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DCS-3010

1. L L L La Figure 4 4 Connection of encoder with differential Complementary outputs via DD1 encoder interface on DC servo drive DCS 3010 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 5 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA In order to reduce or eliminate the impact of high frequency electrical noise is recommended to use shielded network cable Cat 5e for connection encoder interface SED1 or DD1 with DC servo drive Cable to connect the encoder should not be longer than a specific application requires 4 4 Analog input DC servo drive DCS 3010 has the ability to control DC motor via the reference voltage of 0 5 V which is applied to the analog input connector Con 4 in Figure 4 1 External potentiometer with nominal resistance of 1 10 kQ can be directly connected at the analog input connector as shown in Figure 4 5 a Figure 4 5 6 the connection of external motion path generator Voltage at the motion path generator output should not exceed 5 V DC a Motion path generator 1 10k Figure 4 5 Voltage reference analog input DC servo drive DCS 3010 generated over a external potentiometer and b motion path generator 4 5 Logic circuit power supply Logic circuit power supply of drive DCS 3010 is performed via a connector Con 5 see Figure 4 1 Logic circuit supply voltage should be from 18 28 V D
2. Start recording a log file activates by pressing Start and Stop recording by pressing this button again Data will be stored in a file called servo log that is located in the same folder as the ServoTune3 software The following is a small part of the servo log file KAKA KK KK KKK ServoTune log output file kkx xx xk kxx xx xx kxx xx xx xx Date and time 07 12 2012 19 00 05 aO oO oC Time s Position PosDiff Current mA Voltage V 0 020960 401 O O 96223 0 202356 0 401 O O er 0 025676 SAO O O Ona O02 TITZ 401 O O ITs TO 0 029663 401 O O Iaa 02032465 AL O O oaz 0 034584 401 O O 98 209 0 036680 4 00 1 O Isra 0 000000 2390 z O OG 22 OC COLT 2 33 6 13 O Iera 0 003668 Rala 20 O ov ere es 0 005764 349 32 119 9T s02 0 007860 325 39 833 95ed 5 009950 490 44 1310 94 202 Ov GLZo16 2 62 39 t905 J329 0 014672 o 30 230 Tad At that e The first column is time in seconds e The second column is present position of DC motor e The third column is position error tracking error i e difference between specified and current position of DC servo motor is expressed in the steps e The fourth column represents the value of the current through the DC motor expressed in mA and e The fifth column is supply voltage of DC motor expressed in V Data from file servo log file can be easily loaded into any software for drawing and for further analysing Excel MATLAB etc In Figures 9 16 9 17 and 9 18 is shown an example of
3. e type of input interface e frequency of PWM e the logic level at Error output in case of error e digital filter for encoder encoder error detection e password protection of parameters e selection of parameters that will be shown in the main diagram and e maximum current of DC motor In order to accept change of any of the above values in the EEPROM microcontroller it is necessary to press the button OK Figure 9 7 9 10 1 Type of Input interface Control of DC motor is carried out through three command lines The first two command lines in this manual called STEP DIR while the third is ENABLE see Figure 4 2 Optional input interface provides a choice of control modes via the above three command lines or via the analog inputs in the following modes e Step Direction i e STEP DIR ENABLE e StepUp StepDown i e CW CCW ENABLE e Encoder x1 ENABLE e Encoder x2 ENABLE e Encoder x4 ENABLE e Analog input with feedback Analog with FB and e Analog input without feedback Analog without FB NOTE Configuration of input interface type Encoder 1x 2x and 4x are not fully tested DC servo drive DCS 3010 has the ability to control DC motor via the voltage signal of 0 5V which is applied to the analog input Con 4 in Figure 4 1 At the analog input can be directly connected potentiometer with nominal resistance 1 10kQ Figure 4 5 a or external motion path generator Figure 4 5 b Look section 4 4 of this manual Prizma doo
4. Kumanovska str 8 34000 Kragujevac Serbia Page 15 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA If you choose one of the options from the analog input Analog option button will become active and after its activation will appear one of the dialogue shown in Figure 9 8 Analog input without FB control options Forward Reverse Forward lt gt min Threshold 0 Threshold 0 Threshold a a a ea Nmax 1500 APM Threshold 100 my M Reverse direction Nmax 100 x Threshold 100 my Reverse direction Nmin 1500 RPM Encoder Nmin 100 C Disable driver on zero speed Limit acceleration deceleration Limit acceleration deceleration Acc 3000 RPMs Acc 2 E De so ppw oe 2s Figure 9 8 Dialog box for setting parameters a analog input with feedback Analog with FB and b analog input without feedback Analog without FB Dialog box for setting parameters of analog input provides a choice One or two directions of rotation of DC motor Forward or Forward Reverse Change the direction of rotation DC moror Reverse direction Maximum Nmax and minimum Nmin revolution speed o In case of choosing the analog input with feedback Analog with FB values Nmax and Nmin are in revolutions per minute RPM o In case of choosing the analog input without feedback Analog without FB
