VSD-E/XE 160 DualDC manual
Contents
1. 8 1 Basic guide for sizing linear PSU components In short PSU should be sizes so that it does not overload or overheat during any condition in machine use Since servo systems typically have greatly varying load it might be necessary to find effective power consumption by measuring RMS power consumption of the system during at least 10 second period of heavy use If measurements can t be done then maximum RMS power load can be estimated roughly by summing rated power values of motors in the system However in typical machines the average power consumption is significantly less than summed motor power Motor power consumption is proportional to product of actual torque and speed Power Speed Torque Following chart gives rough figure of power requirement in motion systems Moving slowly Moving fast Producing low torque Very low power consumption Low to medium power consumption Producing high torque Low to medium power consumption High power consumption Transformer Transformer size can be selected after RMS power demand is determined One should choose transformer with a safety margin since VA rating of transformers do not equal to RMS watts in linear PSU For example if RMS power consumption is 200 Watts then using of at least 300 VA transformer is recommended Transformer primary voltage should match with the voltage of AC mains network of your area Secondary voltage should be about 12. 6 Vdc Voltage diff from pin IO VCC to lO COM S Optoisolator input threshold current logic 1 6 3 mA All inputs S Optoisolated digital logic input voltage 3 0 to 5 5V CMOS or TTL logic All inputs 8 compatibility Greater voltage range by external resistor U tA e Step pulse minimum hold times 150 ns For logic 0 and 1 Direction pre set before rising step edge 800 ns Step frequency 500 kHz 9 Output continuous current per motor VSD E 160 8A 9 VSD XE 160 11A 2 Output peak current per motor All models Current is g 55 C 20A automatically limited a gt 55 C 15A if temperature is high p b Peak current duration 1 sec Jg Motor output switching frequency 20 kHz E Effective motor output voltage swing 88 96 Percentage of HV 9 voltage Minimum motor inductance per HV supply 0 005 mH V i e with 60V supply voltage 0 005mH 60 0 3mH Minimum motor resistance 0 Ohm www granitedevices fi 3 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 A DEVICES 3 VSD E XE DualDC features Motor support e Supports two independent brushed DC servomotor axis on single drive unit e Voltage range 12 160VDC current range 0 1 20A peak for each motor e Two encoder inputs for single ended and differential quadrature encoders Position control e Infinite motion range e Soft velocity limited recovery motion from error e Drive tracks position during fau
3. Controller External motion controller or command source that controls VSD drive Typically a PC PLC or other step pulse source Drive VSD E XE drive Reference target command target value A user commanded target position RMS Root Mean Square FG Frame Ground A ground potential of enclosure and D Sub connector metal shells of drive FG is internally connected to drive GND through a bypass capacitor GND GND is drive ground potential which is present in following connectors POWER ENC CMD and EXT All GND pins in all connectors are internally connected together to same potential 5V OUT 5V output referenced to GND from several connectors All 5V_OUT s are in same potential and share a common current loading limit see Electrical specifications HV A high voltage amp high current supply for drive Motor power is drawn from HV Logic supply A logic circuity voltage supply for drive Cable shield A metallic EMI shield foil or braid inside cable surrounding all wires www granitedevices fi 5 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver 01 05 4 5 Physical overview All the listed features are documented in more detail in the following chapters Y Figure 1 VSD E physical layout GRANITE 3 DEVICES 3t in Figure 1 Name Description Type Mating part 1 CMD User comman
4. Supply voltage gone below lower voltage limit This may be caused by undersized power supply Q Both motors are always disabled simultaneously manualy and in faults Is it possible to make disabling individual No www granitedevices fi 24 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver 01 05 8 13 Mechanical dimensions The drawings are for VSD XE 160 but similar dimensions are found on VSD E IGES model available GRANITE 4 DEVICES Dimensions mm 50 8 0 2 8 8 0 5 l of amp e 000000000006 oooooooop Hi lo 900000000000 ooooooo ff o Ni K i 1 DTM TT j S OO0OO0OO0OO0OO TO GH DOO OD OOo Doo DoD DO Do Eun fh o O OF g z 3 o 2 o A7 2 L7 een C Or O 9 Q 8 529 Lo ul 146 l 96 4 _ Le 99 1 m Granite Devices Oy 358 44 99 175 33 Opiskelijankatu 4 D 644 http www granitedevices fi FI 33720 Tampere VAT code F120944279 Finland www granitedevices fi 25 25 2009 08 25
