simDrive™ AC Servo drive User manual - CS-Lab
Contents
1. ka er Signal Description 1 2 3 4 CANH CAN bus 5 GND GND OV 6 r 7 8 9 CANL CAN bus housing Shield Wire shielding ta 14 gt simDrive AC Servo Drive User Guide ES CS LAB X 2 L ADO S C ElectronicLaboratory 3 7 CN5 CAN and configuration connector model M4 040K Front view of the device s connector PIN Ji bo Signal Description 1 2 RD RS232 sa CU and FOniipuralipu 3 TxD RS232 diagnosticsandconfiguration 4 5 s DE OO RR a 9 CAN L CAN bus L signal housing Shield Wire shielding gt simDnve AC Servo Drive USER GUIDE 15 EGI CSLAB s c ElectronicLaboratory ratory 4 I O circuits internal construction 4 1 1 Encoder inputs Ext SV enc A C74 120R 14 IN enc A InF IN2 OUT2 IN2 IN3 OUT3 IN3 IN4 OUT4 IN4 D EN EN GN DS261 V32 4 1 2 HALL sensors inputs HALL A l R142 ISO2 4 gt V33 sN 3 Ik GND LTV356T HALL B l ISO3 4 Fi gt V33 D4 a si a a a A A gt 3 GND l HALL B 5 LTV356T IIA A G l LTV356T 4 1 3 STEP DIR control signals inputs a GNDH RT E PT l E aaa E l 1 1 v30B 74LVC86 HCPL 063 16 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 4 1 4 Digital inputs INO IN5 COM IN lt ACPL 224 COM IN lt R86 l L21 o V33 4k7 C9 e gt2. sssssseennnnnzannnnzzenrennzannenznzantnnzantenzzzznnnnaz 34 5 6 PID regulator UNINE ULU UV ULU EE EEEE Ea 35 5 6 1 Initial settings Of PID regulator ss seeennnnnnnnzannnnnnznnnnnnzannenanzannnnnzznnnnnzznnnnnzznnnnnn 35 5 6 2 Manual PID regulator tuning procedure ssssssenennnnzanrnnzzsnrennzantnnnzanrnnzantenzzzzntnnnz 36 5 6 3 Automatic PID regulator tuning procedure ssseeesnnannnnzzonrenzasnnenzzzantnnzantenzzzantanzz 39 5 7 Torque scan function csTorqueScan esssssseessrreesrrrresrrrrssrrersrrereserressreresererssreresereeseeerese 41 6 Drive alarm flags description 43 E Drive overload Charatteti IC uu i E u 44 8 A addition Firmware update 45 8 1 csServoManager utility pdat e uuuu u i igbeto ietienzet bii bidet kisbu teen bad 45 S2 SIMDMVEeT fiflAWAre UD GALS noria 45 9 B addition What is PID controller regulator 46 9 1 What is PID controlle u Lu u u L u u L ia RE EE EA EEANN AARSE AE 46 9 2 PID controller terms parameters operation r 47 9 2 1 THE proportional term P u u a a ayaqa is at 47 922 VC NC OIG ens ayu usa ds 47 92 3 The Derivative
3. COM port number when direct connection through RS232 port lfit sconnection through CSMIO IP controller the controller s IP address and name is displaved COMx X X X X name 5 2 4 4 An address of a device If we connect directly RS232 the address is always 1 but if we connect with a drive through CAN bus and CSMIO IP controller then simDrive CAN address is displayed 24 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 2 5 Entering numerical values Sk lt ma a After we enter the value into text area we should always approve File Took Configuration aer Help it with Enter key Only then the new parameter value will be Mg EW am o nas transmitted to simDrive device e TAW IH varsa al Turina TAL auto tua estoquescan nem teen Regine Venn Megna ri 014 CS Lab s We are able to see if the edited parameter value was approved looking at text area backlight The green backlight color means that the value is approved and sent to the drive and the orange backlight color means that the value hasn t been send to the drive yet 10053 nos 6 000 zs oso amo pooo aa Max Falowing Error Purini PT Regulator Lis Ki Lee Lia K nd o MM M00O Pes Le online CSMID IP AN 192 168 8 48 CSMIO 5 2 6 Saving in non volatile memory Changes made in the drive configuration will be lost after power supply disconnection if we don t press the ic
4. HALL_A HALL B HALL C 5V Out GND GND STEP DIR OUTO E OUT1 E OUT2 E IN1 IN3 IN5 CAN H GND ENC A ENC B ENC Z HALL A HALL B HALL C GND Description Logic power supply 24V DC Step signal positive input of an optocoupler Direction signal positive input of an optocoupler Digital output O Collector Alarm Digital output 1 Collector Homing output Digital output 2 Collector Brake Input 0 4 Homing input Input 2 Reset Input 4 Common inputs pin CAN bus L Encoder A Input Encoder B Input Encoder Z Input HALL sensor A Input HALL sensor B Input HALL sensor C Input 5V Output for encoder and HALL sensors power supply GND OV of encoder and HALL sensors GND OV of logic power supply Step signal negative input of an optocoupler Direction signal negative input of an optocoupler Digital output O Emitter Alarm Digital output 1 Emitter 4 Homing output Digital output 2 Emitter Brake Input 1 Servo ON Input 3 Input 5 CAN bus H GND OV for CAN signals Encoder A Input Encoder B Input Encoder Z Input HALL sensor A Input HALL sensor B Input HALL sensor C Input GND OV l gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory T Permissible output lines load is 50mA Outputs overload may cause their damage Encoder HALL sensors and STEP DIR sign
5. 2 on the toolbar or by selecting Tools JOG and I O control from the menu Current voltage value on pin 18 encoder and Hall sensors power supply of a signal connector Correct value 5V 10 Current value of logic power supply Correct value 24V 10 Power output stage temperature C Current state of torque scanner function csTorqueScan Current state of PID regulators autotuning function Current stage of PID regulators tuning 1 value means that internal motion planner in a drive finished operation and is in idle state Encoder position counter Controller position counter that is counter directly connected with STEP DIR signal The speed is counted on a motor s encoder The speed is counted on STEP DIR control signal converted from frequency to revs min The acceleration is counted on STEP DIR control signal STEP signal freguencv Current deviation from the target position in encoder pulses Max temporarv deviation from target position Current deviation from target speed Max temporarv deviation from target speed that results from measured STEP signal frequency Encoder faulty readouts number This value should be 0 If the value is higher than zero then it means wiring problems or encoder failure Encoder failure is verv rare usuallv it s poor qualitv wiring or no contact of one of encoder signal Value higher than zero also means that positioning errors will appear Mechanical angle of motor