5. PID constants Kp Ki Kd 17000 bo Encoder multiplier x4 v Step multiplier Driver Enable F2 1 Sea 10 1 Automatic adjustment of PID parameters Enable control Software controlled Always enable Sampling Steps Forv Rev Samples Sample F3 mposition Error offset Figure 10 4 Log Encoder multiplier x4 v Step multiplier WWE Connected COM1 38400bps of The auto configuring and adjusting PID parameters is available from ServoTune3 software version v3 07 The dialog for automatic adjustment of PID parameters opens by pressing button AutoPID Figure 10 5 This will display a warning dialog shown in Figure 10 6 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA Page 22 of 24 DCS 3010 V1 05 100 online File About eeXal PID constants Enable control Log gt Software controlled Always enable ik gt Sampling lt gt Steps 500 Forv Rev Sample F3 Samples 500 g 2 Encoder multiplier x4 v AutoPID Driver Enable F2 mposition 80 Step multiplier Error offset 1000 Set 1 Connected COM1 38400bps Figure 10 5 Servo lune3 V3 0 7 A WARNING This PID tuning procedure requires bringing system to oscillation therefore it may potentianly be dangero
6. values Nmax and Nmin are in percents in relation to power voltage of DC motor Width of inactive zone Threshold expressed in mV Number of encoder lines Encoder in case of choosing analog input with feedback Analog with FB Options of disabled DC motor in case that adjusted speed is equal to zero in case of choosing analog input without feedback Analog without FB Parameters of acceleration Acc and slowing down Dec Limit acceleration deceleration o In case of choosing the analog input with feedback Analog with FB values Acc and Dec are in revolutions per minute per one second RPM s o In case of choosing the analog input without feedback Analog without FB values Acc and Dec are in second s 9 10 2 Setting the PWM frequency This option provides the ability to adjust the PWM frequency 10 kHz 12 kHz 14 kHz 16 kHz default 18 kHz and 20 kHz For frequency of PWM bellow 20 kHz can be heard whistling coming from DC motor Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 16 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 10 3 Logic level on Error output in case of error The selection of logic level in case of errors at Error output is presented in the table below Option of choice description Error out High on error In the case of error Error output will be at logical high level Swar alll
7. 024500 3l 3906 24 16 0 027000 590 4150 22 68 0 029500 411 4394 Ae deal 032000 93 4638 PPTA The first column of the file is the time the second column is the current position of the DC motor the third column represents the value of the current through the DC motor in milliamps mA and the fourth column is the change of supply voltage DC motor in volts V The values from the fie odziv dat can easily be imported into the software for drawing diagrams Excel MATLAB i e 9 7 Setting values of tracking error offset Setting of tracking error offset can be performed by entering the desired values in a field named Error offset Name Description Minimum Maximum Recommendation ER Error offset Tracking Error a 32767 bigger than 100 offset To save desire values of tracking error offset into EEPROM it is necessary to press the Set button If the difference of set position and the current position DC servo motor exceeds the set value of tracking error offset Track Error output activates to the control port and OP ER indicator will denote Additionally DC servo motor will be DISABLED Cancelling the tracking error offset is achieved by pressing RESET button or switching off the drive DCS 3010 power supply 9 8 Read the current value of the DC motor position Reading current position of DC servo motor i e encoder position mposition is obtained by pressing the button Get Name Description wats o SS gt Name p Current p
8. In case when it is used fan for cooling recommendation is using filter for dust Drive should not be used in places where in case of failure people safety is in danger financial losses are big or there exist other losses During drive operation should be used all required precautious Does not exclude the possibility that this document contains errors In addition the manufacturer assumes no responsibility for any damage caused by the use of this drive which has occurred as a result of compliance or non compliance with this instruction manual Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 2 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 4 DRIVE OUTLOOK Drive DCS 3010 has 6 connectors from Con 1 to Con 6 as it is shown in the figure 4 1 Configu ration port Con 2 RS Servo Controller RESET a DC motor power supply and connection for DC motor Con 6 6o ooo of Ola o ao ao og taster A a Con 3 O 4 Con 4 may VN TAT TI Logic circuit LED TOPR FID power supply indicators anie Qo e Hi D Con 5 Figure 4 1 Connector positions on drive DCS 3010 4 1 Control connector Digital controls STEP DIR ENA CW CCW ENA or Encoder are brought over the 8 pin RJ45 connector control connector Con 1 as well as Track Error output Track Error output that is activated when the tracking error exceeds the
