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PCE830/40 User Manual

1. DAC Monitor List Table DMxMap Variable Description DAC Out Units DMxGain 1 0 AnalogOutx Actual Analog Output Command V N 1 VelFB Measured Velocity DM2 Default 1 V kRPM 2 VelCmdA Actual Velocity Command VelCmdA 1 3 VelErr Velocity Error 1 4 FVelErr Compensated Velocity Error 1 5 Position Measured Position 1 V Rev 6 PosError Position Error V Rev 7 PosCommand Commanded Position V Rev 8 Icmd Commanded Torque Current 1 V A 9 IFB Measured Torque Current DM1 Default 1 V A 10 AnalogIn Filtered A D Input V V 11 EncFreq Encoder Frequency V Bz 12 EncPos Encoder Position 10 V 4096 Cnts 13 ItFilt Filtered Output Current Amplitude 1 100 14 HSTemp Measured Heat Sink Temperature V C 15 Commutation Electrical Angle V Cycle 16 IU Motor Phase U Output Current 1 V A 17 IV Motor Phase V Output Current 1 V A 18 IW Motor Phase W Output Current 1 V A 19 Motor Phase U Voltage Duty Cycle 1 V 100 20 Motor Phase V Voltage Duty Cycle 1 100 21 Motor Phase W Voltage Duty Cycle 1 V 100 22 VBus Drive Bus Voltage V V 23 ResPos Resolver Absolute Position V Rev 24 Commanded non torque current 1 V A 25 Measured non torque current 1 V A 26 Torque Voltage Duty Cycle 1 V 100 27 Non torque Voltage Duty Cycle 1 V 100 28 VelCmd Velocity Command VelCmd 1 29 DigitalCmdFreq Digital Command Frequency V
2. Selecting a The active move is selected based on the binary state of the MoveSelectBit s and Move initiated by a change of state on the StartMove The table below indicates which predefined move will be activated upon a StartMove state change Move MoveSelectBit2 MoveSelectBit0 0 0 0 0 1 0 0 1 2 0 1 0 5 0 1 1 4 1 0 0 5 1 0 1 6 1 1 0 7 1 1 1 ActiveMove 4 MoveSelectBit2 2 MoveSelectBit1 1 MoveSelectBit0 Move Types The following table lists the move types available Move Type Description Hold Position The motor aborts motion and holds position Velocity The motor ramps up down to a predefined runspeed Incremental The motor travels a predefined distance Absolute The motor travels to a predefined position relative to the home 0 position Turns gearing off Incremental The motor starts an incremental move If a transition occurs on the registration input Registration before the move is complete the motor moves to the latched position Distance Offset Absolute The motor starts an absolute move transition occurs on the registration input Registration before the move is complete the motor moves to the latched position Distance Offset Turns gearing off Home The motor searches for a home reference establishes a home position and returns to the home position Turns gearing off PCE830 40 User M
3. SF gt PosCommand gt PCE830 40 User Manual Danaher Motion PCE840 3 7 Servo Loop Parameters This section describes setting parameters associated with the velocity and position loops In many cases satisfactory operation 1 achieved using either the Create New Configuration or Edit Existing Configuration buttons However in some cases you must adjust the control loop parameters due to large mismatches between motor and load inertia mechanical resonance backlash etc This appendix provides guidance for handling these situations The two anti resonant zeroes ARZO ARZI are assumed to both be off set to zero for this discussion 3 7 1 Current Loop IDN 106 Current Loop Proportional Gain Kip This IDN should be set so that Kip V Amp L 11 in henries 2 1000 IDN 106 Kip Volts Amp 405 6685e 3 IDN 107 Current Loop Integral Gain Kii This IDN should be set so that 50 Hz IDN 107 Hz 12 868 3 2 Velocity Loop Velocity loop bandwidth is the key indicator of system performance Systems with fast settling time must have high velocity loop bandwidth Conversely if the velocity loop bandwidth is low attempting to achieve fast settling time by increasing the position loop bandwidth KPP leads to overshoot and ringing PCE830 40 User Manual 3 49 Danaher Motion PCE840 Velocity Loop PUTA duis
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6. FaultCode Fault Description 1 Velocity feedback VelFB over speed 2 Motor over temperature 3 User 5V low 4 Continuous current fault 5 Drive over current instantaneous 6 Control 12 V under voltage 7 Not Assigned 9 Bus over voltage detected by DSP External Regen Fault 10 Not Assigned 11 Bus under voltage Only if VBus VBusThresh 12 Ambient temperature too low 13 Encoder alignment failed 14 Software and non volatile memory versions not compatible 15 Hardware not compatible with software version 16 UnConfigured drive fault 17 Two AInNull events too close together 18 Position following error fault 19 Parameter memory error 20 Initialization fault 2 Drive over temperature 22 Resolver Fault To further identify this fault see software ExtFault table PCE830 40 User Manual 3 81 840 IDN 129 Continued Danaher Motion The following table lists the values for ExtFault ExtFault ExtFault Description 1 Absolute Resolver Overspeed VelFB gt 21038 RPM 2 Variable Resolver Overspeed VelFB gt max VelLmtxx 1 5 3 Calibration data corrupted 4 Excessive DC offset in current feedback sensor 5 DSP incompletely reset by line power 8 Excessive DC offset in Analog Command A D 9 Not Assigned 10 DSP stack overflow 12 Software and control card ASIC incompatible
7. EF EM EL VUL Lll EL PP Trigger Single Sweep Chri 2 rising edge Enabled Timebase 0 00 0 0 0 0 0 04 0 05 0 06 0 07 00 0 09 0 1 Time in seconds 577 001 sec dv Current Feedback Velocity Feedback The underdamped overshooting velocity loop 15 an unstable waveform It has wasted oscillatory motion It requires extra time to settle Decreasing KVI and or increasing KVP brings the system closer to critically damped Remember when increasing KVP the ARFx filters may need to be increased proportionally In this waveform the oscillating current is a result of the ARFx filters being set too low 2 80 PCE830 40 User Manual Danaher Motion PCE830 Critically Damped 2 rising edge E 0 01 sec div The critically damped velocity loop follows the command without overshoot or undershoot It has the shortest settling time and no wasted motion Get as close to this waveform as possible PCE830 40 User Manual 2 81 PCE830 Danaher Motion 2 5 5 High Inertial Load The maximum inertia for any given system is predominantly limited by the required system performance and the mechanical system Inertia affects system performance in two ways 1 It limits response because torque is required to accelerate an inertial load Larger inertia requires larger torque to accelerate Acceleration is a measure of perfo
8. FaultCode Possible Cause Hex Dec 0xC 12 Ambient temperature is below drive specification Drive s internal temperature sensor has a wiring problem OxD 13 Encoder Alignment failure See ExtFault for additional information OxE 14 Not Assigned OxF 15 Attempt to upgrade the drive s software unsuccessful Contact factory for upgrade details Resolver wiring error Remove J2 and J3 connectors Turn AC power OFF and ON again If FaultCode 2 correct resolver excitation wiring Internal failure Return to factory for repair 0x10 16 Unconfigured drive Red and Green LEDs blinking after power up was fully configured with the drive motor power enable active This fault is reset or the control AC power turned OFF and ON again to get the drive motor operating Ox11 17 The AInNull function was re activated too soon after going inactive This can be caused by switch bounce on the input pin mapped to activate AInNull 0x12 18 The motor is either stalled or partially jammed The value for PosErrorMax is set too sensitive for the loop tuning and commanded motion profiles 0x13 19 Glitch while last saving the NV parameters Corrupted NV memory contents Hardware problem with the NV memory Download parameters to restore drive operation 0x14 20 Initialization Failure See ExtFault for additional information 0 15 21 High drive ambient temperature Restriction of cooling air due to insufficient space around unit Opera
9. Amps Sene 2 per division Offset 0 Amps Channel 2 Source Velocity Feedback Units thick trace Scale 200 per division Offset Trigger Single Sweep chni 2 rising edge Enabled Level o Beset Pacific Scientific SoftScope Timebase 002 sec div 0 000 0 025 0 050 0 075 0 100 0 125 0 150 0 175 0 200 999 Time in seconds 53 711 d Current Feedback Velocity Feedback 2 86 PCE830 40 User Manual Danaher Motion PCE830 From the scope traces record accel current traverse current decel current traverse max velocity and time to accel to traverse velocity Factor out friction and load force from the current Inertial Current A accel current traverse current Polarity matters Or Inertial Current A accel current decel current 2 note polarity matters Inertial Current A 3 8 3 3 2 3 2 10 5 A Inertial Torque Lb in Inertial Current A Kteff Lb in A Inertial Torque Lb in 10 5 2 28 23 94 Lb in Determine acceleration rate AccelRate rpm s traverse velocity rpm acceltime AccelRate rad s AccelRate rpm s 0 10467 AccelRate rad s 2 5 200 0 05 0 10467 1046 7 rad s Determine Inertia Inertia Lb in s Inertial Torque Lb in AccelRate rad s Inertia Lb in s 23 94 1046 7 0 0229 Lb in s By calculating mec
10. Fraction of Rated Speed Rotational Cap Rated Cu Regen Full 210j 35 36 139 Half 53j 35 18j 0j Third 23 35 12 0j PCE830 40 User Manual Danaher Motion Using External Regen High Inertia Rotational energy is proportional to inertia At high speeds a high inertia means lots of regen R wattage needed Using the above example once the speed is low enough so the copper losses from a full torque acceleration are the same as the rotational losses the copper losses also increase in proportion to the inertia This is because if inertia increases by it takes times longer to decelerate If the speed is not too high even with a high inertia external regen may not be needed Counter intuitively the greatest need for regen is when the decelerating torque 15 low and the speed is high In summary the need for regen is a strong function of maximum motor speed Below some speed roughly 1 3 to 1 4 system rated speed an external regen resistor 15 unlikely to be needed PCE830 40 User Manual 6 5 Using External Regen Danaher Motion This page intentionally left blank 6 6 PCE830 40 User Manual Danaher Motion INDEX A AC Power 2 13 3 16 Accessories 4 2 Analog Command 5 6 Analog Input Null 2 40 Analog Schematics 2 23 3 24 Anti resonance filters 2 97 3 53 ASCII Protocol 2 107 B Backlash 2 97 3 54 Bandwidth 2 95 Brake Output 2 34 CcwInh 2
11. Units thick trace Rpm Scale 200 per division Offset o Rpm Trigger Single Sweep None free running Enabled 6 50 Level Reset Print Timebase sec div Switch to Variables This screen capture is not a true representation of the signal waveform due to the sample resolution However counting the peaks over 10 divisions provides adequate results in most cases 2 84 PCE830 40 User Manual Danaher Motion Procedure 2 5 7 Bandwidth PCE830 40 User Manual PCE830 In this example there is an oscillation of 450 Hz 1 Set ARFI 450 Hz 2 0 225 Hz 2 Monitor current again If oscillation is gone increase KVP to excite it again and repeat the procedure If oscillation is the same frequency reduce ARFO and ARFI to further reduce the amplitude of the oscillation 3 Repeat until either the oscillation gets worse or the oscillation frequency changes to match the filter frequency In either case KVP needs to be reduced and or ARFs need to be increased Inertia and Bandwidth The velocity loop bandwidth BW is very useful information when setting KVI and KPP parameters These parameters are totally dependent on the value of the velocity loop bandwidth Unfortunately BW is not readily available It must be calculated based on the total system inertia The total system inertia value is the
12. is too large it will provide overshoot Typically Kvff should not be set larger than 80 for smooth dynamics and acceptable overshoot but should be set to 100 for minimum following error which may be necessary in some applications Overshoot Setting KVFF equal to 100 can result in position overshoot Somewhat lower values may be required if this is a problem KVFF set to 70 80 typically achieves the fastest step response with no overshoot Setting KVFF to less than 10096 gives steady state following error when running at a constant speed 3 4 Advanced Velocity Loop Tuning Continuous Time Transfer Function Approximation 3 58 The transfer function for the velocity loop compensation block 1s sye 16 FVelErr ao 10 9 1 VelEm 2 15 5 Qr 9r 1 VelErr 5 2 15 5 r Definitions for the terms used in the equations above are For ARx0 gt 0 both roots are real and 2 Q _ ARKO 1 For 0 lt 0 roots are complex pair and 2 ARX Qz FVel rr When 20 and ARZI are both 0 the numerator of FEE reduces to 5 7 If ARZO or ARZI is individually 0 the numerator reduces to 2x AX PCE830 40 User Manual PCE840 Danaher Motion The velocity loop compensation is actually implemented as a digital discrete time Discrete Time Transfer system function on the DSP The continuous
13. iro 5 000 Hz ane Chamee Commands NVLoad NVSave Unconfigure Inputs 1 off 2 Q otf 3 Q off 4 Q off 5 Q off 6 Q off Outputs 1 oft 2 3 oft 4 Q oft Scope Switch to Scope Context sensitive help is also available in the Parameter Edit window Press lt 1 gt to get help information about a highlighted variable Information about all variables is available in this way PCE830 40 User Manual PCE830 Danaher Motion Changing A To change the value of a VelCmd click Change and the following window Variable appears jVelCmd Lx Enter new value for VelCmd Target velocity command 500 min 21000 000 max 21000 000 Dk Cancel e Type in new value Click OK to send new value to the drive and return to the On Line Drive Configuration window 2 1 7 Uploading Parameters from the PCE830 Click Upload in the main screen to upload the current parameter values in the drive s RAM to the Parameter Edit screen You can browse and modify them in this screen Afterward you can click Next 2 1 8 Edit a Configuration File Click Edit File in the main screen Select the file you would like to open from the list of files displayed The parameters in the file are loaded in the Edit Parameter screen You can browse and modify them in 2 10 PCE830 40 User Manual Danaher Motion PCE830 2 1 9 Editing The Motor Da
14. Apply 5 Hz ARFI 750 Undo Default Tuning Wizard You can Adjust the slider bar to change Bandwidth e Inertia Ratio KVI and can be altered Click Apply to send the changes to the drive e Click Undo to recover all variables in this page e Click Default to set all variables in this page to default value 2 1 11 Exiting 800 Tools Click Communication Exit in the main menu to terminate 800Tools 2 2 Interfaces and Connections This section describes all the connections to the PCE830 and provides the information required to interface to it In the list below an overbar on a signal name means that the signal is active low logic For example Fault indicates the drive is faulted when it is pulled low Earth Ground Chassis Ground M4 x 12 screw with flat and lock washer 2 12 PCE830 40 User Manual Danaher Motion 2 2 1 Power Board Connector TB1 13 Position Terminal Strip Pin Label Description 1 1 LIC 120 240VAC Control Power TB1 2 L2C 120 240VAC Control Power TB1 3 PE Chassis Ground TB1 4 L1 380 400 480 Input TB1 5 L2 380 400 480 Input TB1 6 L3 380 400 480 Input TB1 7 B Bus TB1 8 R Regen Transistor TB1 9 B Bus TB1 10 PE Chassis Ground TB1 11 U Motor Phase U TB1 12 V Motor Phase V TB1 13 W Motor Phase W AC Power PCE830
15. 5 If Home Switch was selected click on the Digital I O tab Select Home Switch Input as the function for the desired input Home Position Position of Home Reference Distance Offset Position Position Home Position The motor then performs an absolute move to the home position 2 60 PCE830 40 User Manual Danaher Motion PCE830 Registration Move Parameters lt no name assigned yet gt x Drive Motor Drive Type PCE833 Motor Type 42 Mode of Operation Position Predefined Moves Y Digital 1 0 Analog 1 0 Loop Gains Position Controller Predefined Moves Feedback Regl Active Edge Rising Edge In Position limit Counts 2 Active Edge Rising Edge Move 1 Move Parameters for Move 0 Move NRI Distance Offset o counts 211 Run Speed 1000 00000 RPM Reg Select Regi Inp4 Accel Rate 10000 00000 ED DE Decel Rate 10000 00000 RPMsec c n Distance 55536 counts 1 rev 65536 counts Cancel Next gt gt 1 Select either Incremental or Absolute Registration as the Move Type 2 Select Regl Inp4 or Reg2 5 as the registration input Verify that there is No Function defined for the registration input 3 Select the Active Edge for the registration input 4 Setthe Distance to the desired value
16. e e e An input to command zero motion 1 2 Change the value of CmdGain2 to the desired value For Direction set CmdGain2 7 CmdGain To Change speed set CmdGain2 NonZero value To hold zero command set CmdGain2 0 When you activate the Command Gain Select input the command will switch from a scale of Command Gain CmdGain to a scale of CmdGain2 Related See CmdGain CmdGain2 and BIKType Operation Mode in On line Help Parameter s 2 40 PCE830 40 User Manual Danaher Motion PCE830 Gearing On In Position Mode the Digital Command source can be turned on by activating Gearing On input and turned off by deactivating the Gearing On input Deactivate Gearing On to Perform a Homing Move Perform a move to a flying shear start position Hold zero speed until next input An Absolute Move will abort Gearing Gearing On 0 Setup 1 Click on the Digital tab Setup a Start Move input and Move Select Bit inputs for starting the move 2 Click on the Predefined Moves tab Setup a Home move OR Setup an Absolute move to Position 0 the known start position 3 To hold zero speed the Gearing On input is all that is needed Related See DigitalCmd and DigitalCmdFreq in in on line Help Parameter s Position In Torque Mode or Velocity Mode the mode can be switched between Torque and Mode Select Position or Velocity and Position After switching to Position Mode the drive performs e Electroni
17. to 265VAC PCE830 40 User Manual Danaher Motion Chassis Ground PE TB1 3 L1 L2 L3 TB1 4 5 6 380VAC 400VAC 480VAC Regeneration Interface B TB1 7 8 9 Bus Regen Resistor Bus PCE830 40 User Manual PCE840 Convenience connector point for the user to connect the drive s control power and bus power to protective earth ground This pin is directly connected to the chassis and thus to the Chassis Ground Stud Local electrical code may require using the Earth Ground Chassis stud for this function These terminals connect the balanced three phase 380 400 480 VAC power provided by the user to the drive s power output stage bus to drive the motor 380 400 480 VAC three phase mains MUST be WYE type with earthed neutral for PCE840 to be compatible with CE safety standard EN50178 Earthed neutral WYE type mains are strongly recommended for all installations Single phase or lower voltage operation is possible for short periods of time to support installation or testing These terminals provide the connection points for a resistor to absorb regenerated energy from the motor A regeneration resistor goes from B to R In the PCE843 if a regeneration resistor is not needed see an internal regen resistor is factory wired to B and R Bus B on TB1 9 is usually left open High Voltage During normal operation R and B operate at the bus power voltages The 840 regen operates at
18. ENCIN B 261 532 220uF lane 8V UNREG 5 REG T J3 11 RTN An adapter be powered from the serial port 5VDC output on J1 4 as long as the load current on J1 4 J2 14 and J3 10 total less than 250 mA PCE830 40 User Manual 3 37 PCE840 Danaher Motion Using TTL Differential Line Drivers ENCODER PCE800 SUPPLY A m 45V SUPPLYe J CONNECT ONLYIF J2 __ _ 1Or45VDC Q250mA 1 1 5 SUPPLY RETURN 3 6 Inputs and Outputs The PCE840 has six digital user mappable inputs 72 31 to J2 36 three digital user mappable outputs J2 42 to J2 44 and one mappable relay output J2 24 25 which are availablefor users to interface to external devices proximity switch PLC LED In addition the 840 has one analog input J2 1 2 and two analog outputs 72 4 5 that can be set to various output functions 3 6 1 General Purpose Inputs Outputs The PCE840 Input and Output pins are optically isolated from the rest of the PCE840 and each other Below is a table of the applicable IDNs for the PCE840 General Purpose I O IDN s Description Function 34817 34822 PCE840 Input Bits 1 6 Read Input Bit 1 6 34824 PCE840 Input Port Read Entire Input Port 34833 34836 PCE840 Output Bits 1 4 Read Write Output Bits 1 4 34840 PCE840 Output Port Read Write Entire Output Port Service All ofthe above IDNs can be read through the SERCOS Service Channe
19. 5H NO dia NOISH3ANOI 914003 SINN L XHO LINOM e NIVORIQ 5594 INY Ova Nou333s amp S S lt 1 uonsogd lt HOLINON ERENS Ia 03XAQ t 3430 SH31SAS SOINvYHO3MW 2 3 gt NOILISOd 594 J dOOINOILISOdOL A1I2013A 2 5 APT OW HaAIOSdH 51 gt TC adie juni avna 909401 IET ANGYOL 940938 335 044 031710930 nah Li ce QNVINIOO ALIOOTSA LAN asWHd SOINVvHO3IN lsd Lie 0249 035 HOLYHOSLNI 4015 HO LI HO31NI PCE830 40 User Manual 3 50 Danaher Motion Velocity Loop Bandwidth Load Inertia KVP PCE840 The velocity loop bandwidth fyc is given by the equation xw 43 _ 72 _ Kr 0138 is the velocity loop proportional gain in amps rad sec is 0 peak line line motor torque constant in Ib in amp 1s the total inertia motor total load total in Ib in sec2 Any consistent set of units for such as MKS that yield in rad sec2 amp work The motor torque constant is the value of Kr peak published in the Pacific Scientific Motion Control Solutions catalog f is the un
20. Count regen pulses by counting sawtooth cycles on VBus using the built in soft scope during regen The voltage across the regen resistor TB1 7 to TB1 8 can be observed directly 18 an oscilloscope capable of a differential measurement of electrically hot signals is available Monitoring There may be a few applications where bus voltage pump up is excessive but not Bus Voltage high enough to trip the hardware over voltage fault 866VDC Bus voltage is considered excessive if it exceeds 780VDC to 800VDC The built in oscilloscope can be used to monitor how much the bus voltage VBus pumps up at motor deceleration If the scope shows the bus voltage reaching 780VDC to 800VDC connect an external regen resistor to insure long term reliable operation PCE830 40 User Manual 6 1 Using External Regen Danaher Motion Regen Characteristics Mounting and Wiring Regen Mounting 6 2 Pacific Scientific offers an external regen resistor for the PCE800 family Part PRK 200 66 It is a 66 200W metal clad panel mount resistor supplied with a short cable for attachment to the drive This resistor is used with the PCE8x3 s that require a regen resistor For the small number of PCE8x5 installations where regen power exceeds the 100W rating of the internal regen resistor two of these resistors wired in parallel 330 400W combined rating can replace the internal PCE8x5 regen resistor Ohms 66 10 Watts 200 watts manuf
21. Follow these guidelines to prevent damage to the servo drive during operation e Never plug or unplug connectors with power applied Never connect or disconnect any wires to terminals with power applied Never plug or unplug an option card with control power applied If the drive indicates a fault condition find the cause of the fault and fix it prior to resetting the fault or power cycling the drive If personal injury can result from motor motion the user must provide an external hardwired emergency stop circuit outside the drive This circuit must simultaneously remove power from the drive s motor power terminal TB1 11 TB1 12 and 1 13 and disable the drive by disconnecting J2 pin 37 from RTN The motor coasts under this condition with no braking torque If breaking torque is required to quickly stop the motor a dynamic brake can be added that loads the motor s windings resistively The motor should not be loaded until the servo drive is disabled Always remove power from before working on the machine working anywhere machine motion can cause injury The holding brake optional on Pacific Scientific motors is NOT intended to stop a spinning motor It is designed to prevent a stopped motor from rotating due to an applied torque Never power the servo drive with the cover removed or with anything attached to circuitry inside the cover If the drive must be removed from the cabinet wait at least fiv
22. InputG NoFuncin Digital 1 0 Analog 10 Loop Gains Velocity Controller Predefined Moves Feedback Output Functions Outputt Fault lo Output2 No Funcion gt tion 54 Excess Position Error hi Relay Fy Excess Position Error lo Relay Brake lo v Next gt gt In Position Mode indicates synchronization failure for l 2 Warning the master when out of synchronization Help Preventing a position error fault from disabling the drive Click the Edit Drive Configuration OnLine button Change PosErrorMax to the appropriate Motor Counts as a trip threshold Motor Counts 65536 counts rev See PosErrorMax KPP and KVFF in on line Help PCE830 40 User Manual Danaher Motion PCE830 Move Done Setup Related Parameter s Zero Speed Setup Related Parameter s When executing Predefined Moves the Move Done output activates when the motor feedback reaches the final move position InPosLimit sets the window of motor counts to determine if the motor is near final position A smaller window InPosLimit 2 provides more accurate results and takes longer to settle Use the MoveDone output to tell the master control that the drive 1s finished with the move and in final position 1 Click the Edit Drive Configuration OnLine button 2 Change InPosLimit to the appropriate Motor Counts as a trip threshold Motor Counts
23. Model Height Width Depth PCE8x3 254 mm 10 0 121 7 mm 4 79 192 mm 7 56 5 254 mm 10 0 146 7 mm 5 76 192 mm 7 56 Weight Model Weight PCE8x3 3 6 kg 7 9 lb PCE8xS 4 2 kg 9 3 16 PCE830 40 User Manual 5 11 Specifications Danaher Motion Drive Mechanical Outline PCES00 Series Mounting Guidelines 1442 5 68 PCE835 120 9 4 76 PCE833 10 00 2097555589995 L Faceplate detail of PCE83x Faceplate detail of PCE84x The figure above provides the key dimensions for use in physically mounting the product When mounting multiple drives in a row some customers have found the stiffness of the drive and their mounting panel to be too low To increase the mounted mechanical integrity connect to the threaded insert on the top front edge The extra depth for mating connectors is 1 0 or less PCE830 40 User Manual Danaher Motion Specifications 800 Terminal Block Adapter 2x22 PIN CONNECTOR WECO P N 934 22 2x8 PIN CONNECTOR WECO P N 934 08 PCE830 40 User Manual 5 13 Specifications Danaher Motion Fan Option Kit 5172 437 MOUNTING FOR OR 48 32 TYP 2 PL 2 00 222 08 22 t 5 14 PCE830 40 User Manual Danaher Motion Using External Regen 6 USING EXTERNAL REGEN An estimated 10 of applications require that the PCE
24. 3 Decrease both and ARFI by 20 and go back to Step 2 4 The velocity loop bandwidth should now be approximately one quarter the value of ARFO and ARFI For margin reduce ARFO and by 20 Some backlash may be unavoidable especially when gear reduction is used If backlash is present the inertia match must be good load inertia should be roughly equal to motor inertia for good servo performance Gearing reduces the inertia reflected to the motor by the square of the gear reduction from motor to load Select a gear ratio to give the required match PCE830 40 User Manual 2 97 PCE830 Current Ripple KVI 2 98 Danaher Motion The velocity feedback signal in standard PCE830 drives operating with the standard 20 arcmin resolver can have up to 3 p p ripple The resulting motor torque current ripple with no ARFO ARFI filtering is calculated using the following formula Current ripple amps p p TY Speed 20 03 There can be cause for concern when this number exceeds 40 of the drive s or motor s current rating Monitor the motor current using DAC Monitors on J2 4 to insure that actual ripple current with ARFO ARF1 filtering is not excessive Motor current ripple is often reduced by lowering the ARF1 low pass filter break frequencies This benefit is limited by velocity loop bandwidth and stability constraints Velocity feedback ripple
25. 5 Set the Distance Offset to the desired value This is the distance that the motor will travel upon registration PCE830 40 User Manual 2 61 PCE830 2 4 2 Position Mode Step and Direction This mode allows the PCE830 to be controlled by a stepper indexer feeding it with step and direction signals on J2 17 through J2 20 Predefined moves are also available in this mode Danaher Motion Procedure 1 Select Position Mode Step and Direction from the Mode of Operation dropdown list box 2 Specify the number of steps per motor revolution This number must be evenly divisible by four Divide this number by four and fill in Pulses In in the Parameters Edit screen For industry standard step sizes select from the table below Steps Rev Motor Mechanical Deg Step 200 Full 1 8 400 Half 0 9 1000 1 5 0 36 2000 1 10 0 18 5000 1 25 0 072 25000 1 125 0 0144 50000 1 250 0 0072 2 62 PCE830 40 User Manual Danaher Motion PCE830 Step and Direction lt no name assigned yet gt PCE830 40 User Manual 2 63 PCE830 Danaher Motion 2 4 3 Position Mode Electronic Gearing This mode configures the PCE830 to follow external encoder signals applied to the encoder inputs on J2 17 to J2 20 Predefined moves are also available in this mode Procedure 1 Select Position Mode Electronic Gearing from the Mode of Operation dropdown list box 2 Enter the numb
26. AAN 9 ND MMBD914LT1 gt SL E A Probe inputs have a 50 usec latch time PCE830 40 User Manual 2 31 PCE830 Danaher Motion Enable Input This optically isolated input is used to enable the drive and is active high The output J2 37 stage is disabled when this input is inactive A minimum drive capability of 4 mA is required You must supply 10V to 30V to drive this input This input is filtered with a 1 mSec time constant low pass filter to prevent false triggering from noise The Enable input shares a floating return J2 38 with Inputs 1 through 6 A 5 V input CANNOT be used R226 2 2K TO CONTROL LOGIC MMBD914LT1 TLP121GB J2 38 INPUT RTN If the drive s 24V supply is being used connect as shown below MMBD914LT1 TLP121GB 42 38 INPUT RTN 12 39 24 VDC OUTPUT 42 40 24 VDC 2 32 PCE830 40 User Manual Danaher Motion Input RTN J2 38 24 VDC RTN 24 VDC Output J2 39 J2 40 Outl 2 3 Supply Input J2 41 Outputs J2 42 43 44 PCE830 This terminal is the floating common return for the six optically isolated digital inputs and the optically isolated Enable input These two connections provide an auxiliary floating power supply for the user This output is 24VDC 10 and is short circuit protected at 100 mA nominal The maximum load limit for all connections to this supply is 80 mA 24VDC RTN is not connected to Input RTN The PC
27. Conversion Scaling Factor 1 Data Length 4 bytes Units Probe Value IDN 79 65536 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read only by the Master IDN 131 Probe Value 1 Negative Edge Parameter Data IDN Signed Decimal Number Returns the position value latched by the PCE840 drive when a falling edge of the Probe 1 signal has occurred The position is either in resolver or encoder counts depending on the feedback device used to close the position loop This value is scaled using IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units Probe Value IDN 79 65536 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read only by the Master PCE830 40 User Manual 3 83 PCE840 Danaher Motion IDN 132 Probe Value 2 Positive Edge Parameter Data IDN Signed Decimal Number Returns the position value latched by the PCE840 drive when a rising edge of the Probe 2 signal has occurred The position is either in resolver or encoder counts depending on the feedback device used to close the position loop This value is scaled using IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units Probe Value IDN 79 65536 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read only by the Master IDN 133 Probe Value 2 Negative Edge Parameter Data IDN Signed Decimal Number Returns the position value latched by the PCE840 drive when
28. EMU A B gt 71 ROTATION PCE800 BASE UNIT ENCODER PCE830 40 User Manual 3 29 PCE840 Danaher Motion Using TTL differential line drivers ENCODER PCE800 45V SUPPLY 2 45 _ 1 J_ _ _CONNECTONLY IF 2 _ _ _ 14146406 250 SOURCES ENCODER POWER 7 171 CHA CEs PAIR 1611 0 RTN 5V SUPPLY RETURN Using TTL single ended drivers ENCODER PCE800 5V SUPPLY 5 5 SUPPL Ye _ ONLY IF J2 _ _ _ 14145406 250mA SOURCES ENCODER POWER 171 5V SUPPLY RETURN 3 30 PCE830 40 User Manual Danaher Motion PCE840 The list below describes the subset of the available functions and the mappings used as the factory defaults for each of the inputs Fault Reset Input CwInh Input CcwInh Input Input Reg2 Input Input Mapped Off Input J2 34 Input 1 This input is used to reset the amplifier following a fault This input is programmed active high so that an open circuited input does not activate the function During Fault Reset active the output stage 1 disabled and the reset condition will be held in hardware for approximately 0 1 sec after Fault Reset is returned inactive Input 2 This input prevents further motion in the clockwise shaft motion direction This input is programmed active high so that an open circuited input does not activate the function If the shaft is already moving in the cloc
29. InpMap5 InpMap6 OutMapl OutMap2 OutMap3 OutMap4 VelCmdSrc Brake MfgLock AInNull PosErrorMax Fault Motor2 DigitalCmd 0 Move0Distance Move0ODwell MoveODistOffset MoveOHomeDir 0 MovelType Movel Distance Dwell MovelDistOffset MovelHomeDir MovelHomeMode Move2Type Move2Distance Move2Dwell Move2DistOffset Move2HomeDir Move2HomeMode Move3Type PCE830 40 User Manual 10063 10064 10065 10066 10067 10068 10069 10070 10071 10072 10073 10074 10075 10076 10077 10078 10083 10084 10085 10090 10091 10092 10093 10095 10096 10097 10098 10099 10100 10102 10103 10104 10105 10106 10107 10109 10110 10111 10112 10113 PCE830 2 111 PCE830 2 112 Move3Distance Move3Dwell Move3DistOffset Move3HomeDir Move3HomeMode Move4Type Move4Distance Move4Dwell Move4DistOffset Move4HomeDir Move4HomeMode 5 MoveS5Distance Move5Dwell MoveS5DistOffset MoveS5HomeDir Move5HomeMode Move6Distance Move6Dwell Move6DistOffset Move6HomeDir Move6HomeMode Move7Type Move7Distance Move7Dwell Move7DistOffset Move7HomeDir Move7HomeMode ActiveMoveType ActiveDistance InPosLimit ActiveDwell ActiveDistOffset ActiveHomeDir ActiveHomeMode ActiveMove StartMove MoveDone MoveSelectBit0 10114 10116 10117 10118 10119 10120 10121 10123 10124 10125 10126 10127 10128 10130 10131 10132 10133 10134 10135 10137 1013
30. Maximum Value Access State IDN 32813 DM2Gain 0 01 e 1 4 bytes 2 147 483 647 2 147 483 647 Read Write by the Master Parameter Data IDN Signed Decimal Number Sets the analog output gain for DacMap 2 Scale factor depends on the setting of DacMap 2 Refer to Dac Monitor Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State PCE830 40 User Manual 0 01 1 4 bytes 2 147 483 647 2 147 483 647 Read Write by the Master 3 101 PCE840 IDN 32814 DM1Map Mux Select Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32815 DM2Map Mux Select Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32816 EncOut Danaher Motion Parameter Data IDN Unsigned Decimal Number 1 2 bytes 0 75 Read Write by the Master Parameter Data IDN Unsigned Decimal Number 1 2 bytes 0 75 Read Write by the Master Parameter Data IDN Unsigned Decimal Number Sets the line count of the emulated encoder Writing 0 to this IDN internally connects the EncIn input pins to the EncOut output buffers 125 250 500 1000 2000 4000 8000 16000 lines rev 128 256 512 1024 2048 4096 8192 16384 lines rev Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State 3 102 The number of encoder counts per revolution is equal to 4 enco
31. RS 485 TXD RS 485 RXD 4 RS 485 RXD 5 98 76 J 5 98 76 J1 lORTN 5 VDC MULTIDROP MASTER SUBSYSTEM 1 SUBSYSTEM 2 2 18 PCE830 40 User Manual Danaher Motion PCE830 RS 232 to It is often convenient to use an RS 232 to RS 485 RS 422 converter so an RS 232 RS 485 port available on all PCs can be used to connect to multiple axes The figure below Converter shows a typical installation using the B amp B Model 422 RS 232 to RS 422 adapter Installation RS 232 to RS 485 RS 422 adapters are available from many sources An adapter can be powered from the serial port 5 VDC output Jl 4 as long as the load current on J1 4 J2 14 and J3 10 total less than 250 mA Installation Diagram RS 232 OUTPUT L 3a _ 1 RTN PCE830 PCE830 40 User Manual 2 19 PCE830 PCE830 Serial Communications Transceiver Schematic Installation Diagram TXD TO UART RS 485 ENABLE 2 20 Danaher Motion 332 A Bo ANM O 2 RS 232 TXD SNT5155 7 2200pF 9 T O 3 RS 232 RXD SN75155 T 2200pF 5V 1000pF 464 KZ Ox 75176 m 8 RS 485 RXD 1 ZA 464 1000 O 9 RS 485 RXD 75176 1 4 5VDC 6 RS 485 TXD O 7 RS 485 TXD 8 5 RTN V 4 SHIELD PCE830 40 User Manual Danah
32. defined by PosErrorMax PCE830 40 User Manual Danaher Motion Active hi lo OutMapX Example Reading Writing Example PCE840 Each of the digital inputs and outputs can be defined as either active high or active low If the mappable output function bit is configured as active HIGH LOW then when the function bit is asserted the output will be HIGH LOW To map 1 as Enabled Active High write value 0x8002 to IDN32860 To map OUTA as Brake Active Low write value 0x3 to IDN32863 In order to set a pin as a general purpose input the InpMap IDN must be set to zero Reading a Input pin would return the value of the input pin Reading IDN 34824 would return the value of all the input pins as a single word Reading an Output pin would return the appropriate bit value located in the Output port Reading IDN 34840 would return the value of the Output port Writinga0orltoIDNs 34833 34836 Output Pins will set Output Pins to that value or writing a value between 0 and 15 to IDN 34863 Output Port will set the Output port to that value To change the mapping of InpMapl from General Purpose Input default to the Home Switch perform the following 1 Write 0x800F to InpMapl IDN 32817 2 Read the first bit of the Input Port IDN 34824 or read Input 1 IDN 34817 to monitor the state of the input IDN 34817 can only be read using the service channel IDN 34824 can be read using the service channel or
33. load inertia up to 3 motor resolver give acceptable performance without further optimization The most common servo setup problem is adding large load inertia without a corresponding increase in KVP The value of KVP to achieve a desired bandwidth can easily be calculated as Tun d x TOT 58 ve TOT 10267 5 3 6 830 40 User Manual 2 95 PCE830 Example Calculation Problems With High Load Inertia Danaher Motion For example to achieve 75 Hz bandwidth with a PMA22 motor having 20 to 1 load inertia 0 011 Ib in sec2 0 00039 0 011 0 01139 Ib in sec2 Ky 4 31 Ib in amp 10 26 75 201139 2 03 800Tools can also be used to make the calculation Simply enter the total inertia in place of the motor plus resolver inertia when using the Create New Configuration or Edit Existing Configuration buttons and 800Tools calculates the appropriate value for KVP to achieve 75 Hz bandwidth There is no specific answer to the general question What should the bandwidth be In general the higher the velocity loop bandwidth the faster the settling time and the better the rejection of torque disturbances increased stiffness Typically velocity loop bandwidths range from 30 Hz to 100 Hz However too high a bandwidth can lower the damping of resonance in mechanical linkages causing excessive ringing and or wear in coupled mechanics Remember it is
34. 0 Loop Gains Velocity Controller Predefined Moves Feedback Gain and Offset Current Limits Command Gain 1 00000 kRPM volt Positive 100 of peak Offset Voltage 0 00000 volts Negative 100 of peak Velocity Limits Accel Decel Limits High 62650 Accel fi 000000000 00000 RPM sec Low 1140452658 RPM Decel 1000000000 00000 RPM Sec Cancel Nest gt gt Help 2 66 PCE830 40 User Manual Danaher Motion PCE830 2 4 5 Velocity Mode Frequency Command This mode is the same as the Velocity Mode Analog Command except that the command input comes from the Incremental Command inputs on J2 17 through J2 20 The frequency on these input terminals is the variable DigitalCmdFreq and is substituted for the AnalogIn input to the CmdGain scaling The units on CmdGain are krpm kHz Motor Velocity krpm EncFreq kHz CmdGain kRPM kHz 2 4 6 Velocity Mode Serial Command This mode is the same as the Velocity Mode Analog Command except that the command input is the value of Velocity Command VelCmd set over the serial port VelCmd is non volatile parameter and when the 830 40 servo powers up in this mode the initial value of the velocity command is this non volatile value Changing VelCmd over the serial port then sets a new volatile velocity command Changing the non volatile velocity command requires the additional step of issuing the NVSave command PCE830 40 Us
35. 0xC 12 Ambient temperature too low OxD 13 Encoder alignment failed OxE 14 Software and non volatile memory versions not compatible OxF 15 Hardware not compatible with software version 0x10 16 Unconfigured drive fault 0x11 17 Two AInNull events too close together 0 12 18 Position following error fault 0x13 19 Parameter memory error 0x14 20 Initialization fault Ox15 21 Drive over temperature 0x16 22 Resolver Fault To further identify this fault see software variable ExtFault PCE830 40 User Manual 3 127 Danaher Motion PCE840 ExtFault The following table lists the values for ExtFault ExtFault ExtFault Description 1 Absolute Resolver Overspeed VelFB gt 21038 RPM 2 Variable Resolver Overspeed VelFB gt max VelLmtxx 1 5 3 Calibration data corrupted 4 Excessive DC offset in current feedback sensor 5 DSP incompletely reset by line power dip 8 Excessive dc offset in Analog Command A D 9 Not Assigned 10 DSP stack overflow 12 Software and control card ASIC incompatible 13 Actual Model not same as stored in NV memory 14 Unable to determine power stage 15 Drive non volatile parameters corrupt 16 RAM failure 17 Calibration RAM failure 18 Encoder alignment no motion fault 19 Encoder alignment excessive motion fault 20 Encoder alignment motor not