6. Excessive Resonance Lem catbration Fa es Digital inputs S Pre a A sim Driv Digital outputs Position Rst Position Reference Output Current Digital Inputs DC Bus Max Voltage The drive has HOME signal and encoder index synchronization function It means that you can have precise homing even if CNC motion controller doesn t have such function If we want to use it then we connect the HOME signal to the simDrive to one of digital inputs and not to CNC controller and we connect one of the drive outputs to a CNC controller We set the drive digital input as Home In and we set the output as Home Out as well The voltage in the simDrive device may be dangerous for your health and life Before you start any Do not disconnect or connect any wires except diagnostic wire when the device is working It may cause unpredictable motor behavior and in extreme cases it may damage the servo drive 8 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 2 1 Brushless motors AC BLDC gt 3 HALL A B C A B Z 5V Out J E Y UY UU N A A AH AH SERVO CN1 Connector x o SERVO CN3 Connector LU 5 7 a O O x o OY 3 O NVI S8PSYU ZEZSY sat YN fone oO MOLIENNOD SIHL O1 AUDIO AMLAEWDI L3ANNO LNOO ANALOG 1 0 STEP DIR ETHERNET STEP DIR OUTPUTS DIGITAL QUTPUTS 0 15 FS KO a A 3 LLI
7. IN2 Ea 47 gt 4 7 RS kz Essl V33 tad 4k7 COM N lt m UX wise A f GND C25 y 299 RSI 100pF ACPL 224 COM INS ACPL 224 4 1 5 Digital outputs OUTO OUT2 2 ISOl 4 OUTO C gt e 3 OUTO E 120R LTY3361 GND 2 1SO8 4 OUTIIC 3 OUTIJE 120R LTV356T GND 2 1807 4 OUT IC gt 3 QUTZJE LTV356T 120R gt simDnve AC Servo Drive USER GUIDE 17 Es CS LAB S C ElectronicLaboratory 5 Starting and configuration simDrive device was designed for CNC control systems Due to relatively narrow range of application configuration process was simplified so a user operator doesn t have to break through all the dozens of parameters which he won t use anyway The configuration parameters were divided into functional groups what makes the configuration fast and clear The only more difficult thing for not experienced users is PID regulator tuning and configuration of parameters needed when using brushless motors Knowledge and experience are in this case highly valuable nevertheless reading this manual carefully even less experienced users will be able to set the simDrive device properly To configure the drive we need csServoManager configuration utility available free on http www cs Lab eu while a converter and a cable can be purchased in our online store http www cs Lab eu The converter and the cable are not required for configuration if the drive is used with CSMIO IP C
8. Parameter Value ko m II Ann number incl all edges so as for Max following error now we allow for 1 motor rev error K 025 _ O Speed e i c rc Position Current Feedforward Be gt simDnve AC Servo Drive USER GUIDE 35 E CSLAB s c ElectronicLaboratory 5 6 2 Manual PID controller tuning procedure You should connect power output stage power supply HV however be ready to disconnect the power supply in case if something was set incorrectly and motor will start to vibrate or rotate uncontrollably You can use JOG function directly from csServoManager Tools JOG I O control during tuning Step by step tuning process looks as follows e Make sure you won t cause mechanical damage of a machine axis and if any other person doesn t work at the axis as a motor will start to rotate in a moment e Press the A button The driver state should je SN change into Running if there is an Alarm we LILT a gt m tose can delete it by pressing Reset e You should set low motion velocity value about 50 rev min and try to move an axis pressing the revs buttons into the right and into the left If you Use the settings from Initial settings of PID controller section the motor should move Due to very small accelerations the motion can be a bit pon d erou g an d unequa b ut it s norma l onie CSMICHIP gt CAN 1923168848 CSMI IP 9140 Node o When you he
9. The value should be also placed on a motor p nameplate Nominal motor current The value should be also placed on a Current motor nameplate By entering incorrect values in this group you can permanently damage the motor CS Lab s c company does not take any responsibility for damage caused by incorrect drive configuration 5 4 3 Brushless motor parameters AC BLDC This group applies onlv to brushless motors We set the parameters as follows Parameter name Description Motor winding resistance In current software version this parameter is not supported and vou do not have to enter it With R future software versions the parameter can be important for sensorless methods of determining an angle of a rotor a motor commutation Motor winding resistance In current software version this parameter is not supported and vou do not have to enter it With L future software versions the parameter can be important for sensorless methods of determining an angle of a rotor a motor commutation Motor pole pairs number It s verv important parameter which value vou can sometimes find on a motor nameplate or in motor documentation If we do not have knowledge about number of the poles pairs then we can verifv it bv trial and error method Motors usuallv have 4 pairs of poles It won t damage the motor if vou enter incorrect poles pairs number it will cause the motor to jerk and stop After short time vou will see an over current alert
10. further software versions It opens a window where we can verify and or manually set inputs outputs state With further software version it will be possible to manually turn on and control a e 22 gt simDrive AC Servo Drive User Guide Tools gt Show alarms Configuration gt PID tuning Configuration gt Motor parameters Configuration gt IO Signals gt simDrive AC Servo Drive USR GUIDE ES CSLAB s c ElectronicLaboratory motor It opens a window with an alarms list It opens a window for PID regulators tuning Motor parameters settings Drive s digital inputs and outputs configuration Tests window It s not used in normal operation It was designed for tests of some of the function 23 Es CS LAB S C ElectronicLaboratory 5 2 4 Status bar The status bar shows current state and drive connection details 5 2 4 1 Connection state icons Icon Description N No connection This sign blinking means connection attempt If it lights up G constantly it means the connection was established and is active 5 2 4 2 Connection interface Sign Description Direct connection with a PC through serial RS232 port COM port or USB RS232 converter Connection through LAN network a PC communicates via CSMIO IP gt CAN CSMIO IP controller in this case CAN bus drive connection with CSMIO IP controller is required RS232 5 2 4 3 Port Sign Description