9. characteristics of mechanics which is connected at DC motor mass damping etc e Resolution of the incremental encoder mounted on the DC motor e Selected encoder resolution multiplication x1 x2 or x4 and e Some other factors ambient temperature lubricant etc Adjusted PID constants are valid only for that configuration If there is a change of configuration some of the above parameters it is necessary to readjust the PID constants The following is a description of the adjustment of PID constants Encoder resolution in this case is 500 PPR encoder resolution multiplication is x4 so that the overall encoder resolution is 2000 PPR STEP 1 Initial value of PID constants is e Proportional constant Kp 50 e Integral constant Ki 0 i e Derivate constant Kd 0 Slowly increase the constant Kp until you get response similar to the response shown in Figure 10 1 STEP 2 Increase constant Kd until the system response is not calm as is shown in Figure 10 2 The constant Kd may be significantly larger than the constant Kp STEP 3 Gradually increase the constants Kp and Ki to the response as shown in Figure 10 3 Here it should be noted that the constant Ki is much smaller compared to the other two constants Repeat steps 2 and 3 to the point where the shaft of DC motor behaves as locked Also check the motor running at various revolution speeds must not occur oscillation and vibration during operation STEP 4 Final valu
10. o5 OKO Integral gain constant 32768 po ke Derivative gain constant A 32768 EA Pressing the button Get from EEPROM values for Kp Ki and Kd will be read To write new values in EEPROM microcontroller it is necessary to press the Set button NOTE During setting PID constants take all precautions as it may cause oscillation in DC servo motor machine mechanics system Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 11 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA on oI mm a o a D T 9 3 Setting the encoder resolution multiplication Drive DCS 3010 has the capability of software adjustment for encoder resolution multiplication So it is possible to encoders with relatively small number of pulses per revolution to obtain 2 or 4 times higher resolution m Enc Encoder resolution multiplication x1 x2 and x4 EXAMPLE Encoder with resolution 500PPR pulses per revolution will have e 500PPR for encoder multiplication 1x e 500PPR x 2 1000PPR for encoder resolution multiplication 2x and e 500PPR x 4 2000PPR for encoder resolution multiplication 4x 9 4 Setting the steps multiplication Steps multiplicator shows how many steps do the DC servo motor for each pulse on the STEP command line This parameter is useful in the case of using the high resolution encoder but STEP command generator has no possibility of g
11. parameter changes from one recording servo log data file Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 19 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 100 set actual 80 60 40 20 odziv mm O 20 40 60 80 s100 2 4 6 8 10 12 vreme S Figure 9 16 Diagram of set and actual position of DC servo motor greska mm vreme S Figure 9 17 Diagram of the positioning error calculated in mm Figure 9 18 Diagram of the electric current through the DC servo motor 6 vreme S Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 20 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 10 PID CONSTANTS SETUP PROCEDURE NOTE During setting of PID constants take all precautions as it may cause oscillation of DC servo motor mechanics When setting up start from low value of maximum current through the DC motor during which should check the behaviour of DC motor After this gradually increase the set value of maximum DC motor current The values of the PID constants depend on e Characteristic of DC motor moment of inertia supply voltage maximum electric current etc e Physical
12. resistor OC ERROR 45V Cea DA Here it is necessary to note that in line Track f v2 Error should be placed an external pull up resistor pe Optoisolating distance between the input output command lines of control connectors and control electronics on the PCB drive is approximately 5 mm Figure 4 2 Schematic representation of opto isolated inputs and outputs 4 2 The configuration port Parameter setting PID controller constants encoder resolution tracking error offset etc is performed by using PI RS232 IPI USB or PI BT interface for programming and configuration software ServoTune3 Programming interfaces PI RS 232 IPI USB or PI BT can be connected to the DC servo drive DCS 3010 via the configuration port marked as Con 2 in Figure 4 1 10 pin IDC connector A detailed description of the setup parameters of DC servo drive DCS 3010 is given in the instructions for use the software ServoTune3 NOTE Configuration port ground is not galvanic separated from the drive ground It is recommended to use insulation programming interface IPI USB or PI BT 4 3 Encoder connector For DC motor position feedback incremental encoder is used on DC servo drive DCS 3010 Encoder can be connected via encoder connector connector Con 3 in Figure 4 1 Functions of the 8 pin RJ45 connectors are provided in Table 4 2 Table 4 2 Description of encoder connector pins 8 pin RJ45 connector Con 3 Pin No Name Description Function L wt A en
13. 01 March 2014 Minor corrections Ver 1 07 January 2015 Minor corrections in Figure 4 6 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 24 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA
14. C 200 mA It is not necessary that this source to be stabilized it is enough that after rectification apply electrolytic capacitor with minimum capacitance 470 UF Table 4 3 Description of pins terminals in the 2 pin connector Con 5 Logic circuit power supply 4 6 DC motor power supply and connection for DC motor DC motor power supply and connection for DC motor is located on the connector Con 6 Figure 4 1 Table 4 4 Description of pins terminals of connector Con 6 Name Description Function 1a DC motor power supply Vmot 10 100 V DC TE DC motor terminal Connecting DC motor TE DC motor terminal Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 6 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA DC motor power supply voltage V should be 10 15 higher than nominal supply voltage of DC motor i e Vinot 115 U 1 NOTE Power supply voltage of DC motor V must not exceed the maximum value of the drive DCS 3010 supply voltage If after connecting the DC motor to terminal M1 and M2 and after the arrival of the supply voltage the motor starts rotating and then stops and OP ER LED indicator starts to flash 2 times Tracking error indicator see Table 6 1 it is necessary to replace motor terminals M1 and M2 DC motor terminal M1 connect to terminal M2 and DC motor terminal M2 connect to terminal M1 EXAMPL
