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1. 51 ERROR CODES nw EERE R EENS ENE EOE ENDRES 56 Fault Monitoring System WHERE de eI 56 eret petere s etos 58 NO Message RP E 59 Error Handler 1 through 999 60 Built In Test 1000 through 1999 daa shana RA NU ue ERO EESTE TREERE iA 65 Run Time Scheduler 2000 through 2999 sss nehme 66 Motion 3000 through 3999 esce mb pace AEE 67 File System 4000 through 4999 hene ee e he Henne ee hne ness enne hh hene seen nnne nnns 79 Entry Station 3000 through 5999 occccissssseanoaseontunstasdicoaissansnoicesiiansadacgiauswdasdobssadadnaataodaateigenet dadiatead Fa ci qe 81 Loader 6000 through 6999 eee eene e hh ese e e hne e e hnese err h ense rh hee ee rrr eene 83 Translator 7000 ihrough 7999 E ut dope 87 Interpreter 8000 through 8999 Er ei ERR e regret Pes Pre Teva gU 93 Recorder 9000 through 9900 e hne eee aa aie tees 96 Event Handler 10000 through 10999 eee Henne eee nnn Hense ee hehehe 98 Backend Processor 11000 through 11999 emen 99 Internal Communication 12000 through 12999
2. E 14 1 14 2 15 1 15 2 c These faults can only be cleared by cycling power 0 1 2 4 6 9 1 2 1 5 1 2 _ N 58 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting No Message Faults Non Le Watcha spy ee __ Watchdog No Compensation wv Invalid Velocity Control w Y i Bal to enable Encoder Initialization failure w Hardware CW limit switch open lt lt lt 4 Hardware CCW limit switch open BE o switches open Software CW limit switch is tripped EN PCMD gt PMAX amp PLIM 2 p Software CCW limit switch is tripped PCMD lt PMIN amp PLIM 2 Positive and negative analog supply fail v failure during ini w Altera load failure during init E El p i p v gt lt lt i i jp Altera DPRAM failure during init __ DSP load fail during init DSP alive failure during init TetLED Positioner fault SYS MOTION 0 v SYS MOTION must be 1 v BEN MUN Lu qp L cq hs c 77 a e L 2 L SEs qw v __ gw PosiDrive RC Installation Manual 59 BES TNAGZA 55 53 632331 MTY 81 83 54 10 18 QZ
3. 6 7 or C or m Im uem Clock 11 0 0 HB Hb 7 13 Thermostat Thermostat Thermostat High High High Shield Shield Shield Out Out 18 ESV Supply E5VSupply 19 ESV Supply E5V Supply 20 ESV Supply E5V Supply EIC Data T Clock aA H3A JBA k 25 Thermostat Thermostat Thermostat Low Low Low The PosiDrive RC works with sine encoders with Halls feedback sine encoders with C and D channels and sine encoders with ENDAT RS45 serial channels 30 060 090 130 amp 175 ______ y Cosine High B ESV Return ESv Return ESV Return ESV Return or C or H2B H2B or D or 2 EB o o y Thermostat Thermostat High High Ref High Out Index Ref Low Out Index S y ESV Supply ESV Suppl E5V Supply ESV Suppl ESV Supply ESV Suppl a 7 Data Clock 24 BABA 25 Thermostat Thermostat Thermostat Low Low Low The PosiDrive RC works with sine encoders with Halls feedback sine encoders with C and D channels and sine encoders with ENDAT RS45 serial channels Thermostat High 6 E 13 PosDrive RC Installation Manual BES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC DIAGRAMS FOR MOTOR FRAME SIZES 07
4. VIII Flat cable clamp used with ribbon cable I O Filtering Techniques PosiDrive RC Installation Manual 39 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive RC Force Control Industries Inc Filter and Bonding Diagram CABINET ENCLOSURE See Note 1 Back Plane Contactor Fuses Xfmr etc EMI filter L See Note 4 CNC PLC Controller Controller I O EMI filter See Note 8 i 4 iE e See Note 2 See Note 3 See Note 9 Routed to Routed to Motors Motors 40 PosiDrive RC Installation Manual CES TNAGZA MEX 65 53632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC FILTER BONDING DIAGRAM NOTES Note 1 Note 2 Note 3 Note 4 Note 5 Note 6 Note 7 Note 8 Note 9 Input power Enters enclosure from metal conduit Single point ground A bus bar ground bus is an excellent way to achieve this High frequency ground between conductive back panel and enclosure Also a high frequency ground is required between the enclosure and earth ground EMI filter grounding Safety grounds must be provided on the filters Potentials can exist even when the power is off because of the capacitors internal to the filters Bonding of motor cabl
5. PosiDrive RC Installation Manual 95 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Recorder 9000 through 9999 Action Recorder task cannot The recorder task cannot be SYNC Error be created add created This may occur if there memory is not enough memory Add memory or unload tasks that are not necessary 9002 Cannot create recorder Internal error ROOT Fatal Fault mutex exists Recorder is allowed 9004 Invalid record gap The record gap must be a S value must be a positive value positive value 9005 many record Up to 6 variables may be variables specified for recording 9006 Invalid number of Number of points must be a record points must be positive value a positive value 9007 enough memory Not enough memory for record operation Add memory or unload tasks that are not necessary This can happen if the RECORD command specifies more data than can be stored in the available free memory 9010 Failed to store recorded data 9011 Recorder did not attempt to record data that manage to run within a cannot be available single cycle immediately to the recorder and that therefore result in the recorder operation not completing before the end of the cycle This can happen for example if you try to record drive data that need to be accessed from the se
6. VOLTAGE 4 1 115 vac 2 230 VAC 10 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Mounting MOUNTING The PosiDrive RC controller is mounted vertically to the back panel for proper ventilation These products are designed for mounting inside an electrical enclosure to protect them from physical and environmental damage Outline Dimensions RC 10 140 5 52 RC 06 125 4 94 3 5 5 0 22 2x 10 0 0 39 163 0 4 6 42 2 0 0 08 216 0 256 0 8 50 10 08 HEAT SINK PosiDrive RC Installation Manual 11 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Mounting Force Control Industries Inc Hardware Specifications Connection Hardware Motor RCrew Size Torque M3 5 121b in 1 35Nm Ground RCrew cd Logic AWG 28 16 0 5 1 5 1 22 18 AWG 3 75mm Ferrules recommended 18 AWG Type HI 0 14 Weidmuller 4630 0 or equivalent pe HO 75 14 Weidmuller 4629 0 or equivalent 16 14 AWG 1 5mm Hollingsworth XSS0954S OR SS20947SF or equivalent 12 10 AWG 4 6mm Hollingsworth XSS20836 OR 5520832 or equivalent 8 AWG 10mm Hollingsworth R3027BF or equivalent 6 AWG 16mm Hollingsworth R4001BF or equiv
7. ee SYNC SYNC Element 3 is write protected SYNC Attribute cannot be changed Cannot change the attribute in SYNC the current communication phase ASYNC Cannot guarantee error free service channel communication with the drive Controller didn t receive telegram from the drive s This error is generated if there is a timing problem Communication interrupted due to missing telegram s Data telegram type number is out of range 0 7 S S Execution of procedure was SYN completed in the drive with error Execution of procedure was SYNC completed in the drive with error Er Er Error E Er Bring the ring down tq ror ror ror ror ror or 102 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com 12061 12062 12063 rol Industries Inc Error creating MutEx Unable to create MutEx SYNC for the Service channel semaphore for the Service task channel task Cannot create MsgQ Unable to create message queue SYNC to provide service transmission Error creating Service event semaphore 12064 Can t pass Unable to create Service event SYNC semaphore Drive addresses must be Troubleshooting Severity Immediate Fatal Fault Fatal Fault Fatal Fault Error communication phase declared 1 drive address es
8. This error is generated if the coprocessor attempts to access memory outside a segment boundary it may occur at any arbitrary time after the coprocessor instrunction was issued Automaticly generated by the ASYNC CPU if misaligned memory access is made Generally indicates a program ASYNC error eg an out of range argument to trigonometric functions SQRT of negative operand logarithm of zero or negative operand This error is generated when ASYNC instruction attempts to operate on an operand that has not been normalized The result may have reduced significance due to lost low order bits This error is generated when an ASYNC instruction attempts to divide an operand by zero This error occurs if the magnitude of the rounded true result will exceed the magnitude of the largest finite number in the destination format Two related events can contribute to this error 1 creation of a very small operand which can cause some other exception later and 2 overflow upon division producing an inexact result Troubleshooting Fatal Fault Watchdog Fatal Fault Watchdog Fatal Fault Watchdog Fatal Fault Watchdog i un i PosiDrive RC Installation Manual 61 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Ee eee Error Description Data Type Immedi
9. SYN SYN SYN SYN YN YN YN YN YN tri tri tri tri tri lesi fes tri tri tri tri tri d d d d d 8 d d d d d d o o o o o ojo o o o o o o 5 5 5 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 3183 Settling time expired Timeout for acheiving position SYNC Error expired 3184 Maximum trial time Maximum trial time to settle is Error settle is less than less than settling time settling time pending in the motion buffer 3196 Wrong factor value Wrong factor valie specify a specify a non zero non zero value value 3240 Property valid for axis Some motion element Error only properties are valid for an axis only 3241 Delay cannot be used The DELAY command is subject S Error Idle Task with the StartType set to the StartType of the motion to Immediate element being delayed However using StartType Immediate with the DELAY command is not allowed Change the StartType before executing the DELAY command only from the terminal flag low Once this happens though the Motion property can be set high only when the System Motion ON command System Motion The Default System Error Error property can be set Handler sets the System T
10. Vaaxon 30V V maxorr 0 5 V SYS DOUT SYSDOUTS On Configurable Digital Output Common 8 All inductive loads require proper suppression Max Output Current Connector C13 by pinout Analog Input 2 1 2 Configurable Analog Output G ANOUT2 Configurable Analog Output Common 4 Sensitivity Resolution 4 9 mV 12 bit All inductive loads require proper x DM suppression 24V Input 5 7 Connector 7 is Maximum Input Voltage normally used Connector 5 is used to Minimum Input Voltage string power supplies 24 V Return 6 8 Connector 8 is normally used Connector 6 is used to string power supplies Connector C14 by pinout Costsucable E Input Frequency 2 5kHz Opto isolated SYS DIN 17 Through SYS DIN 20 Input Voltage Range 12 to 24 V Nominal Configurable Inputs Common 1 Min On Max Off 10 V 1V Current Demand per 20mA Input Configurable Digital Outputs 6 7 Output Voltage max Vaaxon 30V V maxorr 0 5 V SYS DOUT9 SYSDOUT I0 vin Configurable Digital Output Max Output Current Common 8 All inductive loads require proper suppression 20 PosiDrive RC Installation Manual CES TNAGZA MEX 65 53632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC System Wiring Diagram Overview RC 03 RC 06 A and RC 10 HEAT SINK Top View Front Vie
11. sss 100 Root Process 16000 through 16999 Henne eee e Hhese nee e hh h esee eee eren ne nss eee nnns 106 Encapsulation 17000 through 17099 nnns 107 CUSTOMER SUPPORT Nnm 108 APPENDIX vw tuusessvevessdusetueescccsessiiessvaccevtessnonssbatdsesatudoncdeseeassapedeteesesavaissceesesneus 109 IDIEEERENTIAT INPUT cba ude 109 2 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Safety Instructions SAFETY INSTRUCTIONS Only qualified personnel are permitted to transport assemble commission and maintain this equipment Properly qualified personnel are persons who are familiar with the transport assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 Read all available documentation before assembling and using Incorrect handling of products in this manual can result in injury and damage to persons and machiner
12. 4 5 Input Frequency 2 5kHz i SYS DIN 5 Through SYS DIN 8 Input Voltage Range 12 to 24 V Nominal Configurable Inputs Common 1 Min On Max Off 10 V Current Demand per 20mA Input Configurable Digital Outputs 6 7 Output Voltage max Vaaxon 30V V maxorr 0 5 V SYS DOUT3 SYS DOUT4 Min Om Configurable Digital Output Common 8 All inductive loads require proper suppression I O Connector C11 by pinout Configurable Inputs 2 3 4 5 Input Frequency 2 5kHz SYS DIN 9 Through SYS DIN 12 Input Voltage Range 12 to 24 V Nominal Configurable Inputs Common 1 Min On Max Off 10 V Current Demand per 20mA Input Configurable Digital Outputs 6 7 Output Voltage max Vaaxon 30V V maxorr 0 5 V SYSDOUTS SYSDOUT 6 vin Max Output Current Max Output Current Configurable Digital Output Max Output Current 60 mA Common 8 All inductive loads require proper suppression PosiDrive RC Installation Manual 19 CES TNAGZA 55 53 632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive Force Control Industries Inc Control Specification I O Connector C12 by pinout Configurable Inputs 2 3 4 5 Input Frequency 2 5kHz SYS DIN 13 Through SYS DIN 16 Input Voltage Range 12 to 24 V Nominal Configurable Inputs Common 1 Min On Max Off 10 V 1 V Input Configurable Digital Outputs 6 7 Output Voltage max
13. D When giving position speed or acceleration commands the following units are available Resolver based motors have 65 636 counts per motor revolution Encoder based motors have counts equal to 4x encoder line per motor revolution i e a motor with 2048 lpr encoder has 8192 counts per motor revolution Rotary Units Linear Units Position Counts mm Velocity rpm min sec Acceleration rpm sec min sec 12 LED Display 0 flashing occurs at initial power up of the logic circuit S flashing second phase of power up sequence This shows the controller is in Conmode 1 8 displayed indicates the drive is in position mode 0 displayed indicates the drive is in velocity mode 1 displayed indicates the drive is in analog velocity mode decimal point displayed at bottom corner indicates drive is enabled C2 flashing indicates a fault and indicates the controller is in Conmode 0 To eliminate the C2 fault reset the motion flag by doing one of the following Toggle the Motion Enable input on terminal 2 of connector C9 Type sys motion 1 from the terminal screen Reset the Motion radio button in the bottom of the main Software screen 13 Conmode A The PosiDrive has two Conmodes a Conmode One S displayed compensating for a particular motor or changing a motor parameter b Conmode Two 8 or O displayed changing all other param
14. Varible does not exist Wrong number of dimensions 8021 8022 8023 Element could not be deleted from symbol table Task must be killed first 8024 Invalid task state for the StartTask command Kill task first Bad memory address Bad I O address 8028 8029 8030 Overflow Loader passes invalid context definition Variable for watch does not exist The argument to the SQRT function must be greater than or equal to zero Wrong number of dimentions for watch Element could not be deleted from symbol table Task is still running It may be locked in some end function such as Move Task is not terminated killed it may be locked in some end function such as Move Attempted access to an invalid memory address The error may be due to either a mistake in the application or to memory corruption Attempted access to an invalid I O address The error may be due to either a mistake in the application or to memory corruption Overflow in calculations 8031 8032 8033 8034 8035 Invalid mutex ID Invalid mutex ID The error may be due to memory corruption Invalid semaphore ID Invalid mutex ID The error may be due to memory corruption Error creating the Error while creating the semaphore semaphore The error occurs Invalid program Code segment has invalid check checksum sum The reason is memory corruption when memory is exhausted Invalid operation code Invalid
15. data file verify file reading data from the file The size and existence number of data items that were read from the file does not match the file size or the file doesn t exist No NEXT cam table The end of the cam table has camming terminated been reached and there is no and slave axis stopped next cam table The axis will stop and is taken out of slave mode 3052 3053 3054 3055 3056 Axis is a slave absolute motion not allowed Absolute move not allowed on slave axis 3057 The drive is disabled or in the following mode no motion allowed Master axis unknown specify master source Invalid cam index Can t declare more ca tables Wrong cam table size 3060 3061 3062 70 MEX 55 DIST AUTORIZADO QRO 442 1 95 72 60 Force Control Industries Inc Data Type Severity Immediate Action Po UL o YN SYNC Fatal Fault SYNC PosiDrive RC Installation Manual rror Error IT 58632331 MTY 81 83 54 10 18 ventasQindustrialmagza com Force Control Industries Inc Error Description Data Type Severity 3065 PREVIOUS cam table camming terminated and slave axis stopped Two identical master values inside cam table change cam table The cam table is not monotonic Cam offset not found in the cam table The cam table is already linked unlink table before changing it negative Cam table is empty 3072 3073 3074
16. shown sourcing Common SYS DIN 13 SYS DIN 14 SYS DIN 15 SYS DIN 16 SYS DIN 13 SYS DIN 14 SYS DIN 15 SYS DIN 16 SYS DOUT 7 24V 24V Return oN Oc fk WN ee 24V Return Analog Input 12V Oo gt WN C14 Configurable User I O Inputs can be sinking or sourcing shown sourcing Common SYS DIN 17 SYS DIN 18 SYS DIN 19 SYS DIN 20 1 L 24V 2 SYS DIN 17 x SYS DIN 18 I SYS DIN 19 24V Return L DIN SYS DIN 20 m SYS DOUT 9 gt Config Output SYS DOUT 10 Config Output 24V Common SYS DOUT 9 SYS DOUT 10 24V Return 26 PosiDrive RC Installation Manual GSS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC DIGITAL INPUTS SOURCING OR SINKING All DC inputs can be wired in a sinking our sourcing configuration All inputs on the same connector must use the same configuration SOURCING EQUIVALENT DIGITAL INPUT CIRCUIT FOR CONNECTORS C3 C9 C10 C11 C12 C14 ALTERNATIVE SINKING EQUIVALENT DIGITAL INPUT CIRCUIT FOR CONNECTORS C3 C9 C10 C11 C12 C14 All inputs that share a common pin must be connected as either sinking or sourcing The input commons C9 Pin 1 C10 Pin 1 C11 Pin 1 C12 Pinl C14 Pinl are not connected inside the PosiDrive Likewise the input and output c
17. 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting pe Error Message Error Description The movement has There has been a change in the been recalculated status of the motion between the time movement calculation started but before that movement could be executed Contact technical support Wrong master Wrong definition of master The declaration user will not see this error since the command is filtered before it gets to the Motion Invalid slave Contact technical support specification The element is already Cannot declare a master or a slave gear or cam when the axis is already a slave a slave An absolute position motion is not allowed if the axis is set up as a slave This error occurs when attempting to execute an absolute move command on a slave axis Only incremental moves are allowed on the slave axis Movement cannot be commanded if the drive is disabled or the axis is in a following mode This error is generated when a master declaration is missing Existence of a master is checked when an axis is declared as a slave Internal error This error appears when there is a cam query and the cam is not recognized Cam table cannot be defined The number of cam tables that can be defined is limited to 256 Cam table size must be modulo 16 This error is returned when loading a cam file using the LoadCamData command Problem reading There was a problem while
18. 502 PD RC 001 00 TT ZA SS PosiDrive Series RC DIGITAL SERVO MOTOR CONTROL amp AMPLIFIER INSTALLATION MANUAL FORCE CON TROL Force Control Industries Inc WARNING Read this manual before attempting any installation of the PosiDrive Digital Servo Motor Control and Amplifier GS Nacza 55 53 63 23 31 MTY 81 83 54 10 18 ZZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Record of Manual Revisions Issue No Date Brief Description of Revision 00 05 10 02 Preliminary Issue VGA and PC AT is a registered trademark of International Business Machines Corporation Windows is a register trademark of Microsoft Corporation EnDat is a trademark of Dr Johannes Heidenhain GmbH PosiDrive 1s a pending trademark of Force Control Industries Inc Copyright Information Original printing 2002 Copyright Force Control Industries Inc All rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Force Control Industries Inc except under written agreement 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 responsibility for errors or omissions Neither is any li
19. AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries In Invalid access to the element 1 Bad handle function index Service channel data not initialized 12021 12022 12023 12024 Wrong communication phase refer to Reference Manual Invalid drive address check if axis is Simulated 1202 1202 1202 12029 Internal error Wrong AT number Not enough memory 12030 12031 Internal error No memory to maintain Service container Service transfer not Name transmission too long Name cannot be Name is write 12032 12033 12034 12035 12036 12037 12038 Service transfer data unavailable Initialization error Service channel handshake time out 12039 12040 Missing telegram s communication interrupted c Error Description Element 1 is read only Internal error Contact technical SYN support Internal data structures had not SYN been allocated yet Internal error Contact technical support The command cannot be executed in the current communication phase Refer to the Limitations of the instruction in the Reference Manual There may be a conflict between the axis DriveAddress and Simulated properties If an axis is simulated the drive address must be set to 0 If the axis is real the Simulated property SYN 2 nternal error nternal error nternal error Not enough memory to allocate inte
20. DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Error Handler 1 through 999 Eror Error Message Eror Description bata Type severi immediate Acton CPU Divide error Generated by the CPU ifthe ASYNC Fatal Fault Watchdog divisor of DIV instruction is zero or the quotient overflows the result register CPU Debug Generated by the CPU after ASYNC Fatal Fault each instruction if Trap Flag is set CPU NMI Generated by the CPU when ASYNC Fatal Fault the input to the NMI pin is asserted 4 CPU Breakpoint Generated by one byte ASYNC Fatal Fault breakpoint instruction 5 CPU Detected OverflowThe CPU will generate this ASYNC Fatal Fault error if Overflow Flag is set CPU Bound range Generated by BOUND ASYNC Fatal Fault exceed instruction when the value to be tested is less than the indicated lower bound or greater than the indicated upper bound Invalid opcode This error is generated when ASYNC Fatal Fault Watchdog the CPU attempts to execute a invalid opcode CPU extension not This error is generated if a ASYNC Fatal Fault Watchdog available coprocessor instruction 15 encountered and a coprocessor is not installed CPU double exception This error is generated when ASYNC Fatal Fault Watchdog detected multiple exceptions occur on one instruction of the CPU or an exception occurs in an exception handler CPU Coprocessor This error is generated if the ASYNC Fatal Fault W