5. isolated GND from drive Ground or external optoisolated disable enable circuit 14 45V OUT Non isolated 5V supply drive Not connected or external optoisolated disable enable circuit 15 No function in DualDC Not connected 16 ENABLE Disable amp clear faults input when driving logic 0 Disable enable output or external state Drive enabled when this pin is driven in logic 1 state For testing purposes this pin can be connected to CMD pin 14 to enable drive optoisolated disable enable circuit 1 SPI pins are internally wired to SPI connector Therefore unplug CMD cable when connecting USB adapter to drive www granitedevices fi 9 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver 01 05 8 A DEVICES CMD Disable clearfaults from controller Controller GND PC817 or equiv Figure 6 Making CMD connector fully optoisolated by external disable clearfaults optoisolator This circuit is integrated in VSDEPI board www granitedevices fi 10 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 For puapc firmware Manual ver D1 05 1 SA DEVICES T Installation notes 7 1 Enclosure amp power supply wiring Typical installation of drives in metal enclosure is presented in the figure below For detailed motor wiring diagram please see next chapters Negative HV voltage connected to frame ground FG Star distribution of
6. over voltage or under voltage fault Off Hi Z 10 Blink On Blink Overcurrent caused by bad tuning or short circuit fault With DC Off Hi Z motors also faults if output phases are not properly wired in parallel 11 On Blink Blink Overtemperature Off Hi Z 12 Blink Blink Blink Communication error Check cabling and and possibility of Off Hi Z electrical interference try without HV power on 13 Blink On On Internal error possibly caused by logic undervoltage or too slow Off Hi Z logic voltage rise time If troubles contact us for support See also 11 14 On Off Blink Drive ready for firmware update Off Hi Z 15 Off Blink Blink Firmware upgrade failed cycle power and try again Off Hi Z 16 Off Blink Blink Blinking very slowly Memory checksum error install upgrade Off Hi Z firmware again or contact us if problem stays Hi Z stands for high impedance state output voltages are freely floating between GND and HV For fault troubleshooting please see chapter 12 Troubleshooting amp FAQ www granitedevices fi 17 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc finmware Manual ver D1 05 A DEVICES 10 Using configuration software Before proceeding with this chapter make sure you have installed latest VSD E PC software Software installer is available from Granite Devices web site 10 1 Installing DualDC firmware In order to use drive in D
7. position error I gain Kp This is the integral gain of position PID controller I controller accumulates position error over time and produces torque that is proportional to the integral D gain Kp This is the derivative gain of position PID controller D controller produces torque that is proportional to derivative of position error 10 3 Tuning PID gains for optimum performance PID is a controller that attempts to create a motor output that optimally eliminates position error of servo motor Since each mechanical load machine is different and behavior of PID controller depends on machine dynamics it is necessary to tune PID gains for optimum performance This chapter describes a systematic approach for tuning by using the Test feature and status bar analysis of test Shortly after Test status bar will display a message such as Peak error 41 undershoot 0 counts settling time 47 ms Connect Disable drive Esc Apply Test Peak error 41 counts undershoot 0 counts settling time 47 ms Figure 13 Test results in the status bar www granitedevices fi 20 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puatwe firmware Manual ver 01 05 A Ld Peak error a maximum positive position error in encoder counts during test Smaller the better Undershoot a maximum negative position error in encoder counts during test Smaller the better usually not more than 0 or 1 Settling time a time that is elap
8. test arrangements Noise shielding tips Minimize the parallel running distance between HV and GND power wires to minimize the conductor loop area In other words twist the HV and GND wires together or use cable with two condcutors e lf wiring distance from drive to power supply capacitors is greater than 30 cm and configured peak current greater than 5A it may be necessary to connect a 330 uF 200V capacitor directly to POWER connector terminals between GND and HV pins e Always use separate cables for motor and encoder no matter how small the motor is In shared cable high dV dt of motor outputs may easily couple to encoder wires causing errors 7 4 Protection VSD E has on board fuses for HV bus If protection also against wiring failure is required then an additional fuse after power supply is recommended VSD E has been supplied with 20A slow blow fuse which is adequate for most cases In maximum power DualDC motor operation a higher rating fuse may be necessary supplied by user User may also replace default fuse to a smaller one if lower protection threshold is desired For additional motor protection fuses can be added in series to motor phase wires In three phase motor fusing two leads should be enough in most cases and for DC motor one lead will be sufficient protection It is recommended to do initial testings with reduced HV bus voltage and with lower current fuse rating 7 5 Cooling Additional cooling shou
9. 160 VDC GND GND indino ejqeu3 indur ii1nej dais A JTP A punoa59 Ayddns AS punoJ9 JTp X GRANITE 3 DEVICES Note this connectiod does not have opto isolation punoJ9 deis X SEL j ENCODER DC MOTOR Y axis 2 f Cable shields ENCODER DC MOTOR X axis 1 Figure 8 Typical controller and motor wiring Note CMD pins from 13 to 16 are not electrically isolated It is always strongly recommended to use the external optoisolator circuit for disable input It is also recommended to use shielded cable for motor armature www granitedevices fi 13 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we A DEVICES 8 Power supply VSD E runs on unregulated or regulated isolated power supply which means that there is no galvanic or conductive connection between the AC mains and DC bus A linear transformer based PSU is preferred over switching mode power supplies SMPS for servo systems since transformers are capable of delivering high peak output power just like motors are For logic power a separate regulated 12V power supply is required Warning This is only a very brief guide of powering the system in basic cases An experienced electrician should always be consulted when designing or building power system Pay attention to RMS and peak terms in this text Mixing these may lead to unpredictable results