15. DCS 3010 BRUSH DC MOTOR DRIVE 1 DESCRIPTION DCS 3010 is a microcontroller PWM drive for permanent magnet DC PMDC motors with supply voltage up to 100 V DC and current up to 30 A Drive is based on a 16 bit microcontroller with implemented PID control algorithm As the feedback of DC motor position an Ieee S 7 ms TST ae ND BOS BOIO Ver 2 0 incremental encoder with phase shifted ra e Ree a fs ey g et square signal is used Encoder interface 3 ave 5 M wA Ea enables 1x 2x and 4x encoder resolution ae eae le z m IESE Adjustment of all parameters is performed by using the configuration software ServoTune3 The input control interface enables control via opto isolated lines in next modes STEP DIR ENABLE CW CCW ENABLE Encoder follower in 1x 2x and 4x decoding as well as via analog input within the range 0 5 V with and without feedback there is the connector on the drive for connecting an external potentiometer Build in soft start enables DC motor 1s after powering on decreasing electric shock on start There is an opto isolated output on drive named Track Error which is activated if adjusted value of tracking error offset is exceeded That output can be used for activation of external circuit for DC motor emergency stop Drive has over voltage and over temperature protection If electric current is higher drive can be placed on additional cooler APPLICATION CNC machines Coordinate tables P
16. E Nominal DC motor supply voltage DC is U 48VDC What is the voltage required to power a DC motor Vno 115 U 115 48 55 2VDC 55VDC Calculating the voltage of the secondary windings of the transformer used to supply DC motor is calculated using the expression Vinot 1 41 Usei 1 2 T EXAMPLE For the previously calculated supply voltage of DC motor Vmot 55DVC secondary winding power transformer voltage is 55 Uso 1 2 Vmot _ 1 2 40 2VAC 40VAC 1 41 1 41 The current of transformer secondary winding depends on the characteristics of the connected DC motor and it should be 50 100 higher than motor s nominal current It is necessary to Know that the DC motor in certain operating modes can pull much more current than it is nominal 4 7 The connection of the breakout board 103 R2 and connection the power supply The recommended configuration of the breakout board I1O3 R2 three DC servo drives DCS 3010 and the power supply DCS 3010 is shown in Figure 4 6 Galvanic isolated power supply is recommended for Logic circuit power supply of each DC servo drive DCS 3010 and addition galvanic isolated power supply for the breakout board O03 R2 Power supply for DC motors can be carried out from one power source It is recommended to place a slow blow fuse on supply line Vmot for each drive DCS 3010 NOTE Take care not to create a ground loop while system installation Prizma doo Kumanovska st
17. High on error v Low on error In the case of error Error output will be at logical low level Always low Error output will always be at logical low level independently of the existence of errors 9 10 4 Digital filter for encoder An adjustment of digital filter for encoder is performed through selection of upper cut off frequencies e switched off digital filter Turn OFF e the frequency of filter 6 667 MHz e the frequency of filter 3 333 MHz default e the frequency of filter 1 667 MHz e the frequency of filter 416 7 kHz e the frequency of filter 208 3 kHz e the frequency of filter 104 2 kHz e the frequency of filter 52 1 KHz i e the frequency of filter 26 0 KHz Option of digital filtering of signals from the encoder can be useful in the environment with strong electromagnetic interference which can lead to errors in reading the incremental encoder position 9 10 5 Detecting encoder errors If this option is enabled the drive checks if there is a change at levels of both encoder inputs A and B If this is not the case the output stage will be disabled and OP ER LED indicator will show the encoder error NOTE This option has not been fully tested and it is recommended that the checker remains off 9 10 6 Reading power supply voltage of DC motor and temperature of drive In the appropriate fields framed fields in Figure 9 9 is performed reading power supply voltage of DC motor in volts Supp Voltage and tem
18. ation After the execution of Sample command will be drawn diagrams of DC motor response at step function and charts of the changes of voltage and current through the DC servo motor Figure 9 5 Ja DCS 3010 V1 05 100 online File About ee XP i PID constants Enable control Kp 1 sou Software controlled Always enable Sampling Sheps 500 E For Rev 500 Sample F3 Samples 500 S Sample F3 Encoder multiplier a Driver Enable F2 mpositiom Step multiplier Error offset 3000 F sa 1 set Kd 17000 Connected COM1 36400bps Figure 9 5 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 13 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA The recorded values of the DC motor position power supply voltage and current through the DC servo motor will be saved in a file called odziv dat which is located in the folder that contains software ServoTune3 The following is a small sample of the file odziv dat ARRAS Seryorune Sampling OULPUE F eee rns Dave and time 07 12 2012 07 27 39 Time s Position Current mA Voltage V aO AP oC 0 000000 O 244 2O03 Q00 1500 1 488 ts Me 0 004000 g 1220 ZO x eS 0 006500 26 1464 24 65 0009000 48 T933 TAa TE Ee Je C1500 76 2441 2AL9 0 014000 111 26085 24 65 0 016500 LBZ 26085 Zas 0 019000 200 SLIS Aaa OB 202 150 0 254 3417 Aed 0