36. 2 8 1 Configuring the PCE830 for a Motor with an Incremental Encoder Using an To wire an incremental encoder for primary feedback on the 830 Incremental Encoder 1 Connect the encoder signals and Encoder 5 supply as shown in the diagram below PCES30 J FEEDBACK MOTOR W ENCODER FEEDBACK ENCODER INPUT CHANNEL A ENCODER INPUT CHANNEL A ENCODER INPUT CHANNEL 5 ENCODER INPUT CHANNEL 2 Click the Edit Drive Configuration Online button and select the variable EncPos 2 104 PCE830 40 User Manual Danaher Motion 3 10 11 PCE830 With the motor disabled rotate the shaft in the clockwise direction as viewed from the shaft end as shown in the picture below Am If EncPos decreases as the shaft is rotated swap A and amp connections and repeat Step 3 Click the Create New Configuration button Select the proper motor drive and desired mode of operation Click Next Click the Feedback Tab Select Incremental Encoder as the Commutation Source Enter the correct encoder line count Click Save to File and give the configuration a name Click Download to Drive to send the complete configuration to the drive After the download is complete click YES to save the configuration to non volatile memory Turn AC power OFF and ON again Incremental encoders are not absolute feedback devices An alignment procedure must be performed The motor should perform
37. 240 and or 120VAC The steps below outline the minimum requirements for bringing the ring to phase 4 These steps assume a SERCOS compliant master is being used 1 Set appropriate baud rate axis address and transmission level as outlined in Section 3 11 Setting up Intensity and Baud Rate Using SW4 2 Connect the fiber optic transmitter and receiver to the master On the PCE840 the light gray connector is the transmitter and dark gray is the receiver 3 Connect the motor power and feedback cables to both the motor and drive Connect either 120VAC or 240VAC to 1 1 and 1 2 on the PCE840 and 120 240 480V AC single or 3 phase to to TB1 3 4 and 5 and apply power to the drive 2 After going through the boot up sequence the status display on the drive should display solid 0 and the green LED should be flashing 6 At this point the SERCOS master should be able to initiate a phase run up to phase 2 Refer to the master documentation for information regarding phase run up The status display on the PCE840 should be a solid 2 if the phase run up was successful tu tatu a 830 40 User Manual 3 9 PCE840 Danaher Motion 3 4 2 800TOOLS PCE840 Setup Although a serial interface is not required to configure and run the PCE840 as a SERCOS slave the serial interface can be used as both a diagnostics tool a
38. 3 Select Velocity Command Source as the function of the input to be used to set serial velocity command 4 Click the Velocity Controller tab Set Offset Voltage as desired analog signal command OR provide appropriate incoming external analog signal with the appropriate voltage the latter may be preferred as it permits variable speeds to be achieved 5 Click the Edit Drive Configuration Online button Set CmdGain and CmdGain2 to the desired values for scaling and polarity 6 Set VelCmd2 to desired speed a setting of 0 rpm represents a STOP input A VelCmd2 is NOT tied to the analog input signal coming into the drive 2 54 PCE830 40 User Manual Danaher Motion PCE830 2 4 Selecting Modes of Operation The PCE830 has three distinct modes of controlling the motor shaft and three distinct sources for the shaft command Modes e Torque Control Velocity Control Position Control Commands Analog Command Incremental Digital Pulse Command Serial Port Command Mode of Operation Command Source Position Mode Predefined Moves Digital Inputs Position Mode Step and Direction Step and Direction Position Mode Electronic Gearing External Encoder Velocity Mode Analog Command Differential Analog Input Velocity Mode Frequency Command Frequency Pulse Velocity Mode Serial Command RS 232 RS 485 Torque Mode Analog Command Differential Analog Input Torque Mode Frequ
39. 31 3 31 Clutch brake 2 47 Comcoder 2 106 Command Gain Select 2 40 Configuring the drive 2 4 Connector Kits 4 2 Current Ripple 2 98 3 54 Cwlnh 2 31 3 31 D DAC Monitor 2 24 3 25 DAC Monitor List Table 2 25 3 26 Diagnostics 2 87 3 126 Digital Position Commands 5 6 Dimensions 5 11 E Emulated Encoder Output Signals 5 9 Enable Input 2 32 3 32 Encoder Feedback 2 104 Encoder I O Schematics 2 28 3 29 Encoder Inputs 2 27 3 28 Excess Position Error 2 44 External Regen 6 1 PCE830 40 User Manual Index F Fault Output 2 34 3 33 Fault Reset 2 31 3 31 Forced Air Cooling 1 2 Fusing 5 4 G Gearing On 2 41 Gearing w phase correction 2 49 H Hall sensors 2 106 Homing 2 46 I O Termination 2 13 3 16 Inertia 2 95 3 51 Input Power Specifications 5 3 Installing 800Tools 2 1 J J1 Serial Port 2 16 3 19 J2 Command I O 2 21 3 22 Analog I O Schematics 2 23 3 24 Encoder I O Schematics 2 28 3 29 Inputs 2 30 Output Schematic 2 35 3 34 Outputs 2 33 3 32 J3 Feedback 2 36 3 35 Jog Moves 2 53 M Manuals 4 2 Mappable I O 2 38 Model Identification 4 1 Modes of Operation 2 55 Motor Current Control 5 5 Motor Power 2 13 2 15 3 16 3 18 Mounting Drive 1 2 Mounting Guidelines 5 12 Mounting Specifications 5 11 Mechanical Outline 5 12 Move Done 2 45 Index N Nominal Frequency Response 5 10 Numbering System 4 1 Outl 2 3 2 33
40. 40 User Manual Danaher Motion PCE840 IDN 82 Positive Torque Limit Value Parameter Data IDN Unsigned Decimal Number Value of IImtPlus corresponds to the clockwise direction of the motor and is set in increments Conversion Scaling Factor 0 1 Data Length 2 bytes Units percent of peak current rating of the drive Minimum Value 0 Maximum Value 100 Access State Read Write by the Master in phases 2 4 IDN 83 Negative Torque Limit Value Parameter Data IDN Unsigned Decimal Number Value of IImtPlus corresponds to the counter clockwise direction of the motor and is set in increments Conversion Scaling Factor 0 1 Data Length 2 bytes Units percent of peak current rating of the drive Minimum Value 0 Maximum Value 100 Access State Read Write by the Master in phases 2 4 IDN 84 Torque Feedback Value Parameter Data IDN Signed Decimal Number Gives access to the instantaneous Torque Feedback Value of the PCE840 Conversion Scaling Factor 0 001 Amps 1000 1 Amps Data Length 2 bytes Minimum Value 32768 Maximum Value 32767 Access State Read only by the Master PCE830 40 User Manual 3 75 PCE840 Danaher Motion IDN 85 Torque Polarity Parameter Parameter Data IDN Binary Data Defines the Torque Polarity Parameters Bit Number Bit Setting 1 Inverted 0 Non Inverted Bit 0 Torque command value Bit 1 Additive Torque command value Must be zero Bit 2
41. 65536 counts rev 6 counts 1 10000 rev See InPosLimit in on line Help In any Operating Mode the Zero Speed Output can be used to indicate e Ifthe motor is near zero speed when ZeroSpeedThresh is near 0 e Ifthe motor is at speed when ZeroSpeedThresh is set near target speed 1 Click the Edit Drive Configuration OnLine button 2 Change ZeroSpeedThresh near but not past the desired target speed There is velocity ripple that can cause output bounce if the threshold is set too close to the target See ZeroSpeedThresh in on line Help PCE830 40 User Manual 2 45 PCE830 Danaher Motion Application Examples The following are a few application example setups for the PCE830 Homing Typically motion control applications require the machine to be homed to predefined starting position prior to performing its normal operations Generally a mechanical home switch or a marker pulse is referenced off an encoder to provide the homing reference position e A motor with a resolver drives a load through a 0 5 inch rev lead screw To home the machine the load is required to move at 30 in min in the clockwise direction This is in the direction toward a proximity switch which will be used as the home switch After the switch 15 triggered the load continues to move in the same direction until a marker pulse is seen In this case the marker pulse is from the resolver ResPos 0 The motor then decelerates to a complete sto
42. Command Procedure IDN used to initiate PROBE events on the PCE840 While this IDN is active all probe additional information To activate probing write 3 to IDN 170 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 3 Access State Read Write by Master in phases 2 4 3 88 PCE830 40 User Manual Danaher Motion IDN 185 Length Of The Configurable Data Record In The AT PCE840 Parameter Data IDN Unsigned Decimal Number Maximum number of bytes allowed in the AT as configurable data is 20 bytes Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65535 Access State IDN 186 Length Of The Configurable Data Record In The MDT Read only by the Master Parameter Data IDN Unsigned Decimal Number Maximum number of bytes allowed in the MDT as configurable data is 20 bytes Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65535 Access State Read only by the Master IDN 187 IDN List Of The Configurable Data In The AT Parameter Data IDN IDN ID Number List List of IDNs available for entry into the AT configuration list IDN IDN Description IDN IDN Description 40 Velocity Feedback 400 Home Switch 51 Position Feedback 32857 Resolver Position 84 Torque Feedback 32878 Digital Command Counts 130 Probe Value 1 Positive Edge 32879 Digital Command Frequen
43. Equipment Motor cable baluns reduce the noise the drive can introduce into the machine grounding resulting in an electrically quieter drive When motor cable baluns are correctly applied 1 they are sized for voltage and cable length such that they do not saturate substantial quieting is achieved Less Conducted Link Noise Motor cable baluns lower conducted line noise by reducing the rise time of current flowing in the motor cable shield An external motor cable balun may be required to meet CE when the motor cable is long Cooler Running Drive Motor cable baluns used with long cables provide some reduction in transistor heating and result in a cooler running drive They lower the transistor switching loss by raising the cable common mode impedance during the switching interval Pacific Scientific manufactures external motor cable baluns in different sizes and ratings New wide gap high energy baluns optimized for 480VAC drives like the PCE800 family in development Contact the factory for assistance PCE830 40 User Manual 1 9 Mounting and Installation Danaher Motion 1 2 Safe Operation of the Drive Prevent Damage to the Drive Emergency Stop Avoiding Unexpected Motion Avoiding Electrical Shock Avoiding Burns It is the machine builder s responsibility to insure that the complete machine complies with the Machine Directive EN60204 The following requirements relate directly to the servo controller
44. For example if IDN 45 1 IDN 46 3 then LSB weight of 41 0 001 RPM Conversion Scaling Factor 1 Data Length 4 bytes Units Motor velocity RPM 45 10 IDN 46 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read Write in phases 2 4 IDN 42 Homing Acceleration Parameter Data IDN Unsigned Decimal Number Sets the acceleration a home command is processed at For example if IDN 161 1 and IDN 162 3 then LSB weight of IDN 42 0 001 RPM Sec Conversion Scaling Factor 1 Data Length 4 bytes Units Motor velocity RPM Sec IDN 161 10 IDN 162 Minimum Value 1 Maximum Value 4 294 967 295 Access State Read Write in phases 2 4 PCE830 40 User Manual 3 69 840 IDN 43 Velocity Polarity Parameter Danaher Motion Parameter Data IDN Binary Data Defines the polarity of the velocity data IDNs 36 and 40 Bit Number Bit Setting 1 Inverted 0 Non Inverted Bit 0 Controls velocity command data Bit 1 Must be zero Bit 2 Controls velocity feedback data Bits 3 15 Reserved and must be zero Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0x0 Maximum Value 0x0005 Access State Read Write in phases 2 4 IDN 44 Velocity Data Scaling Type Parameter Data IDN Binary Data Defines the scaling type for the PCE840 For the PCE840 IDN 44 Bit
45. Home Mode Marker Home Mode Switch And Marker Home Mode Present Position N e PCE830 40 User Manual Danaher Motion Values for Communication Source 10063 CommsSrc Commsrc Resolver Commsrc Encoder Commsrc Hall Encoder Values for DriveStatus 10180 DriveStatus DriveStatus Unconfigured DriveStatus Faulted DriveStatus Enabled DriveStatus Disabled PCE830 40 User Manual gt PCE830 2 119 PCE830 Danaher Motion This page intentionally left blank 2 120 PCE830 40 User Manual Danaher Motion PCE840 3 PCE840 The PCE840 SERCOS contains all the hardware and firmware necessary to connect to a SERCOS network Wire the PCE840 according to the Wiring Diagram on page 11 3 This section defines switch settings and lists the SERCOS IDNs the PCE840 supports 3 1 Setting up Intensity and Baud Rate Using SW4 Definition Switch SW4 is used to select the SERCOS baud rate and the fiber optic light intensity power level Switch SW4 The following diagram shows the location of switch S4 oO N i 2 lt Intensity Level SWA 1 Fiber Optic Light Intensity Level ON High power transmission OFF Low power transmission default Baud Rate Baud Rate SW4 2 SW4 3 2 Mbaud default OFF OFF 4 MBaud OFF ON 8 MBaud ON OFF 16 MBaud ON ON PCE830 40 User Manual 3 1 PCE840 Danaher Motion 3 2 Setting
46. Maximum External Regen Duty Cycle Bus Capacitance Energy Absorption From 630V Nominal Bus PCES8x3 2 0 kW N A 2 kW N A 2 6 kW N A 5 1 Anus N A 97 10 kW 200W 6 35J Danaher Motion 8 5 4 3 kW 6 0 kW 4 6 kW 6 3 kW 5 6 kW 7 9 kW 11 0 Arms 15 5 Arms 97 20 kW 100W internal 400W external 6 70J See Section 6 Using External Regen for additional information 5 2 PCE830 40 User Manual Danaher Motion Specifications PCE8x3 8 5 Output Current Ripple Freq f 16 kHz 16 kHz Minimum Motor Inductance 1 1 5 mH 1 7 mH Maximum Motor Inductance 1 1 5H 1 7H Maximum Motor Power 50 m 164ft Cable Length 5 2 Input Power Specifications The drive is capable of direct line operation All units are fully isolated and do not require external isolation transformers The inrush current on the connection to the line is internally limited to a safe level for the drive There are no voltage selection or ranging switches required to operate within the specified voltage input ranges It is your responsibility to supply appropriate fuses or circuit breakers in the AC power motor power lines to comply with local electrical codes The control input power required is between 15 and 25 Watt The AC input motor power depends on output power and the losses in the power stage The control power input has a single UL CSA rated fuse in line with one of the AC line
47. Motion 2 5 2 Velocity Loop Settings Proportional Gain KVP Integral Gain KVI Anti Resonance Filters ARFO ARF1 2 70 The Proportional Velocity Loop Gain KVP is set based on two variables Pacific Scientific selects a default bandwidth BW of 75 Hz to reduce the unknown to one variable The system inertia is the second variable Pacific Scientific chooses a default system inertia that is twice the motor inertia Pacific Scientific assumes the load inertia and motor inertia are a 1 1 ratio as default This default configuration should cover applications that have a load motor inertia ratio from 0 1 to approximately 6 1 without user adjustment You are allowed to set inertia ratio in the New Configuration window of 800Tools If you set the inertia ratio too high the motor will buzz and vibrate the shaft The motor current feedback will oscillate from to peak and this can be seen with the softscope The Integral Velocity Loop Gain is set based on the default velocity BW of 75 Hz KVI is used to reduce steady state error from the velocity loop KVI removes velocity error when you are holding zero speed or running at constant speed Pacific Scientific sets KVI to a stable default value when the load inertia is less than a 6 1 ratio to the motor inertia When the load inertia is larger than 6 1 and the inertia ratio parameter is at default 1 1 you can see velocity overshoot and oscillation in the motor motio
48. Must be zero Bit 2 Position Feedback Data IDN 51 Bit 3 Must be zero Bit 4 Must be zero Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 5 Access State Read in phases 2 4 Write in phase 2 3 72 PCE830 40 User Manual Danaher Motion PCE840 IDN 76 Position Data Scaling Type Parameter Data IDN Binary Data Defines the position scaling type for the PCE840 Bit Number Bit Setting Bits 0 2 010 Rotational Scaling Bit 3 Parameter Scaling Bit 4 0 Degrees Bit 5 0 Reserved Bit 6 0 At the Motor Shaft Bit 7 0 1 0 gt Absolute Format Modulo Format IDN 103 Only Bit 7 may be changed by the Master while in phase 2 All other bits are Read Only Trying to change them results in a Service Channel error Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0x0A Maximum Value 0x8A Access State Read Write in phase 2 Read only in phase 4 IDN 77 Linear Position Data Scaling Factor Parameter Data IDN Unsigned Decimal Number position data IDNs IDNs 47 51 52 103 130 131 132 133 159 and 189 are scaled according to the formula IDN 77 10 IDN 78 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 1 Maximum Value 65535 Access State Read only by the Master PCE830 40 User Manual 3 73 PCE840 Danaher Motion IDN 78 Linear Position Data Scaling Exponent Parameter Data IDN Signed Deci
49. Negative numbers will be returned as the positive equivalent angle modulo 360 Conversion Scaling Factor 0 001 Data Length 4 bytes Units Electrical degrees Minimum Value 360 000 Maximum Value 360 000 Access State Read Write by the Master IDN 32827 EncMode Parameter Data IDN Signed Decimal Number Specifies the type of digital command expected at the incremental position command port EncMode Description 0 Selects Quadrature Encoder Signals 1 Selects Step and Direction Signals 2 Selects Up Down Count Signals 3 Ignores Signal Input and Locks DigitalCmdPosition Conversion Scaling Factor 1 Data Length 4 bytes Units Electrical degrees Minimum Value 0 Maximum Value 3 Access State Read Write by the Master 3 106 PCE830 40 User Manual Danaher Motion PCE840 IDN 32828 EncIn Parameter Data IDN Unsigned Decimal Number Allows the line count of input encoder to be defined Must be set when RemoteFB IDN 32824 1 or 2 Conversion Scaling Factor 1 Data Length 4 bytes Units Encoder line count Minimum Value 1 Maximum Value 65535 Access State Read Write in phase 2 Read only in phases 3 and 4 IDN 32829 ITThresh Parameter Data IDN Unsigned Decimal Number Allows the fault threshold for the IT Fault to be adjusted Pacific Scientific Model Family Minimum Value Maximum Value 84X 0 64 Conversion Scaling Factor 1 Dat
50. Number Bit Setting Bits 0 2 010 Rotational Scaling Bit 3 Parameter Scaling Bit 4 0 Revolutions Bit 5 0 Minutes Bit 6 0 At the Motor Shaft Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value Maximum Value OxA Access State 3 70 Read only by the Master PCE830 40 User Manual Danaher Motion PCE840 IDN 45 Velocity Data Scaling Factor Parameter Data IDN Unsigned Decimal Number velocity data IDNs 36 40 and 41 are scaled by the following formula 45 10 IDN 46 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 1 Maximum Value 65535 Access State Read Write by the Master IDN 46 Velocity data scaling exponent Parameter Data IDN Signed Decimal Number velocity data IDNs 36 40 and 41 are scaled using the following formula IDN 45 10 IDN 46 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 32768 Maximum Value 32768 Access State Read Write by the Master IDN 47 Position Command Value Parameter Data IDN Signed Decimal Number Allows the Master to have access to the instantaneous Position Command value of the PCE840 drive The value is scaled by IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units resolver or encoder counts 65536 IDN 79 depending on feedback device used Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Master Read Reads the instantaneous Position Command Value Master W
51. PCE830 40 User Manual 2 3 PCE830 Danaher Motion 2 1 5 Configuring Your Drive Procedure Click the New Configuration button in the main screen and the following dialog box appears Create New Configuration e Select motor type from the drop down list box add motor to the database please see Section 2 1 9 Editing The Motor e Select drive type from the drop down list box e Select mode of operation For example Velocity Mode Serial Command from the drop down list box e Enter an inertia ratio Inertia Ratio Load Inertia Motor Inertia e Click Next A Digital I O Wizard window appears 2 4 PCE830 40 User Manual Danaher Motion PCE830 WIZARD ojx Please Choose the Input Output you will use mDigital Input Active hi lo Analog Input Null Counterclockwise Inhibit v Clockwise Inhibit Command Gain Select Enable2 Fault Reset GearingOn Home Switch Input Position Mode Select StartMove RunStop Velocity Command Source 7 Move Select Bit Move Select Move Select Input Digital Output Active hi lo Brake Electrical Revs Enabled Excess Position Error p Fault Mechanical Revs Move Done Zero Speed Default du Default Setting You could select input port 4 a
52. PacSci 800Tools Communication Edit Utilities Help Edit Motor Database Upgrade FW Tuning Wizard Oscilloscope Diagnostics 6 Select Open File and locate the appropriate BIN file to download ioii Please open a file gt Download Cancel 7 After the file has been opened the following window appears 3 14 PCE830 40 User Manual Danaher Motion PCE840 10 11 3 5 Dpenning File is C Documents and Settings jiigutrMy Documents SERCOS 25 bin with ChkSum 20666168 goseececcesesococcesesocosoesosocoesccoeccoosoccosssoesssseseseg Open File Download If you check Erase Non volatile Memory all previously saved Non volatile parameters are lost If the upgraded firmware is known to contain changes scaling etc that have an effect on the NV IDNS it is recommended that the Non volatile memory be erased and then saved after the firmware upgrade is complete Click Download to begin the download The download will take approximately 6 minutes The status bar will show the progress of the download When complete the display on the PCE840 will show a small d for done Once the download is complete return the rotary switches to the desired address and cycle power on the drive If the Non volatile parameters where cleared during the download you can begin at the start of this section for a step by step procedure on how
53. Speed RPM KPP Hz Following Error revolutions 1000 10 0 27 2000 10 0 53 5000 10 1 33 1000 20 0 13 2000 20 0 27 5000 20 0 66 revolution In many electronic gearing applications such following The following error can easily exceed one complete motor errors are not acceptable real gears DO NOT have following errors Stepper systems also DO NOT have such errors Feed forward takes advantage of the fact that the PCE830 DSP knows the frequency of the encoder or step inputs and knows how fast the motor should be going at a given instant All or part of this velocity can be added to the velocity command to reduce following error If KVFF is set to 100 96 the steady state following error reduces to zero Overshoot Setting KVFF equal to 10096 can result in position overshoot Somewhat lower values may be required if this is problem set to 70 80 typically achieves the fastest step response with no overshoot Setting KVFF to less than 100 gives steady state following error when running at a constant speed PCE830 40 User Manual 2 101 PCE830 Danaher Motion 2 3 Advanced Velocity Loop Tuning The transfer function for the velocity loop compensation block is Continuous Time Transfer 4 Function 5 to 1 FY 2 Qz Approximation OEM s T G aan e VelErr 5 2 1 3 Definitions for the terms used in the equations above For ARx0 gt 0 both ro
54. The bus voltages comes up within 20 msec of AC bus power being switched ON Bus voltage can be monitored using the variable VBUS PCE830 40 User Manual Danaher Motion 2 6 1 FaultCode List amp PCE830 If FaultCode 6 the Fault LED blinks the value of FaultCode For example if FaultCode 2 the Fault LED blinks twice pausse for 2 seconds then repeats the sequence There is a 2 second pause between each Fault LED sequence Fault LED FaultCode Fault Description 1 Velocity feedback VelFB over speed 2 Motor over temperature Blinking 3 User 5V low 4 Continuous current fault 5 Drive over current instantaneous To further identify this fault see software variable ExtFault Fault LED FaultCode Fault Description 6 Control 12V under voltage 7 Not Assigned 9 Bus over voltage detected by DSP External Regen Fault 10 Not Assigned 11 Bus under voltage Only if VBus lt VBusThresh 12 Ambient temperature too low 13 Encoder alignment failed On 14 Software and non volatile memory versions not compatible 15 Hardware not compatible with software version 16 Unconfigured drive fault 17 Two AlInNull events too close together 18 Position following error fault 19 Parameter memory error 20 Initialization fault 21 Drive over temperature 22 Resolver Fault To further identify this fault se
55. Tools double click on the icon and the following window appears PCE830 40 User Manual 2 1 PCE830 Danaher Motion 800Tools PacSci 800Tools Communication Edt Utilities Hel Main Menu New Configuration Upload C Edit File Ig Edit Online v Diagnostics Drive elocity Mode Command Status Axis 255 Unconfigured estar AEA oj Pinhuaxie W Microsoft Word 800 005 2 1 3 Getting Around in 800Tools 800Tools is a standard Windows application and the normal cursor movement keys operate the same way as in all windows applications lt 1 gt gives context sensitive on line help NOHARA 1 13PM PCE830 40 User Manual Danaher Motion PCE830 2 1 4 Configuring Your System Applying AC Carefully check all wiring connections and ensure that J2 37 is not connected to Power J2 40 Apply AC power to your controller Serial Port To specify the PC serial port that is connected to the PCE830 1 Select Communication Port Axis and the following dialogue box appears Comm Port and Axis Selection x Selection Axis Address f Automatic Detected C Port 2 Select Axis fi Porta Range 1 254 Cancel Ok Test 2 Specify the serial port that a drive is connected with and the axis address of the drive If you do not know the axis address choose Automatic Detected 3 To verify your settings click Test
56. Torque feedback value Bits 3 15 Reserved and must be zero Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 5 Access State Read Write in phase 2 Read only by the Master in Phases 3 4 IDN 88 Receive To Receive Recovery Time Parameter Data IDN Unsigned Decimal Number Required time for the PCE840 between the end of the MDT and the beginning of the next MST Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 350 Maximum Value 350 Access State Read only by the Master IDN 89 MDT Transmission Starting Time Parameter Data IDN Unsigned Decimal Number Value sent by the Master to indicate the starting time in uSec of the MDT This value is calculated and written by the master during phase 2 Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 1 Maximum Value 64000 Access State Read Write by the Master in Phase 2 3 76 PCE830 40 User Manual Danaher Motion PCE840 IDN 90 Command Value Proceeding Time Parameter Data IDN Unsigned Decimal Number Value read by the Master indicating how soon after the MDT the PCE840 can make the received data available for usage Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 1 Maximum Value 64000 Access State Read only by the Master IDN 95 Diagnostic Message Parameter Data IDN Text Data String The diagnostic messages are generated by the drive as text and stor
57. Ye _ ONLY IF J2 _ _ _ 14145406 250mA SOURCES ENCODER POWER 171 5 SUPPLY RETURN PCE830 40 User Manual 2 29 PCE830 Auxiliary Analog Inputs J2 28 29 Inputs 1 6 J2 31 32 33 34 35 36 2 30 T External 24V T Danaher Motion Not Used These six optically isolated connections are user programmable discrete 24 V inputs These inputs share a floating return J2 38 with the Enable Input J2 37 A minimum drive capability of 4 mA 1 required to fully power the opto The user must supply 10V to 30V to these inputs 5 V inputs CANNOT be used Each of the inputs is set and read by software every 2 mSec Each one can be configured to be any of the available functions and the configuration can be changed on the fly via digital communications Your default configuration is stored in the non volatile memory The present state of each of these lines can be read via digital communications The logic polarity of these signals is also software programmable That is an input can be defined to be active low or active high For edge triggered functions the active edge is programmable R226 2 2K 2 37 TO ENABLE R66 CONTROL 1K E LOGIC 2 38 INPUT RTN TLP121GB Logic State InpX with respect to Input RTN Low to 42V Undefined 2V to 10V High 10V to 30V PCE830 40 User Manua
58. a falling edge of the Probe 2 signal has occurred The position is either in resolver or encoder counts depending on the feedback device used to close the position loop This value is scaled using IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units Probe Value IDN 79 65536 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read only by the Master IDN 134 Master Control Word Parameter Data IDN Unsigned Decimal Number Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65536 Access State Read only by the Master IDN 135 Drive Status Word Parameter Data IDN Unsigned Decimal Number Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65536 Access State Read only by the Master 3 84 PCE830 40 User Manual Danaher Motion PCE840 IDN 140 Controller Type Parameter Data IDN Text Data String Allows the Master to read a TEXT description of the drive model number PCE843 Conversion Scaling Factor 1 Data Length 1 Byte data Variable length IDN 142 Application Type Parameter Data IDN Text Data String Allows the Master to read a TEXT description of the Application Pacific Scientific Drive Conversion Scaling Factor 1 Data Length 1 Byte data Variable length IDN 143 Application Type Parameter Data IDN Text Data String Allows the Master to read a TEXT description of the SERCOS specification which the PCE840
59. and supplies PCE830 40 User Manual 2 23 PCE830 DAC Monitor J2 4 5 1 2 Outputs DAC MON FROM 2 24 Danaher Motion These analog outputs are general purpose monitor points The output range is 5 5V with a resolution of 11V 65536 0 168 mV The source impedance is 1 which yields a maximum short circuit to RTN current of 5 mA These outputs are updated every 250 mS There is a 2 5 kHz 4 8 kHz and a 9 6 kHz analog Low Pass Filter on these outputs Each DAC Monitor can be mapped by software to be one of a number of internal variables The scale factor and the frequency of a single low pass filter pole are software adjustable on each output by the DM1Gain DMIFO and DM2Gain DM2FO0 software parameters for DAC Monitor 1 and 2 respectively Variables marked with a are not range clamped and are allowed to wrap around when the signal exceeds the output DAC s voltage range The other variables will clamp at maximum when they exceed the analog voltage range The table on the following page lists the defined signal mappings C102 2200pf fe 4 9kKHz R194 FULL SCALE 5 5 0 3 32K fc 2 5kHz AND 8 6kHz PCE830 40 User Manual Danaher Motion PCE830 DAC Monitor List Table DMxMap Variable Description DAC Out Units DMxGain 1 0 AnalogOutx Actual Analog Output Command V V 1 Vel
60. continued PCE840 32820 InpMap4 32821 InpMap5 32822 InpMap6 32823 EncInFilt 32824 RemoteFB 32826 CommOff 32827 EncMode 32828 Encoder Input 32829 ITThresh 32830 StopTime 32831 VBusThresh 32832 VelLmtHi 32833 VelLmtLo 32835 CoastTime 32836 CommEnbl 32837 Motor 1 Name 32838 Motor 2 Name 32840 Kvff 32841 ARZO 32842 ARZI 32843 ARFO 32844 ARFI 32845 Firmware version 32846 Encoder Data Scaling Method 32847 Encoder Modulo Value 32853 CommSrc Commutation Source 32857 ResPos Resolver Position 32858 Last Fault 32859 Last ExtFault 32860 OutMapl 32861 OutMap2 32862 OutMap3 32863 OutMap4 32866 Analog Input Voltage Offset ADOffset 32870 Motor Protection Threshold Value I 2 tFilt 32871 1 Motor Protection Low Pass Filter Value I 2tF0 32872 14 Motor Current Value 32875 State of Hall Sensors HallState 32876 Offset Angle for Hall Sensors HallOffset 32878 Digital Command Counts DigitalCmd PCE830 40 User Manual 3 7 840 IDNs continued 3 8 Danaher Motion 32879 Digital Command Frequency DigitalCmdFreq 32880 AnalogOutl 32881 AnalogOut2 32882 Analog Current Limit Value AnalogILmt 32883 Analog Current Limit Gain AnalogILmtGain 32884 Analog Current Limit Filter AnalogILmtFilt 32885 Analog Current Limit Offset AnalogILmtOffset 32886 Actual Positive Current Limit ActualILmtPlus 32887 Actual Negative Current Limit ActuallILmtMinus 34817 PCE840 Inpu
61. continuous current fault trip dependent on the measured heat sink temperature to limit the continuous output current Control voltage under voltage detection The user 5V output is short circuited to I O RTN protected The user 24V output is short circuit protected All control outputs are short circuit protected to I O RTN When a drive is powered up without valid parameters the power stage cannot be enabled and no damage occurs to the drive 3 126 PCE830 40 User Manual Danaher Motion Fault Generation Fault Code List PCE840 The following sequence occurs when the protection circuits generate a fault e The fault source is latched e The output stage is disabled e The Fault mappable output function is activated e The LED indicates the appropriate fault code Faults are cleared by activating the Fault Reset input or by turning the 120 240V AC Control Power OFF and ON again The following table lists the 840 codes FaultCode Fault Description Hex Dec 0 1 1 Velocity feedback VelFB over speed 0x2 2 Motor over temperature 0x3 3 User 5V low 0 4 4 Continuous current fault 0x5 5 Drive over current instantaneous 0x6 6 Control 12V under voltage 0x7 7 Not Assigned 0x9 9 Bus over voltage detected by DSP External Regen Fault OxA 10 Not Assigned OxB 11 Bus under voltage Only if VBus VBusThresh
62. g Max Step Freq 800 200 100 or 50 kHz PCE830 40 User Manual Danaher Motion Velocity Loop Maximum Stable Bandwidth Update Period Range Command Resolution Velocity Loop Compensation Parameters Range Depends on Ipeak KVP Resolution KVI Range KVI Resolution ARFO0 Range ARFI Range ARZO Range ARZI Range CMDGAIN Range CMDGAIN Resolution Specifications gt 400 Hz 250 uSec 0 to 21 000 RPM 0 001 RPM 0 to 12 6 Ipeak 1 rad sec 16 bit 0 to gt 200 Hz 16 bit 0 01 to gt 1 5 Hz 0 01 to gt 1 5 Hz 0 to gt 1e5 Hz or off 20 to gt 1e5 Hz or off 0 to 315 000 RPM V 0 to 10 Ipeak V 2 16 bit mantissa ARx0 set to a negative number allows complex poles zeros In this case ARx1 becomes the and the corresponding ARx0 is the frequency in Hz PCE830 40 User Manual Specifications Position Loop Maximum Stable Bandwidth Update Period Position Range Position Error Range Command Resolution Position Loop Compensation Parameters KPP Range KPP Resolution KVFF Range KVFF Resolution General Max Delay AC Line To Control Supply On Max Delay AC Line To Fully Operational Environmental Storage Temperature Humidity non condensing Altitude Danaher Motion gt 100 Hz 1 mSec 0 to 32768 Rev 0 to 4500 Rev 2 16 Rev 0 33 arc min 0 Hz to gt 150 Hz 16 bit 0 to 199 9 16 bit 1 0 Sec 2 0 Sec 40 to 70 10 90 1500 m 5000 feet 5 4 Resolv
63. if this IDN is not performed and the Master goes to phase 3 the PCE840 will declare a fault and go to phase 0 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 3 Access State Read Write by the Master in phase 2 IDN 128 Communication Phase 4 Transition Check Command Data IDN Binary Data Command Procedure IDN used to check whether the PCE840 is ready to proceed into phase 4 This IDN must be performed and successfully completed prior to going into phase 4 If all IDNs identified in IDN 19 have not been completed or if the waveshape is incomplete or if this IDN is not performed and the Master goes to phase 4 the PCE840 will declare a fault and go to phase 0 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 3 Access State Read Write by the Master in phase 3 3 80 PCE830 40 User Manual Danaher Motion IDN 129 Manufacturer Class 1 Diagnostic PCE840 Parameter Data IDN Binary Data The data in this IDN contains the current manufacturer specific fault code If no fault is present in PCE840 this value will be zero The low byte of the data is the Fault Code that is displayed on the PCE840 drive The high byte of the data is the Extended Fault Code If the fault code has an associated extended fault code it will be displayed here Most fault codes do not have extended fault codes
64. inductance causing output over current faults KIP or KII improperly set causing excessive output current overshoots PCE830 40 User Manual 2 91 PCE830 Danaher Motion Fault LED ON Fault LED remains ON when FaultCode gt 6 FaultCode Possible Cause 6 Insufficient control AC voltage on 1 1 to 1 2 External short on signal connector Internal drive failure 7 Not Assigned 9 Disconnected external regeneration resistor on TBI External regeneration resistor ohmage too large yielding Bus OverVoltage fault External regeneration resistor short circuit Motor AC power input voltage too high 10 Not Assigned 11 Check the measured bus voltage VBus and the fault threshold VBusThresh to make sure they are consistent 12 Ambient temperature is below drive specification Drive s internal temperature sensor has a wiring problem 13 Encoder Alignment failure See ExtFault for additional information 14 Not Assigned 15 Attempt to upgrade the drive s software unsuccessful Contact factory for upgrade details Resolver wiring error Remove J2 and J3 connectors Turn AC power OFF and ON again If FaultCode 2 correct resolver excitation wiring Internal failure Return to factory for repair 16 Unconfigured drive Red and Green LEDs blinking after power up was fully configured with the drive motor power enable act
65. inertia reflected to the motor shaft motor inertia Ib in s velocity loop bandwidth Hz torque constant effective Problems With It would seem from the above that setting KVP is simply a matter of increasing its High Load value to compensate for load inertia Unfortunately the following problems often Inertia interfere particularly when the load inertia is large compared with the motor s inertia 1 Mechanical resonance between motor and load cause high frequency oscillation 2 Backlash between motor and load effectively unload the motor over a small angle Within this small angle the increased bandwidth results in oscillation 3 Ripple in the velocity feedback signal results in large motor ripple current if KVP is large As a general rule any system with KVP set higher than 5 times the medium bandwidth setting requires adjustment to the default ARFO and ARF1 settings Motor plus resolver inertia 0 00039 Ib in sec2 for the 22 motor 15 found in the catalog 800Tools motor data screen is found in the catalog as Krnws 4 31 Ib in amp or by using the Back EMF Constant 31 2 Volts KRPM shown on 800Tools motor data screen in the following formula Kr nus Ke rms 1 06 8 volts krpm Kr nus 0 707 3 52 PCE830 40 User Manual Danaher Motion Resonance Anti resonance Filters IDN 32841 IDN 32842 IDN 32843 PCE840 Mechanical resonance is c
66. inputs PCES800 Control Power Supply Input Voltage Range RMS 85VAC to 265V AC 47 to 440 Hz single phase or 130VDC to 370VDC Ride Through Time 90VAC 50 Hz gt 0 7 50 Hz cycle For AC Line Drop 120VAC 60 Hz gt 2 1 60 Hz cycles 240VAC 60 Hz gt 13 3 60 Hz cycles PCE830 40 User Manual 5 3 Specifications PCES800 Motor AC Power Supply Danaher Motion Model Voltage Range Transformer Maximum Number RMS Phases Suggested AC Line PCE8x3 323VAC to 528 VAC 3 2to4kVA 100 8 5 323VAC to 528 VAC 3 6 to 12 300 Maximum AC Line is specified to limit the mains surges to the drive Bus Voltage nominal 380VAC 400V AC 480VAC 507VDC 533VDC 640VDC 800 Inrush Current amp Fusing Model Inrush Peak Inrush Recommended Line Fuse Number Current cold PulseWidth Part Number Manufacturer Rating Size PCE8x3 175A 1 msec KTK 20 Bussmann 20A 600V AC 1 5 x 0 41 8 5 175 1 5 msec KTK 30 Bussmann 30A 600V AC 1 5 x 0 41 5 4 PCE830 40 User Manual Danaher Motion Specifications 5 3 Performance Characteristics the specified operating ambient temperature and over the specified operating line voltage Unless otherwise specified the below specifications are worst case limits and apply over Motor Current Control Motor Phase Current Waveform Motor
67. its encoder alignment check upon power up AND assertion of the hardware enable For additional information on incremental encoder alignment consult the online help of the PCE830 software Encoder Alignment Overview or contact Pacific Scientific Applications Engineering for assistance PCE830 40 User Manual 2 105 PCE830 Danaher Motion 2 8 2 Configuring the PCE830 for a Motor With a Comcoder Using a To wire up a comcoder hall encoder for primary feedback on the PCE830 perform the Comcoder following l Connect the comcoder as shown in the diagram below PCE830 HALLS 1 HALLS 2 MOTOR HALLS 3 W COMCODER 1 0 ENCODER INPUT CHANNEL ENCODER INPUT CHANNEL A ENCODER INPUT CHANNEL 15 ENCODER INPUT CHANNEL B J3 e ea A 1 2 3 4 5 7 8 2 Click the Edit Drive Configuration Online button and select the variable HallState 3 With the motor disabled rotate the shaft slowly in the clockwise direction Verify that HallState repeats the following sequence 6 4 5 1 3 2 4 IfHallState does not sequence in this manner swap any two hall sensor phases and repeat step 3 5 Click the Create New Configuration button Select the proper motor drive and desired mode of operation Click Next 6 Click the Feedback tab Select Comcoder Hall Encoder as the Commutation Source 7 Enter the correct encoder line count 8 Click Save to File a
