nearest bigger value from the table 1 from attachment 1 and set the jumpers X3 amp X4 If the calculated value is above 60 O Ri 180kQ set the Ri Resistor to 400 kQ o Ri 400 kQ Ri 180 kQ X amp 1234567 olololo PBB RIEXT 0 Q don t use o 000 oo 00 00 RIEXT 63 Q O O o There are 2 7 128 possible combinations for RIEXT value Behind jumpers are resistors X3 1 1 0 X3 2 1 66 0 X3 3 220 X3 4 330 X4 1 6 80 X4 2 15Q Tel 358 0 201 2121 e Fax 358 01201 2121 205 VRCON 9 X4 3 33 Q Example X3 3 and X3 4 are connected ga sa SO RR O O O So RIEXT is 1 1 66 0 0 6 8 15 33 57 46 Q 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 10 VR CON INSTRLLRTION 2 INSTALLATION Internal components and circuit boards are at high potential when the frequency converter is connected to the power source his voltage is extremely dangerous and may cause death or severe injury if you come into contact with it WARNING 2 1 Installing the option board Following installation guidelines should be followed carefully to get the best performance of the system Improper installation of the system might cause to disturbances which may in RID conversion generate extra enco
9. moved E Make a sufficiently wide opening for your cable by cutting the grid as wide as necessary 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 12 VACON INSTRLLRTION Close the cover of the control unit and the cable cover 2 2 Installing the resolver Connect the resolver after setting the jumpers Use cable clamp in the lower part of the NXP drive to connect cable shield Strip the cable so that the shield is exposed only from the part that is fitted to the clamp 2 3 Additional cabling instructions The resolver and other control cables should not be in parallel with power cables supply and motor cable Motor cables Frequency converter At least 300 mm _ Power supply cables Motor cables At least 500 mm Supply cables I At least 200 mm Control cables The feedback signals might also suffer from the noise coming from motor and supply cables Use shielded symmetrical motor cables It is recommended to connect the motor cable shield with 360 emc bushing The motor and supply cables should not be in parallel with resolver signal cable Tel 358 01201 2121 e Fax 358 01201 2121 205 DIAGNOSTICS VACON 13 3 DIAGNOSTICS The panel shows in the G7 3 that board is OPT BC Monitor values from 7 3 2 shows 7 3 2 1 Resolver Freq Hz 7 3 2 2 Resolver Speed Rpm 7 3 2 3 Sim Pulses rev 7 3 2 4 Encoder 2 Freq 1920 Encoder 2 Speed Parameter values from panel
10. ulses are converted to incremental encoder signal by the ASIC circuitry The incremental pulses are used for calculating rotation speed in the NXP control card The conversion from resolver sin cos singals to digital pulses is called RTD Resolver To Digital conversion N 256 10 bits N 1 024 12 bits T 360 N T Tt Phase A Phase B no Phase 4 TIA Simulated Encoder signals from the RTD ASIC Tel 358 0 201 2121 e Fax 358 0 201 2121 205 VACON 5 1 5 Connectors and jumpers X21 X10 13 X16 3 4 Yellow LED 2 TL Er a ida WE a OT NI 0 6 8 9 S t E Z z RED LED 1 5 1 Terminal data Connector Pins 11 to 20 are in X2 45 connector PIN 11 is behind PIN 1 etc x PIN Name Description Excitation LO OC 8 lt gt pre Freeze signal HTI x 9 ENC2_C LEncoder Input ChannelC PA Encoder Simulation Output Channel AN Encoder Simulation Output Channel AN Ca 8 _____________ Encoder Simulation Output Channel B _ o Encoder Input Channel B 24 hour service 358 0 40 8371 150 e Email vaconldvacon com 6 9 VR CON Jumper Settings 1 X21 C pulse source selection Incremental C pulse Zero pulse to control board is read from the resolver attached to the option board Default C pulse is External Read from FRZ input 2 X10 and X13 Gain selection The r
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