11. notice that due to variety of motors and Wet 500 RPM Tuning Rigiditv 40 mechanical systems the autotuning may not work rma propertv for everv one of them and it mav be Dist 0 5 Rev necessarv to tune the PID manuallv Autotuning function is available in a PID tuning window and to open it click Configuration PID tuning from a menu or click HE icon on the toolbar and go to Autotuning tab Usually we recommend keeping default settings if you have any problems you can just experiment using other settings We start the autotuning by clicking Start A motor starts to rotate and you can see a progress bar The procedure may take few minutes gt simDnve AC Servo Drive USER GUIDE 39 Es CS LAB S C ElectronicLaboratory 5 6 3 1 Autotuning configuration parameters Parameter Velocity Acceleration Distance Tuning rigidity Description Max motion velocity during autotuning By default it is 500 RPM if such rotation speed in not safe for a machine or it exceeds motor capacity then you should decrease it Autotuning acceleration By default 3000 RPM s For small accelerations the autotuning may be less precise so you should decrease the parameter only if it is absolutely necessary Distance of motion By default 0 5 rev Higher values can make the autotuning lasts longer Greater rigidity means better positioning but also oscillations are more likely to happen Less rigidi
12. or position and or velocitv tolerance overrun alert Pole pairs 30 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 4 4 Motor constants Parameter name Description Motor torque constant stated in Nm A If you do not have documentation of your motor then enter 0 Voltage constant stated in V 1000RPM If you don t know this value you can enter 0 but it will decrease positioning quality at dynamic acceleration braking This value can be easily Voltage constant determined it s enough to set motor revs on 1000 rev min after the motor was initially tuned and then read Current PID Output parameter value from the parameters monitor list We enter absolute value of that parameter into this area Torque constant 5 4 5 Feedback Incremental encoder Parameter name Description Pulses number per encoder rev resolution The parameter has special relevance for brushless motors as an encoder enables precise motor commutation The value we enter here should be actual resolution manufacturers usually inform about of the Pulses rev value because they don t include a quadrature decoder Incorrect value won t cause the motor damage but it won t be working properly Sometimes it won t be even able to perform one single rev and sometimes after few revs taken current starts to increase rapidly and over current alert shows up Depending on an encoder type it can be necessary to reverse pulses counting
13. rotor defined bv an encoder Electronic angle of motor rotor defined bv encoder Brushless motors only Electrical angle of motor rotor gt simDrive AC Servo Drive USER GUIDE 27 Es CS LAB S C ElectronicLaboratory 28 Electrical angle sensorless HALL sensors state Phase U current Phase V current Phase W current Vector id current Vector iq current id Vector reg error iq Vector reg error Peak output current DC bus voltage DC bus voltage Min DC bus voltage Max Output power Current PID output Velocity PID output Position PID output defined by HALL sensor Absolute difference between the angle and electrical angle from encoder shouldn t exceed 45 Higher value means incorrect configuration of HALL sensors wrong order of HALL sensors connection or interferences on an encoder caused by poor quality wiring Brushless motors only Electrical angle defined by mathematical model of a motor It requires correct settings of inductance and resistance parameters of motor windings Brushless motors only Current HALL sensors state It allows you to quickly check if all three sensors are working properly Current U phase current of a motor Current V phase current of a motor Current W phase current of a motor Brushed motors d vector current Its values should be close to 0 Current consumed by a motor that provides a torque Current id vector adjustment deviation brushl
14. there is no correction because it is not necessary e Motor position 1 Error 0 1 1 The output 10 1 10 e Motor position 5 Error 0 5 5 The output 10 5 50 e Motor position 5 Error 0 5 5 The output 10 5 50 As you can see above correction is greater the larger the error value is and direction of the correction is opposite to the error direction This part of the PID controller is effective at larger error values for smaller error values it is not doing very well 9 2 2 The integral term I For some users unfamiliar with mathematics the integral may sounds scary in fact the term operation is very easy An output of the integral term of PID controller depends on the position error and the duration of the error Let s assume that the Integral eliminated most of the position error but there a small error left due to friction e g 10 p of an encoder With so small error the Proportional control does not correct too much and its output is not able to overcome the friction SO the motor stands and the error remains Here we have the Integral term T To simplify let s assume that the controller works once per second and Ki gain 1 In this situation f output will look like this e Time t 0s output 0 e Time t 1s output 10 gt simDnve AC Servo Drive USER GUIDE 47 Gijs CSLAB s c ElectronicLaboratory e Time t 2s output 20 e e Time t 10s outpu
15. BL 230V AC DIGITAL INPUTS 16 31 DIGITAL INPUTS 0 15 24V Supply 230V AC o lt gt c N 24V DC gt simDnve AC Servo Drive USER GUIDE 9 Es CSLAB s c ElectronicLaboratory ratory 2 2 Brushed motors DC PE NAM SERVO CN3 Connector SERVO CN1 Connector CS POWERMODULE 230V AC 325V DC ANALOG Y o PE STEP DIR STEP DIR OUTPUTS DIGITAL OUTPUTS 0 15 PEO 230V AC DIGITAL INPUTS 16 31 DIGITAL INPUTS 0 15 24V Supply O lt gt c N 230V AC 24V DC 10 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 3 PINs description on drive connectors 3 1 Connectors arrangement M4 040K model CN3 power output stage connector CAUTION HOT SURFACES ak L MOTOR 325V CN5 CAN and configuration CN4 CAN connector _ NOISNVdX3 EXPANSION CN3 Power output stage connector CN2 Configuration connector CN1 Signal connector gt simDnve AC Servo Drive USER GUIDE 11 E CSLAB s c ElectronicLaboratory 3 3 CN1 Signals connector Front view of the drive s connector from the soldering side Pin number 1 WwW WON DW KR W NH Further description next page 12 Signal 24V STEP DIR OUTO C OUT1 C OUT2 C INO IN2 IN4 IN COMMON CAN L ENC A ENC_B ENC_Z