10. 41 times smaller than desired DC bus voltage To convert DC bus voltage to transformer secondary voltage use equation Bridge rectifier U Upc secondary 1 41 Bridge rectifier should be able to handle peak current of rectification Typically a very high peak currents can be present during power up and during motor peak loads Use at least safety factor of 3 when choosing rectifier current rating compared to RMS current Rectifier may need cooling to prevent overheating damage www granitedevices fi 14 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we Ld Capacitors VSD E HV bus accepts unregulated power with up to 5096 ripple voltage however designing a supply with maximum of 10 to 2096 ripple is recommended To solve required power supply filter capacitor size use equation I T C load U ripple where C is required capacitance in Farads loaa is the peak load current T cycle time of rectified voltage and Urippie is the desired maximum ripple voltage Calculation example 1 If you need 70 Vdc DC bus voltage and you choose to design for 2096 ripple then 70 20 14 V ripple Urppe voltage is allowed 2 If you are using full wave rectifier for 50 Hz mains voltage then cycle time T is 0 01 seconds If your peak power load is 500 Watts then liaa becomes 500W 70V 7 2 A 4 By substituting these values in equation above the minimum required capacitor value becomes lo
11. EAO AAA AAEE KOTE ENEE N 18 10 1 Installing D alDC firmwares siina ee roter enne netten dne aa EKE Ea E Ea EEE EE 18 10 2 Setting parameters With DCtool m cene ere sreee tnter e iren anes vnd ces as e eee Sur ku uere euh 18 10 3 Tuning PID gains for optimum performance eee nnne rne EEEE nE 20 11 Connecting DualDC drive to VSDEP sinian an nre eap RR LE Xen KAASE EAE EEEREN nein 23 12 Troubleshooting amp FAQ esent pos cert xc erinnere rire ree neha Piae Tode c eh Rd Cure a c Rd Dada anda 24 13 Mechanical dimensiOns noie aaa a a iiai AEE EAO EEEE A NTa 25 Please notice This manual discusses only about VSD E 160 and VSD XE 160 models with DualDC firmware installed In all other cases please use another manual If you wish to install DualDC firmware to drive continue reading this manual For practical approach to drive installation please also read Getting Started with VSD E amp VSD XE manual downloadable from product site Specifications are subject to change without notice Warning Never operate this drive with non isolated power supply l e rectified 115VAC mains voltage or with autotransformer Doing so may be lethal especially due to non isolated logic circuity and very high earth currents of this product Granite Devices or its personnel will not carry any consequences or give any warranty if this rule is broken VSD E XE has been designed only for electrically isolated power supply F
12. GRANITE DEVICES reliability first In DualDC mode Table of Contents Timportant Notices CHEESE I HR UTUIBRLRNE TE 2 2 Electrical specification S s sse edet nt ntet ker rer sa tach inian iada aree x A iade A MR kr cheba Ss leesdastagecanes RUM 3 3 VSD E XE DualDC features 0 0 anaran ane TA AAKA Eaei aa O REA nee nee ten nen nnns 4 4 Terms and definitions ciii ec spetete ie RE ERR URRBRRRRRRARNARRUQ RA E EAA DEAE EE RRRSARARPIPERISDRPIRiUKA 5 sms 6 oxseglacsm An 7 6 1 POWER Meise EET 7 6 2 enspas nns 7 6 3 ENC ECONNECTO En 8 6 4 CMD iCONMGCION S 9 VA iuge 11 7 1 Enclosure amp power supply wiring eiecit tere euenire ea ean e un R RENE REB sein RENT ai 11 yorxereeine ne c 11 piste 12 Ve M dre mem 12 TI COON Gro e E 12 7 6 Example wiring diaQraM 0 ttt mener nnne rh nen an hns n rte n enirn nnne nnn rn nenne 13 POWE SUPPLY EH EID T 14 8 1 Basic guide for sizing linear PSU COMPONENTS eene nnne n rn nn rn EEEa 14 82 Example Circuits 2eecc2 EcL 15 8 3 Power up SEQUENCE siisii eneinio eedan naio iE A ESSEE Ea Eara VOTE Veron Gua r Pa aaa ru XE NER RED RIS 16 9 LED Status IMGICAtONS irta ERU 17 10 Using config ratioh SOTEWOaFe iacent i dto cepe crabe EE NE E EAA
13. NABLE input while power supplies are switched on Drive begins motor control after ENABLE input value is set to logic 1 www granitedevices fi 16 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we In 9 LED status indicators The VSD E has three LEDs green red and blue which have combinations of blinking and steady states to indicate current status or fault Blinking sequences have varying styles to make them easier to remember and distinguish later Drive statuses versus led statuses are described in the table below Only the fault that occurred first is displayed in LED indicators Other active faults that can be viewed in GDtool might have followed consequently as chain reaction after first one occurred No Green Blue Red Status Motor output LED1 LED2 LED3 status 1 Blink Blink Off Drive initialization in progress On driving 2 Off On Off Enabled and running On driving 3 Blink On Off Recovering from follow error or from disabled state On driving 4 Off On Blink Input motion command range error On driving 5 Off Off Blink Following error Off Hi Z 6 Blink Off Blink Motion error Motion stalled or encoder failure Off Hi Z 7 Off Blink Off Disabled by user Off Hi Z 8 Off Off On Other fault get details via SPI bus or contact us for support Off Hi Z 9 Off Blink Blink HV bus