68. maximum motor speed is not too high a drive typically does not need regen because the rotational energy is handled by the drive caps and motor resistance The following example uses a PCE8x3 with a simple inertia load If the deceleration time from very high speed to zero speed at full torque takes 100 msec the peak shaft power at the beginning of the deceleration is estimated at about 4 2 kW at 480V AC mains The shape of the power pulse is triangular The rotational energy to be absorbed is 210 joules 0 5 x 4 200 watts x 100 msec The caps in the PCE8x3 are rated to absorb 35 joules The copper loss of a medium size motor operating at the drive continuous rating is often in the 40 watt range At x3 pk current the motor copper loss is in the 360 watt range In 100 msec the motor copper for a full current deceleration absorbs about 36 joules 7360 watts x 100 msec The balance of 139 joules 210 joules 35 joules 36 joules is dissipated in the regen resistor Now reduce the max speed by half The rotational energy is reduced by four to 53 joules The deceleration time is reduced by two so motor copper energy loss is reduced by two to 18 joules The bus cap absorption energy remains at 35 joules As a result the 53 joules of rotational energy is handled by the copper loss and bus caps without the need of a regen resistor If the max speed was reduced to about one third the cap alone could handle the rotational energy
69. min 250 rpm VelCmd2 is a storable serial velocity command that will be used to set the speed for Velocityl Velocity2 and Velocity3 will obtained by use of the analog input on the PCES830 Either the user can provide their own external analog signal OR make use of the drives ability to produce an analog offset using ADOffset For this example ADOffset is set to 1 volt This is used to calculate the appropriate scaling factor to scale this analog signal into a speed reference Velocity2 1000 rpm CmdGain krpm V AnalogIn V ADOffset V CmdGain 1 0 krpm 1 0 V 1 0 krpm V Velocity3 250 rpm CmdGain2 krpm V AnalogIn V ADOffset V CmdGain2 0 25 krpm 1 0 V 0 25 krpm V If an external analog signal is provided to vary the analog input then a wide range of jogging speeds are possible PCE830 40 User Manual 2 53 PCE830 Danaher Motion Motion Profile Velocity Command Gain Select inactive RPM Determined 1000 DecelLmt rpm s so Y 250 N Determined by AccelLmt rpm s Command Gain Select active Velocity Command Velocity Command Source inactive Source active Procedure 1 Create a new configuration and select Velocity Mode Analog Command as the mode of operation 2 Click the Digital tab Select Command Gain Select as the fucntion for the input to be used to select scaling polarity of incoming analog command signal
70. pass filtered in hardware at 10 kHz This only applies if a Hall feedback sensor is being used These connections provide the resolver excitation output 9 2V rms at 6510 42 Hz 75 mA rms maximum load These outputs are fully short circuit protected to COMMON or to each other at room temperature 25 C but at ambient temperatures above 50 C shorts longer than 5 minutes may cause damage These two inputs are intended to connect to a positive temperature coefficient thermostat or normally closed thermostatic switch imbedded in the motor windings When the resistance between these terminals becomes greater than 6 2 the drive will fault and indicate a Motor Over Temperature fault This circuit directly interfaces with Pacific Scientific s standard motor PTC RTN is connected to RTN PCE830 40 User Manual Danaher Motion PCE840 Encoder Inputs CH B 43 12 13 14 15 These differential inputs expect quadrature encoder feedback signals These two input pairs are differential and are detected by 26LS32 type RS 422 compatible line receivers As differential inputs the recommended common mode range is 7V with respect to I O RTN and the guaranteed differential voltage logic thresholds are 0 2V Recommended drivers should be able to source and sink gt 3 mA to from these inputs 220y4F 261532 CH IN 2204F TO DECODE 13 14 1K ur Scout CH BIN
71. settled 21 Encoder alignment test failed 22 Encoder alignment motion overflow fault 23 Hall Commutation invalid configuration 24 Hall Commutation overspeed 25 Hall Commutation invalid hall state 26 Hall Commutation invalid hall transition 27 I t Drive 28 I 2 t Motor 29 DP RAM Test A 30 DP RAM Test 5 3l DP RAM Test Run 1 32 DP RAM Test Run 0 33 DP RAM Test C 65 Data Read Only 66 Data Bounds Error 67 Execute no such command 68 RT not implemented 69 FC not implemented 3 128 These fault states CANNOT be reset with the Fault Reset function They require the line control power to be turned OFF and ON again PCE830 40 User Manual Danaher Motion PCE840 3 9 1 Troubleshooting A table of faults and their possible causes is listed below FaultCode Possible Cause Hex Dec 0 1 1 Loose or open circuit wiring to the resolver feedback connector J3 Actual motor speed exceeded 1 5 Max Of VelLmtLo or VelLmtHi or 21 038 RPM which is the over speed trip level For Encoder velocity feedback RemoteFB 2 check that EncIn is set properly 0x2 2 Loose or open circuit wiring to motor PTC thermal sensor J3 8 J3 9 High ambient temperature at motor Insufficient motor heat sinking from motor mounting Operating above the motor s continuous current rating 0x3 3 Short circuited wiring on the output J2 25 0 4 4 Mechanically jammed m
72. shown Pinouts vary among computer manufacturers Check the hardware reference manual for your machine before wiring Cabling A 6 foot 1 8 m RS 232 Cable with 9 pin connectors and a 9 pin to 25 pin adapter Diagram is available from Pacific Scientific The Pacific Scientific order number is RS 232 5600 RS 232 RXD RS 232 TXD 9 CONTACT FEMALE D SUBMINATURE CONNECTOR TYPICAL CABLES 9 PIN FEMALE 9 PIN MALE Shielded wiring is recommended for the serial communications cable to minimize potential errors from electrical noise PCE830 40 User Manual 2 17 PCE830 Danaher Motion 2 2 2 2 RS 485 RS 422 CONNECTIONS RS 485 Up to 32 PCE830s can be connected in parallel to a multidrop master The PCE830s RS 422 must each have a unique address set in software Once the address is set the Axis Connections Selection function in 800Tools must be used to select the designated axis address Then either the RS 232 or RS 485 link can be used to communicate with the selected axis For example the RS 232 link can be used to completely setup and test an individual axis before connecting it into the multi axis configuration RS 485 RS 422 connections to J1 are shown below A multidrop interconnection diagram showing multiple axes connected to a single host is also shown Connection Diagram RS 485 TXD RS 485 RXD RS 485 TXD RS 485RXD COMMON 9 CONTACT FEMALE D SUBMINIATURE RS 485 TXD
73. supports the following bits in this IDN Bit Number Description Bits 0 2 Phase Indicates current phase Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 0x0007 Access State Read only by the Master IDN 15 Telegram Type Parameter Parameter Data IDN Binary Data This IDN indicates which set of IDNs are to be supported in the AT MDT The PCE840 supports the following parameter configurations 0 7 inclusive Configuration 0 No AT or MDT IDNs Configuration 4 IDN 47 Position Command in the MDT IDN 51 Position Feedback in the AT Configuration 7 User defined AT and MDT Refer to IDNs 16 and 24 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 7 Access State Read Write in Phase 2 Read only in Phase 3 and 4 3 64 PCE830 40 User Manual Danaher Motion PCE840 IDN 16 Configuration List Of AT Parameter Data IDN IDN ID Number List List of IDNs which are to be included in a User Defined AT The data contained in this list is governed by the following restrictions Each must be included in the list of Valid AT IDNs Refer to IDN 187 Total number of AT IDNs must be 8 or less Total number of bytes transferred must be 20 or less This must be written when IDN 15 7 Custom Telegram Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read Write in Phase 2 Read on
74. the RTN pins must be connected to Earth ground Pacific Scientific recommends making this connection at an earth ground point in the cabinet reserved for single point grounding of all I O Returns drives and supplies PCE830 40 User Manual Danaher Motion PCE840 DAC Monitor These analog outputs are general purpose monitor points The output range is J2 4 5 1 2 Outputs DAC MON PCE830 40 5 5V with a resolution of 11V 65536 0 168 mV The source impedance is 1 kQ which yields a maximum short circuit to I O RTN current of 5 mA These outputs are updated every 250 mS There is a 2 5 kHz 4 8 kHz and a 9 6 kHz analog Low Pass Filter on these outputs Each DAC Monitor can be mapped by software to be one of a number of internal variables The scale factor and the frequency of a single low pass filter pole are software adjustable on each output by the DM1Gain DMIFO and DM2Gain DM2FO0 software parameters for DAC Monitor 1 and 2 respectively Variables marked with a are not range clamped and are allowed to wrap around when the signal exceeds the output DAC s voltage range The other variables will clamp at maximum when they exceed the analog voltage range The table on the following page lists the defined signal mappings C102 2200pf fe 4 9kKHz FROM R184 DAC 3 32K FULL SCALE 5 5 0 fc 2 5kHz AND 8 6kHz User Manual 3 25 PCE840 Danaher Motion
75. the command source can be switched between VelCmd and VelCmd for e Clutch Brake with holding torque if VelCmd2 0 e Velocity preset select if VelCmd2 is non zero In Position Mode the command source can be switched between VelCmd and VelCmd2 for Switching between electronic gearing follower and velocity preset command Click the Edit Drive Configuration OnLine button Change VelCmd2 to the desired preset value Un Activate the input mapped for Velocity Command Source to select the VelCmd2 value See VelCmd VelCmd2 BIKType Operation Mode in on line Help PCE830 40 User Manual Danaher Motion PCE830 Outputs Table following table lists the mappable output functions available for the Digital and OutMapX Relay Outputs Mappable Output Function Description Brake default Indicates when the motor is not powered and a mechanical brake is needed to hold the motor Electrical Revs Square wave whose frequency is equal to the motor electrical frequency Enabled Indicates whether power can flow to the motor Excess Position Error Asserted when there is excess following error for an extended period of time following error limit is defined by PosErrorMax Fault default Indicates whether the drive has faulted and is disabled Mechanical Revs Square wave whose frequency is equal to the resolver s electrical frequency which is typically equal to the mech
76. the cyclic channel PCE830 40 User Manual 3 41 PCE840 Danaher Motion 3 6 2 Probe Registration Functionality In a typical application probes are used to define the position of a part or the depth of a hole or cut When the probe touches the surface the switch closes and the position data is latched Position registration uses the closure of a proximity switch photo eye or similar device to signal the latching of position data On the PCE840 during probing and registration position latching is perfomed by the drive Guidelines The PROBE 1 function must reside on Inp4 J2 34 when probe registration is in use The PROBE 2 function must reside on Inp5 J2 35 when probe registration is in use The two probe functions work identically but require additional setup prior to use when compared to other Input functions When RemoteFB lor2 IDN 32824 Probe 2 cannot be used to latch position Probe 2 is used only as the marker pulse input for homing Probe 1 can be used to latch position encoder position When RemoteFB 0 Probe 1 and Probe 2 can be used to latch position resolver position Probe Table Below is a list of IDN s related to the Probe functionality IDN Description Function 130 Probe 1 Positive Edge Returns Probe 1 Positive Edge Data 131 Probe 1 Negative Edge Returns Probe 1 Negative Edge Data 132 Probe 2 Positive Edge Returns Probe 2 Positive Edge Data 1
77. the resulting motion at the end of any mechanical linkages that typically matters not the response at the motor shaft It would seem from the above that setting KVP is simply a matter of increasing its value to compensate for load inertia Unfortunately the following problems often interfere particularly when the load inertia is large compared with the motor s inertia 1 Mechanical resonance between motor and load cause high frequency oscillation 2 Backlash between motor and load effectively unload the motor over a small angle Within this small angle the increased bandwidth results in oscillation 3 Ripple in the velocity feedback signal results in large motor ripple current if KVP is large As a general rule any system with KVP set higher than 5 times the medium bandwidth setting requires adjustment to the default ARFO and ARF1 settings Motor plus resolver inertia 0 00039 Ib in sec2 for the 22 motor 15 found in the catalog or 800Tools motor data screen is found in the catalog as Krnws 4 31 Ib in amp or by using the Back EMF Constant 31 2 Volts kKRPM shown on 800Tools motor data screen in the following formula Kr nus 1 06 8 volts krpm Kr nus 0 707 2 96 PCE830 40 User Manual Danaher Motion PCE830 Resonance Anti resonance Filters Procedure Backlash Mechanical resonance is caused by springiness between motor inertia and load inertia Thi
78. the written data would be placed into the output port the high byte is ignored the input bit IDNs 34817 34822 and output bit IDNs 34833 34836 can be used through the use of realtime control status bits Use Control Bit IDNs 301 or 303 to update up to two output points within the cyclic channel update time Writing an output bit IDN into either of the two allocation of control bit IDNs will cause the value of the realtime control bit in the MDT to be placed into that output bit Example write one of the output bit IDNs 34833 34836 into IDN 301 or IDN 303 Then use the output bit IDN Ex 34833 to set the state of the output point It will be updated within the cyclic channel update time Use Status Bit IDNs 305 or 307 to update up to two input points within the cyclic channel update time Writing an input bit IDN into either of the two allocation of status bit IDNs will cause the value of the input bit to appear in the realtime status bit returned in the AT Example write one of the input bit IDNs 34817 34822 into IDN 305 or IDN 307 Then use the input bit IDN Ex 34817 to read the state of the input point It will be updated within the cyclic channel update time Writing 34817 PCE840 Input Bit 1 to IDN 305 Allocation of Realtime Status Bit 1 will cause the value of Input Bit 1 to appear as Status Bit 1 in the cyclic AT status word Writing 34822 PCE840 Input Bit 6 to IDN 307 Allocation of Realtime Status Bi
79. time transfer function is converted to the discrete time domain by a backward Euler mapping Function 1 27 1 Sum 250 usec where Mode Selection and Command Processing Zh Da 901 1304 MATEL 034 JasuoQdwv doo uonisog pur ja 23S Wdi SISPUUDIaA TPUDIBA 30A ujBojeuy doo 1d yoojoA Hf 1 295 073 s p T p m mM 2 3 30941919 ZH lt 53s au SCALE uegpug el JU Say lt yeas 8 3 59 PCE830 40 User Manual PCE840 Danaher Motion 3 8 IDN Attributes This section contains a list of Identification Numbers IDNs in numerical order for the PCE840 3 8 1 SERCOS Specific Parameters IDN 1 Control Unit Cycle Time Parameter Data IDN Unsigned Decimal Number Sercos Cycle Rate This is the update rate for AT and MDT IDNs This value must be at least 1000 1 mSec for Velocity mode and 2000 2 mSec for Position mode operation The maximum value is 64000 64 mSec Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 01000 Maximum Value 64000 Master Read Phase 2 Always reads 0 64 mSec Current value Master Read Phase 3 or 4 Value written to this drive while in Phase 2 Master Write This
80. to identify the waveshape downloaded to the PCE840 controller By convention the 4 ASCII character abbreviation of the motor name is converted to an integer and downloaded along with the waveshape For example if this variable is 0x53494E45 S 0x53 T 0x49 N Ox4E 0x45 Used to assign a label to Wave Shape Generation Table created Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 0 Maximum Value OxFFFFFFFF Access State Read Write in Phase 2 Read only in Phase 3 and 4 PCE830 40 User Manual 3 109 PCE840 IDN 32838 Motor 2 Name Danaher Motion Parameter Data IDN Binary Data The Motor variable is a 32 bit long unsigned long integer which is used to identify the waveshape downloaded to the PCE840 controller By convention the 4 ASCII character abbreviation of the motor name is converted to an integer and downloaded along with the waveshape Used to assign a label to Wave Shape Generation Table created Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32840 Kvff 1 4 bytes 0 OxFFFFFFFF Read Write in Phase 2 Read only in Phase 3 and 4 Parameter Data IDN Unsigned Decimal Number Allows following error to be reduced when running at a constant speed When the drive is commanded to run at a constant speed kvff 1000 will reduce the steady state following error to zero but will cause overshoot A value of 700 1s typic
81. unbalanced The phase to PE voltage of balanced mains measures about 57 7 of the line line voltage so 380 400 480Vgys mains measures 220 231 277 nominal meeting the EN50178 requirement for the PCE800 series of 300Vems max 380 400 480 Delta or WYE Unearthed Mains 1 4 5 6 Phase to neutral PE voltages of unearthed WYE or delta mains often measure balanced and below the 300Vgys requirement of EN50178 However the lack of neutral point earthing means the balance is not as well maintained as with an earthed neutral Pacific Scientific is unable to ensure the unearthed 380 400 480VAC mains are compatible with CE safety standard EN50178 You are advised to consult your CE safety engineer about unearthed mains For reference the PCE830 40 human safety barrier internal spacings are 5 5mm 380 400 480 Delta WYE Earthed Unbalanced Mains 1 4 5 6 Some three phase mains are earthed in an unbalanced manner One example is a delta or WYE with one phase voltage earthed 480VAC mains of this type measure phase to PE 480VAC 480VAC and Another example is a delta mains with the mid point of one delta leg earthed 480VAC mains of this type measure phase to PE 240VAC 240V AC and 416V AC Since the phase to PE voltage of these mains exceeds the EN50178 design limit for PCE830 40 creepages and clearances the PCE800 series is not rated for operation on these mains PCE830 40 User Manual Danaher Motion Control P
82. up Serial Addresses Using Switches SW5 and SW6 The two hexademical rotary switches SW5 and SW6 are used to set the axis address for each PCE840 on the SERCOS ring Definition Procedure Switch SW5 and SW6 The following diagram shows the location of switch SW5 and SW6 The view shows the location of the switches looking at the front of the PCE840 A Each PCE840 must have a unique serial address The diagram below shows the SW5 and SW6 switch settings The 8 bit address consists of two hexadecimal digits The low and high digits are determined by the position of SW5 and SW6 1894 M 5 fy T o tS Dy The axis address is set to 1 by default at the factory PCE830 40 User Manual Danaher Motion PCE840 Procedure 1 Remove power from the 840 servocontroller 2 Refer to the table below to set the 840 to the appropriate address Address Table Address SW6 SW5 Address SW6 SW5 0 0 0 18 1 2 1 0 1 19 1 3 2 0 2 20 1 4 3 0 3 21 1 5 4 0 4 22 1 6 5 0 5 23 1 7 6 0 6 24 1 8 7 0 7 25 1 9 8 0 8 26 1 9 0 9 21 1 10 0 A 28 1 11 0 B 29 1 12 0 C 30 1 13 0 D 31 1 14 0 E 32 2 0 15 0 F 16 1 0 TA 3 17 1 1 255 Repeater Application Only Not Allowed for SERCOS Applications 3 Re connect power to the PCE84
83. value on the Analog Current Limit Input J2 6 Conversion Scaling Factor 0 01 Data Length 4 bytes Units Hz Minimum Value 0 Maximum Value 100 000 000 Access State Read Write by the Master IDN 32885 Current Limit Offset Voltage Parameter Data IDN Signed Decimal Number AnalogILmtOffset allows the Master to set the offset in volts that is added to the Analog Current Limit Input J2 6 Conversion Scaling Factor 0 001 Data Length 2 bytes Units Volts Minimum Value 10 000 Maximum Value 10 000 Access State Read Write by the Master IDN 32886 Actual Positive Current Limit Parameter Data IDN Unsigned Decimal Number AnalogILmtPlus allows the Master to display the actual positive current limit float value used by the drive Conversion Scaling Factor 0 01 Data Length 2 bytes Units of peak current rating of the drive Minimum Value 0 Maximum Value 10 000 Access State Read only by the Master 3 120 PCE830 40 User Manual Danaher Motion PCE840 IDN 32887 Actual Negative Current Limit Parameter Data IDN Unsigned Decimal Number AnalogILmtMinus allows the Master to display the actual negative current limit float value used by the drive Conversion Scaling Factor 0 01 Data Length 2 bytes Units of peak current rating of the drive Minimum Value 0 Maximum Value 10 000 Access State Read only by the Master IDN 34817 Input Bit 71 Parameter Data IDN Binary Data Allows the Maste
84. velocity loop BW look for velocity oscillation or overshoot Range 0 to 636 Hz ARFO should velocity BW 2 and lt 1 000 000 Hz ARFI should be velocity BW 2 and lt 1 000 000 Hz ARFO and filter values should increase proportionally with Veloicy loop BW The default BW is 75 Hz assuming an inertia ratio of 2 JM If you increase BW using KVP you should also increase the filters with the following relation New ARFx Default ARFx K New KVP 2 Default KVP M M 1 Contact factory for notch filter information used for In Band resonances PCE830 40 User Manual 2 71 PCE830 Danaher Motion 2 5 3 Position Loop Settings Proportional Gain KPP Feedforward Gain KVFF Default Adjust Limits 2 72 The Proportional Position Loop Gain is set based on velocity BW of 75Hz The velocity command from the position loop is generated from position error and KPP For larger values of KPP the velocity command is larger for a given position error KPP provides position synchronization with a small constant position error while following a position command frequency The position error will be proportional to the speed command by the value of KPP If KPP is set too large compared to velocity BW you can see velocity overshoot or oscillation similar to a large KVI The Velocity Feedforward Gain KVFF is used in applications that require near zero position error KVFF is
85. was designed to V01 02 Conversion Scaling Factor 1 Data Length 1 Byte data Variable length IDN 147 Homing parameter Parameter Data IDN Binary Data Defines the HOME parameters used by the PCE840 Home Mode IDN147 Value Hex Dec Current Position is Home 0x77 119 Home to Marker CW Direction 0x34 52 Home to Marker CCW Direction 0x35 53 Home to Switch CW Direction 0x54 84 Home to Switch CCW Direction 0x55 85 Home to Positive Edge of Switch then 0x14 20 Marker CW Direction Home to Positive Edge of Switch then 0 15 21 Marker CCW Direction Home to Negative Edge of Switch then 0x16 22 Marker CW Direction Home to Negative Edge of Switch then 0x17 23 Marker CCW Direction Only Bits 0 1 5 and 6 may be changed by Master while phases 2 4 other bits are Read Only trying to change them results in a Service Channel error PCE830 40 User Manual 3 85 PCE840 Danaher Motion A Writing 0x77 to IDN 147 makes the current motor position the home Zero position Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0x0014 Maximum Value 0x0077 Access State Read Write by Master in phases 2 4 IDN 148 Drive controlled homing procedure Command Data IDN Binary Data Command Procedure IDN used to initiate Home event on the PCE840 During the Home event all velocity and position data received from the Master is ignored with the e
86. 0 4 Repeat steps 1 through 4 for other units on the ring Make sure to give the other units unique addresses PCE830 40 User Manual 3 3 PCE840 Danaher Motion 3 3 Identification Numbers IDNs This is the list of SERCOS IDNs which are supported by the PCE840 For Introduction List of supported IDNs 3 4 1 00 10 tn FW A m BR A HB DB HP HP gt NNN l2 YH RRP YA tn 23 An gt ODN DN intimi Ss a Control Unit Cycle Time TNevc Communication Cycle Time Tscvc Shortest AT Transmission Starting Time T1min Transmit Receive Transition Time TATMT Minimum Feedback Processing Time T4min AT Transmission Starting Time T1 Feedback Acquisition Capture Point T4 Command Value Valid Time T3 Position of Data Record in MDT Length of Master Data Telegram Class 1 Diagnostic Interface Status Telegram Type Parameter Configuration List of AT IDN List of all Operation Data IDN List of Operation Data for CP2 IDN List of Operation Data for CP3 IDN List of Invalid Operation Data for CP2 IDN List of Invalid Operation Data for CP3 Configuration List of the MDT IDN List of all Procedure Commands MST Error Counter MDT Error Counter Manufacturer Version Primary Operation Mode Velocity Command Value Velocity Feedback Value Homing Velocity Homing Acceleration Velocity
87. 048 4096 8192 16384 125 250 500 1000 2000 4000 8000 16000 833 kHz 2900 RPM 11600 RPM 1 Quadrature Pulse Specifications Danaher Motion General 3 dB Bandwidth gt 1500 Hz 45 Phase Lag gt 400 Hz Resolver Excitation Frequency 6510 42 Hz Max Tracking Rate gt 48600 RPM Max Recommended Rate 25 kRPM Max Tracking Acceleration gt 16x106 RPM sec Maximum Feedback Cable Length 50 m 164 ft Nominal Frequency Response 3 dB 0 dB MAGNITUDE EM SERERE 4 90 i PHASE 12 dB 90 Deg VelFB ARESPOS 0 00025 18 dB 180 Deg 24 dB 270 Deg f AL al 1 10 100 1000 10000 FREQUENCY Hz PCE830 40 User Manual Danaher Motion Specifications The PCE8300 packaging is totally enclosed single axis panel mount The figure on the next page gives the key dimensions for use in physically mounting the product When mounting multiple units on one panel there should be at least 25 mm 1 of air space on the sides and 40 mm 1 5 of air space above and below the unit When mounting multiple drives in a row some customers have found the stiffness of the drive and their mounting panel to be too low To increase the mounted mechanical integrity connect to the threaded insert on the top front edge The overall drive panel dimensions and mounted depth not including mating connectors is listed in the chart below The extra depth for mating connectors is 1 0 or less Dimensions
88. 1 1 1 5 SUPPLYe 1 T _ _ CONNECTONLYIFJ2 _ _ _ 14146406 250mA 1 1 1 gt TWISTED PAIR 5V SUPPLY RETURN 2 3 Mappable I O Functions The 830 has six user mappable inputs J2 31 to J2 36 three user mappable outputs 72 42 to J2 44 and one mappable relay output J2 24 25 which are available for users to interface to external devices proximity switch PLC LED Inputs Table following table lists the mappable input functions available for the Digital Inputs InpMapX Mappable Input Function Description Analog Input Null Nulls the analog input by setting ADOffset to old ADOffset minus AnalogIn Counterclockwise Inhibit Inhibits motor motion in the counterclockwise direction when asserted default Clockwise Inhibit default Inhibits motor motion in the clockwise direction when asserted Command Gain Select Switches the analog input scale factor between CmdGain and CmdGain2 Enable 2 Second enable function Fault Reset default Resets drive faults Gearing On Turns electronic gearing on Home Switch Input Home switch input for a homing move Move Select Bit 0 1 2 Determines the active move No Function Turns off mappable input functionality Position Mode Select Switches the active mode of operation to position mode Run Stop Selects between normal operation and setting the velocity command to Zero Start Move Initiat
89. 13 Actual Model not same as stored in NV memory 14 Unable to determine power stage 15 Drive non volatile parameters corrupt 16 RAM failure 17 Calibration RAM failure 18 Encoder alignment no motion fault 19 Encoder alignment excessive motion fault 20 Encoder alignment motor not settled 21 Encoder alignment test failed 22 Encoder alignment motion overflow fault 23 Hall Commutation invalid configuration 24 Hall Commutation overspeed 25 Hall Commutation invalid hall state 26 Hall Commutation invalid hall transition 27 I t Drive 28 I 2 t Motor 29 DP RAM Test A 30 DP RAM Test 5 31 DP RAM Test Run 1 32 DP RAM Test Run 0 3 82 Continued PCE830 40 User Manual Danaher Motion PCE840 IDN 129 Continued ExtFault Continued ExtFault ExtFault Description 33 DP RAM Test C 65 Data Read Only 66 Data Bounds Error 67 Execute no such command 68 RT not Implemented 69 FC not Implemented These fault states CANNOT be reset with the Fault Reset function and require the line control power to be turned OFF and ON again IDN 130 Probe Value 1 Positive Edge Parameter Data IDN Signed Decimal Number Returns the position value latched by the PCE840 drive when a rising edge of the Probe 1 signal has occurred The position is either in resolver or encoder counts depending on the feedback device used to close the position loop This value is scaled using IDN 79
90. 3 32 Overshoot 2 101 3 58 P PC User Interface 2 1 800 Family 4 1 Accessories 4 2 Performance Characteristics 5 5 Position Loop 2 98 3 55 Position Mode 2 56 2 64 Electronic Gearing 2 64 2 65 5 3 Predefined Moves 2 56 Step and Direction 2 62 2 63 Position Mode Select 2 41 Power LED 2 88 3 127 Predefined Moves 2 39 Protection Circuits 2 87 3 126 Protective Earth PE Ground 2 14 2 15 3 17 3 18 R Regl Input 2 31 3 31 Reg2 Input 2 31 3 31 Regeneration Interface 2 13 3 16 Registration Moves 2 50 Resistance 2 15 3 18 Resolver Position Signal 5 8 Resolver Velocity Signal 5 9 Resonance 2 97 3 53 Run Stop 2 42 Danaher Motion S Servo Loop Parameters 2 93 3 49 Simple ASCII Protocol 2 107 Specifications 5 1 Environmental 5 8 Input Power 5 3 Output Power 5 1 Position Loop 5 8 Resolver Feedback 5 9 Velocity Loop 5 7 Status LEDs 2 88 3 127 T Torque Mode 2 68 Analog Command 2 68 Frequency Command 2 69 Transfer Function 2 102 3 59 Transformers 5 4 Troubleshooting 2 91 3 129 Tuning 2 69 V Velocity Command Source 2 42 Velocity Loop 2 93 3 49 5 7 Velocity Mode 2 66 Analog Command 2 66 Frequency Command 2 67 Serial Command 2 67 Weight 5 11 Wiring Diagram 1 3 2 Zero Speed 2 45 PCE830 40 User Manual
91. 32824 KVFF is the velocity feed forward gain In the absence of velocity feed forward KVFF 0 the commanded velocity is proportional to the position following error This means that the actual position lags the commanded position by a value proportional to the speed The error is smaller for larger values of KPP The following table gives a sample of the following error magnitude 830 40 User Manual Speed RPM KPP Hz Following Error revolutions 1000 10 0 27 2000 10 0 53 5000 10 1 33 1000 20 0 13 2000 20 0 27 5000 20 0 66 The following error can easily exceed one complete motor revolution In many electronic gearing applications such following errors are not acceptable real gears DO NOT have following errors Stepper systems also DO NOT have such errors Feed forward takes advantage of the fact that the PCE840 DSP knows the frequency of the encoder or step inputs and knows how fast the motor should be going at a given instant All or part of this velocity can be added to the velocity command to reduce following error If KVFF is set to 100 96 the steady state following error reduces to Zero 3 57 PCE840 Danaher Motion IDN 32840 This IDN should be set so that IDN 32840 Kvff 10 Increasing Kvff reduces steady state following error position loop null error proportional to speed and gives faster response time However if
92. 33 Probe 2 Negative Edge Returns Probe 2 Negative Edge Data 169 Probe Control Specified which probe edges are active 170 Probe Cycle Command Allolws the beginning of a probe cycle 401 Probe 1 Returns the current state of Probe 1 pin 402 Probe 2 Returns the current state of Probe 2 pin 405 Probe 1 Enable Enables the latching of data upon a Probe 1 edge 406 Probe 2 Enable Enables the latching of data upon a Probe 2 edge 409 Probe 1 Positive Latched Returns a 1 when Probe Positive Edge data has been latched 410 Probe 1 Negative Latched Returns a 1 when Probe Negative Edge data has been latched 411 Probe 2 Positive Latched Returns a 1 when Probe 2 Positive Edge data has been latched 412 Probe 2 Negative Latched Returns a 1 when Probe 2 Negative Edge data has been latched Service Channel All the above IDNs can be accessed through the Service Channel For the probe function to take place several IDNs must be set up prior to an event 3 42 PCE830 40 User Manual Danaher Motion IDN 169 IDN 170 IDN 405 IDN 406 PCE840 Probe Control Parameters Bit Number Setting 0 Probe 1 Positive Edge 0 Positive edge inactive 1 Positive edge active 1 Probe 1 Negative Edge 0 Negative edge inactive 1 Negative edge active 2 Probe 2 Positive Edge 0 Positive edge inactive 1 Positive edge active 3 Probe 2 Negative Edge 0 Negative edge inactive 1 Negative edg
93. 8 10139 10140 10141 10142 10144 10145 10146 10147 10148 10149 10150 10151 10152 10153 10154 10155 10156 10157 10158 Danaher Motion PCE830 40 User Manual Danaher Motion MoveSelectBit1 MoveSelectBit2 GearingOn MoveORegsSelect Movel RegSelect Move2RegSelect Move3RegSelect Move4RegSelect Move5RegSelect Move6RegsSelect Move7RegSelect ResolverPosition EncoderPosition Reg2ResolverPosition Reg2EncoderPosition ReglActiveEdge Reg2ActiveEdge ActiveRegSelect HomeSwitch HallState HallOffset DriveStatus PCE830 40 User Manual 10159 10160 10161 10162 10163 10164 10165 10166 10167 10168 10169 10170 10171 10172 10173 10174 10175 10176 10177 10178 10179 10180 PCE830 2 113 PCE830 Identifier Codes for Float Variables 2 114 AnalogIn AnalogOutl EncFreq Velocity ARFI Kvi ItFO Kpp Kvp Kvff DMIFO ADFO ADOffset Ipeak DM1Gain CmdGain CommOff ItFilt VelCmd VelErr Icmd IFB FVelErr DM10Out VelFB DM2Out Kip AnalogOut2 StopTime DM2Gain DM2F0 VelCmd2 VelCmdA HSTemp IU IV IW 00 10 c _ BR BWW WWW 52 52 99 NNN NNN N RR RRR RR CO DN gt _ DO WON NH HW Danaher Motion PCE830 40 User Manual Danaher Motion IqCmd VBusThresh Vbus AccelLmt DecelLmt VelLmtHi VelLmtLo Bl B2 K2 ARZO ARZI 0
94. 830 Analog Current Limit J2 6 Outputs J2 8 9 10 11 CHAOUT CHAOUT CH B Out CHBOUT J2 12 13 CH Z OUT CHZOUT J2 14 J2 15 5VDC RTN 5VDC RTN 2 26 Danaher Motion This input limits the current flow to the motor when a voltage is applied with respect to I O RTN These two output pairs are differential TTL incremental position signals generated by the Resolver feedback electronics These outputs are quadrature encoded to emulate an optical encoder The resolution of these signals 1 e the emulated line count is set by the EncOut parameter These outputs are buffered by 26LS31 type RS 422 compatible line drivers Maximum recommended load current is 20 mA which corresponds to a minimum line to line load resistance of 100 2 This drive capacity corresponds to ten RS 422 compatible inputs such as the PCE830 encoder inputs These outputs are indefinitely short circuit proof to These two terminals function as a differential TTL marker pulse The output pulse occurs once per motor shaft revolution starting at resolver position 0 and its width is approximately one quadrature encoder width This output comes from a 26LS31 type RS 422 compatible line driver Maximum recommended load current is 20 mA which corresponds to a minimum line to line load resistance of 100 This drive capacity corresponds to ten RS 422 compatible inputs such as the PCE830 encoder inputs This output is indefinitely sho
95. 8x3 be equipped with a regen resistor The regen resistor is built into the PCE8xS Need for The clearest indication that an external regen resistor is needed is that the drive fault Regen on over voltage when the motor decelerates The Fault LED is solid on and the variable FaultCode shows over voltage or external regen fault As the motor decelerates mechanical energy is regenerated back to the drive Initially this energy goes into the bus capacitors and pumps up their voltage With an external regen resistor connected the pump up of the bus voltage is clamped at about 830VDC Without a regen resistor the voltage can continue to rise and at about 866VDC an over voltage fault occurs The need for regen is a strong function of maximum motor speed Below some speed roughly 1 3 to 1 4 system rated speed an external regen resistor is unlikely to be needed For an explanation of why this is see the section at the end of this appendix Regen Need is a Strong Function of Maximum Motor Speed Estimating The regen resistor power is pulsed and each pulse is approximately 1msec The Regen instantaneous regen power is 10KW in the PCE8x3 and 20K w in the PCE8x5 By Power counting the average number of regen pulses per second it is possible to estimate the average power in the regen resistor 8 3 Average regen power Average of pulses per sec x 10W PCES8x5 Average regen power Average of pulses per sec 20W
96. AlInNull Lo 0x0007 PosBIk Select Inp Hi 0x8008 PosBIk Select Inp Lo 0x0008 CmdGain Select Inp Hi 0x8009 CmdGain Select Inp Lo 0x0009 Start Move Inp Hi 0x800A Start Move Inp Lo 0x000A Move Select BitO0 Hi 0x800B Move Select BitO0 Lo 0x000B Move Select Bitl Hi 0x800C Move Select Lo 0x000C Move Select Bit2 Inp Hi 0x800D Move Select Bit2 Inp Lo 0x000D Gearing On Inp Hi 0x800E Gearing On Inp Lo 0x000E Home Switch Inp Hi 0x800F Home Switch Inp Lo 0x000F PCE830 40 User Manual 2 117 PCE830 Values for OutMapX 10072 10075 Values for Pre defined Move Types Values for Homing Moves 2 118 Danaher Motion Convert value from hex to decimal for Serial ASCII Protocol No Function Fault Out Hi Fault Out Lo Enabled Out Hi Enabled Out Lo Brake Out Hi Brake Out Lo MechRev Out Hi MechRev Out Lo ElecRev Out Hi ElecRev Out Lo Zero Speed Out Hi Zero Speed Out Lo Excess PosErr Out Hi Excess PosErr Out Lo Move Done Out Hi Move Done Out Lo 0x0000 0x8001 0x0001 0 8002 0 0002 0x8003 0x0003 0 8004 0 0004 0 8005 0 0005 0x8006 0x0006 0x8007 0x0007 0 8008 0 0008 10092 10099 10106 10113 10120 10127 10134 10141 10148 Move Type None Move Type Velocity Move Type Incremental Move Type Absolute Move Type Home Move Type Incr Reg Move Type Abs Reg 0 ON d 10098 10105 10112 10119 10126 10133 10140 10147 10154 Home Mode Switch
97. Bz 30 I 2 t I 2 t Filtered Current 1 V olpeak 2 These variables are allowed to wrap around when the signal exceeds the output voltage range 3 26 PCE830 40 User Manual Danaher Motion PCE840 Analog Current Limit 12 6 This input limits the current flow to the motor when a voltage is applied with respect to RTN AnaloglIImtGain must be non zero the default is Zero The analog input is read through an 8 bit A D converter The range on the analog input is 0 10 volts AnalogILmtOffset is added to the voltage read The sum is then low pass filtered by AnalogILmtFilt The filter output is multiplied by a gain AnaloglLimtGain The input to the multiplier is in volts The units of AnaloglILmtGain are in Ipeak volt And the result is 1 percentage of the drive peak output current see Ipeak If the result is less than 0 then it is clamped to zero by the negative clamp The analog current limit AnalogILmt is set equal to 10096 minus result of the analog input The actual positive and negative current limits used by the drive are ActualILmtPlus min ILmtPlus AnaloglILmt ActualILmtMinus max ILmtMinus AnalogILmt AnalogiLmtOffset 10 Volts AnaloalLmtFilt H2 AnaloglLmtGain lpeakVolt Analog Current gt Limit 820 0 10 Volts AnalogiLmt 10096 Ipeak Example Assume ILmtPlus 100 ILmtMinus 100 AnalogILmtOffset 0 volts AnalogILmtFilt 1000 Hz Ana
98. C that the registration move is complete The PLC initiates the cycle to repeat itself PCE830 40 User Manual Danaher Motion Calculate Move Parameters Motion Profile PCE830 First calculate distance to move Distance Offset after sensing registration input Roller Circumference x Roller Diameter 1 inch 3 1415 inch Distance for motor to move 1 inch move 3 1415 inch rev 0 31832 revs Distance Offset 0 31832 motor rev 65536 counts motor rev 20861 counts Next calculate the minimum deceleration rate necessary to ensure coming to a complete stop within the 75 millisecond specification Decel Rate 2 0 31832 revs 60 0 075 seconds 2 6791 rpm s Finally calculate the minimum distance the motor should move to ensure the registration input is seen every cycle Distance 8 inch 0 31832 rev inch 65536 counts rev 166892 counts Distance Offset Travel distance Velocity RPM Start Reg1 Move rising Move active edge Done active PCE830 40 User Manual 2 51 PCE830 Procedure 2 52 Danaher Motion Create a new configuration and select Position Mode Predefined Moves as mode of operation Click the Digital tab Select Start Move as the function on Input3 to initiate a preset move Select Move Select Bit 0 as the function on Input4 to setup a preset move based upon an external input Select Move Done as the function on Out3 Allregistratio
99. Current Limits IDN 82 IDN 83 IDN 32829 3 132 To protect the motor and drive set the limits to Clockwise Current Limit ILmtPlus This IDN should be set so that ILmtPlus min 100 100 5 Ies Ipeak Where 1 is the motor s rms terminal current rating IDN 82 of Ipeak 10 1 e for a 9x3 ILmtPlus of 5096 or 7 5A set IDN 82 500 Counter clockwise Current Limit ILmtMinus This should be set so that ILmtMinus min 100 100 5 Tes Tpeak Where is the motor s rms terminal current rating IDN 83 of Ipeak 10 1 e for a 9x3 ILmtMinus of 5096 or 7 5A set IDN 83 500 Application requirements may constrain ILmts even further ItThresh sets the maximum continuous output current as a percentage of before the I T thermal protection faults the drive This IDN should be set so that IDN 32829 ItThresh min 60 100 3 IMTRcontinuous IPR The following table lists the peak current rating for each of the drives in the PCES800 family Pacific Scientif Model Ipeak Amps 8x3 15 0 8x5 30 0 PCE830 40 User Manual Danaher Motion Model Identification 4 MODEL IDENTIFICATION 4 1 System Basic Servo Drive Package Order Numbering PCES8XY 001 Z PCE8 Servo Drive Family Designation Command Interface Designation 3 RS 232 485 10VDC Step Dir Indexing 4 SERCOS Option Power Level 3 3 75 A us co