16. E OO ltiaae 24 52 PACING UIC HIE V GlU65 u a i coca Pe 25 5 2 6 SAVING in non volatile MEMOFV scccccseeeeccceesececcesecsccuesececcusecsssuseesecesecsssusecssseesesesaees 25 5 3 Parameters Monitor window real time parameters preview 26 l gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 4 Motor parameters CONFIQUATION ccccccsseccccsseceesesececceneccceeesececeeececeeueccesaenecessuseceesegeeeeeas 29 DA L MOTO VDE A OA 29 5 4 2 Nominal motor parameters Blad Nie zdefiniowano zaktadki 5 4 3 Brushless motor parameters AC BLDC a 30 344 IMOLOL AP An 31 5 4 5 Coupling linecremental encoder ermita 31 5 4 6 HALL sensors rotor position coupling ss sseesnnnnnnnnznnnnnnzannnnnzznnennzannnnnzznnnnnnzn netta 31 5 4 Reference signal STEP DIR uuu wa wassaakakapaqkunankaqakaqapaskuskasakakakapuqkayaapuyakskaysukakyawaqakaka 32 0 5 J GIO O Cra 32 5 5 Digital inputs outputs configuration nn 33 5 5 Digitalinbuls fin ON e Un II 34 5 5 2 Default inputs functions assignement sseessnnnnnnzannennnzannnnnzannnnnnzantennzannenanzantnnaz 34 5 5 3 Digital outputs FUNCTIONS r 34 5 5 4 Default outputs functions assignement
17. MAN ICSLABs LAB y MA www cs lab eu ZO simDrive ryan f UU Nesses o ke ea tesse CAUTION ces Al HOT a ll www cs lab eu Hill midd F LU TEL Applies to hardware version v1 Applies to firmware version v2 00 Rev 1 0 copyright 2014 CS Lab s c E CSLAB s c ElectronicLaboratory INDEX e TOCO ea E a GT i ER 4 J Signsusedimthise A 4 T S Cr CON E ae tido 4 J Technical data SCS 5 1 4 Drive and brushless motor running checklist 1 00 sse eessnnnnnnzannennzzntrenzznnnnnzzontnenzzntnenzznnnna 6 lt Block connection Scheme AAA A 8 21 Brushless motors AC BLDC nenons Taen a d ii 9 2 2 Brushed motors DC al 10 PINs description on drive connectors 11 3 1 Connectors arrangement M4 040K model oooccnccccnonccnnnnononicinnnonaninonnnonaniconnnonanononnos 11 3 2 Connectors arrangement M4 075K model ss sess senneennzznnnenenzznnannzznzzsnanzzznzzznnenezznzznnnnta 11 al A 0 12 3 4 CN2 communication connector model M4 075K ooncnncccnnnncnnnncnnonononnnonanonnnnononinononos 13 3 5 CN3 power output stage connector 14 3 6 CN4 CAN connector model M4 040K ooocccccccnnnccnnnnononocnnnnonanocnnnnonanoconnnonanocnnnononinononos 14 3 7 CN5 CAN and con
18. NC motion controller by CS Lab company and connected with the controller via CAN bus chapter 5 2 2 Connection through CAN bus The first drive run you should always perform with power output stage power supply turned off First set motor type I O signals verify E Stop signal work and set initial small values of PID regulator gains chapter 5 6 PID regulator tuning Only then you can switch power output stage voltage and start further configuration e 18 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 1 Configuration diagnostic software utility installation 5 1 1 USB RS232 converter installation If we use USB RS232 converter purchased from CS Lab company we should install driver first USB RS232 converter driver setup program is installed during simDrive Software Package setup by default 8 simDrive Software Package 2 090 Setup La Please check the components that you want to install and uncheck the ones that you do G not want to install then press Next to continue Installation type Or select the optional i Documentation required a you wish to U Firmware required I i Firmware Llploader required i USB Serial converter Description Position your mouse over a component from the list to view Required space 30 2 MB EEA imDrive Software Package Setup When simDrive setup finishes you can click on windows start menu a
19. OC ous acceleration in a CNC controller increase capacitors capacitance in a power supply or to use a special power module by CS Lab company that allows for braking resistor connection Overload Motor input current was exceeded for too long chapter 7 Drive overload characteristic Mo e to oznacza zbyt Motor overload we Wigi IN gt 2 du e obciazenie mechaniczne silnika awarie silnika bad le skonfigurowane parametry silnika Short circuit alarm Means power supplv wires short circuit Over current motor malfunction power output stage malfunction protection It may also appear at incorrectly set current PID regulator or very rapid acceleration deceleration Powerouicdiciane It means driver overheat You Should wait till the driver cools ae down and if the problem persists then you assure better cooling for the driver and a control cabinet Rotational speed of a motor differs too much from the set speed It Following error l means to high revs or incorrectly set motor parameters or PID velocity controller regulators Power supply voltage of a power output stage is too low This To low voltage on a alarm also occurs if HV voltage wasn t entered also at too weak DC bus power supply or if power supply of a power outputs stage is broken A driver wasn t able to keep set positioning tolerance You should check settings of a max following error in a PID tuning settings or correct acceleration braking ra
20. als operate in TTL 5V standard Higher voltage may cause A outputs circuit damage in the device If it s necessary to connect the mentioned signals in 24V standard then please contact with CS Lab company first to consult and select correct converter Next to the digital inputs and outputs there are default functions assigned in square brackets The sign means that input output in reversed logic that is OV is an active state and 24V is inactive state Connection made in accordance with the default function assignment has the advantage that you do not have to configure inputs and outputs when starting the drive 3 4 CN2 communication connector model M4 075K e Front view of the device s lt 4 connector m Signal Description ene 1 GND GND OV 20 77 IXD Transmitting line RS232 3 EXt SV 5V 100mA output 4 RxD Receiving line RS232 5 NC 6 NC gt simDnve AC Servo Drive USER GUIDE 13 Es Cs LAB S C ElectronicLaboratory 3 5 CN3 power output stage connector lt Connector view from the top SOOO PIN Signal Description number 1 7 HV Power supply of power output stage 2 HV Power supplv of power output stage 3 Ground 4 W Motor power supply W phase 5 V Motor power supply V phase 6 U _ Motor power supply U phase 3 6 CN4 CAN connector model M4 040K Front view of the device s connector
21. ar squeaks or you get an overload or short circuit alarm you should decrease PID current controller values group Current PI regulator Decrease the K by A fit won t help try to decrease the parameter again by and additionally the K parameter also by Very rare some untypical motors theoretically refuse to cooperate but practically we haven t noticed a situation like that o If the motor jerks and the drive shuts down or the motor makes only a fraction of a revolution and current increases till alarm overload state appear then one of possible reason may be Encoder counting direction set incorrectly Incorrect connection of HALL sensors HALL signals polarization set incorrectly Incorrect motor s phases connection Motor s pairs of poles number entered incorrectly Failure of motor windings HALL sensors or an encoder e If the motor rotates then part of the hardest work is behind us and now we can start the real tuning description below 36 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory u Y ctServoManager 2014 CS Lab oc Sie e Leave the JOG tab and go to Motion planner ere bie Jools Conhgereten Windew Help and 100RPM velocity and about 1500 RPM s x 284 m hose Y 10 Contret 106 acceleration position equal to encoder impulses IONA per rev number 1 motor revolution set gt F Relative e Make sure if the motion in 1 m