14. UE3 HU GND LOGIC U LOGIC_GND Figure 10 Switching mode power supply SMPS circuit 8 3 Power up sequence Before powering up the first time it is highly recommend to check all connections for correctness It is advised to use multimeter to make sure there is no short circuits in connections and all voltage polarities are correct Powering up Powering up logic and HV bus can be done in any order or simultaneously If logic power is being connected first drive will wait for HV bus rise before initiating motor control Pin STEP2 pin 10 in CMD connector should be held at logic O or keep unconnected while powering up logic supply voltage If logic 1 is driven to STEP2 during power up drive will enter into DCtool configuration mode which disables normal operation Correct pin setting is ensured in VSDEPI breakout board design Power rise times Very fast rise time on HV bus voltage must be avoided to prevent damage on power components Don t place a mechanical switch or relay right before HV inputs Instead place switch devices before filtering capacitors or transformer HV bus rise time should be longer than 5 milliseconds If logic voltage rise is too slow drive may generate an error status which can be reset by power cycling see chapter LED status indicators Logic voltage rise should be faster than 50 milliseconds Delaying power up If necessary drive motor control start up can be delayed by driving logic 0 value to E
15. ad T _ 7 2A 0 01s U ippie 14V Note capacitor voltage rating should be at least 20 greater than rectified DC bus voltage to provide sufficient safety headroom Warning during motor deceleration drive pumps energy back from kinetic energy to power supply which leads to capacitor voltage rise Power supply capacitors may be charged up to drive s over voltage fault level up to about 200 Vac C 0 00514Farads 5000 uF Fuses Use slow blowing fuses that can withstand the peak currents required by drive under all normal load conditions Finding optimal fuse size may require experimenting 8 2 Example circuits Following figures show simplified PSU cases Line filters may be required before AC input to comply with local EMI regulations Note that fuses are optional with VSD E DRIUE1 HU GND LOGIC_U LOGIC_GND DRIVE2 FUSE1 TR1 1 HU ACT in 1 GND i LOGIC_U LOGIC_GND DRIVE3 HU GND LOGIC_U LOGIC_GND Figure 9 Simple transformer based linear PSU up to about 500 Watts www granitedevices fi 15 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc timware Manual ver D1 05 we Ld Drive can be powered also by a switching mode power supply SMPS A diode D1 and capacitor C1 are required to prevent regenerative current from flowing back to SMPS DRIUE1 FUSE2 HU GND LOGIC_V LOGIC_GND DRIVE2 SWITCHING PSU HU GND LOGIC_U LOGIC_GND RC in DRI
16. d I O port 8x2 pin header 0 1 16 pin IDC connector centers kit 2 SPI SPI port 6x1 pin header 0 1 GD USB adapter centers ordered separately 3 EXT No function in DualDC mode Leave unconnected 4 POWER Power supply amp brake resistor connector Removable terminal included block 5 ENC Encoder Hall sensors and home switch 15 pin female D Sub 15 pin male D Sub input connector connector kit 6 MOTOR Motor output connector 25 pin female D Sub 25 pin male D Sub connector connector kit 7 F1 HV power fuse 0 25x1 25 6 35x32 3AG or 3AB fuse mm included 8 LED1 Green indicator led Green led Plastic core optical fiber kit 9 LED2 Blue indicator led Blue led Plastic core optical fiber kit 10 LED3 Red indicator led Red led Plastic core optical fiber kit Notes e All mating connectors are included in optional VSD E installation kit ordered separately e Optional optical fiber can be used to bring led signals to enclosure front panel www granitedevices fi 6 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc finmware Manual ver D1 05 we In 6 Connectors 6 1 POWER connector This is a modular removable high current connector for logic supply high voltage supply and regenerative resistor For high current 710 A applications dual wiring for GND and HV should be used to minimize resistance wiwleiwlwlw i Lo LJ I 12U GND HU AD Figure 2 Power connector pin out S
17. etup with two exceptions Insert 4 jumpers to jumper places entitled as JP2 and JP3 Connect flat ribbon cables only to X CMD and Z CMD ports It is also possible to mix up to two single axis drives and a DualDC drive by following setup Insert 2 jumpers to JP2 Connect DualDC drive to Z CMD Connect single axis drives 1 or 2 to X CMD and Y CMD When using DualDC s ave axis option see DCtool any DualDC specific settings aren t necessary since controller VSDEPI sees drive as single axis unit Therefore no jumpers are needed and all ports are usable This allows connecting up to 8 DC servos to VSDEPI www granitedevices fi 23 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we Ld 12 Troubleshooting amp FAQ Q I m getting following error faults In this fault measured motor position differs target position more than user specified limit Try increasing follow error limit or adjust PID gains or other settings to reduce following error Q I m getting overvoltage or undervoltage faults Measured HV bus voltage is not within user specified fault limits Most common reasons include e Regenerative supply pumping During motor braking supply voltage tends to increase as motor acts as generator To verify this attach voltmeter to PSU to check voltage during fault To prevent this use regenerative resistor see chapter Error Reference source not found Error Reference Source not found e