19. cessary perform manual fine tuning of PID parameters Page 23 of 24 Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA DCS 3010 V1 05 100 online Gra DCS 3010 V1 05 100 online File About File About Pa Auto PID g PA Auto PID o B E T time m Bo D T time ee driver me while Enable driver m while M FowRey M pari M FowRev x sampling Oscillation is not detected Oscillation is not detected PID regulation criteria Calculated parameters PID regulation criteria Calculated parameters Aggressive Kp at Aggressive Kp Normal Ki Normal Ki Less agaressive Kd O Less aggressive Kd Driver E Figure 10 8 Figure 10 9 gt DCS 3010 V1 05 100 online 3 o fi r DCS 3010 V1 05 100 online File About File About pm 3 ee Xa i Steps Recording time g 120 S 100 s E Sample Fa PID constants Enable control V Forw Rev mE Enable driver only while Kp O Software controlled sampling Always enable ae K na Oscillation is detected at f 52 7344 Hz Sampling Kd e69 5 PID regulation criteria Calculated parameters Steps so M Forv Rev O Aggressive Kp 875 ce Samples o Sample F3 ipli Encoder multiplier Normal Ki 50 7568 AutoPID O Less aggressive Kd 6968 89 Driver E ipli Driver Enable F2 mpasition Step multiplier Error offset 1000 g 000 Br Figure 10 10 Figure 10 11 DOKUMENT REVISION Ver 1 0 January 2014 English version Ver 1
20. coder channel pull up resistor 4 7 KQO I A A encoder channel Fo Tn rh i B encoder channel pull up resistor 4 7 KQ 5 4 B B encoder channel Encoder ae a SfM ef cf f L__ Sot Encoder power supply source 5 V 250 mA max eT 8 GND GND Encoder Use an incremental encoder with phase shifted square TTL outputs It is recommended to use encoder with a minimum number of encoder pulses lines of 200 PPR On the drive is the source of power supply for incremental encoder 5V 250 mA max Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 4 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA On the DC servo drive DCS 3010 can be connected encoder with single ended outputs A and B Figure 4 3 or encoder with differential complementary outputs A A B and B outputs Figure 4 4 Encoder interface SED1 at the A and B inputs has pull up resistors of 4 7 KQ DCS 3010 a YOY Jeposuy 8p8c RJ45 Shilded network cable Encoder interface Cat 5e SED1 8p8c RJ45 AGS V GND b 8p8c RJ45 Shilded network cable Encoder interface Cat 5e DD1 8p8c RJ45 Figure 4 3 Connection of single ended encoder with DC servo drive DCS 3010 via a SED1 encoder interface and b DD1 encoder interface DCS 3010 YOY Japoouz Il Oklopljeni ni kabl mre ni ka DD1
21. cted power supply incorrectly connected and defective DC servo motor strong electromagnetic discharge close to contactor etc can damage the drive Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 9 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 ServoTune3 INSTRUCTIONS MANUAL To adjust the parameters of drive DCS 3010 use the configuration software ServoTune3 Figure 9 1 The software consists of a single file and to install it is necessary to copy the file to the desired folder on your computer The configuration software servoTune3 will works on Windows XP Windows Vista or Windows 7 operating system software ServoTune3 enables e Adjusting the PID controller constants e Adjusting the encoder resolution gt KX i multiplication J Servo offline File About j j nli FID constants Enable control Adjusting the steps multiplier a n Enable disable of drive DCS 3010 ee e Setting the number of steps to K a capture the response of DC motor Kd Sampling on step function and drawing Steps 500 For Rev diagrams of the motor position Samples 500 Semple Fa response diagram of voltage and current change e Adjusting values of Tracking error offset e Read the current value of the position of DC servo motor e Recording of log file with the values of set position current pos
22. e pull down menu 1s 2s 3s 4s and 5s Whereas during the recording system response required bringing the system into oscillation it is recommended that this time be as short as possible Alternately reversing DC motor when recording step function option Forw Rev It is recommended that this option should be active Option Enable drive only while sampling It is recommended that this option should be active The process of automatic adjustment of the of PID constants involves gradually increasing the constant Kp With every change of constants Kp it is necessary to press the Sample F3 or function key F3 to record the system response The parameter Kp is increased gradually and gently until it comes to the appearance of the oscillation of the system such as that shown in Figures 10 8 10 9 and 10 10 It is important to note that in these figures are not shown all the steps in gradual increasing of the parameter Kp servoTune3 software will recognize that there is a system oscillation as is shown in Figure 10 10 Oscillation is detected and will suggest PID controller constants Kp Ki and Kd according to the given criteria There is a choice of the following criteria Aggressive Normal or Less aggressive Pressing the OK button Apply calculated PID parameters will be stored in EEPROM microcontroller Check the behaviour of DC servo motor according PID parameters calculated on this way Figure 10 11 If ne