22. arity almost never can be kept so when we want to mill a square we get a diamond shape There is no way to correct these inaccuracies as after we switch the power on the gantry s both side drives are like stuck together In a system based on simDrive servo drives and dedicated CNC controller CSMIO IP S the slave axis function is implemented in a different way namely the function is done by CSMIO IP S controller This controller during homing performs special procedure of geometry correction in which these both side drives of our sample milling machine gantry work independently as completely separate axes Only after geometry correction is done the both side drives will be electronically linked to work as one According to the above the slave axis function implementation in the drive would be pointless The function is done by dedicated CSMIO IP S controller gt simDnve AC Servo Drive USER GUIDE 49 E CSLAB s c ElectronicLaboratory ratory 11 D addition Diagnostics via Mach3 software simDrive servo drive can be connected through CAN bus with dedicated CNC controller CSMIO IP S In current firmware version it lets for the drive diagnostics directly in Mach3 and there is no need to use USB RS232 or to start csServoManager In Mach3 select Plugin Control gt CSMIO IP plugin from the menu go to Expansion modules tab and click simDrive In the newly opened window you will se
23. coder signal tvpe Differential PC connection RS232 configuration Connection with a motion controller CAN bus diagnostics Ambient 0 C do 50 C temperature range Relative humidity 10 do 95 without condensation Recommended power supplying way is 230V AC power supply by CS Lab s c company The difference between maximal drive power and recommended motor comes from the fact that the drive should have some power reserves to be able to overload the motor The second reason is limitation of heat given off from the drive Brushless motors BLDC AC and linear AC must have digital HALL sensors Recommended resolution 1000 8000 in fact 4000 32000 including all edges gt simDnve AC Servo Drive USER GUIDE 5 G CSLAB s c ElectronicLaboratory 1 4 Drive and brushless motor running checklist Below you can find a checklist with all the activities and operations needed to start up a new drive These operations are listed in the order they should be done In further chapters you will also find detailed description of the activities described below Y Operation name Make necessary electrical connections e Motor encoder e Motor Hall sensors e Phases U V W and motor ground e O signals Servo on Reset Alarm e STEP DIR control signals STEP DIR e CAN bus e 24V logic power supply don t turn the power supply on yet e HV power output stage power supply don t turn the power suppl
24. direction Incorrect value entered won t cause the motor damage but the motor won t be working properly Usually in this situation the motor jerks and goes into alarm state Reversed 5 4 6 HALL sensors rotor feedback Parameter name Description It s a very important parameter for brushless motors Sometimes the HALL sensors used in a motor have reversed logic In this case we select this option If we are not sure about that incorrect setting won t cause the motor damage but it won t be working properly It causes motor jerking after we turn on the power or when we try to move Invert HALL signals gt simDnve AC Servo Drive USER GUIDE 31 E CSLAB s c ElectronicLaboratory 5 4 7 Reference signal STEP DIR Parameter name Description Change of motor revs direction The parameter affects only I i i nvert dir external STEP DIR signal control 5 4 8 Electronic gearing Sometimes the connected motor have a high resolution encoder e g 4000072 and a CNC controller is not able to provide STEP signal with enough frequency to fully exploit motor revs range As an example motor with 400005 ae gt encoder has 3000 nominal revs and 5000 maximal revs rev rev 83 33 9000 Now We can easilv calculate max frequencv of STEP signal rev 83 33 x 400007 3 33 MP 3 33MHz Let s assume that we connect the drive to CSMIO IP M motion controller which prov
25. e gt simDnve AC Servo Drive USER GUIDE 41 Es CS LAB S C ElectronicLaboratory The ripples measurement procedure requires a motor to be in motion and mechanically mounted on a machine so you need to be careful and verify if there is enough space for the motion by default a motor during autotuning rotate by 0 5 of a rev and also if no one else works on the machine at the moment For proper operation of csTorqueScan function constant mechanical load is required If a machine mechanics doesn t assure that for example an axis drive is on a straight tooth bar the measurement should be done on an unloaded motor it needs to be demounted and probably PID controller detuning will be necessary as a motor without mechanical load requires other settings of velocity and position regulators O To keep your changes saved after power is off press 8 icon after autotuning is finished 42 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 6 Drive alarm flags description You can open current alarms and warnings information window from the menu Tools show alarms or click a icon from the toolbar Alarm name Description Overvoltage on a power output stage DC circuit The alarm shows up when we power the power output stage with too high voltage or if energy received from a motor during braking raises power To high vol 5 supply voltage up In the second situation we should decrease