21. Directive on Machines 89 392 EEC and the EC Directive on EMC 89 336 EEC EN 60204 and EN 292 must also be met In connection with the Low Voltage Directive 73 23 EEC the harmonized standards of the EN 50178 series are applied to the amplifiers together with EN 60439 1 EN 60146 and EN 60204 The manufacturer of the machine or plant is responsible for ensuring that they meet the limits which are required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrangement of filters treatment of connectors and the lay out of cabling can be found in this documentation Conformance with the EC Directive on EMC 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo drives within the European Community The servo drives have been tested by an authorized testing laboratory in a defined configuration with the system components described in this documentation Force Control Industries Inc is not responsible for any divergence from the configuration and installation described in this documentation and is not responsible for the performance of new measurements or ensuring that regulatory requirements are met Force Control Industries Inc s PosiDrive products and systems have been successfully tested and evaluated to the limits and requirements of the EC Directive on EMC 89 336 EEC and the EC Directive on Low Voltage 72 73 EEC The product lines have been evaluated to E
22. E Cable Leni gth ss 5 eiana t Resolution and Accuracy FILTERING mS CE Filterin TeCnniques ys E xe M hes 36 Input Power Filtering EET 37 PosiDrive RC Installation Manual 1 AN MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Contents Force Control Industries Inc Motor Line Tag l 37 39 Filter and Bonding anir iE SSE enas 40 Filter Bonding Diagram 6 41 CONTROLLER 42 STATUS DISPLAY P 42 UNDERSTANDING rr SERE ton eap rei te br eere due eod cm 43 OPERATIONAL MODES PER EET SR HUE P RR VE DHT 43 SYSTEM wscssssines 43 Remote Enable Input REMOTE tau te seu seria Risa Free aoo aee EL s e 44 Configurable Inputs INI IN2 1 3 44 Configurable A
23. Fatal Fault MOT CIRCULAR MOT JOG System automatic The velocity is not zero ASYNC Fatal Fault braking therefore the element is stopped by the system This can occur for example when a slave axis has passed its position limits The asis is then stopped by the system is issued form the terminal Wrong motion type Internal Error Invalid command S given In all motion commands the appropriate value of the command parameters is checked MOT LINEAR 3250 Invalid Motion Type Motion E Er old are LINEAR or Error E Er old 3251 RTS set motion failed Internal error The RTS failed to AYNC Fatal Fault in initialisation set the motion enable flag The error can occur during the RTK initialization or during the suspend resume transitions RTS clear motion Internal error The RTS failed to ASYNC Fatal Fault failed in initialisation clear the motion enable flag The error can occur during the RTK initialization or during the suspend resume transitions PosiDrive RC Installation Manual 77 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Action Following error when There is no motion commanded ASYNC Error Drive is disabled motion 18 stopped but still there is a position drive disabled Check error The maximum position value of PEMAX error PEMax may be set too low or the axis may
24. ROOT Fatal Fault Watchdog table of mnemonics Token name already exists Symbol table of token The symbol table allocated for ROOT Fatal Fault Watchdog mnemonics is full token mnemonics is full There is not enough memory available to create an internal data structure Add more memory 11004 Unable to create There is not enough memory ROOT Fatal Fault Watchdog symbol table for available to create an internal mnemonics data structure Add more d Unable to create There is not enough memory ROOT Fatal Fault Watchdog symbol table for user available to create an internal names labels data structure Add more 11006 to delete Internal error Contact technical ROOT Fatal Fault Watchdog symbol table for support mnemonics 11007 Unable to delete nternal error Contact technical ROOT Fatal Fault Watchdog symbol table for user support names labels dl dad Rd defined support 11009 d Symbol table of Not enough memory for SYNC Error Idle Task user names labels is translation Add memory or full unload tasks that are not necessary 11010 d Token mnemonic Internal error Contact technical SYNC Error Idle Task 5 is invalid support unknown d Number of Internal error Contact technical SYNC Error Idle Task parameters at line does support not match the token DE not supported yet support 11013 d Symbol or label Internal error Contact technical SYNC Error Idle Task 5 ha
25. SYNC AS out of range Manual Virtual output is out of range out of range Refer to Sys Vout in Reference 5024 Contact technical support Fast data array index Index specified for fast data out of range must be within the range Refer Reference Manual Fast data are not initialized The SYNC host must write valid data Refer to Sys Vin in Reference 5023 Virtual output index Manual to fast data properties in before the MC reads it 5025 5026 Incorrect fast data check sum 5027 Invalid Fast Data Internal error Contact technical semaphore id support 5030 Unknown error Internal error Contact technical Terminal support SYNC ASYN ASYNC 5036 Error code is invalid Internal error Contact technical support Force Control Industries Inc Severity Immediate Action Fatal Fault Watchdog Idle Task u UT Fatal Fault Watchdog Fatal Fault Watchdog Fatal Fault Watchdog C C 82 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Loader 6000 through 6999 Error Message Error Description Data Type Action 5000 6001 Task already exists When loading a user task or defining a new event a process with the same name may already exist Source Load OnEvent Failed to open Failed to open a program file fo SYNC
26. allowed 7117 Missing end onevent Missing end onevent statement SYNC Error statement 7118 Then statement A then statement is missing in missing the if statement 7113 Expression can only Expression can only contain SYNC contain strings strings C C 92 PosiDrive RC Installation Manual BES TNAGZA MEX 65 53632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Interpreter 8000 through 8999 Error Message Error Description No Enor Division by zero Division by zero Stack underflow Interpreter stack underflow The possible cause is memory corruption or Translator generated invalid code Memory exhausted 8000 8001 8002 Stack overflow Functions stack underflow Interpreter stack underflow The possible cause is memory corruption or Translator generated invalid code Functions stack Memory exhausted overflow Array index Invalid array index value underflow Array index overflow Invalid array index value Task not found Task operation failed Reason requested task does not exist Invalid breakpoint Attempt to set breakpoint to location invalid location Example on comment line or on existing breakpoint Out of memory End function error Memory exhausted Add more memory or unload unnecessary The task is still not terminated 8006 8007 8008 8009 8010 t
27. be moved by external force or the drive may not be tuned properly Envelope error when There is no motion commanded ASYNC Error Drive is disabled motion is stopped but still there is an envelope drives disabled Check error The maximum position value of PEMAX error PEMax may be set too low or the axis may be moved by external force or the drive may not be tuned properly 3255 Fatalerror _____ Contact technical support SYNC _ FatalFault 78 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting File System 4000 through 4999 Error Description Data Type Severity Action 7000 5 5 4001 Error opening file for Error opening file for Retrieve SYN Retrieve 4002 Error opening the file Error opening the file for Send SYN for Send 4003 Creating message pipe Internal Error SYN Error for upload 4004 Creating message pipe Internal error SYN Error for download 4005 message Internal error ASYNC Error pipe for upload Error Error 4006 message Internal error ASYNC Error pipe for download 3007 Upload ask exits SYNC E 3008 Download task exists imema enor SYNC Em 4009 Creatin
28. cannot be enabled just with Remote Enable software enable EN 1 is required However once PosiDrive is enabled user can disable or enable with Remote enable Configurable Inputs INI IN2 IN3 These 12 to 24 VDC inputs are defined by the INXMODE variable INIMODE IN2MODE IN3MODE Placing the appropriate value in INXMODE sets up the inputs to be used for such features as CC CCW clockwise counter clockwise hardware position limits homing and more When set for the CC CCW hardware position limits the inputs prevent any further motor travel in their respective direction but do not disable the PosiDrive or prevent motion in the opposite direction These inputs are opto isolated and considered active enable current must flow through these signals to allow the system to operate This provides a feature to reduce the possibility of personal injury Energizing both the CW and CCW hardware position limits causes the PosiDrive to enter the HOLD mode The default settings of these inputs are for the hardware position limits The Status Display flashes an L upon power up indicating that a travel limit has been tripped If these position limits are not in use set LIMDIS 1I 44 PosiDrive RC Installation Manual CES MNaczea MEX 55 53 63 23 31 MTY 81 83 54 10 18 SAL DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Controller Operation Configurable Analog Outputs ANOUTI amp
29. counts 1500 65536 65536 quad counts R D Converter Specifications System accuracy using resolver feedback is affected by several components The following table gives the user information on the inaccuracy that each of these components contribute to the total accuracy of a standard PosiDrive RC 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 3 Total Worse case 19 Resolver Accuracy Specifications Sine Encoder The PosiDrive RC can receive an analog or sine encoder feedback device to monitor the motor shaft position As opposed to a digital encoder which generates incremental square wave signals a sine encoder outputs analog differential sinusoidal signals These sine signals are quadrature decoded and passed to an interpolation circuit that breaks each 360 cycle into 256 parts before passing it to the drive s control board Thus the resolution seen by the drive is 256 times the fundamental sinusoidal track on the motor s encoder The advantage of this approach is the ability to achieve high encoder resolution while maintaining a relatively low input frequency through the cable and into the PosiDrive RC The encoder interface includes three groups of wires 34 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ve
30. in the run time only 3147 RTS delete failed Internal Error The RTS failed to SYNC Fatal Fault delete an element At the end of the deletion task the system failed to delete the RTS entry Recovery action is not needed because the task is already dead 3148 Computing too late The precomputation is late For ASYNC Error immediate motion changes suc as immediate move or speed override a precomputation time delay is assumed Normally this delay should be sufficient to complete computation This error generally indicates that the system is too heavily loaded 3149 Unable to create Internal Error The VxWorks is SYNC Fatal Fault system resource unable to crate the resource Queue Semaphore Possible cause No more memory VxWorks down parameters parameters 3151 Profiler in motion Internal Error Certain profiler SYNC Fatal Fault settings can be done only when the acceleration is zero 3152 nvalid profiler status Internal Error The profiler is SYNC Fatal Fault state driven If an invalid status is encountered this error occurs 3153 RTK continuously Internal Error The RTK isina AAYNC Fatal Fault interrupting continuously repeating stop state _ CNN NN reached Usually by a JOG command HEN GNE NN reached Usually by a JOG command 3156 No previous package Internal Error In the SYNC Fatal Fault precalculation process a pointer of the previous package in the m p ring is needed 3158 Property va
31. monitored If the variables INXMODE set these inputs for CW CCW hardware position limits they are monitored for an open circuit condition Although not necessarily an error condition motor operation can be effected by these inputs The PosiDrive RC ignores the hardware position limits if you set LIMDIS 1 The worst case RCenario is that further motion in the given direction is not allowed with an L in the status display If both CW and CCW position limit inputs have detected an open circuit condition the PosiDrive RC enters into Hold position state HOLD 1 Low voltage power supply faults Out of tolerance values on the 12 VDC analog supplies displays an A and disables the PosiDrive Memory reliability During the initialization process upon power up the run time variables memory RAM Random Access Memory and the program memory EPROM Electrically Programmable Read Only Memory are tested If a RAM fault is detected T is displayed and the PosiDrive halts If an EPROM fault is detected a c is displayed and the PosiDrive halts The user configuration non volatile memory EEPROM Electrically Erasable Programmable Read Only Memory is also checked for integrity upon power up Any diRCrepancy 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 E in the status display Motor Over
32. not declared 12065 12066 12067 12068 12069 12070 tri tri tri tri lesi fes d d d d 8 o o o o ojo gt zt 5 short long changed at this time assignment statement 12071 Cannot proceed to This error occurs if the system SYNC ASYNC Error communication phase cannot be advanced to 1 check baud rate communication phase 1 This drive addresses can happen if the baud rates in the drives and controller are not matched It can also happen if there is a conflict between the SYNC DriveAddress property and the Simulated property If an axis is simulated the drive address must be set to 0 If the axis is real the Simulated property must be set to 0 Off The drive address has Each axis must be assigned a already been assigned unique drive address There ma d o 12073 12074 12075 to another axis not be multiple drives with the same address ee og simulated axis for simulated axis Invalid request for The message received by the SYNC Fatal Fault service channel Service channel task has an transmission incorrect structure Internal error pre ee structure Internal error 12076 Uknown operation Internal error SYNC Error command default by an user is too long 12077 12078 PosiDrive RC Installation Manual 103 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 v
33. selectable through the OPMODE variable The analog input to the PosiDrive is differential signals received at the two inputs are subtracted from each other to create a difference used to command the rest of the system This type of input has a high degree of noise immunity and in many cases allows for ground isolation between systems This analog input also has a low pass filter ANLPFHZ1 ANLPFHZ2 to prevent high frequency noise from entering the system The input voltage from the differential receiver is applied to a precise 14 bit Analog to Digital A D conversion system The A D conversion system is read by the microprocessor every 50015 for the position loop modes every 250uS for the velocity loop mode and every 62 5uS for the torque current loop mode of operation PosiDrive RC Installation Manual 43 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Controller Operation Force Control Industries Inc Encoder based units come with the additional benefit of a Dual Gain ANDG1 ANDG2 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 input voltage extending the resolution to a 15 bit equivalent Above 4V the system uses the straigh
34. set to 1 high if it 1s turned to the right as you look at the front of the PosiDrive RC controller The switch is set to 0 low if it 15 turned to the left as you look at the front of the PosiDrive RC controller Install and Configure A Install and configure the Software on your PC Be sure to read and follow the instructions in the Software Installation section Motor Selection A Using the Startup Wizard in the Software select your particular motor B Configure the PosiDrive RC for your particular motor if this was not done at the factory Tuning Refer to the Tuning section for further details A Using the Startup Wizard in the Software tune the PosiDrive RC velocity loop for the motor and load B Enable the system PosiDrive RC Installation Manual CES MNaaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Read Before Installing 11 Programming Tips A Develop an application using the Software A sample Getting Started Program is provided in this document see the table of contents as well as in the PosiDrive RC Installation Manual B The Config prg program task starts automatically when the PosiDrive RC is powered up Use it to define global variables C The Autoexec prg program task automatically starts when the PosiDrive RC is powered up Use it to start other tasks that control the application
35. string ROOT Fatal Fault translator string file file in root Source Root 6037 Failed to create mutex Failed to create loader mutex in ROOT Fatal Fault ITCB initialization Source Root 6038 Failed to create sync Root there is one common ROOT Fatal Fault semaphore sync semaphore for creating tasks and events 6039 Failed to retrieve Failed to retrieve system SYNC ASYNC Fatal Fault system settings settings 6040 Failed to create Failed to create temporal ROOT Fatal Fault command line files command line files ITCB init Source Root 6043 Cannot delete task Failed to delete the input SYNC STDIN message queue for a task 6045 No permission stop Reset ALL is not allowed if any SYNC the task s first task is running 6046 File cannot be loaded This error occurs when trying to SYNC load config prg system or other reserved file C C C Error YN YN YN 6047 Invalid Translator Invalid mutex Internal error S Fatal Fault mutex due to memory corruption or limited memory 6048 Invalid operation code Invalid operation code atal Fault 5050__ Unknown evor Unknown emer sal Fault 86 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Translator 7000 through 7999 Error Message Error Description Data Type Severity Action 7000 No Trans
36. subroutine has already been Translation Error exists defined 7009 Translator temp file Internal error The temporary SYNC could not be opened file of the translator could not be opened 7010 Value out of range Valueoutofrange out of Valueoutofrange YNC Eror fs 7011 Subroutine could not The symbol table is an internal SYNC Fault be added to symbol data structure If information table cannot be written to it then probably there is not enough memory Add more memory Call could not be The symbol table is an internal SYNC Fault added to symbol table data structure If information cannot be written to it then probably there is not enough memory Add more memory PosiDrive RC Installation Manual 87 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com tri m Z Hd Z Z 213 Elo A ec Troubleshooting Force Control Industries Inc Error Description Data Type Severity Immediate 7013 Undefined motion The motion element axis you Translation Error element in command are trying to use is undefined 7014 Axis cannot be added The symbol table is an internal to symbol table data structure If information cannot be written to it then probably there is not enough memory Add more memory 7015 Axis is already The axis being declared already Translati
37. system fault by triggering the Configurable Inputs INxMODE INx Motor Thermostat Input THERM THERMODE The PosiDrive RC provides a motor thermostat input on the C2 connector that can be configured for different types of thermal protections THERMTYPE as well as manipulation of how the PosiDrive responds to a motor thermal condition THERM THERMODE THERMTIME Force Control Industries Inc PosiDrive servo motors and cables connect the thermostat through the feedback cable The input to the PosiDrive RC should be electrically closed through the thermostat for proper operation The PosiDrive normally flashes an H in the Status Display when this input is electrically opened If a motor thermal device is not used THERMODE is set to 3 to disable the feature and turn the H status display indicator off PosiDrive RC Installation Manual 45 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Controller Operation Force Control Industries Inc Core Processors A 40 MHz embedded controller and a 40 MHz DSP controller are the heart of the PosiDrive RC They use its internal operating system to monitor inputs adjust outputs communicate serially maintain servo control and monitor faults The motion profile generation programming and communication are handled by 100MHz x86 compatible embedded microprocessor running real time operating system The fla
38. token COP usually due to memory corruption Task is interrupted by A task debugging command OnEvent or OnError such as Step or StepOver etc is disabled due to an interrupted state of a task The task switche to this state if it is interrupted by OnError or OnEvent Entry Station output buffer overflow Error probably is caused by an inoperable host o user task sends too many messages Entry Station output buffer overflow Force Control Industries Inc Error Description Data Type Task is stopped ae YN YN YN ions S Under Underflos in calculations S iE S YN YN Severity Immediate Action Fatal Fault E H rror eo tri d d d H d E s 3 o o o E je o m 5 5 m 5 gt Fatal Fault Fatal Fault Fatal Fault Tj esl S E E E RE 2 2 g c d o 94 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 8038 The value passed to The value passed to the YN he function is out of function is out of range range 8039 Nesting of TRY block Nesting of TRY block is not is not a