100. Danaher Motion Single Axis Brushless Servo Drive PCE830 40 User Manual Pacific Scientific Part Number MAE800 Document Number M PE 800 0301 Record of Manual Revisions ISSUE NO DATE BRIEF DESCRIPTION OF REVISION 0 Preliminary issue for review 1 Initial release Copyright Information O Copyright 2002 Pacific Scientific rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Pacific Scientific Company except under written agreement All rights are reserved No part of this book shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Pacific Scientific Company that is furnished for customer use ONLY No other uses are authorized without written permission of Pacific Scientific Company Information in this document is subject to change without notice and does not represent a commitment on the part the Pacific Scientific Company Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respe
101. E830 requires an external 12VDC 24VDC power source for the outputs This power source must be capable of supplying at least 150 mA These optically isolated outputs are current sourcing at 0 to 50 mA maximum External output supply should be limited to 30V These outputs are short circuit protected Current folds back to about 25 mA during a short circuit The external output supply J2 41 is shared by the three outputs 1 9V at 25 mA 2 25V at 50 mA Ioff 5 pA Response time 1 msec Clamp voltage 40V nominal Each of the outputs is set and written to by software every 2 mSec Each one can be configured to be any of the available functions and the configuration can be changed on the fly via digital communications The user s default configuration is stored in the non volatile memory The present state of commanded outputs can be read via digital communications The logic polarity of these signals is also software programmable That is an output can be defined to be active low or active high For edge triggered functions the active edge is programmable PCE830 40 User Manual 2 33 PCE830 Fault Output Brake Output Output Mapped Off Outputs ON State OFF State 2 34 Danaher Motion The list below describes the subset of the available functions and the mappings used as the factory defaults for each of the outputs Output 1 This output is low when the drive is faulted or has no control power
102. FB Measured Velocity DM2 Default 1 2 VelCmdA Actual Velocity Command VelCmdA 1 3 VelErr Velocity Error 1 V kRPM 4 FVelErr Compensated Velocity Error 1 V kRPM 5 Position Measured Position 1 V Rev 6 PosError Position Error 1 V Rev 7 PosCommand Commanded Position 1 V Rev 8 Icmd Commanded Torque Current V A 9 IFB Measured Torque Current DM1 Default 1 V A 10 AnalogIn Filtered A D Input V V 11 EncFreq Encoder Frequency 1 V Hz 12 EncPos Encoder Position 10 V 4096 Cnts 13 ItFilt Filtered Output Current Amplitude 1 100 14 HSTemp Measured Heat Sink Temperature 1 V C 15 Commutation Electrical Angle 1 V Cycle 16 IU Motor Phase U Output Current 1 V A 17 IV Motor Phase V Output Current 1 V A 18 IW Motor Phase W Output Current 1 V A 19 Motor Phase U Voltage Duty Cycle 1 100 20 Motor Phase V Voltage Duty Cycle 1 100 21 Motor Phase W Voltage Duty Cycle 1 100 22 VBus Drive Bus Voltage V V 23 ResPos Resolver Absolute Position V Rev 24 Commanded non torque current 1 V A 25 Measured non torque current 1 V A 26 Torque Voltage Duty Cycle 1 100 27 Non torque Voltage Duty Cycle 1 100 28 Velocity Command 1 29 DigitalCmdFreq Digital Command Frequency 1 V Hz 30 I 2 t I 2 t Filtered Current 1 V olpeak 2 These variables are allowed to wrap around when the signal exceeds the output voltage range PCE830 40 User Manual 2 25 PCE
103. IDN can only be written in Phase 2 IDN 2 Communication Cycle Time Parameter Data IDN Unsigned Decimal Number The values must be the same as IDN 1 Control unit cycle time Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 01000 Maximum Value 64000 Access State Read Write in Phase 2 Read only in Phase 3 and 4 3 60 PCE830 40 User Manual Danaher Motion PCE840 IDN 3 Shortest AT Transmission Starting Time Parameter Data IDN Unsigned Decimal Number Time required by the PCE840 after the MST before it is able to send the Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State 1 2 bytes us 20 20 Read only by Master IDN 4 Transmit Receive Transition Time Parameter Data IDN Unsigned Decimal Number Time required by the PCE840 after the end of transmitting the AT before it is ready to receive the MDT from the master Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State 1 2 bytes us 20 20 Read only by Master IDN 5 Minimum Feedback Processing Time Parameter Data IDN Unsigned Decimal Number Time required by the PCE840 to acquire and compile the AT data prior to the MST Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State PCE830 40 User Manual 1 2 bytes us 300 300 Read only by Master 3 61 PCE840 Dana
104. ION TO BE DEFECTIVE AS A RESULT OF DEFECTIVE MATERIALS OR WORKMANSHIP IN ACCORDANCE WITH SELLER S STATED WARRANTY IN NO EVENT SHALL SELLER S LIABILITY EXCEED THE TOTAL PURCHASE PRICE SET FORTH IN THIS ORDER GENERAL INDEMNITY Buyer agrees to hold Seller harmless from any and all liability and to pay all costs and attorney s fees for injury or damage to persons or property caused in any manner by Goods covered by the order while in possession or under the control of Buyer or Buyer s successor in interest SAFETY The equipment described herein has been developed produced tested and documented in accordance with the corresponding standards During use conforming with requirements the equipment is not dangerous for people or equipment Use conforming with requirements means that the safety recommendations and warnings detailed in this manual are complied with and applicable regulations for safety machine directives etc and noise suppression EMC Directives are observed while operating the drive At the end of its lifetime dispose of or recycle the drive according to the applicable regulations Installation and wiring of the drive must be completed only by qualified personnel having a basic knowledge of electronics installation of electronic and mechanical components and all applicable wiring regulations Commissioning of the machine utilizing the drives must be done only by qualified personnel having a broad knowledge of electronics a
105. ItThreshA VBusFTime CmdGain2 ZeroSpeedThresh DigitalCmdFreq MoveORunSpeed Move0AccelRate Move0DecelRate MovelRunSpeed Movel AccelRate Movel DecelRate Move2RunSpeed Move2AccelRate Move2DecelRate Move3RunSpeed Move3AccelRate Move3DecelRate Move4RunSpeed Move4AccelRate Move4DecelRate Move5RunSpeed MoveSAccelRate MoveS5DecelRate Move6RunSpeed Move6AccelRate Move6DecelRate PCE830 40 User Manual 42 43 44 45 46 48 49 50 51 52 53 54 55 56 83 84 90 91 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 PCE830 2 115 PCE830 2 116 Move7RunSpeed Move7AccelRate Move7DecelRate ActiveRunSpeed ActiveAccelRate ActiveDecelRate IntgStopThresh DtThresh 124 0 DtFilt AnalogILmt AnalogILmtGain AnalogILmtFilt AnalogILmtOffset ActuallLmtPlus ActualILmtMinus 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 Danaher Motion PCE830 40 User Manual Danaher Motion PCE830 Values for Convert value from hex to decimal for Serial ASCII Protocol InpMapX 10066 10071 No Function 0x0000 Fault Reset Inp Hi 0x8001 Fault Reset Inp Lo 0x0001 RunStop Inp Hi 0x8002 RunStop Inp Lo 0x0002 Enable2 Inp Hi 0x8003 Enable2 Inp Lo 0x0003 VelCmdSrc Hi 0x8004 VelCmdSrc Lo 0x0004 Inhibit Hi 0x8005 CW Inhibit Inp Lo 0x0005 CCW Inhibit Inp Hi 0x8006 CCW Inhibit Inp Lo 0x0006 AInNull Hi 0x8007
106. L1C L2C TB1 1 2 These terminals connect the 120 240 VAC power provided by the user to the 120VAC 240VAC drive s control voltage power supply Control power L1C L2C TB1 1 2 are NOT connected internally to bus power L1 L2 TB1 4 5 amp Control Power PCE830 40 User Manual The control voltage for the PCE830 controllers is input to a switching power supply This input accepts voltages ranging from 85VAC to 265VAC 2 13 PCE830 Chassis Ground PE 1 3 L1 L2 L3 TB1 4 5 6 380VAC 400VAC 480VAC Regeneration Interface B R B TB1 7 8 9 Bus Regen Resistor Bus Danaher Motion Convenience connector point for the user to connect the drive s control power and bus power to protective earth ground This pin is directly connected to the chassis and thus to the Chassis Ground Stud Local electrical code may require using the Earth Ground Chassis stud for this function These terminals connect the balanced three phase 380 400 480 VAC power provided by the user to the drive s power output stage bus to drive the motor 380 400 480 VAC three phase mains MUST be WYE type with earthed neutral for PCE830 to be compatible with CE safety standard EN50178 Earthed neutral WYE type mains are strongly recommended for all installations Single phase or lower voltage operation is possible for short periods of time to support installation or testing These terminals provide the connection points for a
107. LVER 54 COS Input 5 SHIELD RTN 6 RESOLVER EXCITATION Output 7 RESOLVER R2 EXCITATION RTN Output 8 MOTOR PTC Input 9 MOTOR PTC RTN Input 10 5VDC 11 RTN 12 FEEDBACK ENCODER CHANNEL A 13 FEEDBACK ENCODER CHANNEL A 14 FEEDBACK ENCODER CHANNEL B 15 FEEDBACK ENCODER CHANNEL B Feedback Resolver S1 S2 S3 54 Inputs J3 1 2 3 4 Hall2 Hall3 J3 1 2 3 2 36 Danaher Motion These connections provide the inputs for the resolver s sine cosine outputs Differential inputs with 75V usec common mode impulse range and 25 input impedance This only applies if a Resolver feedback device is being used These three single ended hall channel sensor inputs are detected by 5 VDC CMOS compatible commutation signals with 60 spacing These inputs are each internally pulled up to SVDC via 10 resistor These input signals are low pass filtered in hardware at 10 kHz This only applies if a Hall feedback sensor is being used PCE830 40 User Manual Danaher Motion Resolver R1 Excitation R2 Excitation RTN Outputs J3 6 7 Motor PTC PTC RTN Inputs J3 8 9 Encoder Inputs J3 12 13 14 15 PCE830 These connections provide the resolver excitation output 9 2V rms at 6510 42 Hz 75 mA rms maximum load These outputs are fully short circuit protected to COMMON or to each other at room temperature 25 C but at ambie
108. Maximum Value Access State IDN 32862 OutMap3 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32863 OutMap4 PCE840 Parameter Data IDN Binary Data OxFFFF Read Write by the Master Parameter Data IDN Binary Data OxFFFF Read Write by the Master Parameter Data IDN Binary Data Refer to Map List Column for the desired function Set Polarity bits as Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State PCE830 40 User Manual OxFFFF Read Write by the Master 3 115 PCE840 Danaher Motion IDN 32866 ADOffset Parameter Data IDN Signed Decimal Number Adjusts the steady state value of the analog command input Conversion Scaling Factor 10 000 Data Length 4 bytes Units Volts Minimum Value 150 000 Maximum Value 150 000 Access State Read Write by the Master IDN 32870 D2tThresh Parameter Data IDN Unsigned Decimal Number Allows P t motor protection threshold value If I2tFilt exceeds I2tThresh the drive will fault Conversion Scaling Factor 1 Data Length 2 bytes Units of Ipeak Minimum Value 0 Maximum Value 100 Access State Read Write by the Master IDN 32871 I2tF0 Parameter Data IDN Unsigned Decimal Number I2tF0 sets the low pass filter break frequency for the filter used to implement the t motor drive thermal protection I2tF0 and I2tThresh set the thermal protection for the mot
109. N IDN ID Number List List of IDNs stored to and from non volatile memory IDN IDN Description IDN IDN Description 15 Telegram Type Parameter 32818 InpMap2 32 Primary Operation Mode 32819 InpMap3 41 Homing Velocity 32820 InpMap4 42 Homing Acceleration 32821 InpMap5 55 Position Polarity Parameter 32822 InpMap6 76 Position Data Scaling Type 32823 EncInFilt 82 Positive Torque Limit Value 32824 RemoteFB 83 Negative Torque Limit Value 32826 CommOff 100 Velocity Loop Proportional Gain 32828 Encoder Input EncIn 101 Velocity Loop Integral Action Time 32829 ITThresh 103 Modulo Value 32830 StopTime 104 Position Loop Kv Factor 32831 VBusThresh 106 Current Loop Proportional Gain 1 32832 VelLmtHi 107 Current Loop Integral Action Time 1 32833 VelLmtLo 140 Controller Type 32835 CoastTime 147 Homing Parameter 32837 Motor 1 Name 159 Monitoring Window 32838 Motor 2 Name 32807 Pole Count 32840 Kvff 32809 Filter Value for ADFO 32841 ARZO 32810 DMIFO 32842 ARZI 32811 DM2F0 32843 ARFO 32812 DM1Gain 32844 ARFI 32813 DM2Gain 32846 Encoder Data Scaling Method 32814 1 Mux Select 32847 Encoder Modulo Value 32815 DM2Map Mux Select 32853 CommSrc Commutation Source 32816 Encoder Output EncOut 32866 ADOffset 32817 InpMapl Conversion Scaling Factor 1 Data Length 2 bytes data Access State Read only by the Master PCE830 40 User Manual 3 91 PCE840 Danaher Motion IDN 194 Acceleration Command Parameter Data IDN Unsigned Decimal Num
110. Polarity Parameter Velocity Data Scaling Type Velocity Data Scaling Factor Velocity Data Scaling Exponent Position Command Value Position Feedback Value 1 Motor Feedback PCE830 40 User Manual Danaher Motion IDNs continued 52 55 76 7 78 79 80 82 83 84 85 88 89 90 95 96 99 100 101 103 104 106 107 110 127 128 129 130 131 152 133 140 142 143 147 148 159 160 161 162 PCE830 40 User Manual PCE840 Reference Distance 1 Position Polarity Parameter Position Data Scaling Type Linear Position Data Scaling Factor Linear Position Data Scaling Exponent Rotational Position Resolution Torque Command Value Positive Torque Limit Value Negative Torque Limit Value Torque Feedback Value Torque Polarity Parameter Receive to Receive Recovery Time TMTSY MDT Transmission Starting Time T2 Command Value Proceeding Time TMTSG Diagnostic Message Slave Arrangement Reset Class 1 Diagnostic Velocity Loop Proportional Gain KVP Velocity Loop Integral Action Time KVI Modulo Value Position Loop Kv Factor KPP Current Loop Proportional Gain 1 KIP Current Loop Integral Action Time 1 KII Amplifier Peak Current Communications Phase 3 Transition Check Communications Phase 4 Transition Check Manufacturer Class 1 Diagnostic Probe Value 1 Positive Edge Probe Value 1 Negative Edge Probe Value 2 Positive Edge Probe Value 2 Negative Edge Controller Type Application Type SYSTEM Interface V
111. ROL 8 LOGIC TLP121GB 42 38 INPUT RTN J2 39 424 VDC OUTPUT RTN J2 40 24 Input RTN This terminal is the floating common return for the six optically isolated digital J2 38 inputs and the optically isolated Enable input 24 VDC RTN These two connections provide an auxiliary floating power supply for the user 24 VDC Output This output is 24VDC 10 and is short circuit protected at 100 mA nominal J2 39 J2 40 The maximum load limit for all connections to this supply is 80 mA 24VDC RTN is not connected to Input RTN Outl 2 3 The 840 requires an external 12VDC 24VDC power source for the outputs Supply Input This power source must be capable of supplying at least 150 mA J2 41 3 32 PCE830 40 User Manual Danaher Motion Outputs J2 42 43 44 Fault Output Output Mapped Off Output Mapped Off Outputs ON State OFF State PCE830 40 User Manual PCE840 These optically isolated outputs are current sourcing at 0 to 50 mA maximum External output supply should be limited to 30V These outputs are short circuit protected Current folds back to about 25 mA during a short circuit The external output supply J2 41 is shared by the three outputs 1 9V at 25 mA 2 25V at 50 mA lorr 5 pA Response time 1 msec Clamp voltage 40V nominal Each of the outputs is set and written to by software every 2 mSec Each one can be configured to be any of the available functions a
112. S 485 RXD 75176 1 4 5VDC 6 RS 485 TXD 7 RS 485 TXD 8 5 RTN V 4 SHIELD PCE840 3 21 PCE840 Danaher Motion 3 5 3 Command I O J2 44 Position D subminiature female Pin Description Pin Description J2 1 Analog Command Input J2 23 No Connect 2 2 Analog Command Input J2 24 Relay Output Out4 J2 3 RTN J2 25 Relay Output Out4 J2 4 Analog Output DACMonitorl J2 26 No Connect J2 5 Analog 2 DACMonitor2 J2 27 No Connect J2 6 Analog Current Limit Input J2 28 Analog Input 2 J2 7 VORTN J2 29 Analog Input 3 J2 8 Encoder Output Channel J2 30 RTN 2 9 Encoder Output Channel J2 31 Input 1 Fault Reset J2 10 Encoder Output Channel B J2 32 Input 2 CwInh J2 11 Encoder Output Channel B J2 33 Input 3 CcwInh J2 12 Encoder Output Channel Z J2 34 Input 4 J2 13 Encoder Output Channel Z 2 35 Input 5 Reg2 J2 14 5VDC Output J2 36 Input 6 J2 15 RTN 5 RTN J2 37 Enable Input J2 16 RTN J2 38 Input RTN J2 17 Command Encoder Input Channel Step J2 39 24VDC Output RTN 2 18 Command Encoder Input Channel A Step 72 40 24VDC Output J2 19 Command Encoder Input Channel B Dir J2 41 Outl 2 3 Supply Input 12 20 Command Encoder Input Channel B Dir J2 42 Outl Fau
113. SCII representation lt STX gt Addr CmdCode PDID Value CS CR STX Framing character denoting start of message Addr Address of drive 0 255 Optional field CmdCode for read W for Write for Command PDID The ID number of the variable parameter To distinguish floats from integers 10000 was added to PDID of integers Value Value data to be written to parameter variable Only used for W write messages CS Checksum Optional field CR Framing character denoting end of message PCE830 40 User Manual 2 107 PCE830 Reply Message Format Description of Fields Examples 2 108 Danaher Motion lt STX gt RspCode CS CR STX Framing character denoting start of message RspCode V if Value data is returned E is error is returned Value Value of variable parameter CS Checksum This optional field is used only if the command message used a checksum CR Framing character used to denote end of message If the command message is valid 1 The reply to a read returns the value of variable parameter 2 Thereply to a write command also returns the value of the variable parameter after it was written 3 Thereply to a command is simply an echo of the message received 1 Write MovelDistance Integer 10100 a value of 6553600 without using the optional Address field Command Sent lt STX gt W 10100 6553600 214 lt CR
114. Shaft Torque Ignoring motor magnetic saturation Peak hot Instantaneous Bandwidth Maximum Bandwidth Recommended Bandwidth Bandwidth Variation For Fixed Motor L Bandwidth Variation For 4 2596 AC Line Variation Update Period Recommended Motor Electrical Frequency Multiply by 1 06 for cold Kr PMA motors PCE830 40 User Manual Back EMF Matched Pseudo Sine Nm Agms Dr ive Ipeak Arms Nm Anys 2 1 5 kHz 1 0 kHz 10 2 62 5 400 Hz 5 5 Specifications Analog Command Maximum Differential Range Maximum Single Ended Range Full Scale Tolerance Linearity Monotonic to S N Ratio Referred to Full Scale Full A D Bandwidth 150 Hz A D Bandwidth 10 Hz A D Bandwidth Offset Maximum Unadjusted Offset Offset Drift CMRR Digital Position Commands Modes Maximum Input Rate For Fast Decode Quadrature Decode Max Line Frequency Step Dir Decode Max Step Frequency Up Dn Count Max Frequency Minimum Fast Decode Pulse Width Fast Decode Direction Setup Time Fast Decode Direction Hold Time Relative Timing For Filtered Decode Danaher Motion 13 5 Volts 21 Volts 5 worst case 1 typical 0 1 Full Scale lt 27 Full Scale 14 bits 16 bits 18 bits Adjustable to 0 50mV 250 uV C typ gt 30 dB 60 Hz Quadrature Encoder Step amp Direction or Up amp Dn Count 800 kHz 800 kHz 800 kHz 0 6 uSec 0 6 uSec 0 6 uSec 4 8 or 16to 1 e
115. This line can be used to indicate a problem with the drive Output 2 This output is low when the control power is off or when control voltage is on and the drive is disabled Enabled 0 This output is pulled high otherwise This output is intended to drive a normally open relay that in turn powers a mechanical brake on the motor shaft for applications that require a positive shaft lock when the servo drive is off Output 3 Output Mapped Off 4 ce Von 1 97 25 mA 2 25 50 mA lon 010 50 During shart circuit folds back to 25 mA 3 to 30V Opto _ lorr 5 pA max 36 Transient Surge Protector clamps 40 nominal PCE830 40 User Manual Danaher Motion PCE830 Outputs Driving Typical Loads 42 41 Out1 2 3 Supply Input 12 42 Out _42 43 Out2 J2 44 Out3 24V Relay 24 Opto Input Display Output Schematic 45V EXTERNAL OUTPUT SUPPLY J2 41 FROM CONTROL LOGIC 74HC1D 15 36 Transient Surge Protector 30 MMBT2222ALT OUTPUT J2 42 43 44 PCE830 40 User Manual 2 35 PCE830 2 2 4 Base Servo Drive User I O Connections J3 FEEDBACK 15 Position D subminiature female Pin Description 1 RESOLVER SI SIN Input Hall 1 2 RESOLVER 53 SIN Input Hall 2 3 RESOLVER S2 COS Input Hall 3 4 RESO
116. a Length 4 bytes Units percent Minimum Value 0 Maximum Value 100 Access State Read Write by the Master IDN 32830 StopTime Parameter Data IDN Unsigned Decimal Number The StopTime variable is associated with the RunStop I O Function It determines the maximum time after RunStop transitions to Stop that it will take the drive to disable This IDN corresponds to an obsolete function DO NOT USE Conversion Scaling Factor 0 001 Data Length 2 bytes Units Seconds Minimum Value 2 Maximum Value 32 000 Access State Read Write by the Master PCE830 40 User Manual 3 107 PCE840 Danaher Motion IDN 32831 VBusThresh Parameter Data IDN Signed Decimal Number Allows the Bus Undervoltage threshold to be set If set to a negative number turns off the bus undervoltage fault Conversion Scaling Factor 1 Data Length 2 bytes Units Volts Minimum Value 1 Maximum Value 1 000 Access State Read Write by the Master IDN 32832 VelLmtHi Parameter Data IDN Signed Decimal Number Maximum value allowed for the velocity command into the velocity block Also sets the overspeed fault threshold if VelLmtHi gt VelLmtLo Overspeed fault set at 1 5 max of VelLmtHi VelLmtLo Conversion Scaling Factor 0 001 Data Length 4 bytes Units RPM Minimum Value 21 039 000 Maximum Value 21 039 000 Access State Read Write by the Master IDN 32833 VelLmtLo Parameter Data IDN Signed Decimal Number Minimum value allowe
117. about 800VDC These are dangerous voltages PCE840 Regen Resistors Motor Power PE TB1 10 Motor Case Ground U V W 1 11 12 13 Motor Phase 3 18 Danaher Motion The table below lists the recommended values for regen resistors To order 660 200W regen resistor from Pacific Scientific use part number PRK 200 66 Model Resistance Regen Resistor External Regen Location Resistor PCE843 660 External 660 10 200W 1500V min isolation PCE845 330 Internal factory wired External 400W option 1 7 to TB1 8 100W see below Regen Resistance MUST be in the range as shown below Model Resistance PC843 60 to 720 PC845 30 to 36 Q For safety it is recommended that the external resistor be mounted on a grounded panel or use a grounding wire connected to a mounting screw The terminals of the resistor must not be grounded In a few installations heavy duty regen may be needed In such cases it is necessary to increase the regen resistor wattage without changing its ohms The recommended way to increase regen wattage is shown below PCES843 Wire to B and R four 660 200W resistors in series parallel 66 2 800W SS PCE845 Cut off wires to B and R from internal regen resistor Wire to B and R two 66Q 200W resistors in parallel 330 400W Wait 10 minutes after Bus Power is removed for the bus cap vo
118. acific Scientific recommends that you save the configuration to a file as a backup Changing values on the Parameter Edit Window only affects the PC RAM copy You must download them to the drive to take affect 800Tools sets the drive variable Enable to 0 at the beginning of the download To enable the drive you can use the Variables screen to set Enable I If the downloaded parameters were NVSaved turning control AC power OFF and then ON again will also return Enable to its default value of 1 PCE830 40 User Manual 2 7 PCE830 NVSave to Drive Verify Setup Enable the Drive PN Danaher Motion To save the configuration to the drive s non volatile memory 7 Y our configuration has been downloaded 4 9 Do you want to have it saved in the drive s non volatile memory IF you answer the changes will be lost when the drive is powered down e Click Yes to save to the drive s non volatile memory e Click Finish To verify that the set up procedure worked turn the control AC power OFF and then ON again The Power LED should be BLINKING If both LEDs are still blinking repeat the set up procedure The 830 is configured as a serial port commanded controller The current loop is properly compensated for the selected motor and the servo parameters have been setup to give medium response approximately 75 Hz velocity loop bandwidth with the unloaded motor Additional default settings have also been ma
119. actor 1 Data Length 2 bytes Minimum Value 0x0A Maximum Value 0 18 Access State Read Write in phase 2 3 112 Read only in phases 3 and 4 PCE830 40 User Manual Danaher Motion PCE840 IDN 32847 Encoder Modulo Value Parameter Data IDN Unsigned Decimal Number Allows the master to set the Encoder Modulo value IDN 32846 Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 10 Maximum Value 2 147 483 647 Access State Read Write in phase 2 Read only in phases 3 and 4 IDN 32853 CommSrc Parameter Data IDN Unsigned Decimal Number Selects between resolver incremental encoder or hall encoder feedback for motor commutation CommSrc Feedback Device 0 Resolver Encoder 2 Hall Encoder CommSrc IDN 32853 must be set BEFORE PoleCount IDN 32807 RemoteFB 1DN32824 must be set before CommSrc IDN32853 Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 0 Maximum Value 2 Access State Read Write in all phases IDN 32857 Resolver Position Parameter Data IDN Unsigned Decimal Number ResPos returns the absolute resolver position within one revolution The PCE840 has 65536 resolver counts per revolution This IDN will therefore return a value between 0 and 65535 This IDN is NOT affected by Position Modulo IDN 103 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65535 Access State Read Write by th
120. acturer rating 300 watts Terminals 0 25 inch standard fast on Isolation 3 500 V to case Cable 2 ft 214AWG with spade lugs For the PCE8x3 the regen resistor is mounted external to the drive The 8 5 regen resistor is built in and factory wired to pins 7 and 8 If an external regen resistor is used with the PCE8x5 the internal regen resistor must be disconnected by removing its wires from TB1 The Pacific Scientific supplied PCE830 40 regen resistor comes with a cable long enough so it can be mounted adjacent to the drive and wired to the drive Mounted on Grounded Panel EER 10 200W 3 500 Isolation Part PRK 200 66 0 25 TAB Terminal Regen Cable 2 wire 14 AWG During normal operation B R and B operate at the bus power voltages A 480VAC system operates at about 800VDC These are dangerous voltages Wait 10 minutes after Bus Power is removed for the bus cap voltage to decay to a safe level before touching the regen resistor or wiring The voltage on the bus caps can be monitored with a voltmeter from BUS TB1 7 to BUS 1 9 PCE830 40 User Manual Danaher Motion Drive Regen Terminals Safety Non Pacific Scientific Regen Resistors High Power Regen Using External Regen 1 7 marked to TB1 8 marked The resistor terminals are standard 0 25 fast ons The resistor can be mounted any distance from the drive using a cust
121. ad Inertia PCE830 The velocity loop bandwidth fyc is given by the equation xp 43 _ 72 Kr where KVP is the velocity loop proportional gain in amps rad sec is 0 peak line line motor torque constant in Ib in amp Jror is the total inertia motor total load total in Ib in sec2 Any consistent set of units for such as MKS that yield in rad sec2 amp work The motor torque constant is the value of Kr peak published in the Pacific Scientific Motion Control Solutions catalog f is the unity gain open loop crossover frequency of idealized rigid single mass system See hardware specifications for maximum fv value The Create New Configuration and Edit Existing Configuration buttons set KVP to achieve a velocity loop bandwidth of 75 Hz 800Tools assumes there is a matched load on the motor shaft and the motor has no mechanical brake or other secondary devices installed fve Velocity Loop Bandwidth Hz 75 Hz default From the formula for bandwidth you can see that bandwidth changes inversely with total inertia If the load inertia equals the motor plus resolver inertia the velocity loop bandwidth is half the values shown If the load inertia is ten times the motor plus resolver inertia the bandwidths are one eleventh these values Clearly KVP must be increased to compensate for increased load inertia if bandwidth is to be maintained Typically
122. aher Motion 3 5 4 Feedback J3 FEEDBACK 15 Position D subminiature female Pin Description RESOLVER S1 SIN Input Hall 1 RESOLVER S3 SIN Input Hall 2 RESOLVER S2 COS Input Hall 3 RESOLVER 4 COS Input SHIELD I O RTN RESOLVER EXCITATION Output RESOLVER R2 EXCITATION RTN Output MOTOR PTC Input JAI AI WN MOTOR RTN Input 5VDC VO RTN N FEEDBACK ENCODER CHANNEL A 92 FEEDBACK ENCODER CHANNEL FEEDBACK ENCODER CHANNEL B PCE830 40 User Manual PCE840 3 35 PCE840 Feedback Resolver S1 S2 S3 S4 Inputs J3 1 2 3 4 Halll Hall2 Hall3 J3 1 2 3 Resolver R1 Excitation R2 Excitation RTN Outputs J3 6 7 Motor PTC PTC RTN Inputs J3 8 9 3 36 Danaher Motion These connections provide the inputs for the resolver s sine cosine outputs Differential inputs with 75V usec common mode impulse range and 25 input impedance This only applies if a Resolver feedback device is being used These three single ended hall channel sensor inputs are detected by 5 VDC CMOS compatible commutation signals with 60 spacing These inputs are each internally pulled up to 5VDC via 10 resistor These input signals are low
123. aling Factor Parameter Data IDN Unsigned Decimal Number Sets the Maximum Position Deviation allowed by the PCE840 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State 16 2 bytes 1 65535 Read Write by the Master in phases 2 4 IDN 162 Acceleration Data Scaling Exponent Parameter Data IDN Signed Decimal Number acceleration data is scaled by the following formula IDN 161 10 IDN 162 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State PCE830 40 User Manual 16 2 bytes 32766 32765 Read Write by the Master in phases 2 4 3 87 PCE840 Danaher Motion IDN 169 Probe Control Parameter Parameter Data IDN Binary Data Defines the PROBE parameters used by the PCE840 Bit Number Bit Setting Bit 0 Probe 1 Positive Edge 0 gt Positive edge is not active 1 gt Positive edge is active Bit 1 Probe 1 Negative Edge 9 gt Negative edge is not active 1 gt Negative edge is active Bit 2 Probe 2 Positive Edge 0 gt Positive edge is not active 1 gt Positive edge is active Bit 3 Probe 2 Negative Edge 0 gt Negative edge is not active 1 gt Negative edge is active Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 0 0 Access State Read Write by Master in phases 2 4 IDN 170 Probing Cycle Procedure Command Command Data IDN Binary Data
124. ally used Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32840 ARZO 0 1 2 bytes Percent 0 1 999 Read Write by the Master Parameter Data IDN Unsigned Decimal Number ARZO is the first velocity loop compensation zero Please refer to Section 3 7i Servo Loop Parameters for y loop p p additional information Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State 3 110 pese a 1 4 bytes Hz 20 100 000 Read Write by the Master PCE830 40 User Manual Danaher Motion IDN 32842 71 PCE840 Parameter Data IDN Unsigned Decimal Number ARZI is the second velocity loop compensation zero Please refer to Section 3 7 Servo Loop Parameters for additional information Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32843 1 1 4 bytes Hz 20 1 000 000 Read Write by the Master Parameter Data IDN Unsigned Decimal Number ARFO is the first velocity loop compensation anti resonance low pass filter corner frequency Please refer to Section 3 7 Servo Loop Parameters for additional information mage pM Conversion Scaling Factor Data Length Units Minimum Value Ma
125. and motor current ripple can also be reduced by specifying a higher accuracy resolver The parameter KVI sets the lag break frequency of the velocity loop KVI is equal to the frequency in Hz where the velocity loop compensation transitions from predominantly integral characteristics to predominantly proportional characteristics Drive rejection of torque disturbances increase as KVI increases Default values for KVI are fye Hz 25 75 200 KVI Velocity Loop 1 7 5 0 13 3 Lag Break Freq Hz default If the drive is used within a position loop either with BlkType 2 or when using an external position drive and BlkType 1 KVI should be equal to or less than 0 1 times the velocity loop bandwidth If position loop is used KVI can be set to 0 25 times the velocity loop bandwidth or higher if some ringing can be tolerated In general the response to a velocity command step or truncated ramp has velocity overshoot for non zero values of KVI PCE830 40 User Manual Danaher Motion PCE830 2 2 Position Loop When is set equal to 2 a position loop is configured outside the velocity loop The velocity loop must be set up and evaluated in terms of bandwidth BEFORE attempting to setup the position loop KPP The position loop proportional gain KPP determines the settling time of the position loop KPP is the bandwidth of the position loop in Hz assuming an idea
126. ange 4 Sets the maximum acceleration rate of the motor 5 999993472 000 RPM sec Change 6 4 on Sets the maximum acceleration rate of the motor Scope 999993472 000 RPM sec Change Switch to Scope Off 11 Assert the hardware enable on the drive and in the variables screen select and set the software enable to 1 12 If both the software and hardware enables have been set the green status LED on the PCE840 should be ON 13 Select VelCmd2 in the variables screen and set it to a non 0 value Performing this step causes motion 3 12 PCE830 40 User Manual Danaher Motion PCE840 14 If the motion command is successful switch the control mode back to SERCOS control and bring the ring to phase 4 The 840 requires that certain IDNs The list is contained in IDN 18 be written for a succesful phase 2 to phase 3 transition This list currently contains 10 IDNs which are The master typically handles setting this list except for IDN 15 and IDN 32 IDN 15 and IDN 32 need to be set by the master in phase 2 before a phase 2 to phase 3 transition can be initiated 15 Once in phase 4 the parameters that had been previously set with 800Tools and IDN 15 and 32 can all be saved to non volatile memory This can be accomplished by writing a 3 to IDN 264 which runs the NVSave procedure command 16 At this point the SERCOS master configura
127. anical Rev sec Move Done Indicates that a move is complete No Function Turns off mappable output functionality Zero Speed Activated when the motor s speed goes below the speed threshold set by the parameter ZeroSpeedThresh Active hi lo Each of the digital outputs can be defined as either active high or active low If the mappable output function bit is configured as active HIGH LOW when the function bit is asserted the output is HIGH LOW For example if Move Done is configured as active high when the move is complete the output goes high PCE830 40 User Manual 2 43 PCE830 Procedure Excess Position Error Setup Related Parameter s 2 44 Danaher Motion To assign a mappable output function to a digital output 1 Click either the Create New Configuration or Edit Exisiting Configuration button 2 Select the appropriate Motor and Drive Type and the Mode of Operation Click Next 3 Click the Digital I O tab Select the output or relay that is being assigned a function 4 Select the desired function from the drop down list box Drive Motor Drive Type Motor Type 42 Mode of Operation Velocity Mode Serial Command Input Functions Inputl Faut Reset Input2 Clockwise Inhibit hi Input3 Counterclockwise Inhibit hi gt Input4 Command Gain Select hi Input5 Position Mode Select hi
128. anual 2 57 PCE830 Danaher Motion 3 Click on the Predefined Moves tab to configure the parameters associated with each of the predefined moves Velocity Move lt no name assigned yet gt g s 2 g 3 g ES St 2 58 PCE830 40 User Manual Danaher Motion PCE830 Homing The homing functionality of the PCE830 allows the user to establish a home position based on four different home references The table below lists each of the references used for homing and describes how each establishes the home position Home reference Description Home Switch Transition of Home Switch Requires one of the Digital Inputs to be mapped to the HomeSwitch function Marker Pulse Internal resolver marker pulse Home Switch Marker Pulse Transition of Home Switch then marker pulse Use Present Position Current position is established as home position marker pulse Select Inp4 if the encoder Z channel is to be connected to digital Input4 or Reg2 Inp5 when connecting to digital Input5 Make sure the mapping for the input used is set to No Function If using encoder feedback the physical Z channel from the encoder is used as the Marker Pulse If using resolver feedback all home moves to a marker pulse will be based on Using resolver position equal to zero ResPos 0 Resolver Marker Pulse If using encoder feedback all home moves to a marker pulse will be based off the Using
129. aused by springiness between motor inertia and load inertia This may result from belts flexible couplings or the torsional stiffness of shafts In general the stiffer the couplings the higher the resonance frequency and the easier it is to tune the system for good performance If the velocity loop breaks into an oscillation at a frequency well above the calculated velocity loop bandwidth a resonance problem may exist A second symptom is that the frequency of oscillation 15 relatively constant even with changes to ARFO and ARFI Two digital anti resonant low pass filters and are included in the velocity loop Their purpose is to lower the gain above fyc especially at any resonant frequency gt so oscillations do not occur Recommended values are fye Hz Hz Hz 25 100 200 75 100 default 750 default 200 1500 10 ARZO IDN 32841 and ARZI IDN 32842 are generally not needed and should be set to 0 which eliminates them entirely However for advanced compensation ARZO and ARZI can be used to add lead compensation or used together to add a notch filter ARZO positive sets the zero frequency in Hz If ARZO is less than zero ARZO sets the underdamped zero pair frequency in Hz and ARZI sets the underdamped pair Q First velocity loop compensation zero This IDN should typically be set to ARZO Hz 100 0 The units of ARZO are 0 01 Hz Se
130. b cig Print Download To Drive Your configuration is complete now but you should either save it in a file or download it to a drive Press one of the buttons above to save this configuration Back Finish gt gt Help 7 Select Download Drive Upon completion of the download the following screen is displayed PCE830 40 User Manual 3 11 PCE840 Danaher Motion CT xi 2 Your configuration has been downloaded Do you want to have it saved the drive s non volatile memory IF you answer NO the changes will be lost when the drive is powered down Mo 8 Click No 9 Click Finish on the next screen At this point the main 800TOOLS screen should be displayed The default tuning parameters for the unloaded motor have now been downloaded to the drive 10 Select Edit Online and the following screen 15 displayed On Line Drive Configuration E x Variables and Parameters Commands Drive PC843 Motor PMA22B NVLoad Mode Velocity Mode Serial Command Controls power to the motor Enable fi Change _ Target velocity command selected when VelCmdSre 1 2 10 000 RPM Sets the proportional gain of the velocity loop Inputs Outputs 0 098 amps rad sec Change 1 1 Sets the maximum acceleration rate of motor 3 off 2 Off JaccelLmt 999993472 000 RPM sec Ch
131. ber Sets the acceleration rate a velocity command is processed at Acceleration Deceleration Conversion Scaling Factor 1 Data Length 4 bytes Units Motor acceleration RPM sec IDN 161 10 IDN 162 Minimum Value 1 Maximum Value 4 294 967 295 Access State Read Write in phases 2 4 IDN 263 NVLoad Command Data IDN Unsigned Decimal Number Commmand Procedure IDN used to load saved IDNs from Non Volatile NV memory to the drive s active memory IDN263 is typically executed in phase 2 eliminating the need to initialize many of the IDNs listed in IDN192 This will reduce the initialization time Conversion Scaling Factor 1 Data Length 4 bytes Units Motor acceleration RPM sec IDN 161 10 IDN 162 Minimum Value 0 False Maximum Value 3 True Access State Read Write in phases 2 4 IDN 264 NVSave Command Data IDN Unsigned Decimal Number Commmand Procedure IDN used to save IDNs to Non Volatile NV memory from the drive s active memory The master need not write to these IDNs as part of the drive initialization thereby substantially reducing the time required to bring the SERCOS ring to Phase 4 Conversion Scaling Factor 1 Data Length 2 bytes Units Minimum Value 0 False Maximum Value 3 True Access State Read Write in phases 2 4 3 92 PCE830 40 User Manual Danaher Motion PCE840 IDN 301 Allocation Of Realtime Control Bit 1 Parameter Data IDN Unsigned Decimal Number The Master sends t