23. enerating pulses of sufficiently high frequency Step multiplier Step multiplication To write desire values in EEPROM microcontroller it is necessary to press the Set button NOTE Higher values for the step multiplier can lead to unsmooth movement especially at low speed 9 5 Control of enable input on drive DCS 3010 Options for control of drive DCS 3010 enable input are shown in Table below Alternatives Software controlled In this mode ENABLE input at control connector Con 1 Figure 4 1 is activated If there is logical unit at the ENABLE input the drive is active and will carry out the commands that come from STEP and DIR command lines In the case that at ENABLE input is logic zero then the e Enable drive DCS 3010 is disabled commands STEP and DIR are A control not carried out and DC motor is not under voltage this option is often used if it is necessary to manually rotate the DC motor Always enable In this mode ENABLE input at control connector Con 1 Figure 4 1 is not activated Drive is always activated enabled Enable control From software ServoTune3 can be performed selection of ENABLE mode of drive DCS 3010 during setting parameters The change of check box can be performed by pressing the function key F2 Driver Enable F2 Drive Drive ENABLE selected DC servo motor is under voltage Enable Enable DISABLE not selected DC servo motor is not under voltage Prizma doo Kumanovska
24. es of the PID constants and the response of the motor are shown in Figure 10 4 It is necessary to check determined PID constants during the work of the machine and if it is necessary to correct them Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 21 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA DCS 3010 1 05 100 online File About 7 DCS 3010 1 05 100 online File About ee Key ee Key PID constants Enable control Software controlled Always enable Sampling Steps Forv Rev Samples mposition fo Error offset Driver Enable F2 Connected COM1 38400bps Z Figure 10 1 2 DCS 3010 1 05 100 online Fie About PID constants Log ie Ki Kd vow Encoder multiplier x4 v Step multiplier Driver Enable F2 moe Enable control Software controlled Always enable Sampling Steps Forv Rev Samples Sope mposition o Error offset Connected COM1 38400bps Figure 10 2 DCS 3010 V1 05 100 online File About Encoder multiplier x4 v Step multiplier 1 Sse ee XF il eS XF il PID constants Enable control kaio FF Software controlled Always enable Sampling Steps Forv Rev Samples Sample F3 mposition fo Error offset Driver Enable F2 Connected COM1 38400bps ot Figure 10 3
25. gram The part of dialogue in the advanced settings Advanced setup shown in Figure 9 12 Sampling options allow choosing of e What parameter will be shown in the main diagram and e The thickness of the diagram line that will be plotted Thin Medium and Thick Sampling options Sample current Sample voltage Graph line Thin Ww Figure 9 12 9 10 9 Setting the maximum DC motor current Over the slider shown in Figure 9 13 maximum current of DC motor is adjusted The adjusted value is readable in the appropriate field Maximum current through DC motor can be adjusted in the range of 3 30 A Current limit 1 0 0 A J Figure 9 13 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 18 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 10 9 LOG File recording Recording of Log file with the values of present position and position error as well as present current and voltage at DC motor is activated by pressing the Log button Figure 9 14 which opens the Loging dialog Figure 9 15 PID constants Enable control Adv Setup Kp 1500 O Software controlled Always enable Ki a g he Log T Samplin Kd 17000 ied moe Steps Forv Alev Sample F3 t Encoder multiplier E Fress START wl at Driver Enable F2 mposition Step multiplier Error offset Figure 9 14 Position of Log button Figure 9 15 Log dialog
26. ifunctional red OP ER LED indicator and red LED indicator Imax shows exceeding the maximum set current DC motor Table 6 1 Description of the state multifunctional OP ER LED indicator The control electronics is not under voltage Drive ready to start ENABLE Drive ready to start DISABLE Action needed 2 x Tracking error Increase the value of Error offset Press the RESET button Encoder error Check the condition of the encoder and encoder cable Turn off error detection of encoder Press the RESET button Over temperature protection is activated Provide better cooling of the drive Press the RESET button 5 x Over voltage protection Provide a source with the lower voltage 6 x gt 30 Circuits for setting the level of the maximum Press the RESET button current error Contact the authorized service 7X e Error of microcontroller Press the RESET button Contact the authorized service The limit of activation over temperature protection is set at 70 C The limit of activation over voltage protection is set at 120 VDC 3 x N 7 N N X gt 4x WARRANTY Manufacturer guarantees that all DC servo drives DCS 3010 will work in proper upon delivery Before delivery all DC servo drives DCS 3010 are tested on power supply voltage with connected DC motor in range of 20 90 VDC and output current up to 20A Supply voltage which that exceeds the maximum allowed value incorrectly conne