39. used to tighten the connection between the cable ee and the bus bar Phoenix Contact Part Contact Part ption Cable Diameter Range Diameter Range Type SK8 bars up to 8mm or 0 315 inches TypeSK14 bars 8mm to 14mm or 0 551 inches pe SK20 bars 14mm to 20mm or 0 787 inches e Lai NN pe AB SS Bus bar material 10mm x 3mm copper at varying n pe NLS CU 3 10 lengths The next two figures represent a side and top view of the SK device that clamps down on the shield of the cable The use of the Phoenix SK device is an excellent method for providing a low impedance path between the cable shield and the back panel 14 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC Thumb screw to tighten down shield to bus bar Cable shield compressed lt gt on copper bus bar ee Copper bus bar SK 8 14 20 Shielded Terminal Block Phoenix Contact Side View SKX For Connecting Shield to Bus Bar Support for Bus Bar Copper Bus Bar High Frequency Ground Connection to Back Panel From Bus Bar Phoenix Contact Top View PosiDrive RC Installation Manual 15 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustr
40. 0 095 115 145 190 RESOLVER VERSION MOTOR THERMOSTAT MUST RESOLVER 0 45 X RATIO ENCODER VERSION ENCODER TYPES AND OPTIONS VARY GREATLY PROVISIONS FOR OPERATING WITHOUT HALLS CHANNELS USING SOFTWARE SWITCHES ARE AVAILABLE c INTERNAL TYPICAL HALL INPUT SCHEMATIC PosiDrive MOTOR THERMOSTAT MUST BE CLOSED TO RUN SEE BELOW HALL HALL 3 B HALL 2 A D OPTIONAL HALL HALL 2 B D CHANNEL INPUTS HALL C HALL 1 B C ENCODER COMMON POWER SUPPLY SEE NOTE 1 HALL nA PosiDrive DIFFERENTIAL CHA LINE DRIVES CHA MARKER MARKER NOTES THREE ENCODER SUPPLY CONNECTIONS ARE PROVIDED TO MINIMIZE VOLTAGE DROP IN CABLE THE THREE ENCODER SUPPLY CONNECTIONS ARE HARD WIRED TOGETHER INSIDE THE CONTROLLER ONLY ONE SET NEED BE USED IN LOW CURRENT ENCODERS USING SHORT CABLE LENGTH IF YOU HAVE OPEN COLLECTOR HALLS TIE PINS 22 23 amp 24 TO 5v MOTOR OVERLOAD PROTECTION MOTORS MUST HAVE INTEGRAL THERMAL PROTECTION OR EXTERNAL MOTOR OVERLOAD MUST BE USED THERMOSTAT SWITCH MAY SEE 12 VOLTS AND 20 MA PosiDrive RC Installation Manual 31 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Wiring the PosiDrive Force Control Industries Inc DIAGRAMS FOR MOTOR FRAME SIZES 060 090 130 175 RESOLVER VERSION SHIELD MECHANICALLY TIED TO CONNECTOR P TO MOTOR CASE MOTOR T
41. 0 7 Continuous Power at 230VAC 19 0 7 1 4 Line Input 45 C Ambient Continuous Power at 230VAC 3 Rated Main Output Line Input 45 Ambient Ma Mb Mc Continuous Current Arms hB Je Jo Peak Current Arms for 500mSec_ 91820 Peak Current Arms for 2 See 6 R fo PWM Frequency kHz 16 J6 J s Regen Information LE E nA Extemal Regon Kis Ta a Cid Control Specifications Control Specification Current Loop Maximum Minimum 500Hz 1 RPM Analog 1 2048 x VMAX 0 01 uP clock tolerance Re aration 500 uS 2 kHz Reference Generator Loop 1 mS 1 kHz Resolver Feedback on RC xxR Models C2 Type Control Transmitter Transformer Ratio 0 47 Modulation Frequenc 7 to 8 kHz Input Voltage from drive 4 25VAC Max DC Resistance 1200 Max Drive Current 55 mA AC RMS PosiDrive RC Installation Manual 17 GS Nacza MEX 55 53 63 2331 MTY 81 83 54 10 18 Bw DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive Force Control Industries Inc Control Specification Output Voltage to drive 2VAC Digital Encoder Feedback on RC xxE Models C2 A B with or without Index pulse Required Signals A B Index with or without Halls Channels Halls may be integral or diRCrete f Differential do not connect single ended Signal Type Differential open collector System Voltage 5VDC Maximum Input Frequenc 3MHz or 12MHz af
42. 01 3102 Given value will cause cam table to be non monotonic value not accepted 3104 The movement is calculated until the position limit Initialized the velocity to its maximum Initialized the acceleration to its maximum Initialized the deceleration to its maximum Initialized the jerk to its maximum System entered into following mode all motions aborted Task start failure Task end failure Invalid semaphore ID or time out elapsed 3107 3112 3113 3114 3115 3129 3130 3131 Invalid message Invalid element handle Error Description Data Type The index is out of the cam table range This error is returned when attempting to access a value in the cam table where the index is greater than the number of points in the table The cam table is chained but the data are not in use The given value for the master would cause the table to be non monotonic and so the value is not accepted Internal Error Cannot start the task The error is returned from the VxWorks function Internal Error Cannot end the task The error is returned from the VxWorks function Internal Error Invalid semaphore ID The error is returned from the VxWorks function Internal Error Invalid message received by the Motion Manager The Motion Manager is a message driven task Receiving an invalid message 1 a fatal system fault Internal Error Invalid element handle encountered during the r
43. 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Appendix A APPENDIX A Differential Input For many applications simple pulse and direction stepper motor controllers are matched up with PosiDrive amplifiers The positioning capability of the PosiDrive makes this a very desirable approach to controlling motion with standard low cost controllers One particular challenge is the compatibility between the pulse and direction output and the encoder equivalent input on the PosiDrive The PosiDrive for noise immunity purposes uses a differential line receiver for the pulse input from the controller Whereas many step motor controllers have available a single ended output This is not a direct connect the wires and off you go issue There are a few different methods to establish connectivity between the two servo devices One method is to utilize biasing resistors on the inverting input to the line receiver This is to ensure that the output of the device will switch according to the desired input from the controller Usually two biasing resistors of 300 Ohms are used which get connected to 5V and ground This is illustrated in Figure 1 5V EN PosiDrive C5 300 Ohms JUL E o 1 2 300 Ohms 75ALS173 Receiver Figure A 1 RChematic of Biasing Resistors on Line Receiver This method works but is prone to noise and the values of the resistors coul
44. 42 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 17035 17035 Invalidaxis number Failed to create PCA MsgQ ROOT MsgQ task 17038 Failed to receive a Failed to receive a message fror message from the the procedure command agent procedure command agent command in command 17041 Error in sending Error in sending message to the message to the procedure command agent procedure command agent 17042 Error in setting or Error in setting or getting the getting the priority of priority of the procedure the procedure command agent command agent command agent error agent error 17044 Value should be Value should be positive SYNC positive 17045 S Fault Customer Support Force Control Industries Inc is committed to quality customer service Our goal 15 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 for assistance If you are unaware of your local sales representative please contact us Phone 1 513 868 0900 E Mail info forcecontrol com Visit our web site at www forcecontrol com for software upgrades application notes technical publications and the most resent version of our product manuals 108 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63
45. ANOUT2 OI The 10V 12 bit analog outputs ANOUTI and ANOUT2 are used only for monitoring The setting of this variable allows you to meter various feedback quantities such as velocity current horse power position feedback following error and more This pin is referenced to DC Common pin 4 The digital output O1 OTMODE is toggled in an On Off state to indicate enable disable and used for motor braking inductive loads require proper suppression Configurable Digital I O C9 C10 C11 C12 C14 The configurable digital I O can be accessed from a task or command line with the commands SYS DIN or SYS DOUT Both inputs and outputs may be bit or group addressed Users can also use digital inputs for asynchronous events Fault Output Relay RELAY RELAYMODE The PosiDrive RC provides a drive ready or drive up output in the form of a relay RELAY output The relay RELAY output is controlled by the PosiDrive RC s microprocessor There is a software switch RELAY that configures the relay RELAY output to act as a Drive Ready or Drive Up indicator RELAYMODE 0 Therelay is closed when the PosiDrive is error free and ready to run This is a Drive Ready configuration RELAYMODE 1 The relay closes only when the PosiDrive is enabled This is a Drive Up configuration RELAYMODE 2 The relay opens during a fault when the PosiDrive is disabled You can program this fault output to open on any
46. AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 6012 Failed to create code Cannot allocate code segment SYNC Error segment when loading the task Resource problem Source Load Invalid semaphore ID Failed to take ITCB mutex Bad SYNC Fatal Fault pointer Source any ITCB routine which tries to update ITCB data Load Unload Priority etc OnEvent etc Failed to create data Cannot create interpreter data SYNC Error stack stack when Load or OnEvent is attempted Resource problem Source Load OnEvent Failed to create Cannot create interpreter Func SYNC Error function stack stack when Load or OnEvent Resource problem Source Load OnEvent 6016 Failed to create Cannot create command line ROOT Fatal Fault command line code code segment segment 6017 Failed allocate Cannot allocate memory for SYNC Error memory for event event node Resource problem node Source Load prolog epilog Specified priority Lookup in event list by priority SYNC ASYNC Fatal Fault does not exist or by event itcb idx failed The problem may lie with data reliability because some procedures look for elements in the event list If the element is not in the list the task is aborted Source event list management priority modify Comment cannot happen during normal runtime Invalid event node I
47. C handle internal registers is used 10014 Failed to delete event Failed to delete event entry SYNC entry 10015 Task does not exist Invalid event task name SYNC specified 10016 Eventactiontaskis Event task is active running at SYN active the moment of event deletion 10017 Event action is not Pointer to action code is NULL SYN specified 10018 Failed to create event Error creating mutual exclusion ROOT mutex id semaphore for event handler 10019 Failed to create Error creating synchronization ROOT semaphore id semaphore for event handler 10020 Failed to create event Error creating message queue ROOT message queue id for event handler 10021 Invalid RCanrate Bad value of RCan rate SYNC specified 10022 SINC wal Faulk b tm mj m mimiz E e 51 3 8 3 E 2 ABE g e Sj s 8 S amp 8 S 5 Ezi Prj e 2 e e gt gt SE Fatal Fault Fatal Fault Fatal Fault 98 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Backend Processor 11000 through 11999 Action 11000 SYNC 11001 d COP does not Internal error Contact technical Translation match its number support 11002 Error at line d of the Internal error Contact technical
48. Default 1 Hold Active NE 0 Enable Default Disable 1 Disable E 1 Loads backup firmware Boot 0 Closed Default Diagnostic 1 Boot Diagnostic on power up The 10 position DIP switch is provided for diagnostic and setup purposes This switch provides the following functions Bypass Activating switch 6 causes the drive to bypass configuration CONFIG PRG and AUTOEXEC PRG do not run if this switch is closed Hold Activating Switch 7 normal state 1s closed causes the PosiDrive RC to go into a hold state Disable Activating Switch 8 normal state is closed disables the PosiDrive RC Safe Upgrade Activating Switch 9 allows safe upgrades The normal state is closed The backup version of the firmware is loaded when this switch is open Boot diagnostics If this switch is open the controller prints diagnostic information over C8 PosDrive RC Installation Manual Wiring the PosiDrive RC Top View DIP switches are in the ON or Open position when they are pushed to the right as you are looking from the front of the drive 29 GE mlaazea MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive RC Force Control Industries Inc Feedback For all other types of feedback motors please contact Customer Support C2 Feedback Connector 070 095 115 145 amp 190 4 CosineHigh B B
49. Gear ratio out of range 3076 Desynchronization between tasks while gearing The Cam data array is in use 3077 Cam cycles out of range 3079 No active cam po SYNC The beginning of the cam table ASYNC Note has been reached and there is no previous cam table The axis will stop and is taken out of slave mode Two identical master values SYNC were found inside the cam table when monotonicity was checked Cam table must be monotonic SYNC up or down Monotonicity is checked when an axis is declared as a slave or when a file is loaded into a cam table The specified CamOffset is not found in the cam table The value of the CamOfsfet must be given as one of the Master position values in the cam table File cannot be loaded into the cam table if it is chained The cam table cannot be deleted if it is chained Specification for Time must be SYNC positive The cam table is been checked when loading a file or when an axis is declared as a slave camming mode The gear ratio is out of range Refer to the GearRatio axis property in the Reference Manual tri lesi fes tri tri tri tri 3 s s 5 5 5 5 fe o o o d m m m m 5 When the Cam data array is in use operations on it are limited 1 loading a file into the data array 2 storing the array 3 re create the data array 4 writing slave or master values into the array A cam data array is in use when that array i
50. HERMOSTAT MUST BE CLOSED TO RUN SEE BELOW RESOLVER 0 45 X RATIO ENCODER SINE ENCODER VERSION ENCODER TYPES AND OPTIONS VARY GREATLY PROVISIONS FOR OPERATING WITHOUT HALLS CHANNELS USING SOFTWARE SWITCHES ARE AVAILABLE TYPICAL HALL INPUT SCHEMATIC SHIELD MECHANICALLY TIED TO CONNECTOR eo TO MOTOR CASE RED PosiDrive MOTOR THERMOSTAT MUST BE CLOSED TO RUN SEE BELOW HALL 2 A D OPTIONAL HALL HALL n B HALL 2 B D CHANNEL INPUTS PosiDrive HALL 1 A C HALL 1 B C FONON ENCODER COMMON POWER SUPPLY SEE NOTE 1 DIFFERENTIAL CHA LINE DRIVES CHA ned INPUTS FOR SINE ENCODERS WITH C amp D CHANNELS NOTES THREE ENCODER SUPPLY CONNECTIONS ARE PROVIDED TO MINIMIZE VOLTAGE DROP IN CABLE THE THREE ENCODER SUPPLY CONNECTIONS ARE HARD WIRED TOGETHER INSIDE THE CONTROLLER ONLY ONE SET NEED BE USED IN LOW CURRENT ENCODERS USING SHORT CABLE LENGTH IF YOU HAVE OPEN COLLECTOR HALLS TIE PINS 22 23 amp 24 TO 5 MOTOR OVERLOAD PROTECTION MOTORS MUST HAVE INTEGRAL THERMAL PROTECTION OR EXTERNAL MOTOR OVERLOAD MUST BE USED THERMOSTAT SWITCH MAY SEE 12 VOLTS AND 20 MA 32 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 Sw DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC Feedback Devices For motor positioning and commutation the PosiDrive RC can utilize a resol
51. N50178 and EN60204 as a component of a machine and other relevant standards The Electromagnetic Compatibility EMC of a system is identified in two parts emissions and immunity Emissions are the generation of EMI electromagnetic interference and immunity is the susceptibility levels of the equipment Limits are derived from generic standards EN55081 2 and EN55082 2 for heavy industrial environment The PosiDrive series of drives and BUS Modules have been tested for radiated emissions conducted emissions EFT ESD surge conducted immunity and radiated immunity These tests have been in accordance with EN55011 EN61000 4 2 ENV50140 IEC 1000 4 4 EN61000 4 5 and ENV50141 Installation of the equipment is critical in designing system and machine electro magnetic compatibility EMC The user must apply the installation recommendations in this manual See the installation section and CE Filtering Techniques information when mounting and installing the drive system for CE conformance 4 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Read Before Installing READ BEFORE INSTALLING The directions below are the brief steps for easy installation and setup and application implementation of a PosiDrive RC system Further explanation of these steps follows in this document Detailed instructi
52. OOTING TO QUALIFIED PERSONNEL ONLY HIGH VOLTAGE MAY EXIST UP TO 5 MINUTES AFTER INPUT VOLTAGE IS REMOVED C13 Power Supply 1 2 3 4 5 For daisy chaining power lt 6 4V RETURN OUT 7 24V IN 8 24V Return IN Normally you will use Pins 7 and 8 Pins 5 and 6 are used to daisy chain power Pin 5 is internally connected to Pin 7 Pin 6 is internally connected to Pin 6 22 PosiDrive RC Installation Manual CES MNaaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC POWER DIAGRAM NOTES 1 FUSE 2 and contactor may not be required if input power line is neutral See Note 7 2 Allow 30 seconds after turning power off before reapplying power 3 AC Line wires should be twisted pair 4 The ground of the PosiDrive RC and motor best minimizes ground currents and noise when connected in a star point configuration 5 Cables should be properly bonded to the back panel and implemented as close to the PosiDrive RC side of the cable as possible for effective grounding If bonding is installed the shield on the cable end need not be connected to the star point configuration Only connect the shield on one end of the cable preferably on the PosiDrive RC side 6 See CE Filtering Techniques for further information 7 This system is suitable for use on a circuit capable of delivering not more than 5000 RMS s
53. See the sdd document Cannot execute move When an element has been SYNC Error Element is stopped by stopped with the STOP another task command it is not possible to Move it until the same task that executed the Stop command issues the Proceed command specify axis name only 3045 Wrong speed override The percentage that is given to SYNC Error the velocityoverride function is limited Refer to the Reference Manual for the allowed range 3046 Smooth factor out of Smoothing value given is not SYNC Error Manual for the allowed range 3047 Excessive The Jerk Acceleration ratio SYNC Error Jerk Acceleration defines the time needed to ratio decrease jerk or achieve maximum acceleration increase accel and If this time is shorter then 5 decel motion samples the new Jerk Acceleration is not accepted The ratio is limited by 0 9 PI 5T where T is the cycle time in milli seconds Thus the limit is 282 74 when the cycle time is 2 msec and 141 37 whe the cycle time is 4 msec Use a SmoothFactor from 0 through 100 to get around the Jerk limitations Proceed command may If the task that stopped the SYNC Note be entered from motion was killed or terminal terminated without giving the Proceed command the Proceed command is allowed from the Terminal j 3049 Axis is disabled The axis has been disabled PosiDrive RC Installation Manual 69 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10
54. Temperature The Motor s External Thermostat input is monitored for an open circuit condition You define using THERMODE what happens under this fault condition The worst case RCenario is a power stage disable when an H appears in the status display and the fault relay contacts RELAY are open No compensator In case PosiDrive cannot design a compensator such as after a RSTVAR command CLREEPROM or any change in the motor or PosiDrive parameters a flashing minus sign is displayed and the PosiDrive is disabled This display normally indicates that the PosiDrive does not have a compensation file loaded OverSpeed fault Software continuously monitors the actual feedback speed If the motor speed exceeds the VOSPD limit a J is displayed and the PosiDrive is disabled This normally occurs when there is an improperly tuned system and the load overshoots its commanded speed PowerStage Fault OverCurrent Hardware circuitry monitors load short circuit transistor failure and instantaneous OverCurrent In general a power stage fault cannot be reset by toggling the Remote Enable only by power cycling This condition is indicated by a flashing P in the status display 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 as the command current is limited below what is required to achieve the desir
55. ability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Force Control Industries Inc that is furnished for customer use ONLY Other uses are unauthorized without written permission of Force Control Industries Inc Information in this document is subject to change without notice and does not represent a commitment on the part the Force Control Industries Inc 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 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Contents CONTENTS SAFETY INSTRUCTION vases ccccdescacheccdeccevcclevescecccesscdnessccesctcccesseceacucvscecdseededecessccsedeveseeveseedececcceccevesacececees 3 READ BEFORE INSTALLING ciccscsscccsscccccevestsoccscbatcestescedececsccceuscesdocdscacssesecssscsselecsesecddicnsseacecevaseesese seeds 5 UNPACKING AND INSPECT IN Givissesccscccssccccasscacescdccessccesdcssseccsecvececetsedessesesvsdevctsedesesscccecsecessacsbsaesossescess 9 WARRANTY INFORMATION renoier edri n seccassesdaageaenssecsenssanseadseessaessanseoeseaeesadoatagegedebesasssavoesesoaansasdennaanesetons 9 WSEAS DIBEGTED EE e EE E A E E E EE S 9 NAME PLATE AND MODEL NUMBERG 0cececcesececcecececec
56. acza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error Description Data Type Immediate Action Cannot open Error A file system error occured ASYNC Error None History file while opening Logger file User error handler An error occcured while SYN Error None cannot be created spawning User error handler task Add more memory 52 User error handler Internal error Contact Fatal Fault Watchdog MsgQ failed technical support Reccuring attempt to Only one instance of the User SYNC Error Idle Task define User System System error handler may error handler exist The error code cannot be recognized by the Error Handler 64 PosiDrive RC Installation Manual BES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Built In Test 1000 through 1999 Action me task support semaphore support 1003 System memory The BIT task verifies that at ASYNC Note exhausted unload least 200kBytes of contiguous tasks or add memory memory are not available Unload unnecessary tasks or add memory 1004 Outof memory add Out of memory BIT is not able SYNC Error Idle Task more memory or to allocate needed amount of unload unnecessary RAM for the new handle This tasks can occur in