132. bout 10mm 0 57 of the outer jacket of these cables where the clamp will be exposed to the braided shield before inserting under the clamp and tightening The length of the cable between the drive connection and the clamp should be as short as possible not exceeding 0 6 meters two feet If a ground plane is available at the other end of these cables use a conductive clamp at that end to connect the shield to that ground plane as well Provide a minimum unobstructed space of 100 mm 4 above and below the drive With convection cooling provide 40mm 1 6 free space on either side of each unit With forced air cooling provide 25mm 1 free space on the side of the drive with the heat sink Insure the environment within the cabinet meets the requirements defined in the Specifications section PCE830 40 User Manual Mounting and Installation Danaher Motion ALON jddns ay JY AGIZ 24 01 294085 abeyoa sng ay asnesaq snq jy 34 jjo q ay 0 a qissod jou s y 00833 94 28 HIQNI 8 ANN HS 39029 599029 2IJILN3IDS 21412 4 YOLOW 5521 5 gt QqaH13v3 Connection Diagram 32 404 Q3lno33 2
133. c Gearing e Predefined Moves Hold Position Setup 1 For Electronic Gearing provide a Digital Command Source such as an encoder or step and direction signals Click the Edit Drive Configuration OnLine button Set EncMode to the type of Digital Command Source provided 2 To define moves click on the Predefined Moves tab and the Digital I O tab to define MoveSelectBits and StartMove inputs 3 To Hold Position activate the input Related See CmdGain VelCmd and BIkType Operation Mode in on line Help Parameter s PCE830 40 User Manual 2 41 PCE830 Run Stop Setup Related Parameter s Velocity Command Source Setup Related Parameter s 2 42 Danaher Motion In any operating mode the command source can be switched to 0 rpm for Clutch Brake with NO holding torque StopTime sets the amount of time before disabling the motor after the RunStop function is activated This allows for a controlled stop In Velocity Mode or Position Mode use DecelLimt to decelerate the motor before it disables 1 Click the Edit Drive Configuration Online button 2 Change the value of StopTime When you activate the RunStop input the command switches from operating speed to 0 rpm and the drive disables after StopTime See StopTime in on line Help In Torque Mode the command source can be switched between VelCmd and VelCmd2 for e Torque inhibit if VelCmd2 0 e Torque preset select if VelCmd2 is non zero In Velocity Mode
134. cations 5 SPECIFICATIONS 5 1 Output Power Specifications PCE8x3 8 5 Peak Output Current 5 3 seconds 0 to 40 Ambient 7 5 22 5 Continuous Output Current RMSy Convection 0 to 40 Ambient 3 75 7 5 Forced Air 0 to 40 C Ambient N A 11 25 Peak Output Power 1 sec Idealized Peak rectangular torque vs speed 380 VAC 5 kW 15 2 kW 400 VAC 5 3 kW 16 0 kW 480 VAC 6 4 kW 19 2 kW Drive amp Motor System Peak Typical 380 VAC 2 8kW 8 5 kW 400 VAC 3 1 kW 9 3kW 480 VAC 4 2 kW 12 5 kW To convert to A 0 pk multiply Arms 1 41 Peak current 3 sec PCE8x3 10 6A 0 pk PCE8x5 31 8A 0 pk Above 40 C ambient linearly derate to 50 C rating 0 67 40 C rating Forced air rating of requires 3 6 x 1 fan mounted 2 below drive PCE8x5 internal fan by itself does not provide sufficient cooling for forced air rating Varies with the motor Maximum peak output power with most motors at 480V AC is between 60 and 70 of Idealized Peak Power PCE830 40 User Manual 5 1 Specifications Continuous Output Power Drive amp Motor System 380VAC Convection Forced Air 400VAC Convection Forced Air 480VAC Convection Forced Air RMS Line Current Continuous Output Power 380 400 480V AC Convection Forced Air Power Stage Efficiency Peont Shunt Regulator Power Peak Power 300 mSec Continuous Power with standard regen resistor
135. cess State Read only by the Master 3 96 PCE830 40 User Manual Danaher Motion PCE840 IDN 405 Probe 1 Enable Parameter Data IDN Binary Data This bit must be set by the Master either by Cyclic or Service Channel in order for Probe 1 Data to be latched Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master IDN 406 Probe 2 Enable Parameter Data IDN Binary Data This bit must be set by the Master either by Cyclic or Service Channel in order for Probe 2 Data to be latched Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master IDN 409 Probe 1 Positive Latched Parameter Data IDN Binary Data information Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master PCE830 40 User Manual 3 97 PCE840 Danaher Motion IDN 410 Probe 1 Negative Latched Parameter Data IDN Binary Data information Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 411 Probe 2 Positive Latched Parameter Data IDN Binary Data information Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 412 Probe 2 Negative Latched Parameter Data IDN Binary Data informat
136. city error at speed changes Increase KVP to optimize performance and miminize velocity error If the motor starts to buzz KVP is too large Disable the drive and reduce KVP 20 00 000 secon ds m Velocity Command AL A _____ va E m E a a a E 0 02 sec div PCE830 40 User Manual 2 77 PCE830 Danaher Motion TIP You can get more information by monitoring Current Feedback instead of Velocity Command When monitoring current look for oscillations or spikes that are not related to profile rate changes If these current oscillations are greater than 5 of peak rated current KVP is too large Also if the current is oscillating it reduces available rated current used to drive the profile After KVP is optimized slowly increase KVI up to a maximum of 5 Look for overshoot or oscillation during moves and reduce KVI if unstable Set KVFF 0 and slowly increase KPP to a maximum of 15 Look for overshoot or oscillation and reduce if unstable i 00 000 seconds Iof xi M Channel 1 mem Source Current Feedback Units Amps thick trace Scale Amps per division Pacific Scientific SoftScope lol CK _ T l WW MMN SEL L l1 Current Feedback Velocity Fe
137. clamped to the ground plane described above If cable with a separate inner foil shield and outer braided shield is used Pacific Scientific CE cables for example connect the foil shield to the PE or location on the connector and clamp the outer braided shield to the ground plane If the leads for a motor holding brake are run with the motor leads the holding brake leads must be separately shielded and the shield connected to the PE or location on the TB1 connector e The resolver cable should have inner shields around each twisted pair as well as an overall outer braided shield The inner shields are connected to J3 pin 5 while the outer shield are clamped to the ground plane e The control leads to the J2 connector should have an outer braided shield with the shield terminated through a conductive shell or clamped to the ground plane e When using an external regen resistor if regen cabling is accessible during normal machine operation regen resistor cable should be rated at 600 VDC and shielded with shield connected to PE Grounding the Motor Case Insure that the motor s case is connected to PE ground by connecting the fourth wire 1 10 in the motor cable to the motor case If the motor is not properly grounded dangerous voltages can be present on the motor case due to capacitive coupling between the motor windings and case PCE830 40 User Manual Danaher Motion Mounting and Installation 1 1 6 Long Motor P
138. cond velocity loop compensation zero This IDN should typically be set to ARZI Hz 100 0 The units of ARZI are 0 01 Hz First velocity loop compensation anti resonance low pass filter corner frequency This IDN should typically be set so that IDN 32843 ARFO Hz 100 1000 for Gentle Response 15000 for Medium Response 150000 for Stiff Response PCE830 40 User Manual 3 53 840 IDN 32844 Procedure Backlash Current Ripple 3 54 Danaher Motion Second velocity loop compensation anti resonance low pass filter corner frequency This IDN should typically be set so that IDN 32844 ARFI Hz 100 2000 for Gentle Response 75000 for Medium Response 10000000 for Stiff Response 1 Set both and ARFI to 400 Hz and set low enough to prevent oscillation 2 Increase KVP slowly until oscillation at the resonant frequency just begins Reduce KVP slightly until the oscillation just stops Compute the velocity loop bandwidth using the formula given at the beginning of this section If the velocity loop bandwidth 1s less than 25 times the value of ARFO and proceed to Step 3 Otherwise go to Step 4 3 Decrease both ARFO and ARFI by 20 and go back to Step 2 4 The velocity loop bandwidth should now be approximately one quarter the value of ARFO and ARF1 For margin reduce and ARFI by 20 Some backlash may be unavoidable especially when gear re
139. ct the 9 pin serial port socket on the PCE830 40 to the PC If this cable is unavailable a simple 3 wire cable can be made using the wiring diagram shown on page 1 3 If you are using the drive s 24VDC supply connect I O RTN J2 38 to 24 output RTN J2 39 The last connection needed is to provide the hardware enable to the PCE830 40 via J2 37 and 24V on J2 40 Preferably connect a toggle switch between 12 37 and J2 40 a toggle switch is not available a clip lead that can connect or not connect J2 40 to J2 37 will do PCE830 40 User Manual 1 1 Mounting and Installation Danaher Motion Installing the PCE800 Servo Drive 1 1 1 2 mmi em Mounting the Drive The PCE830 40 drives are designed for operation in a cabinet Follow these installation instructions Mount the drives vertically inside a cabinet on a flat solid electrically conductive mounting surface connected to PE protective earth ground and capable of supporting the weight of the unit Remove the paint on the mounting surface over an area extending at least 12 mm 0 5 from the mounting bolts to achieve good electrical connection over a large area between the drive and grounded mounting surface Install conductive clamps near the drive on the mounting panel ground plane for electrically connecting the outer shield of certain cables defined below to the panel The conductive clamps can also be attached to PE on the front of the drive Remove a
140. ct to former issues Limited Warranty Includes software provided by Pacific Scientific Seller warrants that the Goods sold hereunder are free from defects in material and workmanship for the product warranty period of each item of Goods Product Warranty Periods are listed below Seller warrants its Good s only to the original purchaser the Customer and in the case of original equipment manufacturers or distributors only to their original consumer the Customer There no warranties whatsoever on Goods built or acquired wholly or partially to a buyer s designs or specifications This express warranty 15 in lieu of and exclude all other warranties express or implied by operation law or otherwise including THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE WHETHER KNOWN TO SELLER OR all other such warranties being hereby expressly disclaimed by Seller and waived by Buyer Written notice of claimed defects shall have been given to Seller within the period set forth in the schedule below and within thirty 30 days from the date any such defect is first discovered Product Warranty Schedules Brand Products Warranty Period Pacific Products 24 months from date of Scientific manufacture Superior Products 12 months from date of manufacture Kollmorgen Standard Brush type 12 months from date of Motors Electronics and manufacture Accessories Kollmorgen Standard Brushl
141. ctor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 3 Access State Read Write by the Master in phases 2 4 IDN 100 Velocity Loop Proportional Gain Parameter Data IDN Unsigned Decimal Number Allows the master to set the value of kvp Amp rad sec IDN 100 kvp Ipeak 193 38e 6 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65534 Access State Read Write by the Master in phases 2 4 IDN 101 Velocity Loop Integral Gain Parameter Data IDN Unsigned Decimal Number Allows the master to set the value of kvi Hz 101 kvi 51 4719 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 1 Maximum Value 65535 Access State Read Write by the Master in phases 2 4 3 78 PCE830 40 User Manual Danaher Motion PCE840 IDN 103 Modulo Value Parameter Data IDN Unsigned Decimal Number If bit 7 of IDN 76 is set to modulo format the modulo value defines the range that the drive and control must implement This IDN is scaled by IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units Modulo value 65536 IDN 79 Minimum Value 10 Maximum Value 2 147 483 647 Access State Read Write in phase 2 Read only in phases 3 and 4 IDN 104 Position Loop Kp Factor Parameter Data IDN Unsigned Decimal Number Allows the master to set the value of kpp Hz IDN 104 kpp 2 4324e 3 for resolver feedback IDN104 4 kpp 2 4324e 3 for encoder feedbac
142. cy 131 Probe Value 1 Negative Edge 34824 Input Port 132 Probe Value 2 Positive Edge 34825 Analog Input 133 Probe Value 2 Negative Edge 34826 Encoder Position 189 Following Distance Conversion Scaling Factor 1 Data Length Access State 2 bytes data Variable length Read Write by Master in phases 2 4 PCE830 40 User Manual 3 89 PCE840 Danaher Motion IDN 188 IDN List Of The Configurable Data Record In The MDT Parameter Data IDN IDN ID Number List List of IDNs available for entry into the MDT configuration list IDN IDN Description 36 Velocity Command 47 Position Command 80 Torque Command 32880 Analog Output 1 32881 Analog Output 2 34840 Output Port Conversion Scaling Factor 1 Data Length 2 bytes data Variable length Access State Read only by the Master IDN 189 Following Distance Parameter Data IDN Signed Decimal Number Allows the Master to read the current instantaneous Position Error This value is scaled by IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units Following Distance IDN 79 65536 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read only by the Master 3 90 PCE830 40 User Manual Danaher Motion PCE840 IDN 192 IDN list of backup operation data Parameter Data ID
143. d e The output stage is disabled e The Fault mappable output function is activated e The LED indicates the appropriate fault code Faults are cleared by activating the Fault Reset input or by turning the 120 240VAC Control Power OFF and ON again See the following table for a detailed list of drive status LED codes Drive Status Fault LED Red Power LED Green Faulted If FaultCode lt 6 Blinking On If FaultCode 3 6 On Enabled Off On Disabled Off Blinking Unconfigured Blinking Blinking Unplugged Off Off on and off in 1 sec It is then off for 2 seconds before blinking the If FaultCode lt 6 red LED blinks the faultcode at a frequency 1 Hz sequence again Nuisance over current trips may occur under the following condition Control power is ON and drive is enabled but bus power mains are switched OFF When AC bus power comes on motor current briefly exceeds the command to clear the saturated current loop integrator Usually this is not a problem but in some motor drive combinations especially when the motor inductance is low the current overshoot can trip the overcurrent detector To avoid this problem do ONE of the following e Switch ON the control power and bus power simultaneously e If control power remains ON while bus voltage is down put the drive in the Disable state DO NOT enable the drive until after the bus voltage comes up
144. d The roller has a diameter of 3 82 inches and must advance roughly 24 inches of material in 1 second A PLC provides an input to emulate a clutch brake operation commanding zero velocity and stopping motor motion A second input from the PLC also reverts the drive to maintain motor position during the cut and seal process The cycle is then repeated First calculate the required CmdGain to provide the necessary speed for the 1 second move Roller Circumference p Roller Diameter p 3 82 inch 12 inch Distance for motor to move 10 24 inch move 12 inch rev 20 revs Velocity 20 rev sec 1200 rpm CmdGain krpm V AnaloglIn V CmdGain 1 2 Krpm 2 5V 0 48 Krpm V Velocity RPM 1200 Determined by n Determined by AccelLmt rpm s DecelLmt rpm s 04 a Velocity Velocity Position Command Command Mode Source Source Select inactive active active PCE830 40 User Manual 2 A7 PCE830 Procedure 2 48 Danaher Motion Create a new configuration and select Velocity Mode as the mode of operation Click the Digital I O tab Select Velocity Command Source as the function on Input4 to switch between the sources of two unique velocity commands Select Position Mode Select as the function on Input5 to switch between velocity and position modes of operation This step is optional depending upon whether your application can tolerate a small amount of drift when commanding zero velocity as a
145. d for the velocity command into the velocity block Also sets the overspeed fault threshold if VelL mtHi gt VelLmtLo Overspeed fault set at 1 5 max of VelLmtHi VelLmtLo Conversion Scaling Factor 0 001 Data Length 4 bytes Units RPM Minimum Value 21 039 000 Maximum Value 21 039 000 Access State Read Write by the Master 3 108 PCE830 40 User Manual Danaher Motion PCE840 IDN 32835 Coast Time Parameter Data IDN Unsigned Decimal Number Allows the amount of time the drive will coast for after the bus voltage drops below VBusThresh before generating undervoltage fault Conversion Scaling Factor 1 Data Length 2 bytes Units Seconds Minimum Value 0 Maximum Value 32 Access State Read Write by the Master IDN 32836 CommEnbl Parameter Data IDN Unsigned Decimal Number Enables commutation of the motor current based on rotor position When the drive powers up CommEnbl is set to 1 When CommEnbl is set to 0 the commutation angle of the current flowing in the motor windings is determined by the value of CommOff When CommEnbl is set to 1 the commutation angle is determined by the sum of CommSrc feedback device electrical angle and the CommOff variable Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master IDN 32837 Motor 1 Name Parameter Data IDN Binary Data The Motor variable is a 32 bit long unsigned long integer which is used
146. de The controller can be enabled at this time by closing the switch between the Enable input 72 37 and 24VDC J2 40 Once enabled the Power LED should be ON The commanded motor speed will be the power up default set to 0 during configuration Because the parameters were saved in non volatile memory the controller can now be power cycled and after power up be ready to run with the parameters established during this session Before proceeding the motor should be attached or temporarily clamped to the table or bench The inertial forces created during speed steps may make the motor hop around PCE830 40 User Manual Danaher Motion 2 1 6 Changing Variables On Line Changing Motor Velocity PCE830 Click Edit Drive Configuration On Line to activate the variables window Select VelCmd from the Variable dropdown list box The current value of VelCmd is displayed On Line Drive Configuration x Getting Help r Variables and Parameters Drive PCE833 Motor Mode Velocity Mode Serial Command Target velocity command 0 000 Deceleration rate of move Move3DecelRate 0 000 5 Incremental or absolute position of move ActiveDistance 71 counts Distance offset from final commanded position ActiveDistOffset counts of home move Switch Low pass filter corner freq for drive I t thermal protection
147. ded load current is 20 mA which corresponds to a minimum line to line load resistance of 100 This drive capacity corresponds to ten RS 422 compatible inputs such as the PCE840 encoder inputs This output is indefinitely short circuit proof to I O RTN These two connections provide an auxiliary power supply for the user This output is SVDC 5 and is short circuit protected at 1 A nominal The maximum load limit for all connections to this supply is 250 mA The 5VDC J2 15 is connected to I O RTN J2 3 J2 7 J2 16 J2 30 CH A IN CH A IN CH B IN IN Step Step Dir Dir Step Up Step Up Step Dn Step Dn These inputs are used as a quadrature encoder step and direction or up and down count format incremental signal source The decoding mode is set by the EncMode parameter The scale factor of this incremental position command input is fully adjustable with software parameters Full decoding speed or more noise immune slow speed decoding is software selectable These two input pairs are differential and are detected by 26LS32 type RS 422 compatible line receivers As differential inputs the recommended common mode range is lt 7V with respect to I O RTN and the guaranteed differential voltage logic thresholds are gt 0 2V Recommended drivers should be able to source and sink 3 mA to from these inputs Each of these inputs has internal bias networks to allow easy connection to single ended sourc
148. der line count 1 2 bytes Emulated encoder count 0 16384 Read Write by the Master PCE830 40 User Manual Danaher Motion IDN 32817 InpMap1 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32818 InpMap2 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32819 InpMap3 PCE840 Parameter Data IDN Binary Data OxFFFF Read Write by the Master Parameter Data IDN Binary Data OxFFFF Read Write by the Master Parameter Data IDN Binary Data Refer to Map List Column for the desired function Set High Low us bits as Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State PCE830 40 User Manual OxFFFF Read Write by the Master 3 103 PCE840 Danaher Motion IDN 32820 InpMap4 Parameter Data IDN Binary Data Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access State Read Write by the Master IDN 32821 5 Parameter Data IDN Binary Data Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access State Read Write by the Master IDN 32822 InpMap6 Parameter Data IDN Binary Data Refer to p Map List Panchos pu Column for the desired function Set High Low D bits as Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access S
149. duction is used backlash is present the inertia match must be good load inertia should be roughly equal to motor inertia for good servo performance Gearing reduces the inertia reflected to the motor by the square of the gear reduction from motor to load Select a gear ratio to give the required match The velocity feedback signal in standard PCE830 drives operating with the standard 20 arcmin resolver can have up to 3 p p ripple The resulting motor torque current ripple with no ARFO ARFI filtering is calculated using the following formula Current ripple amps p p UY Speed gt 20 03 RPM There can be cause for concern when this number exceeds 40 of the drive s or motor s current rating Monitor the motor current using DAC Monitors on J2 4 to insure that actual ripple current with ARFO ARFI filtering is not excessive Motor current ripple is often reduced by lowering the ARFO ARF1 low pass filter break frequencies This benefit is limited by velocity loop bandwidth and stability constraints Velocity feedback ripple and motor current ripple can also be reduced by specifying a higher accuracy resolver PCE830 40 User Manual Danaher Motion KVI IDN 101 PCE840 The parameter KVI sets the lag break frequency of the velocity loop KVI is equal to the frequency in Hz where the velocity loop compensation transitions from predominantly integral characteristics to predomi
150. e Master in phases 2 4 PCE830 40 User Manual 3 113 PCE840 Danaher Motion IDN 32858 Last Fault Parameter Data IDN Signed Decimal Number Returns the last fault occurred in the drive The value of this IDN is NOT cleared by a fault reset command A user can clear Last Fault by explicity writing 0 to this IDN See IDN 129 for description of faultcodes Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 22 Access State Read only by the Master in phases 2 4 IDN 32859 Last ExtFault Parameter Data IDN Signed Decimal Number Returns the last extended fault occurred in the drive The value of this IDN is NOT cleared by a fault reset command user can clear Last ExtFault by explicity writing 0 to this See IDN 129 for description of faultcodes Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 69 Access State Read only by the Master in phases 2 4 IDN 32860 OutMap1 Parameter Data IDN Binary Data Refer to Output Map List Function Number Column for the desired function Set High Low Polarity bits as required Please refer to Sectioni3 5j Interfaces and Connections for additional information Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access State Read Write by the Master 3 114 PCE830 40 User Manual Danaher Motion IDN 32861 OutMap2 Conversion Scaling Factor Data Length Minimum Value
151. e active Probing Cyclic Procedure Command A probing cycle procedure must be active in order for a probe event to be captured This is done by writing a 3 to IDN 170 To cancel probeing control write a 0 to IDN 170 Probe 1 Enable Probe 1 must be enabled in order to capture a probe 1 event Bit Number Setting 0 0 Probe 1 Not Enabled 1 Probe 1 Enabled Probe 2 Enable Probe 2 must be enabled in order to capture a probe 2 event Bit Number Setting 0 0 Probe 2 Not Enabled 1 Probe 2 Enabled The above three items must be done to capture a probe event They may be done in ANY order Once the above items have been set and the correct edge has occurred on the probe time probe data will be latched Once the probe data are latched and ready to be sent to the Master the correct Probe Latched bit IDNs 409 412 will return a 1 when read e The latched position data can be read through IDNs 130 133 The initial default data is 0 Data are updated only after a probe event has occurred The probe event can be reset by clearing any of the four control IDNs IDNs 169 170 405 406 and then re enabling them PCE830 40 User Manual 3 43 840 Example Cyclic Channel Realtime Control Status Bits Example 3 44 Danaher Motion Writing 1 to IDN 169 Probe Control Parameter will cause Probe 1 Positive Edge events to be recorded IDNs 405 and 170 m
152. e minutes after turning off power before removing any cables from the drive or removing the drive from the mounting panel Never connect or disconnect any wiring to the drive while power is applied Always power down and wait five minutes before connecting or disconnecting any wires to the terminals The temperature of the drive s heat sink and housing as well as external regen resistor be as high as 70 C 158 F There is a danger of severe burns if these regions are touched PCE830 40 User Manual Danaher Motion PCE830 2 PCE830 2 1 800Tools This section provides a step by step introduction to setting up the PCE830 This procedure uses the minimum possible equipment to run an unloaded motor and set motor speed from a PC s serial port It is strongly recommended that all first time users go through this procedure to become familiar with the PCE830 and the PC interface software before installing the servo system in a machine 2 1 1 Installing 800Tools Procedure To install 800Tools 1 Insert the 800Tools Installation disk in your CD ROM drive D From the Windows95 or NT Start menu select Run At the Command Line type D setup exe and click OK 2 The install wizard will guide you through the installation A When finished the 800Tools disk should be removed from the PC and stored in a safe place 2 1 2 Starting 800Tools Procedure begin using 800Tools select Start Program Files Pacific Scientific S00
153. e set so that IDN 32809 ADFO0 Break Frequency of Analog Input Filter in Hz 3 6 4 Analog Outputs The analog outputs can be set to various output functions including a user specified voltage The Analog Output function is selected using the DACMAP IDNs IDNs 32814 and 32815 The DACMAP functions must be OFF IDNs 32814 or 32815 zero for user controlled AnalogOut AnalogOutl can be written to using IDN 34841 AnalogOut2 can be written to using IDN 34842 The break frequencies for the Analog Outputs low pass filter IDNs DMIFO IDN 32810 and DM2F0 IDN 32811 IDN 32810 DMIFO sets the frequency in Hz of a single pole low pass filter on the DAC Monitor 1 output J2 4 This should be set so that IDN 32810 Break Frequency Hz IDN 32811 DMZ2FO sets the frequency in Hz of a single pole low pass filter on the DAC Monitor 2 output J2 5 This IDN should be set so that IDN 32811 Break Frequency Hz PCE830 40 User Manual 3 45 PCE840 Danaher Motion Analog IDNs Below is a list of the Analog Input and Output IDNs IDN Description Function 32809 ADFO Break Frequency for AnalogIn in Hz 34825 AnalogIn Analog Voltage Input 32810 DMIFO Break Frequency for AnalogOut 1 in Hz 32811 DM2F0 Break Frequency for AnalogOut 2 in Hz 32812 DMIGAIN Gain for AnalolgOut Scaling varies according to function 32813 DM2GAIN Gain for AnalogOut2 Scaling varies acco
154. e software variable ExtFault PCE830 40 User Manual 2 89 Danaher Motion PCE830 ExtFault The following table lists the values for ExtFault ExtFault ExtFault Description Absolute Resolver Overspeed VelFB gt 21038 RPM 2 Variable Resolver Overspeed VelFB gt max VelLmtxx 1 5 3 Calibration data corrupted 4 Excessive DC offset in current feedback sensor 5 DSP incompletely reset by line power dip 8 Excessive dc offset in Analog Command A D 9 Not Assigned 10 DSP stack overflow 12 Software and control card ASIC incompatible 13 Actual Model not same as stored in NV memory 14 Unable to determine power stage 15 Drive non volatile parameters corrupt 16 RAM failure 17 Calibration RAM failure 18 Encoder alignment no motion fault 19 Encoder alignment excessive motion fault 20 Encoder alignment motor not settled 21 Encoder alignment test failed 22 Encoder alignment motion overflow fault 23 Hall Commutation invalid configuration 24 Hall Commutation overspeed 25 Hall Commutation invalid hall state 26 Hall Commutation invalid hall transition 27 I t Drive 28 I 2 t Motor These fault states CANNOT be reset with the Fault Reset function They require the line control power to be turned OFF and ON again 2 90 PCE830 40 User Manual Danaher Motion PCE830 2 6 2 Fault LED Troubleshooting A table of faults and
155. ed in the operation data of this IDN If IDN 129 0x0314 Faultcode 20 and ExtFault 3 the diagnostic message will be Initialization Fault Calibration data corrupted Fatal Fault Conversion Scaling Factor 1 Data Length 1 byte data Variable length Access State Read only by the Master IDN 96 Slave Arrangement 0 Parameter Data IDN Binary Data The 840 returns its axis address in both the low and high byte of this IDN The PCE840 is not capable of supporting multiple motors on a single drive Valid axis is not capable of supporting multiple motors on a single drive Valid axis Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0x0101 Maximum Value OxFEFE Access State Read only by the Master PCE830 40 User Manual 3 77 PCE840 Danaher Motion IDN 99 Reset Class 1 Diagnostic Command Data IDN Unsigned Decimal Number Command Procedure IDN Used to clear recorded faults in the PCE840 Faults which cause the PCE840 to cycle back to phase 0 are recorded and saved for transmission in phase 2 The PCE840 will automatically notify the Master upon completion of this Command IDN While this Command IDN is being performed other service channel IDNs may be processed Write 3 to IDN 99 to initiate Reset Class 1 Diagnostics this will reset the fault and disable the drive Write 0 to IDN 99 to de activate the fault reset command The drive cannot be enabled while fault reset is asserted Conversion Scaling Fa
156. edback Offset Amps M Channel 2 mmm Source Velocity Feedback Units thick trace 3 5 200 E EE Offset p Rpm Trigger Single Sweep cni 2 rising edge Enabled Level 50 Rpm Timebase 2 Print 002 sec div In this waveform the current feedback is extremely low and the ripple shown is acceptable normal because it is much less than 5 of peak rated current 2 78 PCE830 40 User Manual Danaher Motion PCE830 Overdamped x Current Feedback p po po 2 rising edge 0 01 sec div The overdamped undershooting velocity loop does not respond to velocity changes disturbances quickly It has soft smooth motion It requires extra time to settle Increasing KVI and or KVP brings the system closer to critically damped Remember when increasing KVP the ARFx filters may need to be increased proportionally PCE830 40 User Manual 2 79 PCE830 Danaher Motion Underdamped 27 00 000 seconds xi Channel 1 mem Source Current Feedback E Units Amps thick trace 4 i Amps per division Offset 0 Amps Pacific Scientific SoftScope MEN NN Channel 2 mmm Source Velocity Feedback Units thick trace 5 500 EE Offset p Rpm
157. ency Command Frequency Pulse Each of the drive s operating modes can be easily set up using Create New Configuration Or Edit Existing Configuration buttons of 800Tools The DE Refer to Section 9 7 Servo control block diagrams and additional information on velocity and position loops PCE830 40 User Manual 2 55 PCE830 Danaher Motion 2 4 1 Position Mode Predefined Moves This mode allows the user to define up to 8 distinct moves The predefined moves may be selected and then triggered using the digital inputs on J2 31 through J2 36 Procedure 1 Create a new configuration and select Position Mode Predefined Moves as the mode of operation 2 Click the Digital I O tab to define MoveSelectBits and a StartMove input Digital I O Tab lt no name assigned yet gt x Drive M Motor Drive Type PCE833 gt Motor Type 42 gt Mode of Operation Position Made Predefined Moves M Digital 1 0 Analog 0 Loop Gains Position Controller Predefined Moves Feedback Functions 1 Dutput Functions Input1 Fault Reset hi Output Fault lo Input2 Move Select Oupu2 NoFunon e Input3 Move Select Bitl Qutput3 NoFunction Input4 Move Select Bit2 Relay Function Output 4 Input5 Start Move hi Input6 No Function x Relay Brake lo Next gt gt Help 2 56 PCE830 40 User Manual Danaher Motion PCE830
158. er Feedback Specifications Unless otherwise specified the below specifications are worst case limits and apply over A the specified operating ambient temperature and over the specified operating line voltage Resolver Position Signal Resolution Rev Repeatability Noise No Filtering 150 Hz Single Pole Filtered 10 Hz Single Pole Filtered DC Offset Temperature Drift Absolute Accuracy Drive only Drive with 20 arc min resolver Software Update Time 24 bits 0 0013 arc min lt x27 Rey 0 08 arc min rms lt 2716 Rev rms 0 3 arc min rms lt 2 Rev rms 0 16 arc min rms lt 27 Rev rms 0 04 arc min rms lt 2 Rev C 0 08 arc min C 21 Rey 5 3 arc min 2975 Rey 25 arc min mSec PCE830 40 User Manual Danaher Motion Resolver Velocity Signal Resolution Quanta Noise No Filtering 150 Hz Single Pole Filtered 10 Hz Single Pole Filtered DC Accuracy Typical 25 C Worst case Ripple Drive only Drive with 20 arc min resolver Offset Software Update Time Emulated Encoder Output Signals Available Resolutions PPR Binary Decimal Maximum Output Line Frequency Max Recommended Speed 16384 PPR Max Recommended Speed 4096 PPR Marker Pulse Width PCE830 40 User Manual Specifications lt 0 001 RPM 0 0143 lt 3 RPM rms lt 0 6 RPM rms 0 06 RPM rms 0 01 0 05 0 75 p p at 1000 RPM 3 p p at 1000 RPM lt 0 0001 RPM 250 128 256 512 1024 2
159. er Manual 2 67 PCE830 Danaher Motion 2 4 7 Torque Mode Analog Command This mode allows the differential analog voltage between terminals J2 1 and J2 2 to set the motor s current Since torque command Current command Icmd Kteff controlling current is equivalent to controlling torque The analog input directly controls motor shaft torque output current amplitude in amps per input volt is set by the CmdGain parameter directly in Amp V and should be set by the user to the desired value Procedure 1 Select Torque Mode Analog Command from the Mode of Operation dropdown list box 2 Set CmdGain to the desired value Torque Controller no name assigned yet x Drive Motor Motor Type 42 Y Drive Type Mode of Operation Torque Mode Analog Command Y Digital 1 0 Analog 1 0 Loop Gains Torque Controller Predefined Moves Feedback Gain and Offset Current Limits Command Gain 1 00000 amps volt Positive 100 of peak Offset Voltage 0 00000 volts Negative 100 of peak Cancel Next gt gt Help 2 68 PCE830 40 User Manual Danaher Motion PCE830 2 4 8 Torque Mode Frequency Command This mode is the same as the Torque Mode Analog Command except that the command input comes from the Incremental Position Command inputs on J2 17 through J2 20 The frequency on these input terminals is the variable DigitalCmdFreq and is substituted for the AnalogIn
160. er Motion PCE830 2 2 3 Command I O J2 44 Position D subminiature female Pin Description Pin Description J2 1 Analog Command Input J2 23 No Connect 2 2 Analog Command Input J2 24 Relay Output Out4 J2 3 RTN J2 25 Relay Output Out4 J2 4 Analog Output DACMonitorl J2 26 No Connect J2 5 Analog 2 DACMonitor2 J2 27 No Connect J2 6 Analog Current Limit Input J2 28 Analog Input 2 J2 7 VORTN J2 29 Analog Input 3 J2 8 Encoder Output Channel J2 30 RTN 2 9 Encoder Output Channel J2 31 Input 1 Fault Reset J2 10 Encoder Output Channel B J2 32 Input 2 CwInh J2 11 Encoder Output Channel B J2 33 Input 3 CcwInh J2 12 Encoder Output Channel Z J2 34 Input 4 J2 13 Encoder Output Channel Z 2 35 Input 5 Reg2 J2 14 5VDC Output J2 36 Input 6 J2 15 RTN 5 RTN J2 37 Enable Input J2 16 RTN J2 38 Input RTN J2 17 Command Encoder Input Channel Step 2 39 24VDC Output RTN 2 18 Command Encoder Input Channel A Step 72 40 24VDC Output J2 19 Command Encoder Input Channel B Dir J2 41 2 3 Supply Input 12 20 Command Encoder Input Channel B Dir J2 42 Outl Fault J2 21 No Connect J2 43 Out2 Brake J2 22 No Connect 2 44 Out3 PCE830 40 User Manual 2 21 PCE830 Danaher Motion J2 Diagram The figure below illustrates the pin out for the 44 pin c
161. er of motor resolver counts PulsesOut 1 65536 of a rev that you want the motor to move for the specified number of input encoder quadrature counts PulsesIn Example If the input encoder line count PulsesIn is 1024 4096 quadrature counts per encoder revolution and the motor should make one revolution for every encoder revolution then 1 rev 65 536 resolver counts per 1 rev 4096 encoder counts Because 65 536 is greater than the maximum value for PulsesOut divide both numbers by four This results in 16 384 motor resolver counts for 1024 input encoder counts 2 64 PCE830 40 User Manual Danaher Motion PCE830 Electronic Gearing lt no name assigned yet gt PCE830 40 User Manual 2 65 PCE830 Danaher Motion 2 4 4 Velocity Mode Analog Command This mode allows the differential analog voltage between terminals J2 1 and J2 2 to set the motor s shaft velocity The output shaft velocity per input volt is set by the CmdGain parameter in and should be set by the user to the desired value Procedure 1 Select Velocity Mode Analog Command from the Mode of Operation dropdown list box 2 Set CmdGain to the desired value Motor Velocity KRPM AnalogIn V CmdGain kRPM V Velocity Controller lt no name assigned yet gt x Drive Motor Motor Type 42 Drive Type Mode of Velocity Mode Analog Command Digital 1 0 Analog 1
162. erial port interface J1 6 Not used J1 7 Not used J1 8 Not used J1 9 Not used The information provided in this section should be used to connect the 840 to your computer for firmware upgrades PCE830 40 User Manual 3 19 PCE840 Danaher Motion 3 5 2 1 RS 232 CONNECTIONS RS 232 RS 232 connections on J1 are shown below Cable wiring required for connecting to Connections ther 9 or 25 pin serial ports of most computers are also shown Pinouts vary among computer manufacturers Check the hardware reference manual for your machine before wiring Cabling A 6 foot 1 8 m RS 232 Cable with 9 pin connectors and a 9 pin to 25 pin adapter Diagram is available from Pacific Scientific The Pacific Scientific order number is RS 232 5600 RS 232 RS 232 TXD 9 CONTACT FEMALE D SUBMINATURE CONNECTOR TYPICAL CABLES 3 PIN FEMALE 3 PIN MALE TOPC 25 PIN Shielded wiring is recommended for the serial communications cable to minimize potential errors from electrical noise 3 20 PCE830 40 User Manual Danaher Motion PCE840 Serial Communications Transceiver Schematic Installation Diagram TXD TO UART RS 485 ENABLE PCE830 40 User Manual 332 A Bo ANM O 2 RS 232 TXD SNT5155 7 2200pF 9 T O 3 RS 232 RXD SN75155 T 2200pF 5V 1000pF 464 KZ Ox 75176 m 8 RS 485 RXD 1 ZA 464 1000 O 9 R
163. ersion Homing Parameter Drive Controlled Homing Procedure Command Monitoring Window Acceleration Data Scaling Type Acceleration Data Scaling Factor Acceleration Data Scaling Exponent 840 IDNs continued Danaher Motion 169 Probe Control Parameter 170 Probing Cycle Procedure Command 185 Length ofthe Configurable Data Record in the AT 186 Length ofthe Configurable Data Record in the MDT 187 IDN List of Configurable data in the AT 188 IDN List of Configurable data in the MDT 189 Following Distance PosErrorMax 192 IDN List of Backup Operation Data 263 Load Working Memory Procedure Command 264 Backup Working Memory Procedure Command 301 Allocation of Realtime Control Bit 1 303 Allocation of Realtime Control Bit 2 305 Allocation of Realtime Status Bit 1 307 Allocation of Realtime Status Bit 2 400 Home Switch 401 Probe 1 402 Probe 2 403 Position Feedback Value Status 405 Probe 1 Enable 406 Probe 2 Enable 409 Probe 1 Positive Latched 410 Probe 1 Negative Latched 411 Probe 2 Positive Latched 412 Probe 2 Negative Latched 32800 DSP Debug Address 32801 DSP Debug Word 32802 DSP Debug Dword 32803 32806 ARM Debug Variables 32807 Pole Count 32809 Filter Value for ADFO 32810 DMIFO 32811 DM2F0 32812 DM1Gain 32813 DM2Gain 32814 DMIMap Mux Select 32815 DM2Map Mux Select 32816 EncOut Encoder Output 32817 InpMapl 32818 InpMap2 32819 InpMap3 PCE830 40 User Manual Danaher Motion IDNs
164. es When an input is open circuited it will bias itself to between 2 2v and 2 5V thus the remaining input pair terminal will have a single ended guaranteed logic low for inputs lt 2 0V and a guaranteed logic high for inputs 2 7V These levels are compatible with a TTL driver combined with a pull up resistor Pull up resistor should be 470Q These relay outputs are normally open They are rated for 1 Amp at 30VDC These relays may be opened closed by Out4 When the drive has no control power the relay is open This output is low when the control power is off or when control voltage is on and the drive is disabled Enable 0 This output is pulled high otherwise This output is intended to drive a normally open relay that in turn powers a mechanical brake on the motor shaft for applications that require a positive shaft lock when the servo drive 15 off J2 24 gt B L Normally 42 25 Open gt PCE830 40 User Manual Danaher Motion PCE840 J2 Encoder Interface Schematic ENCODER INPUTS 22TO25V OPEN CIRCUIT J2 19 NCIN B OPTION CARD USER 5VDC EMULATED ENCODER OUTPUTS 42 8 AM26L531 LI L S 1 7 RESOLVER 42 10 AM 6LS31 POSITION P TO EMULATED QUADRATURE LI LT 1 J2 11 es PPR EncOut 42 2 261521 s sia CHZOUT a EncOut 0 PFH7nRIIT 42 13 PASSES CHZOUT lt x