27. ition difference and values of the DC motor electric current e Selection of input interface type STEP DIR ENA CW CCW ENA encoder 1x 2x or 4x or analog input with and without feedback e Selection of PWM frequency e Setting options of digital filter for encoder input e Setting the maximum electric current through DC motor etc Encoder multiplier a Driver Enable F2 mpositior Step multiplier Eror offset 1000 lea B set Figure 9 1 ServoTune3 NOTE Software ServoTune3 is used for adjustment of working parameters of drive DCS 3010 This software is not appropriate to control DC motor 9 1 COM port selection Connection between software ServoTune3 and PC with drive DCS 3010 is achieved via programming interfaces PI RS232 IPI USB or PI BT Setting parameters for the COM port is done through dialogue from the Figure 9 2 which is accessed by selecting option File gt Communication setup or by pressing the icon set the serial number of the COM port that is connected to the interface for programming as well as the desired baud rate If check box Save to EEPROM is activated selected value of baud rate will be recorded in microcontroller EEPROM Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 10 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA Communication setup Serial port COMM port COM1 Communications P
28. ort Standard port types Show only present devices Baud rate configuration Baudrate 39400 ve This ig Bluetooth port Save baud rate to EEPROM i Cancel Figure 9 2 Communication setup dialog At the ServoTune3 application top will appear label that the drive is online with version of firmware Figure 9 3 if communication between PC and drive is established From drive DCS 3010 all parameters will be read and printed in the appropriate fields J DCS 3010 V1 05 100 online Figure 9 3 In the case that communication is not achieved with the drive DCS 3010 after starting software ServoTune3 warning dialog will appear as it is shown in Figure 9 4 and servo offline status in main window as it is shown in Figure 9 1 A Communication error Figure 9 4 Error opening COM port This error occurs when the parameters are not set up correctly number of COM port and baud rate or when the programming interface is not connected to the drive In some cases may occur a breakdown in communication with the drive DCS 3010 and then it is necessary shut down the ServoTune3 software restart the drive DCS 3010 by pushing RESET button and start the ServoTune3 software again 9 2 Setting the PID controller constants Drive DCS 3010 is based on the 16 bit RISC microcontroller with PID control algorithm in it Setting these constants is performed in fields that are shown in the table below Kp Proportional gain constant 32768
29. osition of DC servo motor 9 9 Saving and loading configurations Once adjusted configurations can be saved in a configuration file by selecting File gt Save config or by pressing the button Also the configuration file with all the settings can be loaded into the DC servo drive DCS 3010 by choosing option File gt Load config or by pressing button Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 14 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 10 Advanced Setup Pressing the button Adv Setup Figure 9 6 or icon advanced settings Figure 9 7 Advanced controller options Input interlace Enable password PID constants Enable contral Password E kp 1500 O Software controlled Retype ki 70 A Always enable Log PWM frequency 16 t KHz oa FETS Sampling Sampling options t i Steps 500 ra Forv Alev ee RISEN sample current Sample voltage Set Samples 500 a Sample F3 Encoder digital 3333 MHz ras bd Encoder multiplier filter Graph line Thin a Get nd w Detect encoder errors 7 Driver Enable F2 peste 0 es step multiplier Current limit 1 0 0 A Eror offset 3000 Supp Voltage 85 9 T tee 28 2 E r Figure 9 6 Figure 9 7 Advanced settings include the range of options
30. ositioning Robots Education Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 1 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 2 SPECIFICATIONS Digital control modes via opto isolated lines STEP DIR ENA Input control interface CW CCW ENA and Encoder follower 1x 2x and 4x Analog 0 5 V with and without feedback Via IDC10 connector and programming interface PI RS232 IPI USB or PAMER eet ue Bluetooth BT Pl Build in protections Over voltage and over temperature Dimensions W x L x H 154 mm x 105 mm x 45 mm Weight 300 g NOTE specifications are subject to change without notice 3 SEFETY PRECAUTION Drive installation can perform only person who has appropriate knowledge Supply voltages over 50 V DC can be danger of death If supply voltage is over 50 V DC aluminium heat sink has to be properly grounded Use only galvanic isolated power supply for drive DCS 3010 Opto isolated space between input output command lines and controller electronics on drive printed circuit board PCB is around 5mm For stop in case of emergency it is recommended to interrupt power line of DC motor and if it is possible activate motor brake If temperature on drive exceeds 70 C over temperature protection will be activated It is recommended for drive to be placed in enclosures with good cooling and to ensure additional cooling if it is needed
31. perature of DC servo drive DCS 3010 close to the microcontroller in C Temperature Advanced controller options Input intertace Enable password Password Pih frequency 16 KHz Sampling options Encoder digital filter SS Graph line Detect encoder errors Supp Voltage 859 Current limit 1 0 i 0 A E W aE Figure 9 9 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 17 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 10 7 Entering the password The ServoTune3 software provides the ability to enter password to prevent unauthorized changes to the parameters of DC servo drive DCS 3010 In order to activate this option it is necessary to select a checker Enable password first as it is shown in Figure 9 10 thereby Password and Retype become active and in them is then possible to enter the password When the password is entered then during each of the next start up of ServoTune3 software and the connection to the DC servo drive DCS 3010 dialog window Figure 9 11 for the typing of password will open which becomes a requirement for approach settings Controller access password ES Enable password CONTROLLER 15 PASSWORD PROTECTED Bege m Please enter password Figure 9 10 Password dialogue Figure 9 11 Password dialogue on ServoTune3 software startup 9 10 8 Selection of options of the main dia