57. al for personal injury or equipment damage if the recommended precautions and safe operating practices are not followed Read and be familiar with the safety notices in this manual before attempting installation operation or maintenance to avoid serious bodily injury damage to the equipment or operational difficulty Warning identifies hazards that could result in personal injury or death Caution identifies hazards that could result in personal injury or equipment damage Note identifies information critical to the user s understanding or use of the equipment PosiDrive RC Installation Manual 3 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Safety Instructions Force Control Industries Inc Directives and Standards The PosiDrive RC product series has been successfully tested and evaluated to meet UL cUL 508C for U S and Canadian markets This standard outlines the minimum requirements for electrically operated power conversion equipment frequency converters and servo amplifiers which are intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipment Mark Conformance Servo drives are incorporated in electrical plants and machines for industrial use When the servo drives are built into machines or plants the operation of the drive is prohibited until the machine or plant meets the requirements of the EC
58. alent 4 AWG 25mm Hollingsworth R5100BF or equivalent 2 AWG 35mm Hollingsworth R7998BFN or equivalent Distance CK100 Kit mm C2 C4 C7 plus 2 ft 0 69m of stranded bus ribbon C8 Force Control Industries Inc Mating Connector Vendor Info Weidmuller BL3 5 13 Cat No 161574 Hardware p Control Industries Inc DL Men Info PCD ELFP04110 c14 Vendor Info Weidmuller 160048 Info Weidmuller 160948 Pin Pin Coding Element Vendor Info Weidmuller 169343 Element Vendor Info Weidmuller 169343 12 PosiDrive RC Installation Manual CES TNAGZA MEX 65 53632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC WIRING THE POSIDRIVE RC Wire the PosiDrive RC according to the System Wiring Diagrams pages 22 through 29 Be sure to apply 24 VDC for power to C13 24 VDC for motion to C9 and apply 24 VDC for hardware enable to C3 Wire the power 115 230 VAC Wire the motor and feedback Refer to the appropriate Feedback Wiring Diagram page 31 or 32 for additional information Wiring Requirements Particular care should be used when layout of an enclosure is designed Separate power wires from small signal wires The following guidelines highlight some important wiring practices to implement Control and signal cables must be separated from power and motor cables Distance of 8 inches 20centimeters is sufficie
59. asks Run time error in the external to interpreter function 8011 8012 The task execution has not been terminated This may occur if task is locked within some end function such as Move or Stop The task is not The task is not stopped idled stopped The task is terminated Task is terminated killed Argument for EXP is The range of values for the EXP out of range argument is 7 09782712893383e 02 Values less than the lower limit can be used but will return 0 llegal mathematical Invalid argument for function call mathematical function Argument for LOG 15 The argument to the LOG out of range 8013 8014 8015 8016 8017 function must be greater than Zero PosiDrive RC Installation Manual iran INAGZAL 55 DIST AUTORIZADO QRO 442 1 95 72 60 Data Type Severity Immediate Action me ooo Tale Task Fault Interpreter is prevented from execution YNC r ault Fault ault YNC YNC Interpreter is prevented from execution SYNC Interpreter is prevented from execution Interpreter is prevented from execution SYN SYN SYNC SYNC Error SYNC Fatal Fault SYNC 1 1 Faul r Error r SYNC SNC qme BENE eT fo EE UG 93 58632331 MTY 81 83 54 10 18 ventas industrialmagza com Troubleshooting 8018 Negative parameter in SQRT operator Intepreter got invalid context definition 8019 8020
60. atchdog overrun coprocessor attempts to access memory outside a segment boundary CPU Invalid Task State Automatically generated by ASYNC Fatal Fault Watchdog Segment CPU during task switch if the new TSS specified by the task gate is invalid CPU segment not Generated when loading a ASYNC Fatal Fault Watchdog present segment register of the CPU if the segment deRCriptor indicates that the segment is not currently in memory CPU Stack fault Generated on a stack overflow ASYNC Fatal Fault Watchdog or underflow or if an inter level transition or task switch references a stack segment marked not present 60 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Error Error Message Error Description Data Type Immediate Action CPU General protection fault CPU Page fault CPU Coprocessor fault CPU Alignment error FPU Unnormalized operand FPU divide by zero FPU overflow FPU Underflow Invalid FPU operation Generated when the CPU detects a protection violation which does not fit under another category having a separate interrupt This error is generated on an 80486 protected mode floating point protection fault This error is generated on attempting to access a 4K memory page whose page table entry has the present bit cleared
61. ate Action FPU Precision lost It occurs when the result of an ASYNC Error Idle task operation is not exactly representable in the destination format For example 1 3 cannot be precisely represented in binar form This exception occurs frequently and indicates that some generally acceptable exception has been lost Most applications mask this exception FPU Stack fault Generated the FPU due to ASYNC Error Idle Task stack overflow or underflow Invalid FPU operation Generally indicates a program ASYNC Fatal Fault Watchdog error eg out of range argument to trigonometric functions SQRT of negative operand logarithm of zero or negative operand System Context FPU Unnormalized When an instruction attempts ASYNC Fatal Fault Watchdog operand to operate a non normalized operand the result may reduce significantly due to lost low order bits Most applications mask this exception System Context FPU Zero divide This error is generated when an ASYNC Fatal Fault Watchdog instruction attempts to divide a finite non zero operand by zero System Context FPU Underflow Two related events can Fatal Fault Watchdog contribute to this error 1 creation of a very small operand which can cause some other exception later and 2 overflow upon division producing an inexact result FPU Precision lost It occurs when the result of an Fatal Fault Watchdog operation is not exactly representable in the destination format For
62. bel repeated in the Label repeated in the same same block block If block mismatch If block mismatch While block mismatch While block mismatch For block mismatch For block mismatch Invalid array index nvalid array index Name already declared Name already declared as 7054 7055 7056 7057 7058 as variable or axis 7059 Invalid number of coordinates Name of axis is invalid Variable cannot be deleted from the symbol table Variable not declared Not enough reserved memory space 7060 7061 7062 7063 Error definition allowed only once in program Unmatched end of error definition block Command not allowed into OnError block Wrong index type of array Index must be long Wrong input type Input must be long Data Type 7064 7065 7066 7067 7068 7069 Reserved command name Too many nesting blocks 7070 7071 7072 7073 Invalid name of motion element Invalid property Too many spaces 7074 7075 90 variable or axis Contact technical support Name of axis is invalid Variable cannot be deleted from the symbol table There is not enough memory space to declare the variable Error definition allowed only once in program Unmatched end of error definition block Command not allowed into OnError block The type of the index of the array must be long Wrong input type Input must be long This can occur when wd are trying to querried 1 3 AND 1 4 Var
63. connection is not correct the axis will stop and is taken out of slave mode The actual velocity is limited by the VelocityOverspeed property When the actual velocity exceeds the BEN ASYNC Error Motion is stopped VelocityOverspeed the motion 15 stopped The actual velocity is limited ASYNC Error by the VelocityOverspeed property When the actual velocity exceeds the VelocityOverspeed the motion is stopped If this happens whe motion is already stopped then the drive is disabled This may indicate a drive tuning problem or a noise problem Error Error Error Error rror Drive is disabled E Property value cannot Some properties such as conversion factors cannot be changed while the drive is enabled Refer to the Reference Manual for limitations on instruction execution ee ee ee A The settling time TSettle or SYNC Note TSettleMax must be an integer multiple of 1 ms If it is not the time specified is accepted but the actual settling time is rounded up to the nearest integer multiple of 1 ms The INPOSITION value of the SYNC Note StartType has no meaning when the previous movement is with nonzero final velocity PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries In Time jog is meaningless The index is out of the table range 31
64. cordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 DIST AUTORIZADO QRO 442 1 95 72 60 Force Control Industries Inc 5 2 i S S SYNC il Z A SYNC ASYNC ASYNC ASYNC 5 SYNC nin T 5 5 5 i 5 SYN 5 SYNC SYNC Pol Fatal Enor d o Fatal Fault Fatal Fault Fatal Fault tri o g m d g Z Z d g e g amp ri 2 gt 1 ES ect ge ri e gt 5 5 fe 2 d g tri 5 o S 5 o S d g tri 5 o S d o d g PosiDrive RC Installation Manual CES TNAGZA MEX 65 53632331 MTY 81 83 54 10 18 ventas industrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 12118 Operation data are in accordance with IEC1491 YN Error smaller than the minimum value 12120 Invalid data e g The value you try to write is out SYN invalid bit of range combination i SYNC 12119 Operation data are in accordance with IEC1491 SYNC greater than the maximum value C 12121 Operation
65. d but not required for CE compliance Separation distance of 20 cm 8 in should be sufficient in most cases Where control cables must cross power cables they should cross with an angle of 90 Motor cables and feedback cables exiting the cabinet going to the motor should be separated as much as possible Ideally using separate conduits provides good isolation that limits coupling of noise from motor to feedback cables PosiDrive RC Installation Manual 41 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Controller Operation Force Control Industries Inc CONTROLLER OPERATION Status Display The PosiDrive RC has a seven segment indicator called a Status Display that indicates four types of states Power up Steady State Flashing State and Momentary State The decimal point directly relates to the global PosiDrive RC enable PosiDrive STATE DISPLAY APPEARANCE Steady State No Faults Flashing State Momentary Fault Momentarily lights all display segments forming an 8 the decimal point and then 0 intermittently for several seconds before flashing S Displays the operational mode OPMODE Displays 8 for digital position mode 0 for digital velocity mode Used to indicate an abnormal operating state If a fault was detected a flashing code will be displayed to identify the fault Some codes consist of a sequence of t
66. d change depending on the cable length The input must be biased at a proper level for the non inverting input to change states of the output PosiDrive RC Installation Manual 109 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Appendix Force Control Industries Inc The more desirable the method a more robust solution is to utilize a compatible line driver chip illustrated below PosiDrive a UL A 2 75172 Driver 75ALS173 Receiver Figure A 2 RChematic of Line Driver to Line Receiver This way the input received from the driver chip is ensured to be compatible with the PosiDrive This chip is the 75172 which is the companion to the line receiver 75LS173 on the input to the PosiDrive The connection here is the C8 input located on the top of the PosiDrive and has a 9 pin D shell connector Figure A 2 shows a typical interface to achieve a noise immune connection of a single ended output to a differential input on the PosiDrive 110 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com FORCE CONTROL INDUSTRIES INC Worldwide Leader in Oil Shear Technology Providing Today s Industries with Oil Shear Clutch Brake Drive Systems and Servo Drive Systems That Delivers Flexibility Efficiency Endurance Pe
67. data are Operation data are password SYNC password write write protected protected PosiDrive RC Installation Manual 105 BESS TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Root Process 16000 through 16999 Error Message Error Description Data Type Severity Immediate Action 16026 Config prg failed Config prg failed see error ASYNC Fatal Fault Watchdog history and retrieve trn err for more details 16032 Autoexec prg failed Autoexec prg failed see error ASYNC Error history and retrieve trn err for more details 106 PosiDrive RC Installation Manual BES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Encapsulation 17000 through 17999 Error Description Data Type 17000 17001 Amplifier over Drive over temperature 17002 Motor over Motor over temperature 17003 RESERVED _ y O 17004 Control voltage fault Analog supply failure 12V analog supply failure 17005 Feedback loss fault FeedBack loss 17006 Commutation fault _ 17007 17008 17009 17010 RESERVED J 17011 PE gt PEMAX or PE overflow faul ASYN deviation interface fault Severity Immediate Action Error as 5 o g c uaa zz Error Error Error Er
68. display This fault occurs normally during REGEN operation where the BUS is raised to higher values than that produced by the power supply Bus UnderVoltage an under voltage condition shuts down the PosiDrive and displays a u in the status display This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply C2 A C2 error indicates either a positioner fault such as excessive following error or that there is an error in the running of the application program To obtain additional information on the cause of this error from the terminal window type in errorhistory servoerror Drive OverTemperature The internal heatsink temperature is monitored for an unsafe condition This condition causes a t to be displayed and disables the PosiDrive The PosiDrive eventually cools enough to allow reset or 56 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Feedback Loss Hardware is used to detect a wire break condition in encoder based systems or the presence of the Sine and Cosine resolver feedback signals in resolver based systems The lack or loss of either of these signals causes the PosiDrive to disable and display an r in the status display Hardware Position Limit Inputs The IN1 IN2 IN3 Inputs are constantly
69. e recommended cable length when using the PosiDrive RC to source the encoder is no longer than 50 feet 15 meters Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder 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 PosiDrive RC are differentially connected which normally do not constitute a problem with longer cable lengths RESOLUTION AND ACCURACY A PosiDrive RC 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 Resolver The PosiDrive RC uses either single two poles or multi speed multiple poles resolver feedback to monitor the motor shaft position The resolver functions similar to 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 suRCeptible to noise PosiDrive RC Installation Manual 33 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Wiring the PosiDrive RC Force Contro
70. eal time execution The error is identical to the MOT ERR IELEMENT but this time the source is internal not the interpreter Troubleshooting Immediate SYNC li m ASYNC No a pe 00 ll mE ASYNC Fatal Fault E ote ote te ote te ote ote PosiDrive RC Installation Manual 73 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 3134 memory Internal Error No more free SYNC Fatal Fault memory in the system The memory of the system is exhausted The memory for the motion should be always available Invalid pointer Internal Error Invalid pointer SYNC Fatal Fault encountered during the real time execution zero pointer was found in the RTK or MM task Corrupted task data Internal Error Invalid task data SYNC Fatal Fault Each attached task is represented by a block of data if these data are corrupted a fata system error occurs 3137 Internal Error SYNC Fatal Fault 3138 Bad dimension atema Error The ue SYNC Fatal Fault aaa is invalid 3139 Corrupted data Internal Error During the SYNC Fatal Fault element deletion procedure corrupted data were encountered When the element data are deallocated a number of checks are conducted Among the checks
71. ect statement This expression cannot contain this unit Cannot execute the Drive command for axis The HEX keyword can only be used in a query command OnError can be defined only once in a program Incorrect print format This property is a nodal only property Try block mismatch Cannot write a catch case after the finally case This property is a read only property Undefined pls in command Pls could not be added to symbol table Pls is already defined property Wrong given master typee 3 master types currently defined Dimension mismatch for location Example A B and dimension A lt gt dimension B System camming element does not exist Camming element can only be a system element not a program variable This expression cannot contain this unit Example il i2 MMPS Cannot execute the Drive C C C command for axis C The HEX keyword can only be used in a query command OnError can be defined only once in a program This error occurs if the print format for a print using S statement is incorrect This property is a nodal only property Try block mismatch C C C C A user cannot write another C catch statement after the finally statement C C C C Cannot assign a property to read only Undefined pls in command pec A Pls could not be added to the SYN symbol table This is due to a memory fault Pls is already defined when the SYN user want
72. ed performance This condition is indicated with a flashing F in the status display and is detected by monitoring the FOLD switch variable PosiDrive RC Installation Manual 57 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc WatchDogs In addition the PosiDrive incorporates a watchdog system to maintain software operation integrity Failure of the watchdog mechanism displays three bars on the status display and halts the PosiDrive WatchDog faults can be caused by 1 Syntax or programming error in the Config prg or Autoexec prg file 2 Certain extreme CPU loading conditions 3 More serious problem Contact the factory for support Message Faults Status Displa Fault Message POSSIBLE CAUSE Err Power stage OverTemp overload fan malfunction power stage failure fo OverVoltage excessive decel rate P POverCurent power stage surge current External feedback fault Feedback signal through C8 not correctly detected Resolver line break Resolver line break 1 2 4 n i 1 u Motor over temperature motor overload caused overheating Positive analog supply fail Failure in 12V suppl Negative analog supply fail Failure in 12V suppl gt A 4 NTR r r 18 r r 0
73. efer to the Main Power Diagram and the appropriate Feedback Diagram A Connect the motor cable to terminals M1 M2 and M3 on the front of the PosiDrive RC controller B Connect the feedback cable to connector C2 on the front of the PosiDrive RC controller PosiDrive RC Installation Manual 5 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com 10 Read Before Installing Force Control Industries Inc Inputs and Outputs Refer to the appropriate I O Diagram A Connect the various inputs and outputs see pages 24 through 27 Pay particular attention to the sinking and sourcing diagrams pages 27 and 27 for further information B Connect the Encoder inputs according to the appropriate diagram page 23 Communication and Software Setup DO NOT USE connector C1 To establish communication read the Software Installation section of this guide and follow the procedures outlined in this section If communicating between a PC and the PosiDrive RC a crossed serial or Ethernet cable must be used A Serial Communication Connect the serial cable to connector C7 B Ethernet Communication Connect the Ethernet cable to connector C6 Dip Switches see also page 29 The settings should be Switch 1 1 Switch 2 0 Switch 3 0 Switch 4 0 Switch 5 0 Switch 6 1 Switch 7 0 Switch 8 0 Switch 9 0 Switch 10 0 The switch is
74. emory drives Event definnition not Event definnition is not allowed in event allowed in event action action Event already defined Event already defined in this in this program program Could not create new event symbol Could not create new event symbol Internal error Unmatched ned of Unmatched ned of event event definition block definition block Parameter repitition Parameter repetition not not allowed allowed Undefined event Undefined event Label repeated in the Label repeated in the same S same block block GOTO references non GOTO references non exisiting SYN exisiting label label tring too long limit String too long 80 characters SYN 80 char Too many dimension in a S declaration maximum number of dimensions is 10 Number of dimension does not S match delcaration YNC YNC YNC YNC YNC YNC YNC YNC C Too many dimension in declaration Number of dimension does not match delcaration PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 Troubleshooting Severity Immediate Action Fatal Fault Error rror d d d d d d d d d 3 2012 d d d Q olojo o o o 5 oE n ia 5 o 89 ventas industrialmagza com Troubleshooting 7053 La
75. entasQindustrialmagza com Troubleshooting Action 12079 12080 12081 12082 12083 12084 12085 12086 12087 12088 12089 1 2090 12091 12092 12093 12094 12095 12096 12097 12098 12099 12100 12101 12114 12115 12116 12117 104 Cannot enable axis System Enable property is off RESERVED Minimum value transmission too short transmission too long Minimum value cannot be changed Minimum value is write protected at this time Return back to due to a missed telegram An error occurred on Drive doesn t Item not defined Wrong operation data length Maximum value transmission too short transmission too long cannot be changed Maximum value is write protected at this time Operation data transmission too short transmission too long be changed Operation data are write protected at this time A drive cannot be enabled if the System Enable property is OFF Set this property to on to allow the drives to be enabled and then enable the axis in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 in accordance with IEC1491 Contact technical support CP2 occurrence in its status word The drive does not send answer drive is errorneous was specified _ 8888520028 P oe in accordance with IEC1491 in accordance with IEC1491 in ac