165. es the preset move as defined by the current state of the MoveSelectBit inputs Velocity Command Source Selects between VelCmd and VelCmd2 2 38 PCE830 40 User Manual Danaher Motion PCE830 Procedure To assign a mappable input function to a digital input perform the following steps 1 Click on Create New Configuration or Edit Exisiting Configuration button 2 Select the appropriate Motor and Drive Type and the Mode of Operation Click Next 3 Click on the Digital I O tab Select the input that is being assigned a function 4 Select the desired function from the drop down list box lt no name assigned yet gt x Drive Motor Drive Type CE833 Motor Type 42 gt Mode of Operation Velocity Serial Command Y Digital 1 0 Analog 1 0 Loop Gains Velocity Controller Predefined Moves Feedback Input Functions Dutput Functions Input FautReset h Dutputl Input2 Dutput2 No Function Input3 Counterclockwise Inhibit hi _ Dutput3 No Function Input4 Command Gain Select hi Analog Input Null 10 Function Output 4 InputS Counterclockwise Inhibit hi Counterclockwise Inhibit 10 Clockwise Inhibit hi Relay Brake lo Input amp Clockwise Inhibit lo Command Gain Select hi Command Gain Select lo Cancel Next gt gt Help Active hilo Each of the digital inputs ca
166. ess Motors 24 months from date of manufacture Electronics and Accessories Kollmorgen Standard Step Motors Stepper 12 months from date of manufacture Controls and Accessories Kollmorgen Custom Motion Systems or To be negotiated on a case by case components of any type basis and set forth in the order The Good or parts claimed to be defective must be returned to Seller accompanied by a Return Material Authorization RMA issued by Seller s facility responsible for supplying Goods with transportation prepaid by Customer with written specifications of the claimed defect If a warranty claim is valid Seller shall pay reasonable one way costs of transportation of the defective Goods from either the original destination or the location where defect occurred whichever is closest to Seller s facility Under no circumstances shall Seller be liable for removal of Seller s Goods from Buyer s equipment or re installation into Buyer s equipment NO PERSON INCLUDING ANY AGENT DISTRIBUTOR OR REPRESENTATIVE OF SELLER IS AUTHORIZED TO MAKE ANY REPRESENTATION OR WARRANTY ON BEHALF OF SELLER CONCERNING ANY GOODS MANUFACTURED BY SELLER EXCEPT TO REFER PURCHASERS TO THIS WARRANTY SOFTWARE WARRANTY Computer software programs that may be included in material or Goods sold to Buyer have been designed to perform a given set of tasks as defined in the documentation provided and are offered AS IS It is Buyer s responsibility to deter
167. figuration and select Position Mode Electronic Gearing as the mode of operation 2 Set desired number of commanded motor Pulses Out per the number of encoder Pulses In 3 Click the Digital tab Select Gearing On as the function for the input to initiate gearing 4 Select Start Move as the function on the input used to initiate a preset incremental move 5 Click the Predefined Moves tab Define an Incremental move for the phase advance index move 6 Create a second incremental move for the phase retard index move Registration marks can be used to perform preset registration moves based upon activation of a registration input Typically these moves can be used to advance a product a predefined distance after activation of a proximity sensor input AII registration inputs must be tied to a dedicated registration input on either Input 4 J2 34 or Input 5 J2 35 A conveyor processing material is being driven by a one inch diameter roller directly coupled to a motor incrementing at a constant speed of 1000 rpm There are marks on the material spaced evenly every eight inches on the conveyor These marks are detected by a proximity sensor interfaced into Input 4 on the PCE830 as a registration input Once the sensor is activated the motor advances the conveyor one more inch before coming to a complete stop within 75 milliseconds After the motor has come to a complete stop the drive activates an output signaling a nearby PL
168. gn a unique address between 1 254 inclusive to each drive Pacific Scientific strongly recommends the use of the optional CS checksum field for safe and reliable operation of the PCE830 2 9 1 Pre defined Identifiers Values for Error ReadOnly Codes Bounds Error No Such Command Variable Not Implemented Identifier Codes NVLoad for Commands NVSave Unconfigure Identifier Codes for Integer ILmtMinus Variables ILmtPlus DM1Map Enable Enabled EncIn EncPos FaultCode Inpl Inp2 Inp3 Inp4 PCE830 40 User Manual 65 66 67 68 10001 10002 10003 10005 10006 10007 10008 10009 10010 10012 10013 10014 10015 2 109 PCE830 2 110 Inp5 Inp6 Inputs KpEnc KiEnc KdEnc ElecAngTau EncAlignTime EncAlignTestDist EncAlignRampIcmd Out2 Out3 Out4 Outputs PosCommand PosError ResPos Position PulsesIn PulsesOut EncOut EncMode PoleCount Model AxisAddr ItThresh FwV HwV CommEnbl ExtFault Cwlnh CcwInh PulsesFOut PosCmdSet DM2Map FaultReset RunStop 10016 10017 10018 10019 10020 10021 10022 10023 10024 10025 10026 10027 10028 10029 10030 10031 10032 10033 10034 10035 10036 10037 10038 10039 10041 10042 10043 10044 10045 10049 10050 10051 10052 10053 10054 10055 10056 10057 10061 10062 Danaher Motion PCE830 40 User Manual Danaher Motion CommSrc Enable2 RemoteFB InpMapl InpMap2 InpMap3 InpMap4
169. gt Message Received lt STX gt V 6553600 38 lt CR gt 2 Read MovelDistance Integer 10100 without using the optional Address field Command Sent lt 5 gt R 10100 190 lt CR gt Message Received lt STX gt V 6553600 38 lt CR gt 3 Write Movel RunSpeed Float 98 a value of 60 0 RPM with the Address field Command Sent lt 5 gt 255 W98 60 0 31 lt gt Message Received lt STX gt V59 9992 9 lt CR gt 4 Read MovelRunSpeed Float 98 with the Address field Command Sent lt 5 gt 255 R98 185 lt gt Message Received lt STX gt V59 9992 9 lt CR gt 5 Execute NVSave Command 1 Command Sent lt 5 gt lt gt Message Received lt STX gt C1 lt CR gt PCE830 40 User Manual Danaher Motion Guidelines 1 The Serial ASCII Protocol ignores white space between fields PCE830 2 The Checksum is the decimal sum modulo 256 of all the characters from after the initial framing character STX up to and including the 66 25 character 3 Due to floating point conversions a floating point value sent to the drive may not be exactly equal to the value received from the drive 4 Address 0 is a global address drives process a message sent to address 0 but will NOT reply Address 255 15 a default address drives process messages sent to Address 255 and return a reply When multi dropping PCE830 drives assi
170. h resistor measured separately Four 2000 regen resistors wired in series parallel can handle 800W PCE830 40 User Manual 6 3 Using External Regen Fusing Danaher Motion If the regen transistor in the drive should fail shorted the power to the external regen resistor increases too far above its ratings For three phase 480VAC bus power the power in the regen resistor is about 6 2 kW 640VDC across 66 Q equals 9 7 ADC After a few minutes the regen resistor typically opens but in the meantime the high heat can cause melting and damage to nearby components A remote regen resistor mount such as on top of a cabinet can minimize the potential damage A single 200W regen resistor can in some cases be fused but the fuse type and rating must be carefully chosen Due to the resistance a large pulse of current is not available to clear a fuse While not tested analysis of fuse time current curves indicates the following fuses should work with a single 66 regen resistor and a drive operated on a three phase 380VAC to 480VAC line Mains Voltage Part Number Manufacturer Rating Size 480VAC KTK 5 Bussmann 5A 600VAC 300VDC 1 5 x 0 41 380VAC or 400VAC KTK 4 Bussmann 600VAC 300VDC 1 5 x 0 41 Regen Need is a Strong Function of Maximum Motor Speed Example 6 4 For higher DC rating on the fuse 500VDC the Bussmann KLM may be substituted for the KTK If
171. hanical system 0 024 Lb in s 2 6 Diagnostics and Protection Circuits The drive is fully protected against normal abuse and has two LEDs on the front panel to indicate drive status The servo drive has the following specific protections e Output motor short circuit protection line to line and line to neutral e Interface to Pacific Scientific s standard motor or a normally closed thermostat to sense motor over temperature e Internal monitoring of the power stage heat sink temperature for drive over temperature e Bus over voltage detection e Bus under voltage fault with adjustable threshold e Incorporating the measured heat sink temperature there is an excessive current I t fault This fault limits the peak current time and intelligently changes the continuous current fault trip dependent on the measured heat sink temperature to limit the continuous output current e Control voltage under voltage detection PCE830 40 User Manual 2 87 PCE830 Fau Drive Status LEDs 2 88 Danaher Motion The user 5V output is short circuited to I O RTN protected The user 24V output is short circuit protected All control outputs are short circuit protected to I O RTN When a drive is powered up without valid parameters the power stage cannot be enabled and no damage occurs to the drive It Generation The following sequence occurs when the protection circuits generate a fault e The fault source is latche
172. he number of an IDN whose data i is a variable This BIT variable i 15 then sent in the MDT information The IDNs which can used for Realtime Control bits are IDN IDN Description 405 Probe Enable 406 Probe 2 Enable 34833 Output Bit 1 34834 Output Bit 2 34835 Output Bit 3 34836 Output Bit 4 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Off Maximum Value 34836 Access State Read Write by Master in phases 2 4 IDN 303 Allocation Of Realtime Control Bit 2 Parameter Data IDN Unsigned Decimal Number The Master sends the number of an IDN whose data 15 a B variable This BIT variable i 15 then sent in the MDT information The IDNs which can be used for Realtime bits IDN IDN Description 405 Probe 1 Enable 406 Probe 2 Enable 34833 Output Bit 1 34834 Output Bit 2 34835 Output Bit 3 34836 Output Bit 4 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Off Maximum Value 34836 Access State Read Write by Master in phases 2 4 PCE830 40 User Manual 3 93 PCE840 Danaher Motion IDN 305 Allocation Of Realtime Status Bit 1 Parameter Data IDN Unsigned Decimal Number The Master sends the number of an IDN whose data is a BIT variable This BIT variable is then sent in the AT cyclic Realtime Status Bit 1 data Please refer to Section 3 5 Interfaces and Connections for additio
173. her Motion IDN 6 AT Transmission Starting Time Parameter Data IDN Unsigned Decimal Number The time the PCE840 sends the AT after the end of the MST as measured in u Sec This value is calculated and written by the Master during Phase 2 The value read back is always the current value Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 20 Maximum Value 64000 Access State Read Write in Phase 2 Read only in Phase 3 and 4 IDN 7 Feedback Acquisition Capture Point Parameter Data IDN Unsigned Decimal Number The PCE840 shall acquire the AT data at this time This value is calculated and written by the master during phase 2 The value read back is always the current value Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 0 Maximum Value 63700 Access State Read Write in Phase 2 Read only in Phase 3 and 4 IDN 8 Command Value Valid Time Parameter Data IDN Unsigned Decimal Number At this moment of time the PCE840 shall begin using the data received from the master in the MDT This value is calculated and written by the master during phase 2 Conversion Scaling Factor 1 Data Length 2 bytes Units us Minimum Value 20 Maximum Value 64000 Access State Read Write in Phase 2 Read only in Phase 3 and 4 3 62 PCE830 40 User Manual Danaher Motion IDN 9 Position Of Data Record In MDT PCE840 Parameter Data IDN Unsigned Decimal Number Position wi
174. hus the remaining input pair terminal will have a single ended guaranteed logic low for inputs lt 2 0V and a guaranteed logic high for inputs 2 7V These levels are compatible with a TTL driver combined with a pull up resistor Pull up resistor should be 470Q These relay outputs are normally open They are rated for 1 Amp at 30VDC These relays may be opened closed by Out4 When the drive has no control power the relay is open J2 24 Cc E Normally J2 25 Open gt e 2 27 PCE830 Danaher Motion J2 Encoder I O Interface Schematic ENCODER INPUTS 22 025 OPEN CIRCUIT J2 19 NCIN B OPTION CARD USER 5VDC EMULATED ENCODER OUTPUTS 42 8 AM26L531 LI L S 1 7 RESOLVER 42 10 AM 6LS31 POSITION P TO EMULATED QUADRATURE LI LT 1 J2 11 es PPR EncOut 42 2 261521 s sia CHZOUT a EncOut 0 PFH7nRIIT 42 13 PASSES CHZOUT lt x EMU A B gt 71 ROTATION PCE800 BASE UNIT ENCODER 2 28 PCE830 40 User Manual Danaher Motion PCE830 Using TTL differential line drivers ENCODER PCE800 45V SUPPLY 2 45 _ 1 _ _CONNECTONLY IF 2 _ _ _ 14146406 250 SOURCES ENCODER POWER 7 171 CHA CEs PAIR 1611 0 RTN 5V SUPPLY RETURN Using TTL single ended drivers ENCODER PCE800 5V SUPPLY 5 5 SUPPL
175. illustrates the pin out for the 9 pin connector It shows the front view looking at the PCE830 J1 Diagram 5 485 TXD 5 485 RXD 5 485 TXD 5 485 BVDC SHIELD 1 0 RTN 45vDC 15 232 BVDC 5 232 AXD I O Table Pin Number Input Output Explanation J1 1 5VDC RTN Shield Common shield serial port interface J1 2 RS 232 TXD RS 232 transmitter output from PCE830 J1 3 RS 232 RXD RS 232 receiver input to PCE830 J1 4 5VDC 5VDC output 250 mA maximum between J1 4 and J1 5 J1 5 RTN 5VDC Common serial port interface J1 6 RS 485 TXD RS 485 transmitter output from PCE830 J1 7 RS 485 TXD J1 8 RS 485 RXD RS 485 receiver input to PCE830 J1 9 RS 485 RXD An adapter be powered from the serial port 5VDC output on Jl 4 as long as the load current on J1 4 J2 14 and J3 10 total less than 250 mA The information provided in this section should be used to connect the PCE830 to your computer for use with 800Tools Two communication links are available RS 232 and RS 485 RS 485 allows a single computer to communicate with up to 32 PCE830s in multi axis configurations 800Tools defaults to communicate with axis 255 upon start up 2 16 PCE830 40 User Manual Danaher Motion PCE830 2 2 2 1 RS 232 CONNECTIONS RS 232 RS 232 connections on J1 are shown below Cable wiring required for connecting to Connections ther 9 or 25 pin serial ports of most computers are also
176. implemented in parallel with KPP to inject additional velocity command without requiring position error If KVFF 100 percent the position command frequency is sent directly to the velocity loop as an open loop command Instead of driving velocity with position error on top of zero speed KVFF allows us to drive velocity with position error on top of target speed with nominally zero error KVFF typically causes overshoot and only helps in applications that require position synchronization like electronic gearing KPP Hz 75 Hz 5 KVFF 0 Increasing KPP reduces position error decreasing KPP increases position error Increasing KVFF reduces position error and increases overshoot KPP should be lt velocity BW 5 and 100 Hz maximum KPP ranges from 0 to 100 Hz KVFF should be lt 200 and typically lt 100 KVFF ranges from 0 to 200 PCE830 40 User Manual Danaher Motion PCE830 2 5 4 Manual Tuning with SoftScope Refer to Section2 7 Servo Loop Parameters for additional details Diet i i ti Ye Velocity Loop Procedure 1 Create New Configuration for correct motor and drive models using 800Tools Use the default setup including inertia ratio of 1 1 for the Step and Direction mode of operation 2 In the LoopGains tab of the parameter edit window set KVI KPP and KVFF lt no name assigned yet gt x Drive Motor Motor Type 42 Y Drive Type Mode of Operation P
177. input to the CmdGain scaling The units on CmdGain become Amp kHz Icmd CmdGain A kHz Digital Command Frequency Icmd Icmd Kteff 2 5 Tuning It provides e An easy way to set default tuning parameters e An easy way to change tuning parameters e Displays bandwidth and phase margin based on the inertia ratio you input Tuning parameters are used to optimize system performance The system is ultimately limited by the machine mechanics and power available from the driving motor This chapter will review the tuning process In general start with the most significant limiting factor and increase the limit as high as possible The hierarchy of tuning limits follows this sequence e Position loop bandwidth is limited by velocity loop bandwidth e Velocity loop bandwidth 15 limited by current loop bandwidth and mechanical system natural resonant frequency e Current loop bandwidth is limited by the drive electronics 2 5 1 Current Loop Settings Proportional Proportional Current Loop Gain KIP is set to provide 1000 Hz current loop Gain KIP bandwidth The current loop bandwidth is independent of the mechanical system KIP is preset by 800Tools to the correct value based on motor model Default KIP V A 6 28 MotorInductance mH for 1000 Hz Current BW Adjust Preset by 800Tools do not change For unsupported motor models only use formula described Limits 1000 Hz to 1500 Hz PCE830 40 User Manual 2 69 PCE830 Danaher
178. ion Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master 3 98 PCE830 40 User Manual Danaher Motion PCE840 3 8 2 Manufacturer Specific IDNs IDN 32800 DSP Debug Address Parameter Data IDN Binary Data Used for Manufacturer Investigations Master would write an address to access into this IDN Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access State Read Write by the Master IDN 32801 DSP Debug Word Parameter Data IDN Binary Data Used for Manufacturer Investigations Reading this IDN causes the WORD data located in the address specified in IDN 32800 to be read Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value OxFFFF Access State Read only by the Master IDN 32802 DSP Debug DWord Parameter Data IDN Binary Data Used for Manufacturer Investigations Reading this IDN causes the DWORD data located in the address specified in IDN 32800 to be read Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 0 Maximum Value OxOFFFFSFFFF Access State Read only by the Master IDN 32803 32806 ARM Debug Variables Parameter Data IDN Binary Data Used for Manufacturer diagnostics DO NOT USE PCE830 40 User Manual 3 99 PCE840 IDN 32807 Pole Count Danaher Motion Parameter Data IDN Unsigned Decimal Number Number of motor poles used for moto
179. ity gain open loop crossover frequency of the idealized rigid single mass system See hardware specifications for maximum fv value From the formula for bandwidth you can see that bandwidth changes inversely with total inertia If the load inertia equals the motor plus resolver inertia the velocity loop bandwidth is half the values shown If the load inertia is ten times the motor plus resolver inertia the bandwidths are one eleventh these values Clearly KVP must be increased to compensate for increased load inertia if bandwidth is to be maintained Typically load inertia up to 3 motor resolver give acceptable performance without further optimization The most common servo setup problem is adding large load inertia without a corresponding increase in KVP The value of KVP to achieve a desired bandwidth can easily be calculated as 4 2x 10264 Krams 845 KTRMS PCE830 40 User Manual 3 51 PCE840 Danaher Motion Example For example to achieve 75 Hz bandwidth with a PMA22 motor having 20 to 1 load Calculation inertia 0 011 Ib in sec2 0 00039 0 011 0 01139 Ib in sec2 Ky 4 31 Ib in amp 10 26 75 201139 2 03 31 IDN 100 Velocity Loop Proportional Gain This IDN shoud be set in the PCE840 so that Amps rad sec 27 fye Hz Jtota Kteff 2 IDN 100 Amps rad sec Ipeak 193 38e 6 where Load
180. ive This fault 15 reset or the control AC power turned OFF and ON again to get the drive motor operating 17 The AInNull function was re activated too soon after going inactive This can be caused by switch bounce on the input pin mapped to activate AInNull 18 The motor is either stalled or partially jammed The value for PosErrorMax is set too sensitive for the loop tuning and commanded motion profiles 19 Glitch while last saving the NV parameters Corrupted NV memory contents Hardware problem with the NV memory Download parameters to restore drive operation 20 Initialization Failure See ExtFault for additional information 21 High drive ambient temperature Restriction of cooling air due to insufficient space around unit Operating above the drive s continuous current rating See HSTemp ItFilt and ItF0 for information on measuring thermal margin an A application 22 Resolver signal is lost or intermittent Check resolver cable 2 92 PCE830 40 User Manual Danaher Motion PCE830 2 7 Servo Loop Parameters This section describes setting parameters associated with the velocity and position loops In many cases satisfactory operation is achieved using either the Create New Configuration or Edit Existing Configuration buttons However in some cases you must adjust the control loop parameters due to large mismatches between motor and load inertia mechanical resonance backlash etc This appendix provides g
181. k Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65534 Access State Read Write by the Master in phases 2 4 IDN 106 Current Loop Proportional Gain 1 Parameter Data IDN Unsigned Decimal Number Allows the master to set the value of kip Volts Ampere IDN 106 kip Ipeak 405 6685e 3 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 62000 Access State Read Write by the Master in phases 2 4 IDN 107 Current Loop Integral Action Time 1 Parameter Data IDN Unsigned Decimal Number Allows the master to set the value of kii Hz IDN 107 kii 12 868 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 65535 Access State Read Write by the Master in phases 2 4 PCE830 40 User Manual 3 79 PCE840 Danaher Motion IDN 110 Amplifier Peak Current Parameter Data IDN Unsigned Decimal Number Contains the amplifier peak current Conversion Scaling Factor 1 Data Length 4 bytes Units mA Minimum Value 0 Maximum Value 4 294 967 295 Access State Read only by the Master IDN 127 Communication Phase 3 Transition Check Command Data IDN Binary Data Command Procedure IDN used to check whether the PCE840 is ready to proceed into phase 3 This IDN must be performed and successfully completed prior to going into phase 3 If all IDNs identified in IDN 18 have not been completed or if the waveshape is incomplete or
182. kwise direction then the motor will decelerate to zero velocity with the maximum torque allowed by the user set output current limits This input will have no effect on motion in the counterclockwise direction This input is useful for a clockwise over travel limit switch Input 3 Analogous to the CwInh input except that this input prevents counterclockwise motion Input 4 This high speed input latches motor position within 50 after a transition Input 5 Analogous to Regl input Input 6 Input Mapped Off R227 J2 34 2 2K REG1CO AAA e 3 Pl 2221 DA 14V LOGIC J2 38 E INPUT RTN gt PC400 A Probe inputs have a 50 usec latch time PCE830 40 User Manual 3 31 PCE840 Danaher Motion Enable Input This optically isolated input is used to enable the drive and is active high The output J2 37 stage is disabled when this input is inactive A minimum drive capability of 4 mA is required You must supply 10V to 30V to drive this input This input is filtered with a 1 mSec time constant low pass filter to prevent false triggering from noise The Enable input shares a floating return J2 38 with Inputs 1 through 6 A 5 V input CANNOT be used R226 2 2K VV 5 12 37 z External CONTROL 24V T LOGIC TLP121GB J2 38 INPUT RTN If the drive s 24V supply is being used connect as shown below 22k Nu wn 2 5 TO CONT
183. l Danaher Motion PCE830 Fault Reset Input CwInh Input CcwInh Input Input Reg2 Input Input Mapped Off Input J2 34 J2 38 INPUT The list below describes the subset of the available functions and the mappings used as the factory defaults for each of the inputs Input 1 This input is used to reset the amplifier following a fault This input is programmed active high so that an open circuited input does not activate the function During Fault Reset active the output stage 1 disabled and the reset condition will be held in hardware for approximately 0 1 sec after Fault Reset is returned inactive Input 2 This input prevents further motion in the clockwise shaft motion direction This input is programmed active high so that an open circuited input does not activate the function If the shaft is already moving in the clockwise direction then the motor will decelerate to zero velocity with the maximum torque allowed by the user set output current limits This input will have no effect on motion in the counterclockwise direction This input is useful for a clockwise over travel limit switch Input 3 Analogous to the CwInh input except that this input prevents counterclockwise motion Input 4 This high speed input latches motor position within 50 after a transition Input 5 Analogous to Regl input Input 6 Input Mapped Off R227 J2 34 2 2K REGIO ANN CONTROL LOGIC
184. l Reading an input Channel bit would return the value of the bit located in the input port Reading IDN 34824 would return the value of all the input bits as a single word Reading an output bit would return the value the PCE840 is attempting to drive on the output pin Reading IDN 34840 would return the value the PCE840 is attempting to drive on all the output pins 3 38 PCE830 40 User Manual Danaher Motion PCE840 Example Cyclic Channel Realtime Control Status Example The PCE840 has 00010101 on its input pins The PCE840 is attempting to drive 00001010 on its output pins Reading IDN 34824 would return 0x15 Reading IDN 34817 would return 1 bit zero input byte Reading IDN 34818 would return 0 bit one input byte Reading IDN 34821 would return 1 bit four input byte Reading IDN 34840 would return 0x0A Reading IDN 34833 would return 0 bit zero output byte Reading IDN 34834 would return 1 bit one output byte Reading IDN 34836 would return 0 bit four output byte The only two PCE840 I O IDNs that can be placed in the cyclic channel are IDN 34824 Input Port and IDN 34840 Output Port IDN 34824 Input Port can be placed in the AT and returns 2 bytes of data The AT data would have the input port in the low byte of the return AT data and a zero in the high byte IDN 34840 Output Port can be placed in the MDT and allows the user to write to the output pins once every MST cycle The low byte of
185. l velocity loop Recommended values for KPP are fve Hz 25 75 200 Position Loop Bandwidth Hz 5 15 default 50 In general the higher the value of KPP the faster the settling time However trying to set KPP to a high value with inadequate velocity loop bandwidth results in overshoot and ringing A good trade off is to set KPP to 0 2 times the velocity loop bandwidth Slightly higher values can be used if overshoot can be tolerated PCE830 40 User Manual 2 99 Danaher Motion PCE830 SLNNOD 13VHS lo HOLON Sog2ua3 gt wows 0 n 3OVAH3INI bei ou3 20 1 N3A108 38 eyepdn 9INONLO3T13 N M EE lt ad ORG 1 desea 110389804 g Z 1708980 gt 0804 gt lt NNO lt bb BAOW Position Loop PCE830 40 User Manual 2 100 Danaher Motion PCE830 KVFF KVFF is the velocity feed forward gain In the absence of velocity feed forward KVFF 0 the commanded velocity is proportional to the position following error This means that the actual position lags the commanded position by a value proportional to the speed The error is smaller for larger values of KPP The following table gives a sample of the following error magnitude
186. logILmtGain 10 volt Volts In J2 6 AnalogILmt 0 100 0 100 full current to motor 2 100 20 80 4 100 40 60 8 100 80 20 10 100 100 0 no current to motor Outputs J2 8 9 10 11 CHAOUT These two output pairs are differential TTL incremental position signals Do generated by the Resolver feedback electronics These outputs are CHAOUT quadrature encoded to emulate an optical encoder The resolution of these signals 1 the emulated line count is set by the EncOut parameter These CHBOUT outputs are buffered by 26LS31 type RS 422 compatible line drivers Maximum recommended load current is 20 mA which corresponds to a minimum line to line load resistance of 100 This drive capacity corresponds to ten RS 422 compatible inputs such as the PCE840 encoder inputs These outputs are indefinitely short circuit proof to I O PCE830 40 User Manual 3 27 840 J2 12 13 CH Z OUT CHZOUT J2 14 J2 15 5VDC RTN 5VDC Encoder Inputs J2 17 18 19 20 Relay Outputs J2 24 25 Brake Output 3 28 Danaher Motion These two terminals function as a differential TTL marker pulse The output pulse occurs once per motor shaft revolution starting at resolver position 0 and its width is approximately one quadrature encoder width This output comes from a 26LS31 type RS 422 compatible line driver Maximum recommen
187. lt J2 21 No Connect J2 43 Out2 Brake J2 22 No Connect 2 44 Out3 3 22 PCE830 40 User Manual Danaher Motion PCE840 J2 Diagram The figure below illustrates the pin out for the 44 pin connector It shows the front view looking at the PCE840 300000000000000 D D OOOO AO OOOO OO OOO OOOO e PCE830 40 User Manual 3 23 PCE840 Danaher Motion Command I O Analog CMD These inputs accept the analog command from the user This is a differential input J2 1 2 to an A D It has a maximum single ended input range with respect to I O RTN on Inputs RTN J2 3 7 15 16 3 24 either input of 21V and an input impedance of 50 The full scale differential command input range is 13 5V The offset and single pole low pass bandwidth of this signal is adjustable via a software setup parameter When used as a motion command the gain from this input is also adjustable via a software setup parameter 1200 HZ FILTER J2 2 33 2K 224K 33 2K ANALOG CMD 0 01uf 13 5V FULL SCALE TO A D 42 1 33 2 ANALOG gt IN DSP CMD J2 3 I O RTN gt Always connect RTN J2 3 to the signal ground of the source Failure to do so may result in erratic operation This terminal is signal common for the analog and non optically isolated digital inputs and outputs These pins are internally connected in the drive For protection against line surges one of
188. ltage to decay to a safe level before touching regen resistor or wiring The voltage on the bus caps can be monitored with a voltmeter from BUS TB1 7 to BUS TB1 9 This termination provides a convenient point for the motor ground connection and motor power wire shield Local electrical code may require using the Earth Ground Chassis stud for this function These three terminations provide the 3 phase power output to the brushless motor Observe motor polarity on these connections For example connect U on the drive to U on the motor PCE830 40 User Manual Danaher Motion PCE840 3 5 2 Serial Port J1 The serial port J1 utilizes the 9 contact female D subminiature style connector shown below A brief description of each signal is included in the I O table on following page For additional information please refer to the Serial Communications Transceiver Schematic at the end of this section The figure below illustrates the pin out for the 9 pin connector It shows the front view looking at the PCE840 J1 Diagram NOT USED NOT USED USED NOT USED SHIELD 1 0 5 0 15 232 TxD USED 5 232 RxD I O Table Pin Number Input Output Explanation J1 1 Shield Common shield serial port interface J1 2 RS 232 TXD RS 232 transmitter output from PCE840 J1 3 RS 232 RXD RS 232 receiver input to PCE840 J1 4 Not used 5 VO RTN 5VDC RTN Common s
189. ly in Phase 3 and 4 IDN 17 IDN List Of Operation Data Parameter Data IDN IDN ID Number List The Master receives a list of valid IDNs when this IDN is read Refer to section 3 3 for a complete listing of supported IDNs Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read only by the Master IDN 18 IDN List Of Operation Data For CP2 Parameter Data IDN IDN ID Number List List of required operational data which must be received by the PCE840 before a change to phase 3 can proceed There are 10 IDNs required 1 2 6 7 8 9 10 15 32 and 89 Typically only IDN15 and IDN32 must be configured by the developer because most SERCOS masters set the others valid waveshape must exist prior to phase 3 The 840 has a default value which allows access into phase 3 Partially overwriting the waveshape will prevent access into CP3 Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read Only by the Master PCE830 40 User Manual 3 65 PCE840 Danaher Motion IDN 19 IDN List Of Operation Data For CP3 Parameter Data IDN IDN ID Number List List of required operational data which must be received by the PCE840 before a change to phase 4 can proceed The PCE840 does not require any data in CP3 Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read only by the Master IDN 21 IDN List Of Invalid Operation Data F
190. mal Number position data IDNs IDNs 47 51 52 103 130 131 132 133 159 and 189 are scaled according to the formula IDN 77 10 IDN 78 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 32 768 Maximum Value 32 767 Access State Read only by the Master IDN 79 Rotational Position Resolution Parameter Data IDN Unsigned Decimal Number position data is scaled using IDN 79 Command IDNs IDNs 47 52 103 are scaled by 65536 IDN 79 Feedback IDNs IDNs 51 130 131 132 133 189 are scaled by IDN 79 65536 If IDN 79 32768 counts per revolution the position data 1 scaled by 65536 32768 20132768 65536 If IDN 47 1000 units 2 2000 units If IDN 51 3000 units 1 2 1500 units Conversion Scaling Factor 1 Data Length 4 bytes Units percent Minimum Value 0 Maximum Value 2 147 483 647 Access State Read Write in phases 2 4 IDN 80 Torque Command Value Parameter Data IDN Signed Decimal Number Gives access to the instantaneous torque value of the PCE840 Conversion Scaling Factor 0 001 Amps 1000 1 Amps Data Length 2 bytes Minimum Value 32768 Maximum Value 32767 Master Read Reads the instantaneous current command of the PCE840 Master Write Position and Velocity Mode Always overwritten by new current command generated by the velocity loop Torque Mode Sets the current command of the PCE840 Access State Read Write in phases 2 4 3 74 PCE830
191. marker pulse output from the encoder This channel must be physically wired to one Encoder of the two dedicated registration inputs Input 4 J2 34 or Input 5 J2 35 Select this input using the Reg Select pull down tab The Active Edge rising edge or falling edge must also be defined for the registration input PCE830 40 User Manual 2 59 PCE830 Danaher Motion Home Move Parameters lt no name assigned yet gt x Drive Motor Drive Type Motor Type PMA42P Mode of Operation Position Mode Predefined Moves Y Digital 1 0 Analog 1 0 Loop Gains Position Controller Predefined Moves Feedback In Position limit 5 Counts Move tt Move Parameters for Move 0 Move Type Home 21 Run Speed 1000 00000 RPM oe Accel Rate 10000 00000 RPM sec Homing Home Switch E m Home Switch C5 Decel Rate 10000 00000 RPM sec Home Direction CE Use Present Position ht Cancel Next gt gt 1 Select Home as the Move Type 2 Select the Homing Mode Home Switch Marker Pulse Home Switch Marker Pulse Use Present Position to determine the reference for homing 3 Select Home Direction of motor rotation for home move as clockwise or counterclockwise 4 Define the Distance Offset position the motor should move to after the home switch input has been detected
192. mine if the features of the software programs are suitable for Buyer s requirements and must confirm that the software programs operate correctly Buyer understands that such software programs are of such complexity that they may have inherent defects and that Seller makes no warranty that all software features will perform correctly as supplied For Seller s software utilizing automation servers improper reading and writing data to the automation server can cause the automation server software to malfunction and may cause the automation server and or the program writing to the automation server to crash Improperly reading and writing data to an automation server may cause the device controlled by that automation server to malfunction Seller shall not be responsible for damage to any device or damage caused by any device due to the improper reading and or writing of data to an automation server LIMITATION OF LIABILITY NOTWITHSTANDING ANYTHING TO THE CONTRARY SELLER SHALL NOT BE LIABLE FOR ANY SPECIAL INCIDENTAL INDIRECT OR CONSEQUENTIAL DAMAGES INCLUDING LOST PROFITS ARISING OUT OF THE PERFORMANCE DELAYED PERFORMANCE OR BREACH OF PERFORMANCE OF THIS ORDER REGARDLESS WHETHER SUCH LIABILITY BE CLAIMED IN CONTRACT EQUITY TORT OR OTHERWISE SELLER S OBLIGATION IS LIMITED SOLELY TO REPAIRING OR REPLACING AT ITS OPTION AND AS SET FORTH IN SECTION 10 AND SECTION 11 AT ITS APPROVED REPAIR FACILITY ANY GOODS OR PARTS WHICH PROVE TO SELLER S SATISFACT
193. most difficult number to acquire Once the inertia is known the BW equation is easy to solve BW is the range of frequencies where the motor adequately follows the command As the BW 15 increased the system response is increased higher frequency command is a faster changing command Think of feedback error as a command Higher BW systems respond to feedback disturbances faster How do you calculate BW BW Hz KVP Kteff 6 28 Jt Lb in s2 Kteff Lb in A Ke V krpm 0 08454 0 866 2 85 PCE830 Danaher Motion Inertia There are two ways to calculate total system Inertia 1 Measure all the mechanical parts separately Using a software sizing package similar to Optimizer enter all the mechanical data The sizing package should have a data point for total reflected system inertia 2 During installation of the prototype machine when you are going to test the drive anyway perform the standard motor drive setup You need to be able to create stable motor motion to perform this test If the motor is unstable read through the tuning section to determine how to make it stable Setup an index move The move has to be aggressive to create substantial accel current to increase the signal to noise ratio Run the index move and use the softscope to monitor the velocity and current feedbacks E 00 000 seconds Iof xi Channel 1 mem Source Current Feedback Units Amps thick trace
194. msimtez liz tmv 3740 13 7 1 Current Loop opp 3 49 3 7 2 _Velocity Loop EA T 3 8 DN ATTRIBUTES eese cn iv umi tzfsuIiz tmv 3100 2221 SJERCOS Specific Parameters siii rte 3 60 13 8 2 Manufacturer Specific esee 399 3 9 DIAGNOSTICS AND PROTECTION CIRCUITS eene 371261 BUILT UP a a PTT 3 9 2 Motor Commutation 3 9 3 _ System Protection esee Sod 32 4 MODEL IDENTIFICATION 4 41 BASIC SERVO DRIVE PACKAGE ORDER NUMBERING 5 8 4511 ii PCE830 40 User Manual Danaher Motion Table of Contents 42 PCE800 TECHNICAL tente terere reete terree rires 4 2 umet ndn compu ti Hn es am cct du ine ADU GA E ts a ai ani ean cA i esI 1 4 3 PE BUC ACCESSORIES s dee been 4 2 PCE830 40 User Manual iii Table of Contents Danaher Motion This page intentionally left blank iv PCE830 40 User Manual Danaher Motion Mounting and Installation 1 MOUNTING AND INSTALLATION This section provides information on mounti
195. n The Anti Resonance Filters and ARFI are used as separate low pass filters in the velocity loop to filter out undesired high frequency velocity loop noise The defined filter frequency is the crossover frequency for the low pass filter The filters reduce resonance problems by filtering the noise that excites mechanical resonances at 20dB decade above the defined frequency Each filter individually adds 45 of electrical phase shift lag to the velocity loop at the defined frequency This phase lag can become part of the cause for mechanical resonance if the mechanical natural resonant frequency is lower than the velocity loop crossover In Band In band resonances are very unlikely for a well designed mechanical system PCE830 40 User Manual Danaher Motion Default Adjust Limits PCE830 Te Hz 6 28 Jy Inertia Ratio 1 Lb in s MotorKteff Lb in A KVI Hz 75 Hz 15 motorKteff Lb in A 0 08454 Ke v krpm 0 866 ARFO Hz 75 Hz 2 ARFI Hz 75 Hz 10 Increasing KVP will increase performance and response Decreasing KVP will reduce performance and response Increasing KVI increases stiffness and reducing KVI increases sponginess Increasing ARF s reduces effect of filter on high frequency noise and allows higher velocity loop BW Velocity loop BW should be 0 to 400 Hz Velocity loop BW is also limited by ARFO and ARFI Inertia ratio should be 100 1 KVI should be 15 times
196. n analog input When using this mode of operation during the brake mode VelCmd is equal to zero Set VelCmd2 zero The direction of the velocity move will be controlled by the polarity of the value entered Set AccelLmt and DecelLmt to the desired clutch activation acceleration and brake activation deceleration respectively VelCmd is the velocity commanded through the analog input encoder frequency input or the serial port depending upon the mode of operation selected VelCmd2 is a stored value of velocity that can only be changed serially PCE830 40 User Manual Danaher Motion Gearing w phase correction PCE830 An encoder with a 1024 line count is mounted to a continuous web embosser machine A PCE830 is setup as a position follower such that for every 1 rev of the encoder the PCE830 commands the follower motor to move 1 rev ratio of 1 1 in encoder revs to motor revs The drive will be required to phase advance the follower motor rev when an input from a PLC occurs Likewise the drive will also be required to decrement the follower motor phase retard by rev when another input occurs These phase advance retard moves will allow the servo to emboss the imprints into the web ahead or behind where they typically would be without any phase adjustment First calculate the required gearing ratio between the master encoder and the slave motor A 1024 line count encoder will output 4096 quadrature counts per encoder rev