32. r 8 34000 Kragujevac Serbia Page 7 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA r 15 18VAC 0 5A r ST 15 18VAC 0 5A 3 __ 3 h L geni O i i r Supply AER c T Z Axis a 1 l oo oao oa P2 2 A 7 Axis DCS 3010 15 18VAC 0 5A N m Pl 5 l0 Cha C Y Axis DCS 3010 TO a elf To PC s paraller LPT port Printer cable G p S G oe 3 qT a Tee a S m A E I A f 45V I 5V o Figure 4 6 The connection of the breakout board l03 R2 with 3 DC servo drives DCS 3010 and power supply circuit Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 8 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 5 RESET BUTTON RESET button is placed between configuration port Con 2 and connector for encoder Con 3 see Figure 4 1 By pressing the RESET button it is possible to cancel the present error of DC servo drive In addition pressing the RESET button performs the disable of output H bridge so it is possible to rotate the rotor of DC motor without disconnection of supply voltage 6 LED INDICATORS There are 2 LED indicators on the drive as follows mult
33. set value of the offset Control connector is designed so that the input output card 103 R2 is connected via 1 1 network cable Ethernet cable Pin arrangement is presented in Table 4 1 and a schematic diagram of these pins is shown in Figure 4 2 Tabela 4 1 Pins description of 8 pin RJ45 control connector Con 1 Selected type of digital control Encoder r l nn STEP DIR ENABLE CW CCW ENABLE OUTPUT ee aa cow GND Input 2 4 ore cows B UNIE ENABLE GND N foe Control Port _ ENABLE Input 3 Error output emitter Output 1 utpu Error output Track Error open collector Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Page 3 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA There is a 680 Q resistor at the optocouplers DCS 3010 for STEP DIR and ENABLE command that 680R Ook limits the current to 5mA at the command a voltage of 5V TTL logical level SY i If the logic command voltage at the entrances is higher it should be placed additional 680R resistors at lines 2 4 and 6 and at connector eea Pint DIRI OoOo E Con 1 to ensure that the current does not Pin 3 DIR 5 exceed 5 mA OC E AECE EXAMPLE If the drive DCS 3010 is control OC DIR V4 680R me by using the PLC with 24VDC logic levels it is PTY l necessary in each of the lines 2 4 and 6 to the connector Con 1 add the 3 9 kQ
34. str 8 34000 Kragujevac Serbia Page 12 of 24 Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs Doc DCS 3010 man Ver 1 07 January 2015 by PRIZMA 9 6 Record response of DC motor to the step function In order to adjust the parameters of PID controllers easier ServoTune3 software provides the ability to record the response of DC servo motor and attached mechanics to which is connected to a step function In addition it is possible to set a desired number of steps N D oti Parameters si Mi M ame escription in Sampling p Name Description Steps 100 L Forv Fev Number of Steps 1 32767 Samples 500 Sampling Recording i steps response p Samples Number of read 39767 values Performing a desired number of Number of eps 100 j m steps without steps Serai recording the response Maximum value of Steps should be lower than set value of Error offset Otherwise tracking error will appear and DC servo motor will be disabled Cancelling of tracking error is performed by pressing the RESET button or by switching off the DCS 3010 drive power supply Activate the appropriate function is performed by pressing the Sample or Run Pressing the Sample button or by pressing the function key F3 DC servo drive will handle the given number of Steps By setting the check box For Rev for each pressing of Sample button DC motor will handle a given number of step alternately in one and then the other direction of rot
35. us in some situations Steps Recording time SOS 100 its Sample F3 Oscillation is not detected PID regulation criteria Calculated parameters Aggressive Normal Less aggressive Driver E Cancel Connected COM1 38400bps Figure 10 7 Prizma doo Kumanovska str 8 34000 Kragujevac Serbia Tel 381 34 330 200 web www prizma rs e mail prodaja prizma rs NOTE Method for automatic adjustment of PID constants involves bringing DC servo drive DC servo motor system and mechanical equipment in an unstable state so it is necessary to mention that the system will oscillate Setup procedure of PID parameters in this way the user performs at own risk Within AutoPID dialog which is shown in Figure 10 7 it is possible to set the following parameters Proportional constant Kp Number of Steps to define the step function Pull down menu provides a choice of predefined values for the number of steps 100 150 200 250 300 400 500 750 and 1000 Choose one value of the number of steps corresponding to approximately 5 10 of the number of steps required to DC motor make a full circle EXAMPLE Encoder has 500PPR and selected the option Encoder multiplier x4 In this case it is necessary 500 x 4 2000 steps to the DC motor make a full revolution Recommended values for Steps would be 100 150 or 200 The duration of the measurement of Recording time that can be selected via th

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