76. error YNC Fatal Fault number code 12007 Axis cannot be This error occurs if the SYNC Set CONMODE 2 and enabled check C1 and PosiDrive RC times out while toggle SYS MOTION Remote Enable trying to enable the drive A drive cannot be enabled if the drive is reporting a Cl error or if the drive s hardware enable signal is Off disabled 12009 Invalid access to Drive has indicated that it SYNC Error closing the Service cannot close the service Channel channel Contact technical support 12010 Axis cannot be A drive cannot be enabled if SYNC Error Set CONMODE 2 and enabled check C1 and drive is reporting a C1 error or toggle SYS MOTION Remote Enable if the drive s hardware enable signal is Off disabled 12012 Drive not ready for A drive cannot be enabled if the SYNC Error Set CONMODE 2 and power up drive is reporting a error or toggle SYS MOTION if the drive s hardware enable signal is Off 12013 Drive reports fault in When a drive fault occurs the ASYNC Error Set CONMODE 2 and addi QN MN releases torque 12014 RESERVED p ee Fatal Fault 12015 RESERVED Fatal Fault 12016_ RESERVED p ee Fatal Fault 12017 No access is defined in Contact technical support S the drive b 12018 RESERVED Fatal Fault 12019 RESERVED p Fatal Fault 12020 RESERVED po Fatal Fault 100 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST
77. es The use of armored RCreened motor cables that are bonded as close to the PosiDrive RC as possible are essential for CE compliance and strongly recommended to better the overall performance and reliability of the system Feedback cable bonding is required for CE compliance As with the motor cables the feedback cables should be bonded to the back panel This bonding will do two things First it will cut down radiation from the PosiDrive RC This radiation may be in the form of high frequency energy resulting from internal processor clocks The second thing this bonding effort provides is immunity for the PosiDrive RC Since the feedback device is located internal to the motor it is going to pick up some noise currents and transmit them along the feedback cable The bonding will direct the currents from the shield of the feedback cable to back panel ground This will reduce the amount of noise entering the PosiDrive RC AC power lines that must be routed past other lines such as motor cables or I O lines should cross at a 90 degree angle This will minimize the coupling effect Additionally the power lines should be routed as close to the back panel as possible Any noise currents on the lines may then be capacitively coupled to the ground plane and not to other lines Control I O signals should be kept separate from all power and motor cables if possible Keep control wiring as short as possible and use RCreened wire Bonding is also recommende
78. eters enabling the drive and performing motion PosiDrive RC Installation Manual 7 AN MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Read Before Installing Force Control Industries Inc B Changing Conmodes a Conmode is changed in the Software main screen by the drop down menu Conmode b Conmode is changed at the Terminal screen in the Software by typing the command sys conmode 1 or sys conmode 2 8 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Unpacking and Inspecting UNPACKING AND INSPECTING Open the box and remove all the contents Check to ensure there is no visible damage to any of the equipment Electronic components in this amplifier are design hardened to reduce static sensitivity However proper procedures should be used when handling to avoid damage to equipment Remove all packing material and equipment from the shipping container Be aware that some connector kits and other equipment pieces may be quite small and can be accidentally discarded if care is not observed when unpacking the equipment Do not dispose of shipping materials until the packing list has been checked Upon receipt of the equipment inspect components to ensure that no damage has occurred in ship
79. eueeesueeeeseeeeeueeeeesueeeeeseeeeeeseeeseuegeeeeusueeseueeeraenanees 10 11 Electrical Specifications sies 16 Regen Information 17 Control Spetifica tions EE 17 SYSTEM WIRING DIAGRAM ER VER neaei s gisita addis 21 Main Power Logic Power Power Diagram Notes Encoder VO CODm unie ALON onc a ste un TONG ONTO CLOTS Digital Inputs erteilen ient Sourcing or Sinking Iro I DIP Switch Settings POP M Emm Diagrams for Motor Frames Sizes 070 095 115 145 190 nennen entente tette tete 31 Diagrams for Motor Frames Sizes 060 090 130 175 cccccsesssssesesssseceseseseesssesesesesesceseeeseseecseseeseacseseseseeseaeseseseeeeseaeeeeeeeeseseaeeeeenseaeas 32 FEEDBACK DEVICE S tmu ve dest decode reete e mU dm tu e eere P Su depbus vedere Digital Encoder VE QU EP sa ds Cable Lengths Resolution and Accuracy Resolver Cable Lengths Resolution and Accuracy SINE ENCORE DP
80. example 1 3 cannot be precisely represented in binar form This exception occurs frequently and indicates that some generally acceptable exception has been lost Most applications mask this exception 62 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com FPU Overflow This error occurs if the Fatal Fault Watchdog magnitude of the rounded true result will exceed the magnitude of the largest finite number in the destination format Force Control Industries Inc Troubleshooting Error Error Message Error Description Data Type Immediate Action 31 32 Unknown module ID Internal error Unregistered code of the module encountered in the error code 33 34 35 Failed to write into Error History file An error occured while writing to the log file This can happe if many errors are generated simultaneously 36 37 38 9 3 Task does not exist It s impossible to retrieve erro information about non existent task Generated in response to ERROR or ERRORNUM task query when task does not exist 4 0 41 42 P gt gt The error flow too intense Some error messages may be lost Error message queue overflow Logger message queue overflow The error message flow is too numerous Some error messages may be lost Could not stop Interpreter User process cannot be stopped by the Defaul
81. g upload task Internal error SYNC Error task 4011 Cannot create RAM Internal error ROOT Fatal Fault drive device 4012 Bad initialization Internal error SYNC option 4013 No memory for RAM is not enough memory to SYNC Error drive volume create the RAM disk Possible solution add more memory or delete unneeded files 4014 Host has interrupted file ASYNC transfer transfer operation 4015 No disk space File operation could not be SYN p accomplished due to the lack of disk space 4016 File not found Cannot locate the file 4017 Error opening file Error opening file 4018 Error closing file Error closing file Note Error Error Error Error the file device 4020 Invalid device Invalid device name specified ROOT for the file operation 4021 File cannot be deleted There is no permission to delete SYNC the file 4024 Reading directory An error occured while SYNC executing DIR command 4025 Cannot create Cannot create directory because SYNC directory it already it already exists or access 15 exists or access is forbidden forbidden 4026 Closing directory An error occurred during SYNC execution of the DIR command PosiDrive RC Installation Manual 79 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Fatal Fault Error Error Error Troubleshooting Force Control Indus
82. gram The Message Log displays program syntax errors and can be used to print information during program execution 50 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting The Editor provides single stepping allowing you to execute single lines of the program The Task Manager Window access from menu bar shows the present status of each task including the last executed line of the program this number appears below the Source heading in the Task Manager Window Most Common Problems and Solutions The table below contains a list of the most commonly encountered problems and suggests corrective actions for each problem BASIC Moves gets hung up after Close BASIC Moves Power down drive Change SW 6 Select Device RCreen This is to 0 Restart BM If problem goes away there may be a where RC shows up but after bug in Config prg or Autoexec prg tasks trying to connect BASIC Moves Error in Autoexec prg Check 7ERRORHISTORY BM hangs up terminal for error deRCription The Software locks up during Close the software and delete KMTCPIP from the operation Windows Task Manager access by Ctrl Alt Del Restart the software cl Error Internal System Error To reset set sys conmode 1 then sys conmode 2 c2 Error Sys motion flag turned Check Motion HW Input S
83. here an 8 or 0 is displayed and changes all other parameters enabling the drive and performing motion A Conmode is changed in the Software main RCreen by the drop down menu Conmode or at the Terminal RCreen by typing either sys conmode 1 or sys conmode 2 If sys conmode 0 you will encounter a C2 error Operational Modes The PosiDrive RC has the ability to assume different modes of operation It is factory configured in OPMODEI Analog Velocity Controller but may be reconfigured by the user Not all commands and variables are active or meaningful in every OPMODE OPMODE 0 Digital Velocity Controller The PosiDrive RC is configured as a velocity loop controller and is controlled by issuing a velocity command JOG jog command OPMODE 1 Analog Velocity Controller The PosiDrive RC is configured as a velocity loop controller and is controlled through either a 10V analog input signal The commanded velocity is proportional to the input voltage by the AnalogVelocityRCale factor OPMODE 8 Position Controller Digital Position Mode The PosiDrive RC is configured as a digital positioning controller This is the default mode but can also be caused by issuing a Move command System I O This section diRCusses the I O features of the C3 connector except for the Thermostat input on C2 Analog Input ANIN1 ANIN2 the position velocity or torque loop can receive its command from an analog voltage source and is
84. iables cannot be declared with the same name as a reserved command name Too many nesting blocks nvalid name of motion element Invalid property Too many consecutive spaces i a command DIST AUTORIZADO QRO 442 1 95 72 60 Force Control Industries Inc Data Type SYNC SYNC S i SYNC SYNC i 5 SYN SYN SYNC 5 SYN Immediate gt Q zt 5 Severity error error error error error error error error error error error BE 2 Index of array must The number of elements inan SYNC error a constant value array must be declared with a constant value EN error With block mismatch A With block definition must YNC error end with the End With statement Case Select block Case Select block mismatch SYNC mismatch PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 ventasQindustrialmagza com Force Control Industries Inc 7076 7077 7078 7079 7087 7090 7091 7092 7093 7094 7095 7096 7097 7100 7102 7103 7104 7105 7106 7107 Error Message Motion element must be an axis Invalid motion element This property isn t a system property Wrong given master type Dimension mismatch System camming element does not exist Camming element can only be a system element Wrong input type for the sel
85. ially connected which normally do not constitute a problem with longer cable lengths PosiDrive RC Installation Manual 35 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Wiring the PosiDrive Force Control Industries Inc RESOLUTION AND ACCURACY Internal resolution of the system can be derived through the following calculation Encoder line resolution x 256 x 4 quadrature System accuracy is largely dependent upon the accuracy of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used Filtering CE Filtering Techniques The PosiDrive RC system PosiDrive RC and motor meets the CE Mark standards stated in the front of this manual Apply proper bonding and grounding techniques deRCribed earlier in this section when incorporating EMC noise filtering components to meet this standard Noise currents often occur in two types The first is conducted emissions passed through ground loops The quality of the system grounding RCheme inversely determines the noise amplitudes in the lines These conducted emissions are of a common mode nature from line to neutral ground The second is radiated high frequency emissions that are usually capacitively coupled from line to line and are differential in nature To properly mount the filters the enclosure should have an unpainted me
86. ialmagza com Wiring the PosiDrive Force Control Industries Inc System Interconnect Connector information and the system connections up to the motor power and feedback connections are listed in the following tables Electrical Specifications Product Model RC 03 RC 06 RC 10 l15Vac 10 30 1 3 IE KVAatll5 1 oa Continuous Current amps at 115VAC 39 77 J Peak Current amps for 500 mSec 115 11 7 23 1 Peak Current amps for 2 Sec 115AC 78 154 J KVAat23000 Jose 18 J Main Input Power Continuous Current amps at 230 10 139 77 Peak Current amps for 500mSec at 230 peer 10 Peak Current amps for 2Sec at 230 A 178 154 J Line Fuses FRN R LPN or equivalent 10 20 J Peak Current amps for 500mSec at 230 30 Close 3m5 Open 2m5 OverFemperature rip oe 30 C m 20 28 LSA 30 025 5 to 45 C Storage temperature C 0 to 70 10 to 90 Environment w o no corrosive gasses or dust Altitude Derate 5 per 1000 ft 300m above 3300 ft 1000m Vibration 0 5 g 16 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC Product Model RC 03 RC 06 RC 10 Continuous Power at 115VAC 1 Line Input 45 Ambient 0 35
87. ing less data in the cyclic data allocate data structures Try ata element too long Cannot transmit very long data SYNC Error through the Service channel 12042 12043 1 2044 Error calculating T2 Error calculating MDT starting increase cycle time or time There is an expected time 12046 12047 12048 12049 baud rate Error calculating T3 Error calculating T4 Error calculating TEND No service data Service channel hand shake time out overlap between the AT s and the MDT Either increase the cycle time increase baud rate o simplify the telegrams Error calculating command value valid time The time calculated for T3 exceeds 1 ms Error calculating feedback acquisiton capture point The SYNC time calculated for T4 exceeds 1 ms id transmittion time n empty Internal Error Service channel handshake time out Drive does not acknowledge service transmission BE l 1 12051 12052 12053 12054 12057 12058 12059 12060 changed Attribute is write Service transfer not error free ttribute transmissio too long Missing telegram s communication interrupted Wrong predefined data telegram number Communication phase 3 transition check failed Communication phase 4 transition check failed Wrong element The element range is 1 7 number C Internal error 2050 Attribute transmission Internal error too short
88. intain motor shaft position Like the previous loops the position loop is digital and uses resolver encoder and sine encoder feedback signals to determine actual motor position The PosiDrive also accepts a position signal from an external feedback device e g load encoder It samples at a rate of 2 kHz and can be configured for three different modes of operation 1 Using a MOVE and HOME commands the PosiDrive executes simple absolute incremental indexing and homing motion profiles 2 Homing types HOMETYPE are available that home to a particular analog input level and position count triggering either through the configurable inputs or the remote enable In this mode of operation the PosiDrive also accepts an external load feedback signal through the C8 connector DUALFB 1 This helps eliminate the positional inaccuracies due to gear backlash and poor coupling by positioning according to the load s position not the motor shaft s position 3 The PosiDrive RC also operates in the position mode when the PosiDrive is in the hold position state Torque Loop Operation The PosiDrive RC has many internal variables used to examine and dictate system operation Many of these variables and their locations in the Software are presented graphically to enhance meanings and relationships CURRENT SAMPLING The current loop receives corrective feedback from the current sampling circuitry The current sensors use closed loop hall sa
89. is verification that all allocated motion packages are deleted if not the error is set 3140 RTS blocked Internal Error The RTS didn t Fatal Fault release the semaphore The RTS releases this semaphore periodically but if the semaphore is not released after two time periods this error is set It is an indication that the RTS is not functioning properl or that the interrupt handler stopped 3141 Bad profile data Internal Error Profiler error p Fault Invalid data for the profile calculation given 3142 RTS element add Internal Error The RTS failed to Fatal Fault failed add an element The RTS refused to add new element in its table 3144 RTS clear motion Internal Error The RTS failed to uM Fatal Fault failed clear the motion enable flag The error can occur during the RTK initialization or during the suspend resume transitions RTS set motion failed Internal Error The RTS failed to ASYNC Fatal Fault set the motion enable flag The error can occur during the initialization or during the suspend resume transitions 74 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 3146 RTS overrun clear Internal Error The RTS failed to SYNC Fatal Fault failed clear the overrun flag Occures
90. l Industries Inc CABLE LENGTHS It is important to use properly shielded cable and to keep it away from other noise radiating devices and cables Do not run the feedback and motor cables in the same conduit Force Control Industries Inc has tested cable lengths up to 750 feet 229 meters without degradation of performance However performance may vary depending on motor and resolver type Tests were performed with standard Force Control Industries Inc cable and its low impedance Force Control Industries Inc PosiDrive motor resolver Please consult factory for cable and resolver impedance specifications when long cable runs above 250 feet 76 meters are desired Force Control Industries Inc recommends twisted shielded pair for feedback cables RESOLUTION AND ACCURACY The PosiDrive RC 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 PosiDrive RC 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 PosiDrive RC s resolution capabilities VLIM RPM RDRES Counts Rev Encoder Eqv Output C4 gt 6100 4096 4096 quad counts 1500 to 6100 16384 16384 quad
91. lation Errors No Translation Errors 7001 Error writing to Error writing to ouput file of internal translator translator The translator uses a output file temporary file on the RAM disk Add more memory or delete unneeded REC files This error aborts the translation Error writing to Error writing to the temporary SYNC internal translator file of the translator The temporary file translator uses a temporary file on the RAM disk Add more memory or delete unneeded REC files This error aborts the translation process Error writing to Error writing to the error file of SYNC translator error file the translator The translator error file is stored on the RAM disk Add more memory or delete unneeded REC files This error aborts the translation process Error writing to Error writing to the map file of SYNC translator MAP file the translator This error aborts the translation process Errors found during Errors were found during SYNC translation translation This general message is returned after a LOAD command if translation errors were found in the task The error severity is FATAL FAULT if a translation error is found in the CONFIG PRG file 7006 Variable could not be Internal error Add more SYNC added to internal memory This error will abort symbol table the translation process 7007 Variable already A variable can be declared only Translation Note declared once 7008 Subroutine already The
92. llowed allowed 8040 Invalid time or date Invalid time or date entered 8041 Nothing to retry Retry command is applicable anly after a run time error 8042 Task is busy Task is busy debugging is not allowed This happens when task is inside the end function 8043 Element could not be Element could not be deleted deleted while while programs are in memory programs are in memory 8045 Cannot stop Cannot stop or debug S unbreakable task unbreakable task SYNC SYNC 8046 nvalid Serial Number Invalid Serial Number format YNC format YNC YNC YNC YNC YNC YNC YNC code 8049 Wrong type of Wrong type of variable variable 8050 Argument for The maximum value of the S trigonometric argument to a sin x or cos x is function is out of 9 223372036854699 18 8051 The result of The magnitude of the result is S mathematical function greater than the maximum value overflows 8052 Element could not be Element could not be added to S added to symbol table symbol table Internal Error Internal Error 8053 No permission stop Motion should be stopped S the motion first before Reset 8054 Serial number has Serial number has invalid S invalid format format 8047 Invalid Authorization Invalid Authorization code sz z sll sl slat sl z s asl s E E E 515 a
93. lready SYNC Error denied has been opened If it was open for reading you cannot open it for writing 4041 available file No file deRCriptors available at SYNC deRCriptors the current directory 4042 name The file name is illegal from the SYNC File system s point of view 4050 Volume not available Volume not available E 4051 Internal file system Internal error S error i NENNEN YNC 4052 Opening directory An error occured while YNC accessing a directory YNC 4053 Unknown error An unknown error code was S Fatal Fault generated while the File System was in operation 80 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Entry Station 5000 through 5999 Action 5000 driver support 5002 Failed to create ouput Faled to create pipe Add ROOT Fatal Fault Watchdog pipe add more memory memory pipe support 5004 Failed to create input Not enough memory to create ROOT Fatal Fault Watchdog task add more task Add more memory memory 5005 Failed to create output Not enough memory to create ROOT Fatal Fault Watchdog task add more task Add more memory memory 5006 Failed to create aled to create sync semaphore ROOT Fatal Fault Watchdog semaphore add more add more memory memory drive
94. lue cannot SYNC be changed while drive is disabled 3159 No memory for axis more free memory in the S definition system The memory of the system is exhausted YNC 3160 Wrong PLS index Wrong PLS index SYNC 3161 Can t declare more A maximum of 65536 PLS can PLS s be declared Pp i y O 3162 PLS property cannot Certain PLS properties cannot S be set while PLS is be set while the PLS is enabled enabled First disable the PLS then change the property value PosiDrive RC Installation Manual 75 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting 3163 PLS value cannot be accessed before the PLS data are created PLS position index out of range PLS position data must be monotonic 3166 3167 3168 PLS Enable must be binary 0 or 1 Fatal Fault the error number is not defined by the programmer 3169 3170 3171 PLS cannot be deleted while it is enabled 3172 3173 Element is stopped by another task issue PROCEED command Current property cannot be changed for a Master axis 3177 3178 3179 Cannot MOVE IMMED Proceed motion Disable time out expired 1 ms phase reduced to 0 3182 76 PLS output polarity The PLS output polarity must must be binary 0 or 1 be binary 0 or 1 Wrong value for the Wrong value for the repetition repetition interval interval PLS Hyste