26. e e Encoder position counter e Following error e Motor load current absorbed by a motor e Hall sensors state e Drive state e Digital inputs and outputs state e Power output stage temperature e Alarms shown as easy control led Moreover if we connect simDrive servo drives with a controller through the CAN bus information about axis disabling cause an alarm type will be saved in CSMIO IP log if situation like this happens In case of any problems it can make diagnostics easier a CSMIO IP diagnostic window 2010 CS Lab s c General info Digital IO Analog 10 Expansion modules Debug Connected expansion modules CAN 104 Device S N 1122334455 Firmware CSMIO IP S V2 500 Oct 24 2014 09 44 39 FPGA ver 3 00 active simDrive address 104 Alarm Flags Rotor Positioning Failed Hsien ta Motor Connection Fin Current Fio veociy Fio Position oveross vae Temperature Esp Active Hw Limi Active EEPROM Matunction deteur Contig Loaded oc Bus Ovewoltage oc Bus Undewoltage vae PWM Faul shortcircuit van Excessive Resonance LEM calibration Fa es Digital inputs daa aa A 473 gt simDriv Position Rst Digital outputs aia Temperature 220 Vcc 24V Voltage Device State DC Bus Max Voltage If we want to connect more than one drive through the CAN bus you need to set CAN addresses for the driv
27. eration for that you need to set the necessary signals in CNC software e g Mach3 It is good to test simDrive outputs by setting the output on manual mode and clicking set clr buttons Change assignment of the function to I Os in configuration window if necessary gt gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory Y Operation name Verify motion control STEP DIR signals operation For that select from the list in parameters gt monitor window Reference Position and make a move in CNC software it does not matter if the motor will not move at the moment as there is no power on a power output stage Reference Position counter should increase or decrease its value it depends on motion direction in CNC software If it is a motor bought from CS Lab s c and configuration template had been loaded before you can skip this point Open motor parameters configuration window and set the parameters e Motor type ass e Nominal voltage and current values and nominal revs x e Pole pairs number e Resistance and inductance of windings If it is unknown enter 0 e Torque and voltage constants if unknown enter 0 e Encoder counting direction and pulses number per encoder rev incl all edges it s a value usually presented by a manufacturer as x4 e g if it stays 2500 on the encoder for us it mean 10 000 e Set HALL signals negation if necessary Save the config
28. es Look at 5 2 2 chapter CAN bus connection 50 gt simDrive AC Servo Drive User Guide
29. ess motors only during operation values should be close to 0 Current iq vector adjustment deviation during operation values should be close to 0 Max temporary current consumed by a motor Current voltage on DC bus Minimal temporary voltage on DC bus You can preview how much the voltage decrease under load Maximal temporary voltage on DC bus You can preview how much the voltage increase during breaking Current output power motor consumption power Current regulator output value V RMS Velocity regulator output value A Position regulator output value RPM gt gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 4 Motor parameters configuration We strongly recommend to use simDrive 325 VDC servo drives together with motors offered by CS Lab company There are configuration templates for these motors ready for download and thanks to them we do not need to set the motor parameters ourselves O however the simDrive is enough universal to be set correctly to work with almost every synchronous AC BLDC or brushed DC motor Caution There are different types of brushless motors AC Generally we differentiate two types of T them synchronous with permanent magnets and asynchronous simDrive servo drive just like most other servo drives available on the market requires synchronous motors The asynchronous motors often used on spindles require an inverte
30. ess runs automatically Start the csServoManagerSetup exe file downloaded from www cs lab eu en or provided on a CD attached to a package Then click Next gt till the end of the installation process Copyright c 2014 CS Lab s c Please close all active programs to avoid any conflicts and press Next to begin the setup procedure or Cancel to exit this wizard 5 2 csServoManager general rules and notes In csServoManager utility software there were only necessary options implemented for configuration and diagnostics This way the software is simple in operation so you can cope with it easily Below you will find rules notes of using this software 24 Connection Setup bE xU 2 siMDrive AC SERVO E CSLAB s ectypa O 5 2 1 Connection with a drive After we start the csServoManager we will see a window where we choose a drive to connect with and interface language as well First click Scan button You will see all detected 1 CSMIO IP gt CAN CSMIO IP 9140 192 168 8 48 CSMIO IP 9 140 104 devices in the list They will be divided into devices connected through serial port and devices connected to CSMIO IP controller via CAN bus If the application won t find any devices you should verify your wiring logic power supply 24V and if USB drive is installed if we use USB RS232 converter You should also verify CAN addresses assignment chapter below If yo
31. figuration connector model M4 040K 15 1 O circuits internal construction 16 11 Encoder pu S u un E asas na psiapi 16 4 1 2 HALL sensors inputs sassssssssssssssssssas 16 41 3 STEP DIR Control signals INDUTS aaa esI er nanira s TONELE N AAEE 16 4 1 4 Digital inputs INO INS ccccccsssccssssesccnesesscscssescsccsessencusssesecsescencuessencusesesscuesssncucsseseess 17 4 1 5 Digital outputs OUTO OUT2 17 5 Starting and configuration 18 5 1 Configuration diagnostic software utility installation 19 5 1 1 USB RS232 converter installation 19 5 1 2 csServoManager utility software installation 20 5 2 csServoManager general rules and notes rr rr 20 5 2 1 Connection With ip uu a u akanan EENES ER 20 5 22 CAN DUS CONNECTION cre uu ua pusa ka id 21 52 TOO A G ua nus a ida ti ia as 22 De SOE OOP a CG PEE u a A
32. hen CNC controller and software control the motion e g Mach3 and CSMIO IP If everything works fine the drive is ready to work gt simDnve AC Servo Drive USER GUIDE 7 E O A CSLAB s c ElectronicLaboratory 2 Block connection scheme Below you will find connection demonstration scheme of three phase brushless motor AC and brushed motor DC It is easy to notice that both schemes are almost the same For DC motor we use only extreme phases for power supply U and W of which we connect DC motor to U phase and to W phase Moreover in case of DC motor there is no need to use HALL sensors CAN bus connection is optional but recommended if we use the drive with CSMIO IP x controller and Mach3 software Thanks to the CAN connection with CSMIO IP controller we get additional capability for fast drive diagnostics directly in Mach3 software In case of breakdown the drive status will be saved in a log file Drive I O signals connection with a motion controller is also optional but we recommend Alarm Reset Servo ON and E Stop signals connection F simDrive address 104 Alarm Flags oto Positioning Failed Hater va Motor Connection FD Curent Fi veociy eo Position overcas Temperatura E Stop Active Hw Lint Active EEPROM Mattunetion f deteur Config Loaded DC Bus Overvoltage mo DC Bus Undervoltage va PWM Fault shortcircuit