197. n be defined as either active high or active low If the mappable input function bit is configured as active high low and if the input is HIGH LOW the mappable input function bit is asserted For example if Fault Reset is configured as active high when the input is high Fault Reset is asserted PCE830 40 User Manual 2 39 PCE830 Danaher Motion oe Input Analog Torque Mode or Analog Velocity Mode the Command voltage can be nulled u to e Reduce drift at zero volt command Set 50 analog offset for commanding bi directional motion with a single polarity adjustable voltage command source Related See AnalogIn and ADFO in On Line Help Parameter s Setup 1 Connect the Analog command source to J2 1 and J2 2 2 Activate the input momentarily to offset the command for zero motion 3 To reduce drift command zero volts and remove small offsets with the null 4 set bi directional motion with a single polarity input convert a to 10V analog command to 5V by commanding 5 0V on the analog input when you null the analog input Use Command Gain CmdGain to scale the input voltage for appropriate output Command In Torque Mode or Velocity Mode except Serial Velocity the command scale can be Gain Select switched between CmdGain value and CmdGain2 value for A Direction input that changes polarity of a jog command A complex motion input that changes speed Setup Click the Edit Drive Configuration Online button
198. n moves must be tied to a dedicated registration input on either Input 4 J2 34 or Input 5 J2 35 Select No Function for either Input 4 or Input 5 on the Digital I O tab Click the Predefined Moves tab Setup an Incremental Registration move The registration move is the number of counts set in the Distance Offset window This move is activated by the user as active on the rising or falling edge of this input Distance Offset 20861 counts Run Speed 1000 rpm Reg Select Reg 1 Inp4 Accel Rate 10000 rpm s Reg 1 Active Edge Rising Edge Decel Rate 10000 rpm s gt min 6791 rpm s Distance 200000 counts gt min 166892 counts PCE830 40 User Manual Danaher Motion PCE830 Jog Moves A motor is mechanically linked to a pulley with a 1 91 inch diameter which drives a conveyor at 50 inch sec The motor rotates the pulley at a constant speed to feed products past a scanning station Occasionally the drive will be required to run the conveyor at two additional speeds 100 inch sec and 25 inch sec to meet production needs and running different products through the scanning station First calculate the required motor velocity s to advance the conveyor Pulley Circumference Pulley Diameter 1 91 inch 6 inch 1 motor rev Velocityl 50 inch sec 1 rev 6 inch 60 sec min 500 rpm Velocity2 100nch sec 1 rev 6 inch 60 sec min 1000 rpm Velocity3 25 inch sec 1 rev 6 inch 60 sec
199. nal information The IDNs which can be used for Realtime Status bits are IDN IDN Description 400 Home Switch 401 Probe 1 402 Probe 2 403 Position Feedback Value Status 409 Probe 1 Positive Latched 410 Probe 1 Negative Latched 411 Probe 2 Positive Latched 412 Probe 2 Negative Latched 34817 Input Bit 1 34818 Input Bit 2 34819 Input Bit 3 34820 Input Bit 4 34821 Input Bit 5 34822 Input Bit 6 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Off Maximum Value 34822 Access State Read Write by Master in phases 2 4 3 94 PCE830 40 User Manual Danaher Motion PCE840 IDN 307 Allocation Of Realtime Status Bit 2 Parameter Data IDN Unsigned Decimal Number The Master sends the number of an IDN whose data is a BIT variable This BIT variable is then sent in the AT cyclic Realtime Status Bit 2 data Please refer to Section 3 5r Interfaces and Connections for additional information The IDNs which can be used for Realtime Status bits are IDN IDN Description 400 Home Switch 401 Probe 1 402 Probe 2 403 Position Feedback Value Status 409 Probe 1 Positive Latched 410 Probe 1 Negative Latched 411 Probe 2 Positive Latched 412 Probe 2 Negative Latched 34817 Input Bit 1 34818 Input Bit 2 34819 Input Bit 3 34820 Input Bit 4 34821 Input Bit 5 34822 Input Bit 6 Conve
200. nantly proportional characteristics Drive rejection of torque disturbances increase as KVI increases Default values for KVI are KVI Velocity Loop fve Hz Lag Break Freq Hz 25 1 7 75 5 0 default 200 13 3 Velocity Loop Integral Gain Kvi This should be set so that KVI fj Hz 15 IDN 101 KVI Hz 51 4719 If the drive is used within a position loop either with 2 or when using an external position drive and BIkType 1 KVI should be equal to or less than 0 1 times the velocity loop bandwidth If no position loop is used KVI can be set to 0 25 times the velocity loop bandwidth or higher if some ringing can be tolerated In general the response to a velocity command step or truncated ramp has velocity overshoot for non zero values of KVI 3 3 Position Loop When is set equal to 2 a position loop is configured outside the velocity loop The velocity loop must be set up and evaluated in terms of bandwidth BEFORE attempting to setup the position loop KPP The position loop proportional gain KPP determines the settling time of the position loop KPP is the bandwidth of the position loop in Hz assuming an ideal velocity loop Recommended values for KPP are fye Hz KPP Position Loop Bandwidth Hz 25 5 75 15 default 200 50 In general the higher the value of KPP the faster the settli
201. nd give the configuration a name 9 Click Download to Drive to send the complete configuration to the drive 10 After the download is complete click YES to save the configuration to non volatile memory 11 Turn AC power OFF and ON again 2 106 PCE830 40 User Manual Danaher Motion PCE830 When the hardware enable is asserted the motor initially uses the hall signals for commutation After the first hall state transition occurs the drive adjusts the commutation angle and starts commutation off the encoder To ensure the adjusted commutation angle is within 5 electrical degrees of the correct angle the 830 limits the maximum velocity and maximum acceleration rate at which the motor can rotate until this transition occurs because the motor is still not properly aligned during this period For additional information on the Comcoder Hall Encoder alignment process contact Pacific Scientific Application Engineering for assistance 2 9 Simple ASCII Protocol This applies to firmware version 2 00 and higher Command Message Format Description of Fields The PCE830 supports a simple ASCII protocol for serial communications with devices like PLCs or other electronics capable of handling ASCII strings The simple ASCII protocol command formats are given below The notation is indicates optional field lt gt indicates one character indicates a string of characters Each character is sent using its A
202. nd motion control technology As the user or person applying this unit you are responsible for determining the suitability of this product for the application In no event is the Pacific Scientific Company responsible or liable for indirect or consequential damage resulting from the misuse of this product Read this manual completely to effectively and safely operate the PCE830 40 Comply with the applicable European standards and Directives In Germany these include e DIN VDE 0100 instructions for setting up power installations with rated voltages below 1000V e DIN EN 60 204 Part 1 VDE 0113 part 1 instructions relative to electric equipment in machines for industrial use e DIN EN 50178 VDE 0160 equipping high voltage current installations with electronic operating means Safety Requirements The following requirements must be met to ensure compliance with the Low Voltage Directive 380 400 480 AC mains must be balanced three phase WYE type with earthed neutral Never connect disconnect any drive connectors terminals while the power is switched e The climatic conditions shall be in accordance with EN 50178 climatic class Type B temperature and relative humidity Class 3K3 This drive is to be installed inside motor control cabinet accessible only by qualified personnel e Electronic drives contain electrostatic sensitive devices that can be damaged when handled improperly Qualified pers
203. nd output port 2 Digital I O Setting You can make your choice depended on your hardware connection Clicking Default brings back the default settings Click Clear to clear all selections After selecting I O click Next to go to the Parameter Edit Screen PCE830 40 User Manual This wizard reminders you to set up the digital input and output When the page pops up it shows default setting 2 5 PCE830 Danaher Motion Parameter Edit In a parameter edit screen which is shown below you are allowed to configure additional features of the PCE830 40 During this initial set up the default values on each of these tabs are used lt no name assigned yet gt x Click Next to go to the next page 2 6 PCE830 40 User Manual Danaher Motion Print Parameters Save Parameters to Disk Download To 830 C Program Files PacSci 830T ools cfg mission2 cfg Print Save File Your configuration is complete now but you should either save it in a file or download it to a drive Press one of the buttons above to save this configuration Back Finish gt gt Help e Click Print to print all parameters in the Edit Parameter screen Click Save To File to save all parameters in the Edit Parameter screen to a configuration file on PC disk Click Download To Drive to download the all parameters that were edited in Edit Parameter screen to the drive P
204. nd the configuration can be changed on the fly via digital communications The user s default configuration 1 stored in the non volatile memory The present state of commanded outputs can be read via digital communications The logic polarity of these signals is also software programmable That is an output can be defined to be active low or active high For edge triggered functions the active edge is programmable The list below describes the subset of the available functions and the mappings used as the factory defaults for each of the outputs Output 1 This output is low when the drive is faulted or has no control power This line can be used to indicate a problem with the drive Output 2 Output Mapped Off Output 3 Output Mapped Off ial 1 3 25 Opto 2 25 50 mA lon 0 to 50 During short circuit folds back to 25 mA laa y to 30V Opto _ lorr 5 pA max 35V Transient Surge Protector clamps 40 nominal 3 33 Danaher Motion PCE840 Outputs Driving Typical Loads J2 41 Out1 2 3 Supply Input 12 42 Out _42 43 Out2 J2 44 Out3 24V Relay 24V Opto Input Display Output Schematic EXTERNAL OUTPUT SUPPLY J2 41 FROM CONTROL LOGIC 74HC1D 1SMB36A4 364 Transient Surge Protector BOY max MMBT2222ALT OUTPUT J2 42 43 44 3 34 PCE830 40 User Manual Dan
205. nd to greatly reduce setup time Using 800TOOLS the 840 can be configured as either a Torque or Velocity controller Once configured motor functionality tuning and can all be tested with 800TOOLS 1 Install and run 800Tools and the following screen is displayed Communication Edit Utilities Help Upload Edit File a Edit Online Oscilloscope Diagnostics Control Mode Switch 2 Since the drive can only be controlled by one master at a time you need to click on the control mode switch to switch from SERCOS to serial mode The status bar on the bottom of the 800TOOLS screen indicates the current mode 2 Once the serial control mode has been selected click New Configuration and the following screen should be displayed 3 10 PCE830 40 User Manual Danaher Motion PCE840 TT x Drive Motor Drive Type 845 E Motor Type Tuning Velocity Mode Serial Command Inertia Ratio 0 to 100 n Mode of Operation Cancel Nest gt gt 4 There is no profile generator in the PCE840 Therefore there are no positioning modes available 5 Select the appropriate Drive Type Mode of Operation use Velocity Mode Serial Command and Motor Type Use an unloaded motor and set the Inertia Ratio to 0 6 Continue by clicking Next until the following screen is displayed rp 5 and Settings jigutr 000 Desktop cfg pma22
206. ng and installing the equipment as well as grounding and bonding requirements The equipment is not ready to operate without additional installations cable motor etc All necessary tests and measurements must be made on a typical installation The test installation with all peripheral devices as well as the test results and measurements are recorded in detail in documentation available on request from the manufacturer If the connection method on your machine is different from what is contained in this document or in the event of use of components other than those that we have specified adherence to interference limit values cannot be guaranteed To go through this procedure you will need the following items PCE830 40 Servo Drive Appropriate Brushless Motor with nothing attached to the shaft PC Running Windows 95 98 Windows 2000 or WindowsNT 800Tools Installation Disk Motor Power and Feedback Cables J3 RS 232 Communications Cable J1 DB 44 Connector Mate J2 AC Power Line Wiring Connect the motor feedback and AC Power cables as shown in the following Connections Connection Diagram but do not apply the AC Power at this time It is highly recommended that Pacific Scientific motor and feedback cables be used during setup since improper cabling is the number one cause of start up problems The RS 232 cable made by Pacific Scientific order number 5 232 5600 be used to conne
207. ng time However trying to set KPP to a high value with inadequate velocity loop bandwidth results in overshoot and ringing A good trade off is to set KPP to 0 2 times the velocity loop bandwidth Slightly higher values can be used if overshoot can be tolerated PCE830 40 User Manual 3 55 Danaher Motion PCE840 S1NnOO 13VHS lo HOLON Sog2ua3 gt wows 0 n 3OVAH3INI bei ou3 20 1 N3A108 38 eyepdn 9INONLO3T13 N M EE lt ad ORG 1 desea 110389804 g Z 1708987 gt 0804 gt lt NNO lt bb BAOW Position Loop PCE830 40 User Manual 3 56 Danaher Motion PCE840 IDN 104 Position Loop Proportional Gain Kpp This IDN should be set according to table below Gain settings are determined by the response type Gentle Medium or Stiff IDN 101 IDN 32843 IDN 32844 IDN 104 Response fy Hz KVI Gentle 25 172 10000 20000 2056 Medium 75 515 15000 75000 6167 Stiff 250 1716 150000 10 000 000 20556 IDN 104 KPP Hz 2 432e 3 for Resolver Feedback IDN 32824 0 IDN 104 4 KPP Hz 2 432e 3 for Encoder Feedback IDN 32824 1 or 2 sets position loop bandwidth for all values of RemoteFB
208. nt 40 C 7 5 Apus pk I Accessories N No Accessories Basic Connector Kit T TB Adapter Connector Kit Customization Code 001 Standard Unit xxx 7 Factory Assigned Hardware Customization 5 7 5 cont 40 C 22 5 Agus pk Example Order Numbers Order Model Description PCE833 001 T PCE833 001 T 7 5 ARMS peak standard servo drive CA800 TB TB adapter PCE830 40 connector kit MAE800 830 40 User Manual PCE835 001 A PCE834 001 A 22 5 Arms peak standard servo drive CA800 Basic PCE830 40 connector kit MAE800 830 40 User Manual PCE835 001 N PCE834 001 N 22 5 Arms peak standard servo drive MAES800 830 40 User Manual 845 001 PCE845 001 N 22 5 Arms peak standard servo drive with SERCOS option MAE800 830 40 User Manual PCE830 40 User Manual Model Identification Danaher Motion 4 2 PCE800 Technical Documentation Manual and Documentation MAES800 830 40 User Manual 4 3 PCES00 Accessories Connector Mate Kits 800 15 pin and 44 d subminiature mates for the PCE830 40 servo drive CAS800 TB 15 and 44 pin d subminiature terminal block adapter mates for the PCE830 40 servo drive Regen Resistors PRK 200 66 External regen resistor kit 660 200 Panel mount with cable Fan Kits PFK 120 120VAC Fan PFK 240 240VAC Fan 4 2 PCE830 40 User Manual Danaher Motion Specifi
209. nt temperatures above 50 C shorts longer than 5 minutes may cause damage These two inputs are intended to connect to a positive temperature coefficient thermostat or normally closed thermostatic switch imbedded in the motor windings When the resistance between these terminals becomes greater than 6 2 the drive will fault and indicate a Motor Over Temperature fault This circuit directly interfaces with Pacific Scientific s standard motor PTC PTC RTN is connected to I O RTN These differential inputs expect quadrature encoder feedback signals These two input pairs are differential and are detected by 26LS32 type RS 422 compatible line receivers As differential inputs the recommended common mode range is 7V with respect to I O RTN and the guaranteed differential voltage logic thresholds are 0 2V Recommended drivers should be able to source and sink gt 3 mA to from these inputs 220y4F 261532 220uF TO DECODE 13 14 1K 220 8 COUNT CH B IN 5 REG 5VDC 250 mA MAX J3 11 ENCIN B 261 532 220uF lane 8V UNREG An adapter be powered from the serial port 5VDC output on J1 4 as long as the load current on J1 4 J2 14 and J3 10 total less than 250 mA PCE830 40 User Manual 2 37 PCE830 Using TTL Differential Line Drivers Danaher Motion ENCODER PCE800 5 SUPPLY T
210. nts 12 1 7 Uploading Parameters from the iere casei sese 10 215 po 2 1 9 __ The Motor Database IRE 2 11 Current Loop Settings 25 2 Velocity Loop Settings 2 PCE830 40 User Manual i Table of Contents Danaher Motion 123 5 Mechanical Resonance eripe Gaiden LO 28I 2 6 DIAGNOSTICS AND PROTECTION CIRCUITS 2787 E 2 6 1 FaultCode List eeepc eee ne nuns cece 2 80 12 6 2 LED Troubleshooting 22 2 7 __ __ SERVO LOOP PARAMETERS puc CD QU pcd 21 2 7 1 __Velocity ee ee ne 021 52 7 2 Position 2 99 1 2 73 Advanced Velocity Loop Tuning isisiisimzinzinzinzinzizzizmiizizzizzizzizz 2 4102 2 8 COMCODER OR ENCODER FEEDBACK een INTIDIIVIZDIIZIIZ2IU1l4l 104 1 2 8 1 _ Configuring the PCE830 for Motor with an Incremental 2 104 1 2 8 2 Configuring the PCE830 for a Motor With Comcoder 2 106 29 SIMPLE ASCH PROTOCOL 2 107 3 6 3 __ Analog Input m mmn SA 1 1155 _ 3 7 ___ LOOP PARAMETERS c eeeeeseeesenneni
211. olution 1 motorrev 65536 resolver counts PulsesOut 1 encoder rev 4096 encoder counts PulsesIn PulsesOut cannot exceed 32767 Divide PulsesIn and PulsesOut by four to maintain the desired ratio The new values should then be PulsesOut 16384 PulsesIn 1024 The phase advance and phase retard index move distances must also be calculated The motor must perform an index move of rev 65536 4 16384 counts Therefore program two preset incremental moves of Distance 716384 counts and 16384 counts Phase correction moves are commanded on top of gearing To prevent backward motion of the follower ensure that RunSpeed DigitalCmdFreq It may be necessary to refine the tuning of the system in order to reduce the steady state position following error position lag Steady state position following error can be minimized by increasing the velocity feedforward gain Kvff Setting Kvff to 100 reduces this error to zero However at the expense of potential excessive overshoot Therefore your system may require that Kvff be set to a value less than 100 typically around 7075 8075 For additional information on tuning refer to Section 2 5 Tuning PCE830 40 User Manual 2 49 PCE830 Motion Profile Procedure Registration Moves 2 50 Danaher Motion Phase Advance Correction 500 gt Index Distance 16384 counts 375 mm Velocity RPM Gearing Start On active Move active 1 Create a new con
212. omer supplied cable Recommended cable wire 18 14 AWG 600V rated Teflon The terminals of the regen resistor must be shielded from contact as they are electrically connected to the Bus of the drive The regen terminals are at dangerous potentially lethal voltages whenever the drive bus power is on and for about 10 minutes after bus power is turned off To prevent the metal case of the resistor from becoming a safety hazard in the event of internal resistor failure the resistor case should be grounded by attaching it to a grounded panel Customer supplied regen resistor s can be used Be sure the resistance seen by the drive is within 10 of 66 Q and the isolation of the resistive element is a minimum of 1 500V and it can support pulses of 800VDC between the terminals In an application with very high average regenerated power it may be necessary to increase the wattage of the regen resistor Quick test Does water boil on the surface of the resistor One way to increase the regen resistor power handling capability is to blow air on it A simple way to increase regen power handling capability is to replace a single regen resistor with four similar resistors wired in series parallel Series parallel wiring is two pairs wired in series and the two pairs wired in parallel Use a meter to check the resistance of a combination before attaching it to the drive The resistance of a series parallel combination should measure the same as eac
213. on Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 34833 Output Bit 1 0 001 4 bytes Volts 13 500 13 500 Read only by the Master Parameter Data IDN Signed Decimal Number 1 4 bytes Encoder counts 2 147 483 647 2 147 483 647 Read only by the Master Parameter Data IDN Binary Data Allows the Master to write the value to Output Bit 1 located on J2 42 A User must supply Output Power to have Output Circuitry to operate Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State 3 124 1 2 bytes 0 1 Read Write by the Master PCE830 40 User Manual Danaher Motion PCE840 IDN 34834 Output Bit 2 Parameter Data IDN Binary Data Allows the Master to write the value to Output Bit 2 located on J2 43 User must supply Output Power to have Output Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master IDN 34835 Output Bit 3 Parameter Data IDN Binary Data Allows the Master to write the value to Output Bit 3 located on J2 44 User must supply Output Power to have Output Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master IDN 34836 Output Bit 4 Parameter Data IDN Binary Data Allows the Master to write the value to Ou
214. onnector It shows the front view looking at the PCE830 QUO ODDO OCC CC CODI PFO OOOO OOOO GOOD OO DUC QC OD Co e 2 22 PCE830 40 User Manual Danaher Motion PCE830 Command I O Analog CMD These inputs accept the analog command from the user This is a differential input J2 1 2 to an A D It has a maximum single ended input range with respect to I O RTN on Inputs RTN J2 3 7 15 16 either input of 21V and an input impedance of 50 The full scale differential command input range is 13 5V The offset and single pole low pass bandwidth of this signal is adjustable via a software setup parameter When used as a motion command the gain from this input is also adjustable via a software setup parameter 1200 HZ FILTER J2 2 33 2K 224K 33 2K ANALOG CMD 0 01uf 13 5V FULL SCALE TO A D 42 1 33 2 ANALOG gt IN DSP CMD J2 3 I O RTN gt Always connect I O RTN J2 3 to the signal ground of the source Failure to do so may result in erratic operation This terminal is signal common for the analog and non optically isolated digital inputs and outputs These pins are internally connected in the drive For protection against line surges one of the I O RTN pins must be connected to Earth ground Pacific Scientific recommends making this connection at an earth ground point in the cabinet reserved for single point grounding of all I O Returns drives
215. onnel must follow ESD protection measures For example wear grounded heel and wrist straps when contacting drive The discharge time for the bus capacitors may be as long as 5 minutes After disconnecting the drive from the AC mains wait at least 5 minutes before removing the drive s cover and exposing live parts Follow IEC 536 2 and 1140 for installation protection against electric shock e Installation shall be performed in accordance with local electric codes local accident prevention rules EN 50178 and EN 61800 3 Due to high leakage current this drive is to be permanently installed hard wired The PE connection shall be made by two separate conductors between the earth ground and the two PE terminals on the device Consult the factory before using this product on a circuit protected by a residual current operated protective device RCD External supply line fusing is required PCE8x3 Bussman KTK 20 PCE8x5 Bussmann KTK 30 Motor cable shield must be connected to protective earth covers shall be closed during operation During periods of extreme regeneration or excessively high input voltage the temperature of the regen resistor may exceed 70 When using an external regen resistor if regen cabling is accessible during normal machine operation the regen resistor cable should be rated at 600V DC or higher and shielded with the shield connected to PE Danaher Motion Table of Contents Conte
216. or See IDN 32872 DtFilt If I2tFilt exceeds DtThresh the drive will fault Conversion Scaling Factor 1 Data Length 2 bytes Units Hz Minimum Value 1 Maximum Value 1 000 Access State Read Write by the Master 3 116 PCE830 40 User Manual Danaher Motion IDN 32872 I2tFilt PCE840 Parameter Data IDN Unsigned Decimal Number DtFilt is the filtered value of the square of the currents flowing in the motor DtFilt IU V IW 100 Ipeak low pass filtered by I2tF0 IDN 32871 When exceeds the threshold value specified by I2tThresh the drive will fault Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32873 HallState 0 001 4 bytes of Ipeak 0 10 000 000 Read only by the Master Parameter Data IDN Unsigned Decimal Number HallState indicates the value of the hall sensors HallState 4 Hall 3 2 Hall 2 1 Hall 1 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 32876 Offset Angle for Hall Sensors 1 2 bytes 0 7 Read only by the Master Parameter Data IDN Unsigned Decimal Number HallOffset sets the offset angle for the hall sensors Hall signals are to be wired as shown in the Pacific Scientific High Performance Servo Drives Catalog By default it s value is set to 0 degrees Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Acce
217. or CP2 Parameter Data IDN IDN ID Number List List of required operational data which has not been received by the PCE840 before a change in phase to phase 3 can proceed Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read only by the Master IDN 22 IDN List Of Invalid Operation Data For CP3 Parameter Data IDN IDN ID Number List List of required operational data which has not been received by the PCE840 before a change in phase to phase 4 can proceed Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read only by the Master IDN 24 Configuration List Of MDT Parameter Data IDN IDN ID Number List List of IDNs which are not included in a User Defined AT The data contained in this list is governed by the following restrictions Each must be included in the list of Valid AT IDNs Refer to IDN 188 Total number of AT IDNs must be 8 or less Total number of bytes transferred must be 20 or less This IDN must be written when IDN 15 7 Custom Telegram Conversion Scaling Factor 1 Data Length 2 bytes data Variable Length Access State Read Write in Phase 2 Read Only in Phase 3 and 4 3 66 PCE830 40 User Manual Danaher Motion IDN 25 IDN list of all procedure commands PCE840 Parameter Data IDN IDN ID Number List List of all COMMAND IDNs supported by the PCE840 IDN99 IDN127 IDN128 IDN148 IDN170 IDN263 IDN264 Con
218. osition Mode Step and Direction Digital 1 0 Analog Loop Gains Position Controller Feedback Velocity Loop Kvp 0 50545 amp rad sec Kvi 5 00000 Hz 15000000 ____ He 750 00000 Hz Position Loop Kpp 15 00000 Hz 0 00000 x Next gt gt Set KVI 0 Set KPP 0 Set KVFF 100 PCE830 40 User Manual 2 73 PCE830 Danaher Motion On Line Drive Configuration Ea Variables and Parameters Commands 0 000 Hz Change Switch to Scope Kv z 0 000 amps rad sec 7 change iE cds _____ 0 000 2 4 1 1 off vt rooopercent change 4 nr 0 0002 change 60 4 off 3 In the Predefined Moves tab of the Parameter Edit window set as Incremental with default profile settings 4 Save the Configuration to disk and download to the drive 5 Click Edit Drive Configuration Online In the Variables and Parameters window type KVP in the first box KVI in the second box KPP in the third box KVFF in the fourth box and StartMove in the fifth box Drive PCE833 Motor Mode Velocity Mode Serial Command Sets the proportional gain of the velocity loop Sets the integral gain of the velocity loop LEE Unconfigure Sets the proportional gain of the position loop Input
219. otor Motion profile acceleration too high Machine load on the motor increased by friction Wiring problem between drive and motor yielding improper motion Drive and or motor under sized for application See HSTemp ItFilt and ItF0 for information on measuring the thermal margin in an application 0x5 5 Motor power wiring 1 4 5 or 6 short circuit line to ground neutral Motor power cable length is enough longer than the data sheet specification to cause excessive motor line to earth ground neutral capacitance Internal motor winding short circuit Insufficient motor inductance causing output over current faults KIP or KII improperly set causing excessive output current overshoots 0x6 6 Insufficient control AC voltage TB1 1 to TB1 2 External short on signal connector Internal drive failure 0x7 7 Not Assigned 0x9 9 Disconnected external regeneration resistor on TBI External regeneration resistor ohmage too large yielding Bus OverVoltage fault External regeneration resistor short circuit Motor AC power input voltage too high 10 Not Assigned OxB 11 Check the measured bus voltage VBus and the fault threshold VBusThresh to make sure they are consistent PCE830 40 User Manual 3 129 PCE840 Danaher Motion
220. ots are real and 27 WARXOVLARXT G2 ARXO For lt 0 roots complex pair and 2 ARKO Qz ARXI When 20 and ARZI are both 0 the numerator of V amp Y reduces to 5 f If ARZ0 or ARZI is individually 0 the numerator reduces to 2x ARZX The velocity loop compensation is actually implemented as a digital discrete time Discrete Time system function on the DSP The continuous time transfer function is converted to Transfer Function the discrete time domain by a backward Euler mapping oz where T 250 psec 2 102 PCE830 40 User Manual PCE830 Danaher Motion and Command Mode Selection Processing 90 IvNY UDEN BO diy 4410 104 HOASE b 030v asyoQwv doo uonsog pulla A asta Wid ANNI aud LIOA fp doo o 22 uie tjpur PM HA ZH b 2 222249 1071922 IHIULTI8A lt u g eua 8 PUDdIBA 2 103 PCE830 40 User Manual PCE830 Danaher Motion 2 8 or Encoder Feedback Setup The PCE830 servo drive can commutate a motor using any one of the following feedback devices e Resolver e Incremental Encoder e Comcoder hall encoder
221. ower Fusing Mounting and Installation The control power 1 1 2 is typically single phase 115VAC to 240 referenced to neutral PE The control power is input to a switching power supply The input TB 1 1 to 1 2 will accept voltages ranging from 85VAC to 265VAC or 120VDC to 375VDC To meet safety standard ENS0178 the voltage from control voltage inputs TB 1 1 2 to PE TB1 3 must be less than 300V RMS e Obtaining control power from the high voltage three phase bus power mains Method 1 Stepdown Transformer 380 400 480V AC 480V AC to 240V AC stepdown transformer 25W to 50W connected line line from 380 400 480V AC mains generates 190 200 240V AC suitable for the AC control power Use of a line filter on the AC control power input is recommended For systems that must meet conducted line noise regulatory requirements a line filter on the AC control power is required Method 2 No Transformer 380 400 ONLY Phase to neutral voltage of 380V AC and 400V AC mains is 220VAC and 231VAC The phase to neutral voltage of these mains is within the range of the AC control supply and can be coupled through a line filter to the AC control power inputs Use of a line filter on the AC control power input is REQUIRED when there is no transformer to block mains spikes from the control supply A phase to neutral connection from 480VAC mains to AC control power without a transformer is NOT po
222. ower Cables and Baluns Pacific Scientific cables are recommended for use with PCE830 40 drives The drives have been tested and characterized using these cables There are two risks in using non Pacific Scientific cables e Drive performance or reliability may be adversely affected The motor cable capacitance characteristics impedance and shield termination affect the switching loss of the transistors in the inverter e The motor power cable insulation can degrade over time and may fail A long cable driven by a switching inverter has internal voltage pulses due to reflections up and down the cable that can easily be twice the bus voltage If the cable is not designed for this type of operation even though it has the correct voltage rating it will not be reliable If a non Pacific Scientific cable is used observe the following guidelines e Motor power cables should be VFD type These cables are rated by the cable manufacturer for Variable Frequency Drive operation e Motor power cables should be 14 AWG 600V to 1 000V e Motor power cable shield and PE wire should be joined and connected to the PE terminal of the drive 830 40 drives operated with Pacific Scientific PCE830 40 cables do not require a motor cable balun for cables up to the maximum specified length 50m but a motor cable balun is RECOMMENDED when motor cable length exceeds 10m 32 ft The reasons for this recommendation are Less Noise Coupling to Nearby
223. p to a position beyond the marker pulse and then reverses direction back toward the marker pulse coming to rest at resolver position of ResPos 10 The drive then activates an output to signal a PLC that the move is done e First calculate the speed of the motor while it s advancing toward the home switch Run Speed 2 30 in min 60 rpm Motion Profile 60L 100 Velocity 1000 Move rpm _ _ N f acfve ResPos 10 Start Home Marker 4100 switch Pulse active input ResPos 0 si active Procedure 1 Create a new configuration and select Position Mode Predefined Moves as the mode of operation 2 Click the Digital I O tab Set up a Home Switch Input a StartMove input and a MoveSelectBit Set up a MoveDone output 3 Click the Predefined Moves tab Setup a Home move using the following parameters Move Type Home Run Speed 60 rpm Accel Rate 1000 rpm Decel Rate 100 rpm Distance Offset 10 counts Reg Select n a Homing Mode Home Switch Marker Pulse Home Direction Clockwise 2 46 PCE830 40 User Manual Danaher Motion Clutch Brake Motion Profile PCE830 A thermal cut and seal machine uses an analog input signal to command a geared motor gear ratio 10 1 to spin a pinch roller that feeds material into the thermal cutter and sealer There is a 2 5 volt signal available to command spee
224. peration to position mode Command Gain Select 9 Switches the analog input scale factor between CmdGain and CmdGain2 Home Switch Input 15 Home switch input for a homing move InpMapX To map as HomeSwitch Active High write value 0x800F to IDN32817 To Example map INP2 as Enable2 Active Low write value 0x3 to IDN32818 Outputs Table The following table lists the mappable output functions IDN32860 to IDN32863 OutMapX available for the 3 Digital and 1 Relay Outputs Bit 0 to bit 2 select the function and bit 15 selects the active state Active High or Active Low Mappable Output Function Function Number Description No Function 0 Turns off mappable output functionality Fault default 1 Indicates whether the drive has faulted and is disabled Enabled 2 Indicates whether power can flow to the motor Brake default 3 Indicates when the motor is not powered and a mechanical brake is needed to hold the motor Mechanical Revs 4 Square wave whose frequency is equal to the resolver s electrical frequency which is typically equal to the mechanical Rev sec Electrical Revs 5 Square wave shose frequency is equal to the motor electrical frequency Zero Speed 6 Activated when the motor s speed goes below the speed threshold set by the parameter ZeroSpeedThresh Excess Position Error 7 Asserted when there is excess following error for an 3 40 extended period of time following error limit is
225. r commutation For encoder based commutation Polecount motor poles 2 Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32809 Filter Values for ADFO additional information Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32810 Filter Values for 1 0 additional information Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State 3 100 Encoder counts rev 2 bytes Motor poles 2 32766 Read Write by the Master in phase 2 Read Write in phases 3 and 4 Parameter Data IDN Unsigned Decimal Number 0 01 100 1 Hz 4 bytes Hz 1 4 17e9 Read Write by the Master Parameter Data IDN Unsigned Decimal Number 0 01 100 1 Hz 4 bytes Hz 1 4 17e9 Read Write by the Master PCE830 40 User Manual Danaher Motion IDN 32811 Filter Values for DM2F0 additional information Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32812 DM1Gain PCE840 Parameter Data IDN Unsigned Decimal Number 0 01 100 1 Hz 4 bytes Hz 1 4 294 967 295 Read Write by the Master Parameter Data IDN Signed Decimal Number Sets the analog output gain for DacMap 1 Scale factor depends on the setting of DacMap 1 Refer to Dac Monitor Conversion Scaling Factor Data Length Minimum Value
226. r to have Input Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master 3 122 PCE830 40 User Manual Danaher Motion IDN 34822 Input Bit 6 Allows the Master to read the value of the Input Bit 6 located on J2 36 User must supply Input Power to have Input Circuitry to operate Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 34824 Input Port 1 2 bytes 0 1 Read only by the Master PCE840 Parameter Data IDN Binary Data Parameter Data IDN Binary Data Allows the Master to read the entire Input Port The data is returned in the following format Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State PCE830 40 User Manual Bit Number Description Bit 0 Input 1 Bit 1 Input 2 Bit 2 Input 3 Bit 3 Input 4 Bit 4 Input 5 Bit 5 Input 6 Bits 8 15 undefined 1 2 bytes 0 0x003F Read only by the Master 3 123 PCE840 IDN 34825 AnalogIn Danaher Motion Parameter Data IDN Signed Decimal Number Allows the master to read the Analog Input on the base unit Refer to the scaling factor document for the correct Analog Input Scaling Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 34826 EncPos Accumulated Encoder Positi
227. r to read the value of the Input Bit 1 located on J2 31 User must supply Input Power to have Input Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 34818 Input Bit 2 Parameter Data IDN Binary Data Allows the Master to read the value of the Input Bit 2 located on J2 32 User must supply Input Power to have Input Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master PCE830 40 User Manual 3 121 PCE840 Danaher Motion IDN 34819 Input Bit 3 Parameter Data IDN Binary Data Allows the Master to read the value of the Input Bit 3 located on J2 33 A User must supply Input Power to have Input Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 34820 Input Bit 4 Parameter Data IDN Binary Data Allows the Master to read the value of the Input Bit 4 located on J2 34 User must supply Input Power to have Input Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 34821 Input Bit 5 Parameter Data IDN Binary Data Allows the Master to read the value of the Input Bit 5 located on J2 35 A User must supply Input Powe
228. ral resonant frequencies If natural resonant frequency is much greater than the servo loop bandwidth there are no problems The mechanical natural resonant frequency is dependent on drive train coupling stiffness and load motor inertia ratio In order to increase the mechanical system natural resonant frequency either decrease total system inertia or increase coupling stiffness When the motor current is commanded sinusoidally above the mechanical system s natural resonant frequency the load can decouple from the motor and no longer follows the motor When the commanded frequency is at the mechanical resonant frequency the load is moving exactly opposite from the command approximately 180 phase lag and the movement can become violent If the load decouples command frequency gt resonant frequency the mechanical system looks like only a motor system to the drive In a servo velocity loop total inertia and loop gain determine system bandwidth When the system jumps from fully loaded coupled to unloaded decoupled the bandwidth jumps from BW to BW Inertia ratio If the inertia ratio is 10 1 and the fully loaded bandwidth is 75 Hz the decoupled BW becomes 750 Hz The system is unstable for any BW more than the drive s limit of 400 Hz We could either reduce the fully loaded BW to 40 Hz by reducing gain or reduce the inertia ratio to 5 1 to resolve the issue of resonance This method allows the system to ride through the resonance wi
229. rding to function 32814 DMIMAP Selects Variable to be mapped to AnalogOutl 32815 DM2MAP Selects Variable to be mapped to AnalogOut2 34841 AnalogOutl Writes AnalogOut1 if IEN 32814 0 34842 AnalogOut2 Writes AnalogOut2 if IEN 32815 0 Example User reads IDN 32825 AnalogIn to be 130 Voltage on AnaloglIn pin is 1301000 0 13 volts The analog input is a differential input to an A D The full scale differential command input range is 13V 3 6 5 DACMap Parameters IDN 32814 DM1Map selects the signal sent to the DAC Monitor 1 output on J2 4 This should be set so that IDN 32814 Monitor from the table on the following page IDN 32815 DM2Map selects the signal sent to the DAC Monitor 2 output on J2 5 This should be set so that IDN 32815 Monitor from the table on the following page Set the value of the DMIMap and DM2Map IDNs 32814 and 32815 before setting the values of DM1Gain and DM2Gain IDNs 32812 and 32813 IDN 32812 DM1Gain sets the multiplicative scale factor applied to the DM1Map selected signal before outputting on DAC Monitor 1 J2 4 DM1Gain This should be set so that IDN 32812 DM1Gain 100 3 46 PCE830 40 User Manual Danaher Motion IDN 32813 DAC Out Units PCE840 DM2Gain sets the multiplicative scale factor applied to the DM1Map selected signal before outputting on DAC Monitor 2 J2 5 DM2Gain This IDN should be set so tha