95. ment If damage is detected notify the carrier immediately Check all shipping material for connector kits documentation diskettes CD ROM or other small pieces of equipment Warranty Information All products covered in this manual are warranted to be free of defects in material and workmanship and to conform to the specifications stated either in this document or product catalog description All Force Control Industries Inc brushless motors and electronics are warranty for a period of 12 months from the time of shipment There are no other warranties expressed or implied including the warranty of merchantability and fitness for a particular purpose which extends beyond this warranty Force Control Industries Inc warrants that the products covered in the manual are free from patent infringement when used for normal purposes Use As Directed The following guidelines describe the restrictions for proper use of the PosiDrive RC system The amplifiers are components built into electrical equipment or machines and can only be commissioned as integral components of such equipment The servo amplifiers are to be used only on earthed three phase industrial mains supply networks TN system TT system with earthed neutral point The servo amplifiers must not be operated on power supply networks without an earth or with an asymmetrical earth If the servo amplifiers are used in residential areas or in business or commercial premises
96. mory or delete unneeded files Call symbol table not Internal error An internal data SYNC Fault created structure could not be created Add more memory or delete unneeded files 88 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com td Hd 3l3 5 E 5 2 o lo S R mi m m gt O A o 3 7031 7032 7033 7034 7035 7036 7037 7038 7039 7040 7041 7042 7043 7044 7045 7046 7047 7048 7049 7050 7051 7052 rol Industries Inc Error Description Data Type SUB symbol table not Internal error An internal data created structure could not be created Add memory or delete unneeded files CALL references non You are trying to calla Translation existent SUB subroutine that does not exist The subroutine must be defined The subroutine is never called SYNC in the program Translator Internal error The Translator ROOT Initialization failure could not be initialized Contact technical support Translator syntax erro The syntax of the expression is Translation wrong Check correct syntax in Reference manual Program structure The program must adhere toa Translation error well defined structure Refer to the section on Tasks in the User s Manual Not enough space for Not enough space for parser S parser stacks stacks m
97. mpling 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 can be monitored by examining the JA and IC variables respectively The microprocessor calculates the equivalent absolute current which is monitored as I Foldback The PosiDrive RC offers two types of Foldback protection for both the motor and PosiDrive The PosiDrive s microprocessor monitors the current feedback signal and develops an 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 48 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Controller Operation DRIVE FOLDBACK This Foldback algorithm monitors current feedback and if the feedback exceeds the continuous current rating of the PosiDrive 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 IMA X output from the PosiDrive for 2 seconds After two seconds the PosiDrive enters Foldback mode FOLD 1 and begins a
98. n Recorder ASYNC Fatal Fault state 9021 Unknown error Invalid error code recognized SYNC Fatal Fault by the Recorder task PosiDrive RC Installation Manual 97 MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Event Handler 10000 through 10999 Error Description Data Type N 10000 10002 Too many events To many events defined S defined 10003 Invalid event task id Failed to create an event handling task This may occur during start up Severity Immediate Action n oo Z 5 E NEM 10004 Invalid mutex id Invalid mutex id 10005 Invalid semaphore id Invalid semaphore id SYNC ASYNC Fatal Fault LS 10006 Invalid event message Invalid message queue id SYNC ASYNC Fatal Fault MEN queue id UT d 10007 Memory allocation Memory allocation failed SYNC fail 10008 Invalid operation code Invalid operation code for ASYNC operation with internal linked list 10009 Invalid RTS element Invalid RTS element otained It ROOT could happen at start 10010 Event condition not Event condition not specified SYNC specified Condition pointer is NULL 10011 Error checking event Event condition function call ASYNC condition failed 10012 Event invalid handle Event invalid handle SYNC atal Fault 10013 Interpreter invalid Invalid pointer to Intepreter SYN
99. n 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 This Foldback feature is designed to protect the PosiDrive electronics not the motor The Configurable Output O1 pin 12 can be configured to indicate a PosiDrive Foldback condition A For PosiDrive 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 elapses before the PosiDrive enters Foldback and only occurs when maximum peak current IMAX is drawn MOTOR FOLDBACK This Foldback algorithm is designed to provide motor protection in cases where the PosiDrive s continuous current rating is above the motor s continuous rating This combination is often desired in applications where maximum peak motor torques are required However the PosiDrive could source current on a continuous basis indefinitely to the motor and would force it beyond its thermal capability Unlike the PosiDrive Foldback you have complete configurability over this feature MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT PosiDrive RC Installation Manual 49 55 53 63 23 31 81 83 54 10 18 Aw DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc TROUBLESHOOTING Troubleshooti
100. n 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 PosiDrive to an error depends on the error s severity There are two levels of severity 1 Warnings simply called errors and not considered faults and do not disable operation 2 Fatal errors fatal faults that disable almost all PosiDrive functions including communications The PosiDrive automatically disables at the occurrence of a fault Executing a A PosiDrive disable command DIS or K followed by the EN command or toggling the Remote Enable line REMOTE resets the fault latch and if the fault condition is no longer present re enables the system Fault Monitoring System The PosiDrive s microprocessor is constantly monitoring the status of many different components In general the PosiDrive latches all fault conditions 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 Status Display enunciated over the serial port and causes a PosiDrive disable Many faults can be reset by toggling the hardware remote enable REMOTE input The following provides a list of some of the more frequent faults the PosiDrive may detect in the unit hardware and operating system Bus OverVoltage an over voltage condition shuts down the PosiDrive and displays a lower case o in the status
101. nal 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 comes either from a direct user input OPMODE 0 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 PosiDrive RC uses a fully digital pole 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 PosiDrive for a given set of motor and PosiDrive 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 PosiDrive 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 PosiDrive RC has a patented sinusoidal waveform generator which uses a technique called Torque Angle Advance to get top performance out of its motors The wa
102. nalog Output 1 13 4 ANOUTI gt m 1 Voltage Range 10V 18 PosiDrive RC Installation Manual CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Wiring the PosiDrive RC Control Specification Encoder Equivalent Output C4 by pinout Output Voltage high 2 5 V min at 20 mA level at 25 A B I amp Complements 1 2 4 5 7 Output Voltage low 0 5 max at 20 mA 8 level at 25 C RS 485 Line Drive Type DS26C31TM Remote Encoder Input C5 by pinout Input Voltage high low 5 V 0 V nominal 2 V level at 25 C A B I amp Complements 1 2 4 5 7 100 Q 8 RS 232 Line Receiver SN75173 See the section on Position Loop for features using this input C5 requires Differential Input For instructions using Single ended Pulse refer to Appendix 1 0 Connector C9 by pinout Remote Motion Input 1 2 Input Frequency 2 5kHz Opto isolated SYS DIN 1 Through SYS DIN 4 Input Voltage Range 12 to 24 V Nominal Consule ipiis 3 Min On Max Off 10 V 1 V iibi urrent Demand per m Input Configurable Digital Outputs 6 7 Output Voltage max Vmaxon 30V V maxorr 0 5 V SYS DOUTI SYSDOUT2 vin On Configurable Digital Output Common 8 All inductive loads require proper suppression Connector C10 by pinout Configurable Inputs 2 3
103. nalog Outputs ANOUTI amp 2 1 emen e eene ren es 45 Configurable Digital I O C9 C10 C11 C12 C14 mee eren e rh en e rhn ene rre n ene 45 Fault Output Relay RELAY emen e nn heh HH een ese eene n nnn een nenne 45 Motor Thermostat Input THERM 45 erirdue so HMM X X X 46 CONTROL LOOPS iie i E n n ree epe EE ES ELA EH EE IR EXE E De e eee LEE ee Re gates NEAR 46 Seryo Loop Description iuc ua rt te editos ETRE oe ee e guessed est aee rodea NEEE RA VL b bete ges 46 Current 00 P M HT Commutation Loop Velocity Loop des wed POSTON OOP Ex Torque Loop Operation Current tenis teet e E Drive Foldback Motor Foldback TROUBLESHOOTING 2 iiti seo era ts aude eU sa ce Togo a Eu e TU EUR Fase PODER GistaeaseChasssaseseccavesesuetss 50 TROUBLESHOOTING TOOLS edic ena Ea ERROR ANS E Fa sn be ede e eH RS ex rane dre di add 50 Software Diagnostic TOOLS iride Samad ee aE ea n a e EREE ig heal Exe prn 50 BASIC Moves Software Diagnostic Tools mee mh Hessen rhe ness nnne here enne 50 MOST COMMON PROBLEMS AND
104. ng tools Software comes with a Status RCreen click on Status button in the upper right hand corner of Main RCreen containing complete error history information This information can also be accessed in the terminal window by entering ErrorHistory Software Diagnostic Tools The Drive I O RCreen click on Drive I O button on the side of the Main RCreen gives you the ability to check the status of the Drive I O on Connector C3 You can also monitor a variety of variables from the Monitor RCreen click Monitor button at the top of the Main RCreen and compare up to three variables at one time The Tune and Record RCreen allows you to evaluate the system s actual performance against a predefined command profile Also from this RCreen you can vary the performance by adjusting the gains until optimum following is achieved BASIC Moves Software Diagnostic Tools In BASIC Moves Software there is a terminal window that allows you to query the drive direction for values and obtain information on errors Common Troubleshooting commands are ErrorHistory List all errors ServoError List active servo error Sys conmode and OpMOde List present operation mode TaskList List status of task loaded in RAM EventList List status of loaded Events The Watch window allows you to display parameters realtime This is an excellent tool to monitor key parameters inputs and outputs throughout the operation of the pro
105. nge override is out of the range of allowed values For example VELOCITYOVERRIDE 1 3017 Axis following error The position error of the axis 15 ASYNC Error Motion is stopped verify PEMax greater than the allowed error a specified by PEMAX Wrong position value Invalid position value given SYNC Error The given position is out of the defined position range for that axis 3019 Internal error Cannot delete an Fatal Fault Watch dog axis The element is moving This error is returned when SYNC Error attempting to enter three Move commands from the terminal Only two move commands are buffered from the terminal The error is also returned when attempting to enable gearing camming when the axis is already in motion Absolute homing There is a maximum homing SYNC Error maximum distance distance defined for a safety exceeded The home measure in cases when homing procedure will be fails stopped 3025 Contact technical support SYNC YNC 3026 Motion inhibited Set Motion on the specified S Error Motion flag to ON element is inhibited by the MOTION property 3027 Contact technical support 3029 Contact technical support 3033 SYNC flag not set set The SyncStart command was Error StartType to SYNC issued upon an element for which the StartType is not defined as SYNC Synchronized There exists a pending C Error movement is pending synchronized movement for the clear sync using motion eleme
106. noise is either common mode or differential The common mode conducted currents occur between each motor lead and ground line to neutral Differential radiated currents exist from one motor lead to another line to line The filtering of the lines feeding the motor provides additional attenuation of noise currents that may enter surrounding cables and equipment I O ports in close proximity Differential mode currents commonly occur with lengthy motor cables As the cable length increases so does its capacitance and ability to couple noise from line to line While every final system is different and every application of the product causes a slightly different emission profile it may become necessary to use differential mode chokes to provide additional noise attenuation to minimize the radiated emissions The use of a ferrite core placed at the PosiDrive RC end on each motor lead shown in the diagram below attenuates differential mode noise and lowers frequency 30 to 60 MHz broadband emissions to within specifications Force Control Industries Inc recommends a Fair Rite P N 263665702 or equivalent ferrite core Wrap each motor lead through the core several times as shown in the figure on the next page Never wrap a ground lead through a core PosiDrive RC Installation Manual 37 55 53 63 23 31 81 83 54 10 18 SAL DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive F
107. not get to Sys Conmode 2 S Check 2SERVOERROR from BASIC Moves terminal for remains on display bad Motor configuration Add statements to application program to set sys conmode 2 PosiDrive RC Installation Manual 53 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Lose communication with Basic Communication with the RC is priority level 2 Do not Move when task s are executing set any task priority levels to 1 or 2 Task Priority level default is 16 One or more BASIC Moves If after cycling power select Debug Reset functions stop working Communications from the menu bar Close and restart BASIC Moves Operating problems For standard operation verify setting of DIP switches SW 1 and 6 must be set to 1 All others to 0 Problems after changing Set DIP switch 6 to 0 Reboot and delete task config prg Autoexec prg or Config prg task or autoexec prg Reboot again with DIP switch 6 set to 1 Program stops running and Error Open the Task Manager in BASIC Moves and review box pops up in BASIC Moves information shown Task Status Error and Source Review information in BASIC Moves Message Log Check 2SERVOERROR in BASIC Moves terminal for error Correct problem causing error Check 7ERRORHISTORY in BASIC Moves terminal Correct problem causing error Very slow communications with Multiple parame
108. not implemented into the system shielded cable is required on the power input wires and proper bonding technologies should be implemented The motor and feedback cables should have the shield exposed as close to the PosiDrive RC as possible This exposed shield is bonded to the back panel using one of the two suggested methods below PosiDrive RC Installation Manual 13 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Wiring the PosiDrive Force Control Industries Inc NON INSULATED CABLE CLAMP The following figures shows how cable bonding is implemented using non insulated metallic cable clamps The first figure demonstrates clamping to the back panel in the vicinity of the PosiDrive RC The second shows a technique for bonding a terminal strip for best results it is recommended not to break the shielding of the cable From the Drive To Motor ALTERNATIVE BONDING METHODS Another option is to use cable bonding clamps offered by Phoenix Contact and others When using the Phoenix Contact parts ensure that a low impedance high frequency ground is connected from the ground bus bar to the back panel using either a flat braid or a copper bus bar The SK parts from Phoenix SK8 SK14 amp SK20 slide onto the bus bar The cable with exposed shield is inserted through the SK piece and the thumbRCrew on top of the SK piece is
109. nt The motion SyncClear command element cannot be moved until the SyncStart command has been issued or the synchronization has been cleared with the SyncClear command Automatic braking The element is being ASYNC Error automatically stopped This can occur when the final velocity is nonzero and there are no pending motion commands 3037 Not stopped The proceed command given to SYNC Error a element that was not stopped 68 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 3038 The element is Cannot define gearing camming SYNC Error stopped from another when the element is stopped by task another task The STOP command also inhibits motion in this case Only the task can The element has been stopped SYNC Error Proceed by a task The Proceed command must come from a task and not from the terminal Only the terminal can A motion element that has been SYNC Error Proceed stopped by a STOP command from the terminal can be Proceeded only by a proceed command from the terminal and not from another task 3041 Nothing to proceed The Proceed command has been SYNC Note not been stopped 3042 Proceed in progress are certain restrictions for SYNC Error the proceed stop commands
110. nt in most cases Control and signal cables must be shielded to reduce the effects of radiated interference When control cables must cross power or motor cables they should cross at an angle of 90 degrees if possible This reduces the field coupling effect Grounding System grounding is essential for proper performance of the PosiDrive RC system A ground bus bar is used as a single point ground for the system Safety grounding is provided to all pieces of the system from a star point In addition to the safety grounding a high frequency ground must be provided that connects the back panel to the enclosure and ultimately to earth ground This provides an extremely low impedance path between the filters drives power supplies and earth ground This high frequency ground is made with the use of a flat braid or copper bus bar Do not use a standard wire for the high frequency ground When connecting high frequency grounds use the shortest braid possible Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels of the PosiDrive RC system Its effect is to reduce the impedance between the cable shield and the back panel Force Control Industries Inc recommends that all shielded cables be bonded to the back panel Power input wiring does not require shielding RCreening if the power is fed to the cabinet enclosure via metallized conduit If metallized conduit is
111. ntasQindustrialmagza com 1 Force Control Industries Inc Wiring the PosiDrive RC A B and complements lines make up the encoder quadrature signals The signals are received differentially at 1V peak to peak amplitudes before being processed by the interpolation circuitry The narrow Index pulse normally appears once per mechanical revolution and indicates a known physical position of the shaft This pulse is received differentially through an op amp before being squared up and sent to the control board Upon power up commutation signals are used to communicate coarse position information The first three signal types give approximate position information so the drive can commutate the motor forward until the Index pulse is found There are situations where the index signal is not available Course position information is used to commutate the motor indefinitely The fourth gives absolute information bypassing the need for the Index signal They are There are no Hall signals if there are no power up commutation signals available The PosiDrive RC can excite two phases and lock the shaft in place It then approximates the position of the locked shaft and uses only the incremental signals to commutate forward until the index is found Hall signals provide information representing the approximate location of the motor shaft 6 transitions per electrical cycle of the motor From this information the motor can six step commutate forward un
112. ntegration with other equipment It may be necessary to place ferrite cores on I O lines to avoid unwanted signals entering and disturbing the PosiDrive RC system or other associated equipment The following chart lists some ferrite parts that may be used for I O filtering and noise attenuation These parts are ideal for providing in line common mode impedance for I O lines Fair Rite Products Corporation has a varied selection which suits most applications Manufacturer Manufacturer s Part Force Control DeRCription Industries Inc Part Ferrishield SS33B2032 Po Clamponcore Ferrishield SS33B2006 J Clamponcore Ferrishield 28 2480 J Clamp on flat cable clamp Ferrishield SA28B4340 Clamp core flat cable clamp FairRite 2643167281 This core must be used with the PosiDrive RC for CE compliance It should be applied to the 24V input power lines and the Remote Enable lines 7 amp 8 on C3 connector with approximately 3 turns through the core I O Filter Recommendations The following figure illustrates the use of multiple turns through a clamp on core The more turns created the more impedance is added to the line Avoid putting the shield in a clamp on core It is undesirable to place an impedance in line with the shield The use of ribbon cable may be common in many cabinets Some ferrite clamps are designed just for ribbon cable use as shown below
113. nvalid event ID NULL SYNC ASYNC Fatal Fault reference to current previous active events Resource probler Source event management priority modif Invalid parent task Invalid parent task ID SYNC Fatal Fault node Requested ITCB idx is not the same as in the event list Data integrity violated Source Load Unload Comment cannot hapen during normal runtime 84 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Action Invalid interpreter NULL pointer to internal SYNC ASYNC Fatal Fault pointer interpreter registers encountered Source event management Comment cannot happen during normal runtime If the error occurs then this task cannot be handled NULL pointer to interpreter but ITCB rat opatan co still exists REI handler 6023 Invalid event list Cannot take event list mutex SYNC ASYNC Fatal Fault mutex for it is invalid Bad pointer Source event management prolog epilog Load Unload OnEvent Failed to delete Cannot delete OnError handler Error OnError handler message queue interpreter Source OnError Invalid OnError Invalid OnError message queue ASYNC Fatal Fault message queue ID Bad pointer Source sending error message to OnError task Illegal task priority priority 0 which is Error reserved for OnError specified S