33. hich makes PID controller work easier Looking carefully at all the three PID terms descriptions we can see that outputs of each term depend on a position error So the controller does not work if the position error is zero The problem is that we want the error to be as small as possible the best if it would be zero because it means the best accuracy of work we do Here we have the Kvrr parameter which reacts in advance before the error occurs Of course working in advance base on prediction and prediction is never 100 sure so some error occur for sure and PID has got then work to do but in practice well matched Kvrr gain is able to decrease temporary position errors even up to ten times ens 48 gt simDrive AC Servo Drive User Guide sel CS LAB S L ElectronicLaboratory 10 Caddition Slave axis Many drives have so called slave axis function available used by mechanics installers operators for slave axis implementation in CNC machines in which single axis is driven by two motors This is not always an optimal solution as these both motors work then like they were mechanically connected Why not You can ask That s what the function is all about right Let s say that we have gantry milling machine and the gantry is controlled by two motors one each side If we turn the power off the motors become oose and the gantry is set in the lowest tension position The problem is that in this situation gantry perpendicul
34. ides 125kHz rev max frequency STEP signal We would just only get 187 Here now the electronic gear comes to the rescue Thanks to it we can set a multiplier x20 and we Set motor s position is expressed by the formula X MOTOR S POSITION INPUT SIGNAL x Y In our example we enter X 20 and Y 1 We are going to multiply the input signal by 20 Obviously using this function we can divide the input signal if there is such a need However it is usually used for multiplying To keep the settings saved after power is off on the toolbar press 8 icon after settings change The input signal multiplying as shown in the example above has negative influence on motor s culture of work and on positioning accuracy According to this fact we do not recommend the multiplying use in applications which require great motion smoothness and precision In such situations we need to use CNC controller that is able to provide STEP signal with enough frequency e g CSMIO IP S which generates 4MHz max frequency STEP signal e 32 gt simDrive AC Servo Drive User Guide 5 5 Digital inputs outputs configuration If we have alreadv set motor parameters then it is time for digital inputs and outputs settings unless the signals were connected in accordance with default settings chapter 5 5 2 and 5 5 4 I O configuration window can be called out from the menu Configuration gt I O signals or by clicking on the s icon on
35. is finished but for new machines or machines that were not used for a long time probably you will have to tune current and position controller once again when mechanics is livened up and run in In case an axis has a tendency to go into vibrations you can try to suppress them by increasing Ka gain of velocity controller If it didn t help you can try to decrease the K of position controller by 10 and K and K of velocity controller as well O To keep the changes saved after power supply is off press 8 icon on a toolbar after you done the changes or select Save to flash from Configuration menu O Remember to approve the values you type n by pressing Enter It is worth to watch Max following error parameter during tuning in a parameter monitor window QR After we finish the tuning we can set max allowed following position error in a PID tuning window approximatelv on a four fold value of measured max following error so if Max following error 23 in a parameter monitor window then we set Max following error parameter in a PID tuning window to 100 38 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 6 3 Automatic PID regulator tuning procedure simDrive servo driver allows for automatic PID Spipregusoetuning A regulator tuning At the beginning we should x gt Start Settings if you don t know what are you doing leave defaults
36. ive won t be possible until E Stop signal is active Limit or limit input is active Restart of a driver won t be possible until any of the hardware limits will be active Resonance detected ESTOP signal active Hardware limit active i If any of the alarm occurs a drive will stop working and disable power output stage A dynamic brake is enabled to slow down quickly If allowed current is exceeded during the braking then over current alarm may occur To start a drive again after alarm state it s required to give Reset on digital input or a reset from i csServoManager utility 7 Drive overload characteristic simDrive servo driver allows for a triple motor s overload for 3 sec However if the motor is only a bit overloaded the allowed time lengthens Below a characteristic of the allowed time of overload vertical axis in its value function horizontal axis t s 1000 t 5 10 100 150 200 250 300 350 e 44 gt simDnve AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 8 A addition Firmware update Firmware updates can be downloaded here http www cs lab eu The zip archives include e Up to date configuration diagnostics utility csServoManager install version e simDrive servo driver firmware files firmware e Uploader which is a software for simDrive firmware updating Firmware Uploader simDrive Servo M4 Series S