230. resistor to absorb regenerated energy from the motor A regeneration resistor goes from to R In the PCE833 if a regeneration resistor is not needed see Appendix E and R are open In the PCE835 an internal regen resistor is factory wired to and Bus on 1 9 is usually left open High Voltage During normal operation B R and B operate at the bus power voltages The 830 regen operates at about 800VDC These are dangerous voltages PCE830 40 User Manual Danaher Motion PCE830 Regen Resistors The table below lists the recommended values for regen resistors To order Motor Power PE 1 10 Motor Case Ground U V W 1 11 12 13 Motor Phase PCE830 40 User Manual 660 200W regen resistor from Pacific Scientific use part number PRK 200 66 Model Resistance Regen Resistor External Regen Location Resistor 833 660 External 660 10 200W 1500V min isolation PCE835 330 Internal factory wired External 400W option 1 7 to TB1 8 100W see below rN Regen Resistance MUST be in the range as shown below Model Resistance PC833 60 to 72 Q PC835 30010360 For safety it is recommended that the external resistor be mounted grounded panel or use a grounding wire connected to a mounting screw The terminals of the resistor must not be grounded In a few installations heav
231. rite Sets the instantaneous Position Command Value This value will be overwritten by the Position Feedback Data when the drive 15 not enabled This value sent over the Service Channel will be overwritten by any applicable cyclic channel data Access State Read Write in phases 2 4 PCE830 40 User Manual 3 71 PCE840 Danaher Motion IDN 51 Position Feedback Value 1 Parameter Data IDN Signed Decimal Number Allows the Master to have access to the instantaneous Position Feedback value of the PCE840 drive The value is scaled by IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units resolver or encoder counts IDN 79 65536 depending on feedback device used Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Master Read Reads the instantaneous Position Command Value IDN 52 Reference Distance 1 Parameter Data IDN Signed Decimal Number Programmable Position offset used during Home Commands The value is scaled by IDN 79 Conversion Scaling Factor 1 Data Length 4 bytes Units resolver or encoder counts 65536 IDN 79 depending on feedback device used Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Master Read Read Write in phases 2 4 IDN 55 Position Polarity Parameter Parameter Data IDN Binary Data Defines the Position Polarity Parameters Bit Number Bit Setting 1 Inverted 0 Non Inverted Bit 0 Position Command Data IDN 47 Bit 1
232. rmance and is limited by the motor and drive combination If the load to motor inertia ratio is very large you will not be able to accelerate the load inertia quickly which limits response to speed changes or speed disturbances 2 Large inertial loads limit available continuous torque because the velocity loop gain needs to be larger for larger inertial loads Large values of velocity loop gain amplify velocity feedback noise as current commands The current ripple due to velocity feedback noise increases measured rms current and component temperature Inertia affects the mechanical system by requiring a proportionally stiff load to motor coupling to maintain a given system bandwidth A directly coupled load can have higher inertia ratios than a belt system due to the stiffness of the coupling device When coupling stiffness is lowered the system s natural resonant frequency is lowered If the system s natural resonant frequency is lowered close to the velocity bandwith crossover frequency the mechanical system may be excited by noise in the velocity loop Under certain conditions the mechanical system resonates 2 82 PCE830 40 User Manual Danaher Motion PCE830 2 5 6 Mechanical Resonance Excitation Inertia Ratio Filtering There is always a mechanical natural resonant frequency It is only a problem if it becomes excited To reduce the possibility of excitation mechanical systems should be designed with very high natu
233. rol Bit IDNs IDN 301 IDN 303 will cause the value of the realtime control bit in the MDT to be placed into that Probe Enable function Writing 409 Probe 1 Positive Data Latched to IDN 305 Allocation of Realtime Status Bit 1 will cause the value of Probe 1 Positive Data Latched to appear as Status Bit 1 in the cyclic AT status word Writing 412 Probe 2 Negative Data Latched to IDN 307 Allocation of Realtime Status Bit 2 will cause the value of Probe 2 Negative Data Latched to appear as Status Bit 2 in the cyclic AT status word Writing 406 Probe 2 enable to IDN 303 Allocation of Realtime Control Bit 2 will cause the value of Control Bit 2 in the cyclic MDT to be written to Probe 2 Enable Writing 405 Probe 1 Enable to IDN 301 Allocation of Realtime Control Bit 1 will cause the value of Control Bit 1 in the cyclic MDT to be written to Probe 1 Enable Use of the Realtime Control Status bit IDNs IDNs 405 406 409 412 along with the cyclic channel IDNs 130 133 results in registration events recorded and acted upon in realtime PCE830 40 User Manual Danaher Motion PCE840 3 6 3 Analog Input This IDN can be read through either the Service or the Cyclic channel IDN 34825 Allows the master to read the Analog Input on the base unit The value of this IDN is AnaloglIn V IDN32825 1000 0 IDN 32809 First order low pass filter corner frequency for the analog input channel on J2 1 2 ADFO This IDN should b
234. rsion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Off Maximum Value 34822 Access State Read Write by Master in phases 2 4 IDN 400 Home Switch Parameter Data IDN Binary Data Allows the Master to read the current state of the Home Switch If more than one input is defined to be the Home Switch the highest Input 1 6 is the value returned Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master PCE830 40 User Manual 3 95 PCE840 Danaher Motion IDN 401 Probe 1 Parameter Data IDN Binary Data Allows the Master to read the current state of the Probe 1 switch The only input pin which can be defined as Probe 1 is Input 4 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 401 Probe 2 Parameter Data IDN Binary Data Allows the Master to read the current state of the Probe 2 switch The only input pin which can be defined as Probe 2 is Input 5 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read only by the Master IDN 403 Position Feedback Value Status Parameter Data IDN Binary Data This bit is set by the PCE840 whenever a Home has been successfully completed This bit starts off CLEARED upon initialization Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Ac
235. rt circuit proof to I O RTN These two connections provide an auxiliary power supply for the user This output is SVDC 5 and is short circuit protected at 1 A nominal The maximum load limit for all connections to this supply is 250 mA The 5 RTN J2 15 is connected to RTN J2 3 J2 7 J2 16 J2 30 PCE830 40 User Manual Danaher Motion Encoder Inputs J2 17 18 19 20 Relay Outputs J2 24 25 PCE830 40 User Manual PCE830 CH A IN CH A IN CH B IN IN Step Step Dir Dir Step Up Step Up Step Dn Step Dn These inputs are used as a quadrature encoder step and direction or up and down count format incremental signal source The decoding mode is set by the EncMode parameter The scale factor of this incremental position command input is fully adjustable with software parameters Full decoding speed or more noise immune slow speed decoding is software selectable These two input pairs are differential and are detected by 26LS32 type RS 422 compatible line receivers As differential inputs the recommended common mode range 1 lt 7V with respect to I O RTN and the guaranteed differential voltage logic thresholds are gt 0 2V Recommended drivers should be able to source and sink 3 mA to from these inputs Each of these inputs has internal bias networks to allow easy connection to single ended sources When an input is open circuited it will bias itself to between 2 2v and 2 5V t
236. s Outputs 2 off 3 off 2 3 Sets velocity feedforward signal amount applied to position loop First anti resonant single order low pass filter corner freq 5 Second anti resonant single order low pass filter corner freq Scope 2 74 6 Click Switch to Scope and the Oscilloscope appears PCE830 40 User Manual Danaher Motion PCE830 7 Setup Channel 1 for Velocity Command and Channel 2 for Velocity Feedback Set the Scales at 200 rpm div Set the Trigger to Chn1 rising edge at 100 rpm level Set the Timebase to 0 02 sec div m Velocity Command l EL Am po 8 Use the Switch to Variables button to command an index move and the Switch to Scope button to monitor progress PCE830 40 User Manual 2 75 PCE830 Danaher Motion 9 Inthe Variables window change the StartMove variable from 0 to 1 to start a move This can be mapped as an input but you can not change it in software if it is mapped Slowly increase KVP between move commands using the change button hhh po b Velocity Feedback PLT ETN LTT TTT TN LTT TAT TT LTT TTT TT ____ 1 rising edge A r a Aa E Bm 0 02 sec div 2 76 PCE830 40 User Manual Danaher Motion PCE830 10 In the Scope window monitor Velocity Feedback to see how it follows the command Look for velo
237. s may result from belts flexible couplings or the torsional stiffness of shafts In general the stiffer the couplings the higher the resonance frequency and the easier it is to tune the system for good performance If the velocity loop breaks into an oscillation at a frequency well above the calculated velocity loop bandwidth a resonance problem may exist A second symptom is that the frequency of oscillation is relatively constant even with changes to ARFO and Two digital anti resonant low pass filters and are included in the velocity loop Their purpose is to lower the gain above fyc especially at any resonant frequency gt fve so oscillations do not occur Recommended values are fye Hz 25 75 200 Hz 100 150 default 1500 Hz 200 750 default 1x10 If the velocity loop bandwidth cannot be raised to an acceptable value without encountering a resonant oscillation follow the procedure below 1 Set both ARFO and ARFI to 400 Hz and set low enough to prevent oscillation 2 Increase KVP slowly until oscillation at the resonant frequency just begins Reduce KVP slightly until the oscillation just stops Compute the velocity loop bandwidth using the formula given at the beginning of this section If the velocity loop bandwidth is less than 25 times the value of and proceed to Step 3 Otherwise go to Step 4
238. ss State PCE830 40 User Manual 1 2 bytes Electrical degrees 0 360 Read Write by the Master 3 117 PCE840 Danaher Motion IDN 32878 Digital Command Counts Parameter Data IDN Signed Decimal Number DigitalCmd indicates the position of the external command encoder J2 17 through J2 20 or the accumulation of step inputs if step and direction input format is used By default it s value is set 0 Conversion Scaling Factor 1 Data Length 4 bytes Units Encoder counts Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Access State Read by the Master in all phases IDN 32879 Digital Command Frequency Parameter Data IDN Signed Decimal Number DigitalCmdFreq indicates the frequency of the digital command signal It is calculated from delta DigitalCmd at position loop update rate Although the values returned do not have fractional parts this variable is communicated as a floating point quantity By default it s value is set 0 Conversion Scaling Factor 0 01 Data Length 4 bytes Units Hz Minimum Value 300 000 000 Maximum Value 300 000 000 Access State Read by the Master in all phases IDN 32880 AnalogOut1 Parameter Data IDN Signed Decimal Number Allows the Master to set the voltage on Analog Output 1 when DacMap 1 equals zero The scaling for this IDN is 5 128 Volts per least significant bit Isb Conversion Scaling Factor 0 001 Data Length 2 bytes Units Volts Minimum Value 5 000 Ma
239. ssible The phase to neutral voltage for 480VAC mains is 277VAC which is outside the range of the AC control supply Use high surge fuses in series with pins 4 5 and 6 Model Fuse PCE8x3 Bussman KTK 20 8 5 Bussman KTK 30 AC control supply TBI pins 1 and 2 is internally fused by a 1A 250V fuse with 50A interrupt capability 1 1 3 Connection to PE Ground TB1 3 and chassis ground point must be connected to Protective Earth ground they are marked with the PE symbol The connection at the Protective Earth ground end must be hard wired not utilize pluggable connections A ground fault detector RCD cannot be depended on for safety PCE830 40 User Manual 1 7 Mounting and Installation Danaher Motion 1 1 4 1 1 5 Grounding Shields for Safety and Low Emissions and Susceptibility Dangerous voltages resulting from cable capacitance exist on some cable shields if the shields are not connected to PE ground If the motor power cable braid shield is exposed it MUST be clamped to PE to avoid a dangerous shock hazard Proper grounding of shields is also required to reduce radiated and conducted emissions as well as to protect against susceptibility to external and self generated noise Follow these shielding requirements carefully e drive end of the motor cable shield must be connected to the PE or location on the connector The shield must also be
240. t IDN 32813 DM2Gain 100 The table below lists the units when DMxGain 1 Monitor Variable Description DAC Out Units 0 AnalogOutX 0 001 V V 1 VelFB Measured Velocity DM2 Default 0 001 2 VelCmdA Actual Velocity Command VelCmdA 0 001 V V kKRPM 3 VelErr Velocity Error 0 001 V V kRPM 4 FVelErr Compensated Velocity Error 0 001 V V kRPM 5 Position Measured Position 0 001 V Rev 6 PosError Position Error 0 001 V Rev 7 PosCommand Commanded Position 0 001 V Rev 8 ICmd Commanded Torque Current 0 001 V A 9 IFB Measured Torque Current DM1 Default 0 001 V A 10 AnalolgIn Filtered A D Input 0 001 V V 11 EncFreq Encoder Frequency 0 001 V Hz 12 EncPos Encoder Position 0 001 V 4096 counts 13 ItFilt Filtered Output Current Amplitude 0 001 100 14 HSTemp Measured Heat Sink Temperature 0 001 V C 15 Commutation Electrical Angle 0 001 V Cycle 16 IR Motor Phase R Output Current 0 001 V A 17 IS Motor Phase S Output Current 0 001 V A 18 IT Motor Phase T Output Current 0 001 V A 19 Motor Phase R Voltage Duty Cycle 0 001 V 100 20 Motor Phase S Voltage Duty Cycle 0 001 V 100 21 Motor Phase T Voltage Duty Cycle 0 001 V 100 22 VBus Drive Bus Voltage 0 001 V V 23 ResPos Resolver Absolute Position 0 001 V Rev 24 Commanded Non torque Current 0 001 V A 25 Measured Non torque Current 0 001 V A 26 Torque Vol
241. t 2 will cause the value of Input Bit 6 to appear as Status Bit 2 in the cyclic AT status word Writing 34834 PCE840 Output Bit 2 to IDN 303 Allocation of Realtime Control Bit 2 will cause the value of Control Bit 2 in the cyclic MDT to be written to Output Bit 2 Writing 34836 PCE840 Output Bit 4 to IDN 301 Allocation of Realtime Control Bit 1 will cause the value of Control Bit 1 in the cyclic MDT to be written to Output Bit 4 PCE830 40 User Manual 3 39 840 Danaher Motion Inputs Table The following table lists the mappable input functions IDN32817 IDN32822 InpMapX available for the 6 Digital Inputs Bit 0 to bit 3 select the function and bit 15 selects the active state Active High or Active Low Mappable Input Function Function Number Description No Function 0 Turns off mappable input functionality Fault Reset default 1 Resets drive faults Run Stop 2 Selects between normal operation and setting the velocity command to zero Enable 2 3 Second enable function Velocity Command 4 Selects between VelCmd and VelCmd2 Source Clockwise Inhibit 5 Inhibits motor motion in the clockwise direction when default asserted Counterclockwise 6 Inhibits motor motion in the counter clockwise Inhibit default direction when asserted Analog Input Null 7 Nulls the analog input by setting ADOffset to old ADOffset minus AnalogIn Position Mode Select 8 Switches the active mode of o
242. t Bit 1 34818 840 Input Bit 2 34819 PCES840 Input Bit 3 34820 840 Input Bit 4 34821 PCE840 Input Bit 5 34822 840 Input Bit 6 34824 PCES40 Input Port Inputs 34825 AnalogIn 34826 EncPos Encoder Position 34833 PCE840 Output Bit 1 34834 840 Output Bit 72 34835 PCES840 Output Bit 3 34836 840 Output Bit 4 34840 840 Output Port Outputs PCE830 40 User Manual Danaher Motion PCE840 3 4 System Startup Configuration and Updates This section outlines the minimum steps required to bring the PCE840 to phase 4 and how to use 800TOOLS to help minimize setup time This section also describes how to use the NV functionality available on the drive and how to update the firmware using 800TOOLS 3 4 1 Bringing the Ring to Phase 4 The PCE840 has been designed to work with all SERCOS compliant masters The PCE840 has been tested with several SERCOS masters Please contact applications engineering for an up to date list This section assumes a SERCOS compliant master is being used and the following items are avaialable PCE840 Servo Drive Appropriate Brushless Motor with nothing attached to the shaft Running Windows 95 98 WindowsNT 800TOOLS CD Motor Power and Feedback Cables J3 RS 232 Communications Cable J1 DB 44 Connector Mate J2 SERCOS compliant controller SERCOS fiber optic cables 2 AC Power Line 480VAC and or
243. tabase Add A Motor To edit the motor database 1 Select Utilities Edit Motor Database 2 Click New Motor to add a motor to the database The following window appears New Motor Definition X Motor Name MYMOTOR Units English Motor Type Metric Enter in a name for the motor For example MYMOTOR Select either Rotary or Linear as the Motor Type Select either English or Metric as the units Click OK 7 Enter the motor parameters in the Motor Database Editor screen Motor Database Extension Editor Motor Name EAM d Motor Type Linear Motor Parameters Back 480000 _______ V DpeskVin sec 1 00000 _____ Stall Current 1 39000 Amps 0 Inductance mH Thermal Time Const 1000000 0 Minutes Commutation Source Incremental Pole Spacing 24000 in Encoder Resolution microns 8 Click OK This motor appears in the motor list of Creating New PCE830 40 User Manual 2 11 PCE830 Danaher Motion 2 1 10 Tuning Wizard The Tuning Wizard helps you to tuning your system It applies only to the velocity loop Select Utilities Tuning Wizard in the main menu After inputting the Inertia Ratio the following window appears rd Tuning Wizard Motor 8328 Drive Pce33 Inertia Ratio fi BandWidth BandWidth Hz Phase Margin E EH o Gentle Medium Stiff 0134 amp rad sec 150
244. tage Duty Cycle 0 001 V 100 27 Non torque Voltage Duty Cycle 0 001 V 100 28 Velocity Command VelCmd 0 001 V V kRPM 65536 No change to variable turn range clamp off 65537 No change to variable turn range clamp off These variable are allowed to wrap around when the signal exceeds the output voltage range DAC monitor outputs have a range of X5V with a resolution of 10V 256 0 039 V PCE830 40 User Manual 3 47 840 Example DAC Map Diagram 3 48 Danaher Motion To view the velocity feedback VelFB signal on an oscilloscope to measure overshoot rise time or other motion performance parameters do the following 1 Commanda4 KRPM move VelFB is the default setting for DM2Map IDN 32815 1 therefore use DAC Monitor 2 J2 5 with respect to pin 5 2 To filter out noise set DM2F0 32811 to 1000 Hz DAC Monitor 2 will display an analog signal representing VelFB 3 Set DM2Gain IDN 32813 The range of the DAC Monitors is 5 volts Set 2 so that the signal is not clamped and a high resolution signal is maintained For example set DM2Gain so that 5 KRPM will correspond to 5 volts S KRPM 0 001 Volt KRPM DM2Gain 5 Volts This implies that DM2Gain 1000 4 Connect the scope probe to DAC Monitor 2 and command a move The velocity feedback signal should be visible on the scope o5 Ea Ze OD gt DAC DMxMop AND UNITS CONVERSION _
245. tate Read Write by the Master 3 104 PCE830 40 User Manual Danaher Motion IDN 32823 EncInFilt Sets the break frequency of the input filters on the Encoder Input pins PCE840 Parameter Data IDN Unsigned Decimal Number Encoder Input Filter Setting EncMode Scaling High Medium Low Lowest 0 Quadrature Max Quadrature Freq 1600000 800000 400000 200000 1 StepDir Max Step Freq 800000 200000 100000 50000 2 Up Down Max Step Freq 800000 200000 100000 50000 3 Hold Count N A N A N A N A N A Conversion Scaling Factor 1 Data Length 4 bytes Units Hz Minimum Value 50 000 Maximum Value 16 000 000 Access State Read Write by the Master IDN 32824 RemoteFB Parameter Data IDN Unsigned Decimal Number Determines the source of Velocity and Position Feedback Must be set before IDN32853 RemoteFB Velocity Feedback Position Feedback 0 Resolver Resolver 1 Resolver Encoder 2 Encoder Encoder Conversion Scaling Factor 1 Data Length 4 bytes Minimum Value 0 Maximum Value 2 Access State PCE830 40 User Manual Read Write by the Master in Phase 2 3 105 PCE840 Danaher Motion IDN 32826 CommOff Parameter Data IDN Signed Decimal Number Allows the commutation offset to be set For Pacific Scientific motors this should be zero For custom motors this should be set for proper commutation
246. their possible causes is listed below If FaultCode lt 6 the Fault LED blinks the value of FaultCode For example if FaultCode 2 the Fault LED blinks twice If Faultcode 26 the Fault LED remains ON FaultCode Possible Cause 1 Loose or open circuit wiring to the resolver feedback connector J3 Actual motor speed exceeded 1 5 Max Of VelLmtLo or VelLmtHi or 21 038 RPM which is the over speed trip level For Encoder velocity feedback RemoteFB 2 check that is set properly Loose or open circuit wiring to motor PTC thermal sensor J3 8 J3 9 High ambient temperature at motor Insufficient motor heat sinking from motor mounting Operating above the motor s continuous current rating Short circuited wiring on the output J2 25 Mechanically jammed motor Motion profile acceleration too high Machine load on the motor increased by friction Wiring problem between drive and motor yielding improper motion Drive and or motor under sized for application See HSTemp ItFilt and ItF0 for information on measuring the thermal margin in an application Motor power wiring 1 4 5 or 6 short circuit line to ground neutral Motor power cable length is enough longer than the data sheet specification to cause excessive motor line to earth ground neutral capacitance Internal motor winding short circuit Insufficient motor
247. thin the MDT that the drive s data begins This value is in bytes and must be an odd value This value is calculated and written by the master during phase 2 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 10 Length Of MDT 1 2 bytes 0 65531 Read Write in Phase 2 Read only in Phase 3 and 4 Parameter Data IDN Unsigned Decimal Number The length of the MDT in bytes This includes data records for all drives This value is calculated and written by the master during phase 2 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 11 Class 1 Diagnostic 1 2 bytes 4 65534 Read Write in Phase 2 Read only in Phase 3 and 4 Parameter Data IDN Binary Data This IDN reports back the status of the motor drive The fault reported in this IDN causes the PCE840 to disable the drive Clearing the fault is required before the motor can be enabled The 840 supports the following bits in this IDN Bit Number Description Bit 15 Manufacturer Specific Fault See IDN 129 for additional information Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 0 8000 Access State PCE830 40 User Manual Read only by the Master 3 63 PCE840 Danaher Motion IDN 14 Interface Status Parameter Data IDN Binary Data This IDN reports back the Communication Interface Status The PCE840
248. thout going unstable because the decoupled bandwidth remains below 400 Hz There is another method to resolve the issue of resonance Anti Resonance Filters are used to prevent noise from exciting a resonance frequency This method works very well if the resonant frequency is much greater than the operating velocity loop bandwidth You can estimate where to place the filters by measuring the current feedback oscillation frequency using the softscope PCE830 40 User Manual 2 83 PCE830 Danaher Motion Example To get a fair estimate set 0 0 KVFF 100 25 Hz MotorInertia 6 28 Kteff ARFI 10 000 With the motor enabled and holding zero speed slowly increase KVP Monitor current feedback with the softscope When the current begins to oscillate gt 5 of the drive IPeak capture the waveform and disable the drive Measure the positive peak to next positive peak cycle time Tc of the current feedback waveform Frequency 1 It is easier to count the number of peaks in 10 divisions and divide into total time TEE EI 5 0 00 0 01 0 02 0 03 0 04 0 05 0 06 0 07 0 08 0 09 0 10 me in seconds 0 317 Ti d 39 673 3 Current Feedback Velocity Feedback Channel 1 mem Source Current Feedback Units Amps thick trace hs Amps _ per division Offset p Amps Channel 2 mmm Source Velocity Feedback
249. ting above the drive s continuous current rating See HSTemp ItFilt and ItF0 for information on measuring thermal margin in an application 0x16 22 Resolver signal is lost or intermittent Check resolver cable 3 130 PCE830 40 User Manual Danaher Motion PCE840 3 9 2 Motor Commutation IDN 32807 Number of motor magnetic poles Polecount which is the same as twice the number of motor electrical cycles per mechanical revolution This IDN should be set so that For resolver based commutation 32853 0 IDN 32807 Polecount Number of encoder counts electrical cycle IDN 32807 4 IDN 32828 Motor poles 2 For encoder based commutation it is required to do an encoder alignment using IDN 32854 Example If the application uses resolver based commutation with an R series motor set IDN 32807 4 R series motors have 4 poles If the application uses resolver based commutation with an S series motor set IDN 32807 6 S series motors have 6 poles If the application uses encoder based commutation with an R series motor and a 1024 line count encoder set IDN 32807 4 1024 4 2 2048 N CommSrc IDN 32853 must set before PoleCount IDN 32807 IDN 32826 CommOff sets the origin for the electrical commutation angle This IDN should be set so that for Pacific Scientific motors IDN 32826 CommOff 0 PCE830 40 User Manual 3 131 PCE840 Danaher Motion 3 9 3 System Protection
250. tion or initialization file depending on the master being used can be configured to include only IDN 263 NVLoad Cycling power on the drive and writing a 3 IDN 263 in phase 2 enables the NVLoad procedure command that loads the previously saved parameters 17 If additional parameters IDNs need to be saved to NV memory refer to IDN 192 complete list bring the ring to phase 4 Set the IDNs to the desired value and perform an NVSave write 3 to 264 to initiate the NVSave procedure command Once the parameters have been saved cycling power or reseting the ring loads the latests saved parameters provided an NVLoad IDN 263 is called in phase 2 PCE830 40 User Manual 3 13 PCE840 Danaher Motion 3 4 3 C840 Flash F W Update This section explains the steps required to update the SERCOS firmware in the PCE840 drive Requirements for performing a Flash update on the drive PC running 800TOOLS RS232 cable pins 2 3 and 5 wired straight through BIN file containing the latest PCE840 flash Steps required 1 Copy the updated BIN file to a directory on the PC that s running 800TOOLS Set the rotary switches on the drive to address 255 FF 3 Cycle power on the drive After cycling power the status display on the drive should spell out upgrade flash and then display a blinking U until the download is started 5 Run 800Tools and select Upgrade FW from the Utilities pull down menu shown below rd
251. to configure and save parameters to the Non volatile memory on the 840 Interfaces and Connections This section describes all the connections to the 840 and provides the information required to interface to it In the list below an overbar on a signal name means that the signal is active low logic For example Fault indicates the drive is faulted when it is pulled low Earth Ground Chassis Ground M4 x 12 screw with flat and lock washer PCE830 40 User Manual 3 15 PCE840 Danaher Motion 3 5 1 Power Board Connector TB1 13 Position Terminal Strip Pin Label Description 1 1 L1C 120 240V AC Control Power 1 2 L2C 120 240V AC Control Power 1 3 Chassis Ground 1 4 L1 380 400 480V AC Input TBI 5 L2 380 400 480V AC Input 1 6 L3 380 400 480V AC Input 1 7 TBI 8 R Regen Transistor 1 9 1 10 Chassis Ground TBI 11 U Motor Phase U 1 12 Motor Phase V 1 13 W Motor Phase W AC Power L1C L2C TB1 1 2 These terminals connect the 120 240 VAC power provided by the user 120VAC 240VAC to the drive s control voltage power supply Control Power 3 16 Control power L1C L2C TB1 1 2 are NOT connected internally to bus power L1 L2 TB1 4 5 The control voltage for the PCE840 controllers is input to a switching power supply This input accepts voltages ranging from 85
252. tput Bit 4 located on J2 45 User must supply Output Power to have Output Circuitry to operate Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 1 Access State Read Write by the Master PCE830 40 User Manual 3 125 PCE840 Danaher Motion IDN 34840 PCE840 Output Byte Parameter Data IDN Binary Data Allows the Master to read write the entire Output Port The data is in the following format Bit Number Description Bit 0 Output 1 Bit 1 Output 2 Bit 2 Output 3 Bit 3 Output 4 Bit 4 15 undefined Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 Maximum Value 0x000F Access State Read Write by the Master 3 9 Diagnostics and Protection Circuits The drive 15 fully protected against normal abuse and has two LEDs on the front panel to indicate SERCOS ring or drive status The servo drive has the following specific protections Output motor short circuit protection line to line and line to neutral Interface to Pacific Scientific s standard motor PTC or a normally closed thermostat to sense motor over temperature Internal monitoring of the power stage heat sink temperature for drive over temperature Bus over voltage detection Bus under voltage fault with adjustable threshold Incorporating the measured heat sink temperature there is an excessive current I t fault This fault limits the peak current time and intelligently changes the
253. trol speed of drive Mode 3 Position Mode Allows use of IDN 47 Position Command over the Cyclic and Service Channel to control position of drive Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 1 Maximum Value 3 Access State Read Write in Phase 2 Read Only in Phase 3 and 4 IDN 36 Velocity Command Value Parameter Data IDN Signed Decimal Number Gives access to the instantaneous Velocity Command value of the PCE840 Conversion Scaling Factor 1 Data Length 4 bytes Units Motor velocity RPM 00 45 10 IDN 46 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Master Read Reads the instantaneous Velocity Command from the PCE840 Master Write Position Mode Always overwritten by new Velocity Command generated from the Position Command Velocity Mode Sets the Velocity Command of the PCE840 Access State Read Write in phases 2 4 3 68 PCE830 40 User Manual Danaher Motion PCE840 IDN 40 Velocity Feedback Value Parameter Data IDN Signed Decimal Number Gives access to the instantaneous Velocity Feedback value of the PCE840 Conversion Scaling Factor 1 Data Length 4 bytes Units Motor velocity RPM 45 10 IDN 46 Minimum Value 2 147 483 647 Maximum Value 2 147 483 647 Master Read Reads the instantaneous Velocity Feedback from the PCE840 IDN 41 Homing Velocity Parameter Data IDN Signed Decimal Number Sets the velocity a home command is processed at
254. uidance for handling these situations The two anti resonant zeroes ARZO and are assumed to both be off set to zero for this discussion 2 7 1 Velocity Loop Velocity loop bandwidth is the key indicator of system performance Systems with fast settling time must have high velocity loop bandwidth Conversely if the velocity loop bandwidth is low attempting to achieve fast settling time by increasing the position loop bandwidth KPP leads to overshoot and ringing PCE830 40 User Manual 2 93 Danaher Motion PCE830 Velocity Loop purs duis 5H NO dia Ma us NOISH3ANOI SINN L XHO LINOM e 554 INY 8 g 8 Ova Nou333s amp S S lt 1 uonsogd VOX lt HOLINON uisa J D JXIACI VBUISA 3430 SH31SAS SOINvYHO3MW 2 3 gt NOILISOd 594 J dOOINOILISOdOL A1I2013A 2 5 APT OW HaAIOSdH 51 gt TC adie juni avna 909401 IET ANGYOL 940938 335 044 031710930 nah Li ce QNVINIOO ALIOOTSA LAN asWHd SOINVvHO3IN lsd Lie 0249 035 HOLYHOSLNI 4015 HO LI HO31NI PCE830 40 User Manual 2 94 Danaher Motion Velocity Loop Bandwidth Default Bandwidth Lo
255. uo2 e nonpuoo papi ojd 6 pjaiys 3 2 pjaius ajqeo 095 104 sdwejp PCE830 40 User Manual 4 dni z buunp p i uuo 13nduio2 perp Block Diagram Danaher Motion Mounting and Installation Mounting The figure below gives key dimensions for use in physically mounting the product Guidelines When mounting multiple drives in a row some customers have found the stiffness of the drive and their mounting panel to be too low To increase the mounted mechanical integrity connect to the threaded insert on the top front edge Mounting Dimensions 1442 5 68 PCE835 120 9 4 76 PCE833 Faceplate detail of PCE83x Faceplate detail of PCE84x PCE830 40 User Manual 1 5 Mounting and Installation Danaher Motion 1 1 2 Connecting to AC Power The PCE830 40 is designed to operate on balanced three phase mains from 380VAC to 480VAC To insure compatibility with CE safety standard 50178 the mains phase voltage to neutral PE must remain within certain limits Compatibility of the PCE800 series with the major types of three phase mains is outlined below 380 400 480 WYE with Earthed Neutral Mains 1 4 5 6 This is the preferred mains for the PCE830 40 and insures that CE safety standard EN50178 is met An earthed neutral forces the phase voltages to remain balanced with respect to neutral PE even if loads are
256. ust still be configured Writing 1 to 405 Probe 1 Enable will enable probe 1 Writing 3 to IDN 170 Probe Command will initiate probing on probe 1 INP4 and probe 2 INP5 At this point if probe 1 INP4 did not transition low to high reading IDN 409 Probe 1 Positive Latch will return a 0 indicating a probe did not take place Reading IDN 130 Probe 1 Positive Edge Data will return 0 After a positive transition on probe INP4 reading 409 Probe 1 Positive Latch will return a 1 indicating a probe had occurred Reading IDN 130 Probe 1 Positive Edge Data will return the latched position To latch position on probe 1 again reset IDN 405 by writingaO0andthenal toit Since probe 2 was not enabled using IDNs 169 and 406 reading probe 2 related IDNs will return 0 Of all the Probe Input IDNs only IDNs 130 133 IDNs which return latched position data can be inserted into the AT The data returned will either be 0 no data has been latched or the last latched data for that probe edge All of the Probe Data Latched IDNs IDNs 409 412 and Probe Enable IDNs IDNs 405 and 406 can be used through the use of realtime control status bits Writing the IDN of a Probe Data Latched into either of the two Allocation of Status Bit IDNs IDN 305 or IDN 307 will cause the value of that IDN to appear in the realtime status bit returned in the AT Writing the IDN of the Enable Probe into either of the two Allocation of Cont
257. version Scaling Factor Data Length Access State IDN 28 MST Error Counter 1 2 bytes data Variable Length Read only by the Master Parameter Data IDN Unsigned Decimal Number Counts all invalid MSTs in communication phases 3 and 4 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 29 MDT Error Counter 1 2 bytes 0 65535 Read by the Master Write only 0 Parameter Data IDN Unsigned Decimal Number Counts all invalid MDTs in communication phase 4 Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State IDN 30 Manufacturer Version 1 2 bytes 0 65535 Read by the Master Write only 0 Parameter Data IDN Text Data String The operation data of the manufacturer version contains the constant string Pacific Scientific Conversion Scaling Factor Data Length Access State PCE830 40 User Manual 1 1 byte data Variable length Read only by the Master 3 67 PCE840 Danaher Motion IDN 32 Primary Operation Mode Parameter Data IDN Unsigned Decimal Number The mode of operation is sent by the Master to the PCE840 during Phase 2 with this IDN Valid modes of operation are velocity position and torque mode Mode 1 Torque Mode Allows the use of IDN 80 Torque Command over the Service Channel to control torque of drive Mode 2 Velocity Mode Allows use of IDN 36 Velocity Command over the Service Channel to con
258. xception of Home Velocity IDN 41 and Home Acceleration IDN 42 Once the drive has finished the HOME event the Position Feedback Value Status will be set IDN 403 The Master must read the new position at this time and begin sending updated Position Commands prior to finishing this Command IDN to avoid Excessive Position Error Faults A To execute homing more than once reset IDN 148 by writing 0 and then 3 Conversion Scaling Factor 1 Data Length 2 bytes Minimum Value 0 deactivate drive controlled homing Maximum Value 3 activate drive controlled homing Access State Read Write by the Master in phases 2 4 IDN 159 Monitoring Window Parameter Data IDN Unsigned Decimal Number Sets the Maximum Position Deviation allowed by the PCE840 Conversion Scaling Factor 16 Data Length 2 bytes Minimum Value 0 Maximum Value 65535 Access State Read Write by the Master in phases 2 4 3 86 PCE830 40 User Manual Danaher Motion PCE840 IDN 160 Acceleration Data Scaling Type Parameter Data IDN Defines the scaling type for the PCE840 Binary Data Bit Number Bit Setting Bits 0 2 010 Rotational Scaling Bit 3 1 Parameter Scaling Bit 4 0 Radian Bit 5 0 Seconds Bit 6 0 At the motor shaft Conversion Scaling Factor Data Length Minimum Value Maximum Value Access State 1 2 bytes 0x0A 0x0A Read only by the Master IDN 161 Acceleration Data Sc
259. ximum Value Access State IDN 32844 1 0 01 4 bytes Hz 10 000 000 10 000 000 Read Write by the Master Parameter Data IDN Unsigned Decimal Number is the second velocity loop compensation anti resonance low pass filter corner frequency Please refer to Sectioni3 7 Servo Loop Parameters additional information 2 Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State PCE830 40 User Manual 0 01 4 bytes Hz 10 000 000 10 000 000 Read Write by the Master 3 111 PCE840 IDN 32845 Firmware Version Danaher Motion Parameter Data IDN Text Allows the Master to read a TEXT description of the current versions fo the ARM and the DSP firmware DSP Version 1 20 ARM version 6 0 DSP and ARM versions continue to change with each build Conversion Scaling Factor 1 Data Length Byte list Access State Read only by the Master IDN 32846 Encoder Data Scaling Method Parameter Data IDN Binary Data Sets the working parameters for the Encoder Position Bit Number Bit Setting 1 Inverted 0 Non Inverted Bits 0 2 010 Rotational Scaling Bit 3 Parameter Scaling Bit 4 0 Degrees Bit 5 0 Reserved Bit 6 0 At the Motor Shaft Bit 7 0 Absolute format 1 Modulo format IDN 32847 Bit 8 0 Non Inverted Encoder Data 1 Inverted Encoder Data Conversion Scaling F
260. ximum Value 4 961 Access State Read Write by the Master 3 118 PCE830 40 User Manual Danaher Motion IDN 32881 AnalogOut2 PCE840 Parameter Data IDN Signed Decimal Number Allows the Master to set the voltage on Analog Output 2 when DacMap 2 equals zero The scaling for this IDN is 5 128 Volts per least significant bit Isb Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32882 Analog Current Limit 0 001 2 bytes Volts 5 000 4 961 Read Write by the Master Parameter Data IDN Unsigned Decimal Number Allows the Master the current limit set float value by the Analog Current Limit input J2 6 Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State IDN 32883 Analog Current Limit Gain 0 01 2 bytes of Ipeak 0 10 000 Read only by the Master Parameter Data IDN Unsigned Decimal Number AnalogILmtGain allows the Master to set the scale factor float value for the Analog Current Limit Input J2 6 Conversion Scaling Factor Data Length Units Minimum Value Maximum Value Access State PCE830 40 User Manual 0 001 4 bytes of Ipeak V olt 0 5 000 000 Read Write by the Master 3 119 PCE840 Danaher Motion IDN 32884 Analog Current Limit Filter Parameter Data IDN Unsigned Decimal Number AnalogILmtFilt allows the Master to set the low pass filter break frequency float
261. y duty regen may be needed In such cases it is necessary to increase the regen resistor wattage without changing its ohms The recommended way to increase regen wattage is shown below PCE833 Wire to B and four 660 200W resistors in series parallel 660 800W PCES835 Cut off wires to and R from internal regen resistor Wire to and two 660 200W resistors in parallel 330 400W PN Wait 10 minutes after Bus Power is removed for the bus cap voltage to decay to a safe level before touching regen resistor or wiring The voltage on the bus caps can be monitored with a voltmeter from 08 TB1 7 to BUS TB1 9 This termination provides a convenient point for the motor ground connection and motor power wire shield Local electrical code may require using the Earth Ground Chassis stud for this function These three terminations provide the 3 phase power output to the brushless motor Observe motor polarity on these connections For example connect U on the drive to U on the motor PCE830 Danaher Motion 2 2 2 Serial Port J1 The serial port J1 utilizes the 9 contact female D subminiature style connector shown below A brief description of each signal is included in the I O table on following page For additional information please refer to the Serial Communications Transceiver Schematic at the end of this section The figureS below

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