114. o create RTS Failure while spawning the ROOT Fatal Fault task Real Time RCheduler task 66 PosiDrive RC Installation Manual BES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Motion 3000 through 3999 Error Message Error Description Data Type Severity Immediate Action 3001 i 3001 Contact technical support SYNC__ Error S 3002 Nonexistent axis Internal error An unknown axis C Fatal Fault Watchdog number was given This error can be caused only through an invalid input from the interpreter 3003 FatalFault Watchdog 3004 error Contact technical support SYNC Error 3005 Nonexistent axis Internal error Invalid axis SYN Fatal Fault Watchdig handle was entered 3006 Element is already The element that is to be SYNC Error Idle Task attached to a task attached is already attached to a task The error can occur in the Attach command or in any command that needs the attachment permission 3007 Invalid mode Internal Error Invalid mode SYNC Fatal Fault Watchdog given In many commands a mode variable is given The mode can have only certain values depending on the command that is issued MOT MODAL MOT NODAL MOT IMMEDIATE 3008 Velocity out of range The value of the velocity is not SYNC Error Idle Task in the allowed range for this system
115. ommons for each connector Pins I and 8 are not connected inside the PosiDrive on C3 C9 C10 C11 C12 and C14 PosiDrive RC Installation Manual 27 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 QZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive Force Control Industries Inc DIGITAL OUTPUTS 28 E Connector C3 can only be wired in as sourcing Connectors C9 C10 C11 C12 and C14 can only be wired sinking SOURCING EQUIVALENT DIGITAL OUTPUT CIRCUIT FOR CONNECTOR C3 Internal PosiDrive Circuitry 300 Q Common SINKING EQUIVALENT DIGITAL OUTPUT CIRCUIT FOR CONNECTORS C9 C10 C11 C12 C14 Internal PosiDrive Circuitry 150 Q Load Common All inputs that share a common pin must be connected as either sinking or sourcing The output commons C9 Pin 8 C10 Pin 8 C11 Pin 8 C12 Pin 8 C14 Pin 8 are also not connected inside the PosiDrive Likewise the input and output commons Pins 1 and 8 are not connected inside the PosiDrive on C3 C9 C10 C11 C12 and C14 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SAL DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc DIP Switch Settings DIP Switch 2 Base Settings Configuration 0 CONFIG PRG or AUTOEXEC PRG do not run on power up 1 Default 7 HOLD Mode 0 Hold Mode Inactive Switch
116. on Note defined exists Use a different name for the axis 7017 Unload all tasks first Unload tasks in memory 7018 Internal translation Internal error SYNC error 7019 Variable does not The variable you re trying to Translation Error exist use doesn t exist Make sure it has been declared 7020 default motion You are trying to use a Translation Error element use the WITH command without explicitly instruction defining a motion element and a default motion element has not been defined by the WITH instruction 7021 Property valid for Axis property only Translation Error Axis only 7022 Could not change axis Internal error Contact technical Translation Error name support 7023 Axis could not be nternal error Contact technical ROOT created support 7071 ROOT 7025 Too many values into Too many values into vector SYNC vector 7026 many variable The maximum number of Translation Error names simplify the variables allowed in an expression expression is 32 7027 Instruction given in The command you are trying to Translation Error invalid context use cannot be used in this context Check the allowed RCope of the instruction in the Reference Manual 7028 PROGRAM must be The PROGRAM keyword must SYNC Error the first line be on the first line 7029 symbol table Internal error An internal data SYNC Fault not created structure could not be created Add more me
117. onducted noise to levels well below the CE limits The implementation of the EMI filter should be done in accordance with the following guidelines Filter should be mounted as close as possible to incoming cabinet power When mounting the filter to the panel remove any paint or material covering Use an unpainted metallic back panel if possible 36 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC Filters are provided with an earth connection All ground connections should be tied to ground Filters can produce high leakage currents Filters must be earthed before connecting the supply Do not touch filters for a period of 10 seconds after removing the power supply Control Type Recommended EMI Line Filter Force Control Industries Inc Part single phase Filter Concepts SF15 3 and 6 amps 3 amp ee _ 6 and 10 amps Recommended Line Filters Motor Line Filtering Motor filtering may not be necessary for CE compliance of PosiDrive RC systems However this additional filtering increases the reliability of the system Poor non metallic enclosure surfaces and lengthy unbonded or unshielded motor cables that couple noise line to line differential are some of the factors that may lead to the necessity of motor lead filtering Motor lead
118. ons are provided in the PosiDrive RC Installation Manual 1 Open the box and remove all the contents Check to ensure there is no visible damage to any of the equipment 2 Mount the PosiDrive RC to the back panel Wire the PosiDrive RC according to the System Wiring diagrams 1 Logic Power for details refer to the Electrical Specifications and Logic Power Diagram A Apply 24 VDC to terminal 7 on connector C13 B Connect DC Common to terminal 8 on connector C13 C To daisy chain power a Apply 24 VDC to terminal 5 on connector C13 b Connect DC Common to terminal 8 on connector C13 Pin 5 is internally connected to Pin 7 Pin 6 is internally connected to Pin 8 2 AC Power for details refer to the Electrical Specifications and the Power Diagrams A Wire the AC power to terminals L1 L2 and L3 on the front of the PosiDrive RC controller B Single phase power can be connected to any combination of L1 L2 and L3 3 Amp models RC 03 can be wired for 115VAC 1e or 230VAC 16e or 230VAC 3e 6 Amp models RC 06 can be wired for 115VAC 1e or 230VAC 16e or 230VAC 3e 10 Amp models RC 10 can only be wired for 230VAC 39 3 Motion Inputs Refer to the appropriate Connector Diagram A Hardware Enable a Apply 24VDC to terminal 8 on connector C3 b Wire DC Common to terminal 7 on connector C3 B Motion Enable a Apply 24VDC to terminal 2 on connector C9 b Wire DC Common to terminal 1 on connector C9 4 Motor and Feedback R
119. orce Control Industries Inc Differential Mode Filtering Common Mode Filtering 2 To Motor From Drive d PE gt To motor Common mode currents occur from noise spikes created by the PWM switching frequency of the PosiDrive RC The use of a ferrite or iron powder core toroid places common mode impedance in the line between the motor and the PosiDrive RC The use of a common mode choke on the motor leads may increase signal integrity of encoder outputs and associated I O signals A list of toroidal and ferrite cores that can be used to make common mode chokes is found in the following tables Size Micrometals T400 26D OD 4 in ID 2 25in HT 1 3in 0029 Comm Gramm Micrometals ST102 267 OD 1 025 in ID 6 in HT 475 in Moments fem stam 38 6mm 21 2mm 21mm 51 1mm 31 5mm 26mm 27 7mm 14 1mm 11 99mm Fair Rite 2643803802 OD 2 3 in ID 1 4in HT 5in emu asss Gam Toroidal Core Recommendations Manufacturer s Part Force Control DeRCription Industries Inc Part _ 36 amps continuous SS 64 amps continuous Pre wound Common Mode Chokes 38 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC I O Filtering I O filtering may be desired depending on system installation application and i
120. ource load OnEvent priority modify Invalid parent task Happens when an attempt to Fatal Fault semapore take parent task sync fails Source Loader OnEvent OnError Cannot load an empty file SYNC fd pO Source Loader OnEvent Invalid translator Happens when an attempt to Fatal Fault mutex take translator mutex fails OnError 6029 Zero file size detected Cannot Cannot load an empty file an empty file 6030 Failed to create user Cannot create default task error ROOT Fatal Fault task error handler handler task spawn message queue Source Load 6031 Command given in Command given in invalid Note invalid context context Nue 6032 Invalid priority range Invalid priority specified 6033 Failed to create Occurs at start up when creating ROOT Fatal Fault translator mutex translator mutex fails Source Loader OnEvent OnError PosiDrive RC Installation Manual 85 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 6034 Failed to open Failed to create permanent ROOT Error translator output file translator output file Source Root 6035 Failed to open Failed to create permanent ROOT Fatal Fault backend output file backend output Source Root 6036 Cannot open Failed to create translator
121. program file reading because it 1 does not exist 2 there are too many open files or 3 there is not enogh memory If this occurs o power up verify that the CONFIG PRG file exists with valid data Bad element index Bad task index passed as a SYNC Fatal Fault parameter Indicates that system data are not reliable anymore Data problem Source Task priority updated event prolog epilog 6004 Array overflow Too many events tasks defined SYNC Error task load event create Source Load OnEvent 6005 Failed to open Failed to create MAP file SYNC Error translator map file Source Loader Cannot open Failed to create translator error SYNC Error translator error file file in root Source Loader 6007 must be killed Cannot unload a task if it is not SYNC Error first in either the Killed state or the Ready state 6008 Task does not exist When unloading the user task SYNC Error or event the process with the name specified may not exist Source Unload EventDelete Task priority get Failed to run Failed to call interpreter SYNC ROOT Error interpreter function or spawn interpreter task Resource problem Source configuration root Load OnEvent exists already exists 6011 Failed to create data Cannot allocate data segment SYNC Error segment when Loading the task Resource problem Source Load PosiDrive RC Installation Manual 83 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST
122. r support 5008 Failed to add device tg Internal error Contact technical ROOT Fatal Fault Watchdog IOsys support 5009 Serial communication Failed to match Block control ASYNC Error error Bad BCC try character in message again 5010 Serial communication Faled to detect new line in ASYNC Error error Bad protocol message data try again Serial communication Faled to format output message ASYNC Error error Bad protocol data format try again 5012 Failed to write Memory exhausted on RAM drive Add memory or delete REC files 5013 Failed to read Internal error Contact technical Terminal EE 5014 Failed to write Internal error Contact technical Terminal translator output support 5015 Failed to create Failed to create mutex for active ROOT Fatal Fault semaphore add more context Add more memory memor support Interpreter support eeu eese qu E support ERN EN dnd Translator support Watchdog 5020 Failed to create Failed to create back end output ROOT Fatal Fault internal file add more file Add more memory memory PosiDrive RC Installation Manual 81 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Data Type SYNC ASYN SYNC SYNC 5021 Failed to create Internal error Contact technical ROOT memory device support 5022 Virtual input index Virtual input is out of range
123. resis must The value specified for the PLS SYN be positive Hysteresis must be positive Cannot attach element Contact technical support MOVE command stop command Wrong output index Wrong output index C Force Control Industries Inc Action In order to operate on a PLS the PLS must be defined using Common Shared As PLS and the PLS data must be created using CreatePlsData This error is returned when attempting to access a non existent PLS position The number of PLS positions is set when creating the PLS data structure using CreatePlsData The data in the PLS data structure must be arranged in aRCending order The order is verified when attempting to enable the PLS BEEN EN Watch dog he PLS Enable must be binary SYN 0orl MN UT PLS cannot be deleted while it r is enabled First disable the PLS using the PlsEnable propert The STOP command is used both to stop motion and to inhibit further motion If the Stop command has been issued from the terminal or a task then the motion element cannot be attached by another task until the Proceed command has been issued Current property of an axis that SYNC is defined a Master axis cannot be changed First disable the Master Slave by setting the Slave property of the slave axis to OFF Contact technical support Disable timeout of the drives expired
124. response to the WdlInit function Add more memory or unload unnecessary tasks 1005 Invalid BIT handle BIT task received an invalid SYNC Error Idle Task handle pointer The handle is generated in response to the Wdlnit function and must be specified in the WdCycle function 1006 Task stuck One of the tasks that should ASYNC Fatal Fault Watchdog report to BIT has not done so A task tells BIT that it will report to init when it executes the Wadlnit function Thereafter the task must execute WdCycle periodically PosiDrive RC Installation Manual 65 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Run Time RCheduler 2000 through 2999 Action 2001 Unrecognized error code ASYNC Fatal Fault 2002 RTS Failed to allocate data structure ROOT Fatal Fault MutEx for MutEx semaphore 2003 RTS semaphore failed Failed to allocate data structure ROOT Fatal Fault for synchronization semaphore 2004 Overlap error ot enough sytem resourses to ASYNC Error all the mandatory system task 2005 Invalid RTS element Cannot perform RCheduling ASYN Fatal Fault I operation over unregistered RTS element 2006 InvalidmutexID Semaphore cannot be taken ASYNC_ Fatal Fault code request for operation ee eee ee ee internal data 2009 Failed t
125. rformance and Dependability Built to Last Guaranteed to Perform FORCE CON TROL FORCE CONTROL INDUSTRIES INC MAIN OFFICE DETROIT OFFICE P O Box 18366 2716 Stair St Fairfield Ohio 45018 Detroit Mich 48209 3660 Dixie Highway Tel 313 842 5393 Fairfield Ohio 45014 Fax 313 842 5399 Tel 513 868 0900 Fax 513 868 2105 E Mail info forcecontrol com Web Site www forcecontrol com CES TNAGZA 55 53 632331 MTY 81 83 54 10 18 EZ DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com
126. rmation PosiDrive RC Installation Manual CES MNaaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Wiring the PosiDrive RC C9 Configurable User I O Inputs can be sinking or sourcing shown sourcing Common SYS DIN 1 SYS DIN 2 SYS DIN 3 SYS DIN 4 1 24V 2 Config Input i 24V Return 4 5 Config Output 6 7 i SYS DOUT snas gt Config Output 24V 8 Common SYS DOUT 1 SYS DOUT 2 24V Retum C10 Configurable User I O Inputs can be sinking or sourcing shown sourcing Common SYS DIN 9 SYS DIN 10 SYS DIN 11 SYS DIN 12 24V 2 Config Input 3 Config Input 24V Return Config Input 4 pg nput 5 6 Hi SYS DOUT 5 gt 7 E SYS DOUT 7 Config Output 24V E Common SYS DOUT 5 SYS DOUT 6 24V Return C11 Configurable User I O Inputs can be sinking or sourcing shown sourcing 4 Common SYS DIN 5 SYS DIN 6 SYS DIN 7 SYS DIN 8 24y 2 SYS DIN 5 Config Input 3 SYS DIN 6 Config Input 24V Return 4 5 6 Config Output 7 ig Output 24V Common SYS DOUT 3 SYS DOUT 4 24V Retum PosiDrive RC Installation Manual 25 BES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive Force Control Industries Inc C12 Configurable User I O Inputs can be sinking or sourcing
127. rnal data structures Add memory or unload unnecessary tasks Internal error There is no memory within DPRAM to maintain Service container data structure M transfer not ready Element 2 has not been S i i The name of IDN may not be changed in accordance with IEC1491 The name cannot be changed in SYN the current communication phase id for the service transfer initialization Service channel handshake time out Drive does not acknowledge service transmission Controller didn t receive telegram from the drive s in communications phase 2 This error is generated when a drive stops functioning I I I SYN Data Type SYNC B ull SYNC Troubleshooting T at ult Or Fatal Fa Or Immediate gt zt o 5 C tri 5 o S m d g C d o m d g 5 5 5 2 2 d g tri 5 S d S d g C C C tri 5 S tri 5 d g C C C Fatal Fault d g Erro PosiDrive RC Installation Manual 101 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action DPRAM overflow Not enough DPRAM space to SYNC Error us
128. ror Error Error Error 2 n gt gt gt eee a Error ASYN Error 17013 Software limit switch PFB gt PMAX or PFB lt PMIN fault fault 17014 RESERVED po 17015 Non volatile data memory fault ASYN memory fault 17016 Non volatile data Non volatile data memory memory checksum checksum fault fault 17017 17018 17019 17020 Internal Error po po 17021 Internal Error Motor over speed fault Error c 4 ul 2 gt gt n Error Error Error Error Error Error Error Error 2 7 17022 17023 Invalid drive or motor No compensation fault configuration 17024 Motor over speed fault Motor over speed fault 17025 Internal error 7 gt n 2 Error Error Error Error Error Error zl 17027 ynchronization Error 17028 Synchronization Error communication fault fault 17030 Internal firmware fault 17031 Positioner fault Positioner fault Check SYS MOTION flag mode active 7 17026 Internal Error gt n n il aoo miro gt n 2 Error Error gt n k Q gt 2 tri tri tri tri S 5 E 5 8 5 5 Error 17034 Invalid configuration number PosiDrive RC Installation Manual 107 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 4
129. rvice channel 9008 Insufficient disk space Record data are stored on the to store recorded data RAM disk There is not enough free space on the disk to store the recorded data Delete files fom the RAM disk and then try executing the RECORD command or the RECORDCLOSE command again 96 PosiDrive RC Installation Manual GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Error Message Error Description Data Type Severity Immediate Action 9013 Creation of System Internal error SYNC Error segment failed 9014 Failed to run Internal error ASYNC Error Interpreter s agent 9015 Invalid MutEx ID Internal error Fatal Fault NEN 9016 Invalid record file Invalid file extension specified SYNC Error extension must be for recorder file Only the REC REC extension is allowed 9017 Recorder hasn t been The RECORD command has to SYNC Error initialized be successfully executed before the RECORDON RECORDOFF or RECORDCLOSE commands can be executed 9018 Wrong index of Internal error Recording ASYNC Error recording variable variable index is out of range 9019 Recording already has The RECORDON and ASYNC Note been completed RECORDOFF commands cannot be executed if the Recording process has already been completed Execute the RECORDCLOSE command in order to save the recorded data 9020 Unknow
130. s the active cam of the axis The specified number of cam cycles is out of range Refer to the CYCLE cam property deRCription in the Reference Manual No cam is defined for the axis This error is returned when the following axis property queries are issued ActiveCam CamCycle CamIndex Troubleshooting PosiDrive RC Installation Manual 71 MEX 55 53 63 23 31 DIST AUTORIZADO QRO 442 1 95 72 60 MTY 81 83 54 10 18 ventas industrialmagza com Troubleshooting 3080 must be cam Cam chain is not connected correctly 3081 Feedback velocity is out of limit Feedback velocity is out of limit when motion is stopped drive disabled 3084 3085 Incorrect parameter value Incorrect number of point coordinates given to this movement Target position will exceed the limit Wrong factor value specify a positive value 3086 3087 3088 3089 be changed while drive is enabled 3096 Minimum position limit must be less tha the maximum limit Time value inaccuracy value is rounded up to nearest integer multiple of 1 ms 3098 Cannot execute InPosition 72 Wrong file extension Wrong velocity over speed value Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action The cam file extension must be SYNC CAM When the axis is moving to the AAYNC next previous table the connection between the tables is checked If the
131. s not been support defined d Calculated length Internal error Contact technical SYNC Error Idle Task of the token s does support not match its predefined value d Out of disk space Out of disk space while SYNC Error Idle Task attempting to write temporary file to RAM drive Add more memory or delete REC files 11019 Invalid Error code Internal error Contact technical Fatal Fault Watchdog support PosiDrive RC Installation Manual 99 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Internal Communication 12000 through 12999 Error Message Error Description Data Type Severity Immediate Action 12001 Service Channel not Drive has indicated that it SYNC Error open cannot open the service channel Contact technical support MDT telegram Overlap between reference ASYNC Error processing overrun generation and transmission Try using a higher baud rate longer cycle time and reducing the amount of cyclic data SYNC 12003 Interrupt Service ISR s duration is too long more Error Routine Overlap use than one communication cycle longer cycle time 12004 Service channel Internal error Timeout during SYNC service channel transmission drive Contact technical support 12005 Service channel Timeout while the Service SYNC busy 5 12006 Undefined error Internal error Undefined
132. s to declare it SYN SYN SYN SYN SYN YN SYN YN SYN SYN Troubleshooting Immediate Action Severity error error error error error error error error error error m 2 d d d S amp S rror E H tri tri tri d d d o o o 5 d o 7108 rror Name of pls is invalid Name of pls is invalid PosiDrive RC Installation Manual 91 CES TNAGZA MEX 55 53 632331 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 7109 The with block must The with block must be closed SYNC Error be closed before before entering a try block entering this block 7110 Cannot use locals Must use a global variable in SYNC Error event block the event conditions 7111 The maximum length The maximum length of the SYNC of the expression must expression must be less than be less than 128 128 characters 7112 Cannot move without The target point is missing from SYNC Error target point the move command 7114 This function cannot This function cannot be used as SYN be used as a condition a condition 7115 The pls cannot be The pls cannot be declared SYN declared within a within a program program 7116 Nesting of try Nesting of try statement is not SYNC Error statement is not allowed