18. graphs To activate response graph select menu item Diagnosis Show response graph after test Span 500 ms or press Ctrl 2 and click Test Example of a good response curve Pay attention to steadily and rapidly decaying position error after initial peak no multiple direction changings Also motor current graph shows no oscillations Motor current graphs should always tightly overlap each other The final response will strongly depend on machine dynamics and sometimes compromises has to be made if ideal response can t be achieved T Response graphs E A4 xl Position error counts A Motor current A Target Achieved Tie span soo ns Figure 14 An example of proper response curve www granitedevices fi 21 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc rimware Manual ver D1 05 GRANITE Examples of the most typical unoptimal bad response curves F Response graphs 2x BESTS xl Position error counts Position error counts Moe A Motor current A Target Achieved Motor current A Target Achieved Time span 500 ms Close Time span 500 ms Close Observation 1 slow decay to zero position error Reason low I gain Observation 2 oscillations after initial peak Reason too high P gain or too low D gain Observation slow oscillations after initial peak Reason too low D or P gain or too high I gain FA Response graphs ajx zix Position er
19. ignal name Function 12V Positive logic supply voltage GND Ground 2x connected parallel internally HV High voltage supply 2x connected parallel internally AO Leave unconnected 6 2 MOTOR connector Motor connector is a 25 pin female D Sub connector with four power outputs and one frame ground FG pin Six output pins are connected in parallel for higher current carrying capacity and maximum current per output pin is 3 3 A Figure 3 Motor connector pin out 25 pin female D Sub Pin Description 1 internally connected to D Sub metal Frame ground FG Connect to cable shield and motor frame shells 14 19 internally connected parallel output D Motor 1 armateure 2 7 internally connected parallel output C Motor 1 armateure 8 13 internally connected parallel output B Motor 2 armateure 20 25 internally connected parallel output A Motor 2 armateure www granitedevices fi 7 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 For puapc firmware Manual ver 01 05 A DEVICES 6 3 ENC connector This is a 15 pin female D Sub connector for two quadrature encoders Both single ended TTL or open collector and differential encoders can be used e To use single ended encoder connect encoder outputs to positive inputs only and leave negative inputs unconnected Single ended encoders are not recommended for much longer than 3 meter cable length e For differential enc
20. ld be used if aluminum plate temperature rises near 70 Celsius during intensive load Improved cooling can be achieved generally by two ways e Adding forced air flow by using a dust filtered fan e Only in VSD E mounting a standard Half brick heat sink on VSD E aluminum plate with thermal grease Two M3 screws up to 8 mm length can be used to mount the heat sink The most efficient cooling can be achieved by combining both methods To reduce drive heat generation logic supply voltage may be lowered to 8 10VDC Also avoid using unnecessary high HV voltage to minimize heating Typical cooling requirements VSD E can be typically used without additional heat sinks and fans when average output current is below 4 Amps and surrounding air temperature below 35 C VSD E can be typically stressed to its maximum ratings without additional heat sinks when moderate air flow is passing by the drive surface fan cooling and cooling air temperature is below 30 C Drive s built in over temperature protection disables motor control if surface temperature rises above 70 C It is recommended to do careful testing at elevated ambient temperatures before making conclusion of system cooling sufficiency www granitedevices fi 12 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 7 6 Example wiring diagram The figure below illustrates VSD E DualDC wiring in typical setup 3 9 12 VDC CONTROLLER a 2 nn a 12
21. lt and restores to correct position after clearing the fault Command inputs e Dual optoisolated step direction inputs step on rising edge e Adjustable step multiplier from 1 to 20X e Step train smoothing filter active when multiplier gt 1 Controller design e Two individual cascaded closed loops o Torque current controller O PID position controller anti windup design e HV bus voltage variation compensation Voltage fluctuations doesn t affect performance Fault detection amp protections e Configurable following error limits from 1 to 16383 encoder counts e Optional motion fault detection with 0 2 second response time e Sensing of DC motor runaway e Sensing of encoder failure e Sensing of mechanically blocked motion Overvoltage detection and power stage shutdown to prevent failures caused by regenerative braking current Undervoltage detection and shutdown Overcurrent amp short circuit detection and shutdown On board HV power fuse Overtemperature protection Internal program amp data memory error detection Other features e Field upgradeable firmware e Eased panel installation and places for optical fibers for bringing LED signals to front panel e Mounting holes for standard Half brick heatsink on VSD E not in VSD XE www granitedevices fi 4 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puupc firmware Manual ver 01 05 4 GRANITE 3 DEVICES 4 Terms and definitions Term Definition
22. luxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we Ld 1 Important notices Be sure to read through this VSD E 160 VSD XE 160 documentation and understand it completely before operating the device If case of questions please contact us for support This manual applies only for VSD E 160 and VSD XE 160 Rev 2 text in back of drive PCB models with DualDC firmware installed If you wish to install DualDC firmware to drive continue reading this manual In all other cases please use another manual Warnings and hazards This drive has been designed to be operated on isolated DC power supply only Optoisolator isolation distance creepage on circuit board is less than 2 millimeters A recommended way for emergency stopping is to cut HV bus voltage and activating motor brake if possible Using optoisolated disable input may not be enough for emergency stopping Drive should be installed in ventilated enclosure Dust filters are recommended when fans are used The worst case operating temperature should not exceed 70 Celsius degrees measured from aluminum plate Drive should not be used in applications where failure or malfunction could lead to danger large financial loss health hazard injury death or other unbearable loss Granite Devices can t be held responsible if such risks are taken This document may contain human errors When operating with drive take every precaution you can Granite Devices do
23. nector Connect USB adapter from PC to drive SPI port Align black wire of adapter cable to SPI pin 1 Start GDflasher Click Connect button oe oe p A connect dialog appears power on drive logic voltage now and press OK www granitedevices fi 18 25 2009 08 25 Fluxeon VSD E amp VSD XE 1960 ro puupc firmware Manual ver 01 05 4 GRANITE 3 DEVICES ini x File Diagnosis Help F r quick documentation hover mouse over controls e Axis 1 Axis 2 ea Motor settings m S Motor continuous current 5200 m otor peak curren m Mot k t 20000 mA Motor inductance 4 99 gt mH es Motor resistance 2 00 Ohm Ki Encoder settings Invert encoder direction Enable encoder failure detection X Enable Anti dither Axis 2 is a parallel slave axis to Axis 1 Position control settings Follow error limit 1900 counts Step multiplier 1 E P gain Kp 500 I gain Ki 1000 s D gain Kd 950 A c Connect Disable drive Esc Apply Test Peak error 41 counts undershoot 0 counts settling time 47 ms Figure 12 DCtool configuration software Controls Connect Establish a connection to drive via USB adapter and download settings from drive Disable drive Sends disable command to drive to let both motors free wheel Apply Upload parameters to drive and save them to drive memory Apply also clears drive faults and re enables disabled drive Test This will run a step disturbance test Test results will be di
24. not take any responsibility of damages that may be caused by following or not following this document Failure to follow given guidelines or operating outside given specifications may damage the device and will void warranty In uncertain cases always contact us for clarification Granite Devices reserves rights to make changes to this document and specifications without notice www granitedevices fi 2 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc rimware Manual ver 01 05 A DEVICES 2 Electrical specifications Important These specifications apply only for VSD E XE Rev 2 the 160VDC model with DualDC firmware See back of drive PCB to verify your drive revision Description Min Typ Max Units Notes a Logic supply voltage 8 9or12 14 Vdc o z HV supply voltage 12 160 Vdc Max surge 180 Vdc z Logic supply current consumption 200 700 mA 200 mA user 8 5V OUT load 2 5V_OUT load combined ENC CMD EXT 0 400 mA Total load E R HV supply current consumption 0 001 38 A Depends on motor 9 load amp speed i Operating temperature heatsink amp PCB 10 70 C E Humidity 0 95 96 Non condensing 9 Q Power dissipation 2 5 20 TBD Ww Encoder count rate 0 500 kHz After 4X decoding E digitally filtered 9 Encoder supply voltage 4 8 5 0 5 2 V A B Z inputs impedance 2000 Ohm 4 Output optoisolator supply voltage 3
25. od response may be achieved with trial and error method Try different PID gains until response is satisfactory Also ensure that motor target amp achieved current curves overlap perfectly the lower graph of test graphs If not adjust motor inductance and resistance settings until matching is achieved www granitedevices fi 22 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc timware Manual ver D1 05 A DEVICES 11 Connecting DualDC drive to VSDEPI VSDEPI VSD E parallel interface board has built in support for DualDC drives Before proceeding please read VSDEPI manual and Getting started with VSD E amp VSD XE guide Any combination of different motor drive modes can be used with VSDEPI QH23 X QH3 4 Q0Hu2 2 OWI V ic4 C8 j f OK4 IZ RELAY jur 3 USD E Breakout board U1 1 Cc 20808 Granite Devices RS T m Eb RS j OB yas st c2 x PARALLEL 1 Ta ng Em AN CES e of 03 Eel AN TP_VCC TP_GND u 7 9 CEO a x Figure 15 VSDEPI with DualDC jumpers marked as green and disabled ports as red VSDEPI jumpers Jumper JP3 re routes step direction signals of Y CMD to X CMD and jumper JP2 re routes signals of A CMD to Z CMD When jumpers are inserted corresponding re routed port becomes unusable Y CMD and or A CMD Examples To configure VSDEPI for 4 axis DualDC setup proceed just like in case of single axis VSDEPI s