133. sh memory firmware that controls the core processor and gives the PosiDrive RC its operating characteristics is saved in EEPROM User programs are stored on Flash Disk DiskOnChip The version number of the firmware is read using the VER command When calling for technical 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 upgradeable through a Control Loops This section deRCribes the servo control loops their characteristics and how to configure them Servo Loop DeRCription The PosiDrive RC provides high performance motor control by controlling up to four distinct closed loop systems within the DSP current commutation velocity position The figure below depicts the control loops graphically oe POSITION LOOP i gah dise VELOCITY LOOP see i COMMUTATION LOOP 3 pcc ccc CURRENT LOOP 4 ISOLATION 330 VDC Control Loop Structure 46 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Controller Operation CURRENT LOOP Since current and torque are proportio
134. t 14 bit conversion Special software algorithms are used to minimize crossover distortion and add 25V of hysteresis Analog systems often require RCaling and offset bias The PosiDrive RC adds an analog offset ANOFF1 ANOFF2 variable to this reading performs an analog deadband ANDB1 ANDB2 adjustment and RCales it through the position loop input RCaling velocity loop input RCaling VRCALE or torque loop input RCaling IRCALE before passing the data to the selected control loop The analog input ANIN variable indicates the analog reading after the offset ANOFF1 ANOFF2 and the deadband ANDB adjustments but before the loop RCaling The ANIN variable range is 22500 counts or mV The PosiDrive RC offers an automatic analog input zeroing function Invoking either the ANZEROI or ANZERO2 command while the PosiDrive RC is enabled or disabled samples motor velocity over a 32 mSec period and updates ANOFF accordingly to cancel out analog input offset This command also incorporates an internal offset mechanism with finer resolution than ANOFF is capable of providing Remote Enable Input REMOTE The opto isolated Remote Enable input REMOTE provides a hardware enable switch This 12 to 24 VDC input disables or enables the power stage output to the motor The signal must be customer supplied to get the PosiDrive to enable in combination with other parameters ACTIVE and operate Do not tap the signal off the logic supply C5 The PosiDrive
135. t system error handler Cannot proceed user error handler 47 48 Error code with invalid Internal error Contact severity technical support 49 Error code with invalid Internal error Contact context info technical support Invalid context value recognized by the Error Handler state machine PosiDrive RC Installation Manual FPU Stack fault Generated on the FPU due to ASYNC Fatal Fault Watchdog stack overflow or underflow ASYNC Fatal Fault Watchdog Failed to create Logger Internal system resource ROOT Fatal Fault Watchdog MsgQ cannot be allocated Failed to create logger Internal error Contact ROOT Fatal Fault Watchdog task technical support i Invalid logger message Internal error Contact ASYNC Fatal Fault Watchdog queue ID technical support Failed to create logger Internal error Contact ROOT Fatal Fault Watchdog mutex technical support Invalid logger mutex Internal error Contact ASYNC technical support Fatal Fault Watchdog Invalid message queue Invalid message queue ID SYNC ASYNC Fatal Fault Watchdog Failed to create Error Internal error Contact ROOT Fatal Fault Watchdog Handler task technical support Failed to create Error Internal error Contact ROOT Fatal Fault Watchdog Handler MsgQ technical support ASYNC Fatal Fault Watchdog Internal error Contact ASYNC Fatal Fault Watchdog technical support ASYNC Fatal Fault Watchdog ASYNC Fatal Fault Watchdog 63 GS N
136. tallic surface This allows for more surface area to be in contact with the filter housing and provide a lower impedance path between the housing and the back plane The back panel should have a high frequency ground strap connection to the enclosure frame and earth ground Input Power Filtering The Force Control Industries Inc PosiDrive RC electronic system components require EMI filtering in the input power leads to meet the conducted emission requirements for the industrial environment This filtering blocks conducted type emissions from exiting onto the power lines and provides a barrier for power line EMI Adequately size the system The type of filter must be based on the voltage and current rating of the system and whether the incoming line is single or three phase One input line filter may be used for multi axis control applications These filters should be mounted as close to the incoming power as possible so noise is not capacitively coupled into other signal leads and cables Take care when routing wires from the load side of the filter to the BUS Module These lines may be noisy and should be separated from other sensitive cabling to avoid unwanted coupling of noise Several manufacturers of these filters are listed below They should be able to recommend the best filter design for most typical motor control applications Force Control Industries Inc has also provided specific filter recommendations that will adequately attenuate the c
137. ter quadrature Maximum Cable Length System Dependent 50 ft 15m recommended Maximum Line Count 10 000 000 Lines per motor electrical cycle Maximum Supply Current from RC 250mA Protection Separate voltage regulator broken wire detector for A B Index and Hall channels illegal Hall code detection Sine Encoder Feedback on XX xxX Models C2 A B with or without Index pulse Required Signals A B Index with or without Halls Channels Halls may be integral or diRCrete Differential do not connect single ended Signal Type Differential or open collector System Voltage 5VDC Maximum Input Frequenc 3MHz Maximum Cable Length System Dependent 50 ft 15m recommended Maximum Line Count 10 000 000 Lines per motor electrical cycle Maximum Supply Current from RC 250mA Protection Separate voltage regulator broken wire detector for A B Index and Hall channels illegal Hall code detection Connector by pinout Maximum Voltage 12 V differential single ended Input Resolution AIN 14 bit Dual Gain 15 bit Analog Input 1 2 3 ANIN1 0 3mV Bit Voltag e Range 10 V Standard ReRCaled Remote Enable 7 8 Configurable Inputs 10 1 Configurable Inputs Common 7 Current Demand per 20mA Input Output Voltage max Vaaxon 34V V maxorr 0 5 V Min On All inductive loads require proper Max Output Current 60 mA 1 mA 1K Q internal series resistance Con ligute Sensitivity Resolution 4 9 mV 12 Bit A
138. ters in the BASIC Moves Watch BM when task s is executing Window can slow down communications Watchdog Error 3 horizontal lines Check Loading of Processor during operation From on display after operating for terminal type Sys AverageLoad and Sys peakLoad some time 54 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Force Control Industries Inc Troubleshooting Watchdog Error 3 horizontal lines Possible error in Config prg or Autoexec prg To check on display at Start up delete Config prg and Autoexec prg from PosiDrive RC File Manager Set DIP switch 6 to 0 Reboot and delete task config prg and or autoexec prg Reboot drive again with DIP switch 6 set to 1 Use Config prg only to define user variables and allocate memory Delete Var_file cfg from terminal Contact factory for assistance PosiDrive RC Installation Manual 55 55 53 63 23 31 81 83 54 10 18 Aw DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error codes In most cases the PosiDrive RC 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 nothing is lost whe
139. the user must implement additional filter measures The servo amplifiers are only intended to drive specific brushless synchronous servomotors from Force Control Industries Inc with closed loop control of torque speed and position The rated voltage of the motors must be at least as high as the DC link voltage of the servo amplifier The servo amplifiers may only be operated in a closed switchgear cabinet taking into account the ambient conditions defined in the environmental specifications Force Control Industries Inc guarantees the conformance of the servo amplifiers with the standards for industrial areas stated in this manual only if Force Control Industries Inc delivers the components motors cables amplifiers etc PosiDrive RC Installation Manual 9 AN MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 Sw DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Unpacking and Inspection Force Control Industries Inc Name Plate and Model Number 111 79000 01 59 RC 06R2SN 00 FORCE ND FORCE CONTROL INTROL www forcecontrol com 513 868 0900 ITROL 0730228790 PosiDrive Series CONTROL MODEL NUMBER 1 2 3 4 5 6 7 8 9 o s R 7 Series RC ENGINEERING 8 9 REVISION AMPS 1 2 OPTIONS 6 3 3Amps FEEDBACK 3 b 0 6 6 Amps LR Resolver 1 0 10 Amps Encoder CONFIGURATION 5 s Standard Incremental
140. til the index signal is detected at which time true position is known and sinusoidal commutation begins These signals are isolated by an opto coupler and can be differential or open collector type signals C D lines are an alternative to Hall signals These lines provide a SIN COS sinusoidal signal where one electrical cycle equals one mechanical revolution identical to single speed resolver feedback Interpolation is performed on these signals and absolute position is known within 256 parts of a mechanical revolution The motor can commutate forward until the Index signal is detected Sine encoders with Endat capability add another approach to communicating commutation position Here absolute position information is stored in the encoder and is serially communicated to the drive upon power up The data is received synchronously by a clock signal provided by the drive Absolute position is known immediately so an index signal is not needed CABLE LENGTHS The recommended cable length when using the PosiDrive RC to source the sine encoder is no longer than 50 ft 15 m Long encoder cables tend to have high DC resistance that may create significant loading affects in the supply lines to the encoder Consider this carefully when designing the system An option that would allow the use of longer lengths would be to put a separate supply at the motor to source the encoder Except for noise suRCeptibility signals returned to the drive are different
141. tries Inc Error Message Error Description Data Type Severity Immediate Action 4027 No memory for file Cannot allocate internal data SYNC Error data structure structure Add more memory or unload tasks that are not needed 4028 Error writing into file Error writing into a file SYNC jEmr 4029 Error reading from file Error reading from a file SYNC Emo 4030 Bad access to the file Invalid pointer to the file SYNC Error handle 4031 File extension is not Only specific file extensions are SYNC Error recognized recognized These are PRG for programs REC for record files CAM for cam files 4032 Cannot access this Access to this type of file is not SYNC Error type of file permitted by the system 4033 File does not exist This message is given when SYNC Error trying to operate on Retrieve Delete Load a file that does exist on the flash disk Root directory is full The number of files in the the SYNC Error root directory has reached the maximum number of files allowed 4035 Invalid semaphore ID Invalid semaphore ID The SYNC Fatal Fault the files 3037 Password valid Invalid password emerei SYNC Eme 4038 Password protected The file cannot be Deleted or SYNC Error Retrieved because it is protected by a password Use the ProgramPassword command to remove the preotection password password s log 4040 File in use access A file with same name a
142. twork administrator To verify hardware connection ping the RC s address through the Start menu Start Run then enter on the command line Ping drives address 52 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Troubleshooting Cannot communicate with Serial Verify your computer s operating system and version connection connector C7 number are supported Example Win 95 version 4 0 or later Make sure you are using a crossed cable containing only pins 2 3 and 5 Check Serial Port Parameters 38400 8 Data bits No parity 1 Stop bit Verify no flow control Check SLIP connection is set up Not PPP Check SLIP set up parameters IP Address on computer set to 91 0 0 1 PosiDrive RC s IP address is fixed at 91 0 0 2 Uncheck IP header compression Uncheck default gateway on remote network if checked In NT package size must be 1006 Make sure you are connected to C7 and right serial port in the PC Cannot Enable Drive Verify 24 volts is applied to both Remote enable input on connector C3 and Motion Input Sys DIN 1 on connector C9 Check for Fault indication on LED display Cannot get to Sys conmode 1 0 Dip switch 1 and 6 not set to 1 or 1 remains on display Drive not configured for motor Configure motor using the software Can
143. variable max velocity cruise velocity final velocity For example VMAX 1 3009 Time value out of Invalid time duration value SYNC Error Idle Task range given The time value usually a time interval is not in the allowed range 3010 Wrong parameter Invalid command value SYNC Error value supplied In all motion commands the appropriate value of the command parameters is checked StopType ProceedType 3011 Not available nodal Internal Error The variable is SYNC Fatal Fault Watchdog package currently not available Nodal variables can be queried also although this feature is not supported by the user command set The nodal package is not always available 3012 Acceleration out of The value of the acceleration is SYNC Error range not in the range of allowed acceleration values For example ACC 1 3013 Deceleration out of The value of the deceleration is SYNC Error range not in the range of allowed deceleration values For example DEC 1 PosiDrive RC Installation Manual 67 GS Nacza MEX 55 53 63 23 31 MTY 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Error Message Error Description Data Type Severity Immediate Action 3014 Jerk out of range The value of the jerk is notin SYNC Error the range of allowed jerk values For example JERK 1 Velocity override out The value of the velocity SYNC Error of ra
144. veform 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 is aligned to the back EMF characteristics of the motor making resolver or encoder alignment to the motor 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 digital and uses the resolver or the encoder feedback signals to calculate actual motor velocity The command for the velocity loop either come directly from user input OPMODE 0 or 1 or the output of the position loop 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 PosiDrive RC offers four velocity compensators methods of regulating velocity and are selectable through the COMPMODE variable The four are Proportional Integral PI Pseudo Derivative Feedback with Feed Forward PDFF Standard Pole Placement and Extended Standard Pole Placement PosiDrive RC Installation Manual 47 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Controller Operation Force Control Industries Inc POSITION LOOP The final control configuration is the position loop The purpose of this loop is to ma
145. ver digital encoder with or without hall effect sensor signals or sine encoder feedback Force Control Industries Inc offers a variety of motors with options for these various feedback devices The feedback requirements are diRCussed below Digital Encoder The PosiDrive RC can use encoder feedback to monitor the motor shaft position The encoder is an incremental device that indicates changes in position The encoder resolution of the PosiDrive RC and the encoder equivalent output is fixed because it is a hardware characteristic of the encoder device The encoder interface includes three groups of wires 1 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 effect sensor 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 CABLE LENGTHS Th
146. w Units must be installed in an enclosure that meet the environmental IP rating of the end product ventilation or cooling may be necessary to prevent enclosure ambient from exceeding 113 F 45 C PosiDrive RC Installation Manual 21 55 53 63 23 31 81 83 54 10 18 Aw DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Wiring the PosiDrive Force Control Industries Inc Power MAIN POWER E STOP EXTERNAL RESISTIVE REGEN UNIT ERH 26 THERMOSTAT gt RESISTOR e NORMALLY OPEN re AUXILLARY POWER V CONTACTOR FROM 3 MAIN POWER x CONTACTOR IN PUSHBUTTON N TO ENERGIZE BN SEE NOTE 7 MAIN POWER MAIN POWER x E CONTACTOR Cy SEE NOTE 5 SEE NOTE amp 5 MA 8 2j SHIELD TO _ 15 i STAR POINT i Oi e S aX n RA i E SEE NOTE 6 i T sew ce E O ii FUSE 1 m e S e i i ON L1 USE 2 E l 2 FUSES STAR 1 L SEE NOTE 2 amp 3 SEE NOTE 1 POINT Bi Da SEE Fuse Recommendation 1 SEE NO L3 ae abi Single Phase Users Connect any two lines _ Lo customer SUPPLIED Qo MOTOR POWER SEE NOTE 5 WARNING THE PosiDrive Series RC OPERATES WITH VOLTAGES AS HIGH AS 230VAC AND 400VDC USE CAUTION REFER INSTALLATION AND TROUBLESH
147. wo or more digits see Troubleshooting section In general these faults will cause a latched disable sometimes controllable through software switches To clear fault toggle SYS MOTION or Remote motion input except for OverCurrent If the encoder initialization function ENCSTART 15 active the OPMODE number will flash at a 3 Hz rate Displays a flashing character C1 Synchronization Error between Control and Positioner boards May happen due to extremely high CPU load C2 Positioner fault SYS MOTION 0 Indicates that SYS MOTION is zero Happens in the following situations 1 Motion input is inactive check state of SYS DIN 1 2 Unhandled application error check Sys Error and ErrorHistory 3 Servo Error check ServoEror When all the error situations reasons are cleared set SYS MOTION to 1 either by toggling Motion input or typing SYS MOTION 1 in the terminal window Flashing PosiDrive RC enabled power to the motor but a motor safety feature has been disabled for example LIMDIS 1 42 PosiDrive RC Installation Manual 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Force Control Industries Inc Controller Operation Understanding Conmodes The PosiDrive has only two Conmodes Conmode one is where an S is displayed and compensates for a particular motor or changing a motor parameter Conmode two is w
148. y Strictly adhere to the technical information regarding installation requirements It is vital to ensure that all system components are connected to earth ground Electrical safety is provided through a low resistance earth connection The PosiDrive RC product contains electrostatically sensitive components that can be damaged by incorrect handling Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface Ground yourself discharge any possible static electricity build up by touching an unpainted metal grounded surface before touching the equipment Keep all covers and cabinet doors shut during operation Otherwise potential hazards could cause severe personal injury or damage to the product Be aware that during operation the product has electrically charged components and hot surfaces Control and power cables can carry a high voltage even when the motor is not rotating Never disconnect or connect the product while the power source is energized to avoid electric arcing and hazards to personnel and electrical contacts After removing the power source from the equipment wait at least 10 minutes before touching or disconnecting sections of the equipment that normally carry electrical charges e g capacitors contacts screw connections To be safe measure the electrical contact points with a meter before touching the equipment These symbols indicate a potenti
149. ymmetrical amperes 240V maximum 8 inductive loads require proper suppression Encoder I O C4 Encoder Equivalent Output D9P 5 Za DC COMMON C5 Remote Encoder Input Top of controller COMMON RESERVED A C5 requires Differential Input For instructions using Single ended Pulse refer to Appendix A PosiDrive RC Installation Manual 23 55 53 63 23 31 81 83 54 10 18 DIST AUTORIZADO QRO 442 1 95 72 60 ventas industrialmagza com Wiring the PosiDrive RC Force Control Industries Inc Communication C6 Ethernet Connector A standard crossed Ethernet cable must be used when connecting directly between the PC and PosiDrive RC If connecting the PC and PosiDrive RC via an Ethernet hub an uncrossed Ethernet cable must used C7 boo Serial Communication Interface 1 1 2 2 RXD 3 3 TXQ 4 2 5 TYPICAL CONNECTION C8 COM2 HMI Interface 1 d 1 2 2 RXD 3 3 TXQ 4 4 5 TYPICAL CONNECTION Do not connect unused pins on C7 and C8 connectors Some manufacturers cables connecting all pins may give unpredictable operation A standard crossed serial cable must be used when connecting directly between the PC and PosiDrive RC VO Connectors C3 vO Interface 24 12V Analog Input FAULT OUTPUT RELAY DRY CONTACTS 24V 24V RETURN Analog Output ANOUT1 See the Electrical Specifications for loading info
150. ys DIN 1 on connector C9 off Check SERVOERROR in BASIC Moves terminal for error Correct problem causing error Check 7ERRORHISTORY in BASIC Moves terminal Correct problem causing error If running a program verify the program did not change any properties designed to only be changed when drive is disabled Example Sys conmode After correcting problem the motion flag can be reset by toggling motion input sys din 1 on connector C9 pin 2 or entering sys motion I from the BASIC Moves Terminal Cannot communication thru HMI port connector C8 PosiDrive RC Installation Manual 51 CES MNaczAa MEX 55 53 63 23 31 MTY 81 83 54 10 18 SALA DIST AUTORIZADO QRO 442 1 95 72 60 ventasQindustrialmagza com Troubleshooting Force Control Industries Inc Cannot communicate with Verify your computer s operating system and version Ethernet connection number are supported Example Win 95 version 4 0 or connector C6 later If point to point connection make sure you are using a crossed communication cable Poll to see if used by another computer If multiple RC users on a network recommend keeping IP Pool on Network and all users use the same IP Pool Verify LAN supports 10Mbits communication and not just 100Mbits Make sure addresses in IP Pool have been created Make sure addresses and subnet mask in IP pool and Host computer s IP work together If communicating via network review addresses with ne

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