26. oder connect positive and negative inverted outputs to corresponding input pins For long cable lengths beyond 3 meters it is may be necessary to terminate differential pairs with 120 Ohm resistors connected from A to A B to B etc A 10 nF capacitor can be connected in series with termination resistor to reduce encoder current consumption Terminators can be soldered inside D Sub connector housing ENC Figure 4 Encoder connector pin out 15 pin female D Sub Pin number signal name Function 1 HOME_SWITCH Home switch input connect switch between this and GND This has no effect on drive operation but switch status is bypassed to CMD connector pin 12 2 No function in DualDC leave unconnected 3 No function in DualDC leave unconnected 4 CHB2 Motor 2 encoder channel B 5 CHA2 Motor 2 encoder channel A 6 CHB1 Motor 1 encoder channel B 7 CHA1 Motor 1 encoder channel A 8 GND GND 9 FG Frame ground FG connected internally also to D Sub metal shells Connect to cable shield 10 GND GND 11 5V_OUT 5V output encoder power see electrical characteristics for maximum load 12 CHB2 Motor 2 encoder channel B connect only when using differential encoder 13 CHA2 Motor 2 encoder channel A connect only when using differential encoder 14 CHB1 Motor 1 encoder channel B connect only when using differential encoder 15 CHA1 Moto
27. oder direction reverses encoder counting direction Correct counting direction is needed for position control stability Enable encoder failure detection Checking this enables encoder failure detection which may prevent motor runaways and mechanical damage Uncheck this if you are getting false triggering Enable anti dither Checking this default is On enables anti dither feature that reduces hunting noise made by motor Axis 2 is a parallel slave axis to Axis 1 Check this to make motor 2 to follow step dir pulses of motor 1 When using this with mechanically paralleled motors i e a table with two leadscrews it is strongly recommended that physical system is fully symmetrical l e both axis should have similar motors similar encoders same drive parameters and similar coupling to load Position control settings Position control settings group contains five parameters that are related position control Parameters are Follow error limit This sets maximum tolerated following error actual vs commanded position If limit is exceeded an follow error fault will be activated Step multiplier This sets input step pulse multiplier I e if multiplier is 4 then motor moves 4 encoder counts with one step pulse Input smoothing filter is automatically activated if multiplier is over 1 P gain Kp This is the proportional gain of position PID controller P controller produces output torque directly proportional to
28. power D Sub shells in electrical contact with enclosure FG OOOO Rectifier Cap OOOO OOOO Transformer Cable shield Switch Fuse Metal enclosure Frame ground FG L PE N Everything connected to FG PE are drawn as thick grey lines AC input Figure 7 Suggested VSD E installation scheme Only one motor is displayed for clarity 7 2 Grounding Drive has two separate grounds for separate purposes which are named as GND ground and FG frame ground GND is the electrical OV potential shared with power supplies and all connector pins labeled as GND Connect GND to power supply OV terminal Frame ground FG is the ground for EMI shielding which is located in D sub connector metal shells and D sub connector pins labeled as FG FG and GND are electrically floating against each other but are connected by EMI suppression capacitor inside drive Make sure that D sub shells make electrical contact to enclosure metal and cable shields are connected to FG through corresponding pins or D sub shells www granitedevices fi 11 25 2009 08 25 GRANITE Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 A DEVICES 7 3 Shielding Shielded cables are highly recommended to avoid interference problems and data errors in communication cables Connect cable shields to FG only from drive end If a compliance for CE or UL is required the system should be characterized as whole in appropriate
29. r 1 encoder channel A connect only when using differential encoder Note both GNDs are the same Any or both of them can be used Note home switch input requires DualDC firmware version 2002 or later www granitedevices fi 8 25 2009 08 25 Fluxeon VSD E amp VSD XE 1960 cor puapc firmware Manual ver 01 05 4 6 4 CMD connector This is a connector for step direction fault output and enable input signals Only pins 1 12 are optically isolated GRANITE 3 DEVICES Figure 5 CMD connector 8x2 0 1 centers shrouded header Pin number signal name Pin function Connection to controller 1 Reserved for future use Not connected 2 IO COM Same as pin 8 Not connected 3 STEP1 Motor 1 Step in Axis 1 step output 4 STEP1 Motor 1 Step in ground reference Ground 5 DIR1 Motor 1 Direction in Axis 1 direction output 6 DIR1 Motor 1 Direction in ground reference Ground 7 IO VCC 3 to 5V supply voltage for optoisolators 3 to 5V supply necessary only if pin 11 is connected 8 IO COM Ground reference for pins 7 12 Ground 9 DIR2 Motor 2 Direction in alternatively SPI pin Axis 2 direction output 10 STEP2 Motor 2 Step in alternatively SPI pin Axis 2 step output 11 FAULT des status output active high alternatively SPI Fault input pin 12 HOMESW OUT Bypassed home switch status from ENC pin 1 Home switch input 13 GND Non
30. ror counts Position error counts 7 Satta Motor current A Target Achieved Motor current A Target Achieved Time span 500 ms Close Time span 500 ms Close Observation instability and slow oscillations Reason too high I gain or too low D or P gains Observation high frequency and audibly loud oscillation Reason too high D gain If tuning procedures don t work In some cases above tuning guides may lead to unsatisfactory results Possible reasons Too high inertial load for given motor Absolute maximum inertia mismatch load inertia vs motor internal inertia is 10 1 Gear or timing belt reduction is necessary if this ratio is exceeded Recommended inertia mismatch is below 3 1 Gearing is typically needed especially in rack amp pinion systems Backlash With backlash servo sees constantly disconnecting and reconnecting load which causes difficulties in tuning Backlash may be present especially in rack amp pinion systems Encoder not mounted directly on motor rear shaft Encoder must be mounted on back of DC motor not anywhere else Not in other end of lead screw or after gearing Machine stiffness is low Low stiffness l e weak construction of machine or bad material selections may form a spring amp mass oscillator which naturally vibrates at some frequencies If problem source can t be located or machine modification is out of scope then using custom tuning procedure may work Go
31. sed before motor is stabilized within 2 encoder counts from zero error Smaller the better Procedure for PID tuning Before proceeding make sure all other than PID parameters are configured properly and motor is holding position HV power on 1 Step by step increase D gain and click Apply and Test until you start hearing quite loud sounds and or non stopping noise from motor Reduce D gain at least 5096 or until motor quietens press Apply and Test to verify Click Test and inspect results 4 fundershoot is zero continue to step 5 If undershoot shows greater than 0 value reduce P and I gains at least 5096 and proceed to step 5 5 Start increasing P gain until motor starts making noise or if undershoot gets greater than zero press Apply and Test to verify between gain increase steps 6 Reduce P gain about 5096 or until motor quietens and undershoot disappears press Apply and Test to verify 7 Start increasing I gain and test each step with Apply and Test buttons Stop increasing until settling time no longer shortens remarkably or until undershoot gets greater than zero 8 Reduce I gain about 3096 from previous value 9 Verify motor behavior with response graph To activate graph press Ctrl 2 and click Test While this procedure works on most of the typical cases it may not work on all machines Sometimes inspection of response graphs are necessary The next sections will give a hint how to optimize gains with help of
32. splayed in status bar below In this test motor is commanded to hold position while drive injects sharp torque command to find out how position control reacts This test simulates instantaneous load change on motor shaft Injected test torque amplitude is 75 of continuous current so changing continuous current limit will have effect on results File menu Save and load settings from file Diagnosis menu Show drive diagnosis dialog and options for viewing drive response graphs www granitedevices fi 19 25 2009 08 25 Fluxeon VSD E amp VSD XE 160 ro puapc firmware Manual ver D1 05 we Ld Motor settings In Motor settings group there are four parameters continuous current limit peak current limit inductance and resistance that need to be set according to motor specifications Find correct values from your motor data sheet After modifying values click Apply button to upload settings Tip for beginning you may use lower current limits for safer operation Encoder settings Encoder settings group contains parameters that are related to encoder or position information The most important setting is nvert encoder direction check box that needs to be set correctly If this setting is wrong motor will rapidly spin until follow error limit is reached and drive enters in follow error fault mode red led flashing If this setting is correct then motor will hold position be careful when testing Parameters are Invert enc
33. ualDC mode a DualDC firmware must be uploaded to drive This replaces the default single axis firmware which can be restored at any point by similar process iol x Before flashing remember to backup your drive settings to a file with GDtool DCtool During flashing drive returns to non configured state To flash firmware 1 Click Connect 2 Open firmware file 3 Click Flash firmware 4 Sit back and relax Flasher is failsafe and drive won t be harmed even if process is interrupted v ca e gt id ca reliability first Connect Open firmware file Elash Firmware Figure 11 GDflasher firmware installer Steps to upload a firmware 1 Disconnect cable from CMD connector 2 Connect USB adapter from PC to drive SPI port Align black wire of adapter cable to SPI pin 1 3 Start GDflasher 4 Click Connect button 5 A connect dialog appears power on drive logic voltage now and press OK 6 Click Open firmware file button and choose a DualDC firmware l e named as vsde 160 dualdc v2000 gdf 7 Click Flash firmware and wait for completion Close GDflaser 10 2 Setting parameters with DCtool Before using DCtool you should have properly wired motors encoders and power supplies Caution the Disable drive button is software based and it should not be used emergency stop Instead always have a fast way to switch off drive power Establishing connection to drive Disconnect cable from CMD con
Download Pdf Manuals
Related Search