37. mps in a CNC controller Incorrect HALL sensors read outs Some sensor can be broken or more often connection faults a bad quality wire or a shield Error state of HALL incorrect connection The error appears also when we have sensors connected DC motor and we still do not have a drive reconfigured In this case you should set a motor type and save the settings and next turn the drive 24V power supply off and on A rotor positioning terror Unsuccessful procedure of a rotor Following error position controller rotor PSG position definition after power is turned on Verify motor settings and connection Unsuccessful calibration of LEM LEM current sensors unsuccessful calibration Contact with service sensors gt simDnve AC Servo Drive USER GUIDE 43 1 CS LAB S C ElectronicLaboratory Alarm name Description CRC32 control value in device memory was incompatible and default settings were loaded It means drive s settings loss and or non volatile memory of a device malfunction If the problem persists after another configuration contact with service Configuration read out error default settings loaded cere nly Non volatile memory breakdown Contact with service breakdown A drive at a standstill verifies if a motor went into oscillations caused by incorrect PID controller settings In case of high oscillations detection the drive turns off to save mechanics of a machine E Stop input is active Restart of a dr
38. nd find simDrive Software Package Install USB Serial Converter After driver installer launching you should follow the screen information After a short time the installation is finished x gt Silicon Laboratories CP210x VCP Drivers for Windows XP 2003 Server Vi iil L ill a GA Existing Installed Instances Detected Select the appropriate application instance to maintain or update Setup has detected one or more instances of this application already installed on your system You can maintain or update an existing instance or install a completely new instance Install a new instance of this application 7 Maintain or update the instance of this application selected below Display Name Silicon Laboratories CP210x VCP Drivers for Windows XP 2003 Server Vista c SiLa nstallShield 9 RS232 converter s driver installation is not required when simDrive device is connected to CSMIO IP CNC motion controller CAN bus connection required In this case a PC can communicate with simDrive device through CSMIO IP controller and CAN bus gt simDnve AC Servo Drive USER GUIDE Unni imire Sofswaee Package 19 Es CS LAB S C ElectronicLaboratory 5 1 2 csServoManager utility software installation csServoManager utility is provided as convenient software installer what basically makes the Welcome to the installation of csServoManager version 2 000 installation proc
39. nfiguration menu click Communication and change the address into 105 o Save the configuration in non volatile memory Configuration gt Save in flash memory o End the connection the first icon on the left on a toolbar e Zaxis drive address change into 106 o Switch off power supply 24V of X and Y drives connect Z axis drive power supply o Connect with the drive and set address 98 in the Configuration gt Communication menu o Save the configuration in non volatile memory Configuration Save in flash memory e Switch OFF and ON the 24V power supply of all the drives so the new settings will be visible for all the devices e Now after clicking Search in the connection window all three drives should appear with their addresses 104 105 and 106 2 Alternatively CAN addresses setting by serial RS232 COM port connection If we have the RS232 wire or the USB RS232 converter we can plug in one by one to each drive connecting and changing the CAN addresses Configuration Communication You should remember to save the configuration every time in non volatile memory Configuration gt Save in flash memory and to switch the drives 24V power supply OFF and ON after that Only then the devices will be shown on the CAN bus with their new addresses gt simDnve AC Servo Drive USER GUIDE 21 E CSLAB s c ElectronicLaboratory 5 2 3 Toolbar The most frequently used functions are available on a toolbar so this way
40. nitor Motion a Encoder Position 0 pulses Reference Position 0 pulses Encoder Velocity 0 00 rpm Reference Velocity 0 00 rpm Reference Acceleration 0 rpm s2 Step Frequency 0 00 kHz 4 Following Error 0 pulses Q Following Error Max 0 pulses 4 Velocity Error 0 00 rpm IN O IN 1 9 Velocitv Error Max 0 00 rpm kud kud Encoder Errors 0 Homeln Servo On Scope control Refresh rate Monitor Commutation Motor Position Monitor 4 Mechanical Angle Encoder 52 49 deg R Electrical Angle Encoder 209 96 deg Eei imb O 0000 Electrical Anale HALL 210 Idea l 1000 Units 4 HI o online CSMIO IP gt CAN 192 168 8 48 CSMIO IP 9140 Node Addr 104 On the left side of the window there is a list with the parameters On the right upper side there is a real time data chart of chosen parameter Under the chart there are options related to it e Refresh frequency the chart refresh frequency e Auto scale automatic manual scale of the chart Y axis e Max Min min max values settings for Y axis if manual scale of Y axis is enabled Under the chart control group there are current digital inputs and outputs of a drive states displayed along with functions assigned to them In the bottom part there is current position rate user s units It can be an angle inch or mm You only have to enter encoder pulses number per the chosen unit in Steps per unit area So if an enc
41. ns or will rotate uncontrollably To keep all settings changes saved after Power is off click on the 8 icon on the toolbar gt simDrive AC Servo Drive USR GUIDE 33 E CSLAB s c ElectronicLaboratory icLaboratory 5 5 1 Digital inputs function Function E Stop Home In Reset Servo ON Limit Limit Description Emergency stop Homing signal input for doming signal and encoder index synchronization Alarm reset Zataczanie koncowki mocv przejscie ze stanu gotowosci do stanu pracy Positive limit Negative limit 5 5 2 Default inputs functions assignment A new drive has input functions assigned by default Obviously you can set it freely but if you connect Default state Inactive Active Inactive Active Inactive Inactive in accordance with the default settings you will not need to set inputs in csServoManager Digital input number Default function 0 Om QO N _ Homing input Servo ON Reset 5 5 3 Digital outputs functions Function Alarm Home out Brake Description Default polarization Reversed Normal Normal Information about an alarm interruption of operation Homing signal output synchronized with encoder index it requires doming input defining for proper operation Motor s electromagnetic brake control The output defined as a brake is active if motor s voltage is enable and a drive works correctly In ready and alarm state the brake
42. oder has 10000p rev and the drive is driven by 20mm pitch ball screw and we want to have the axis position displayed as mm 10000 p rev 20mm rev 500 p mm So we enter 500 into the Steps per unit area e 26 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory Here is a list of parameters which preview is available with their short description PARAMETER NAME Firmware version Drive status Alarm flags Warning flags Digital inputs Digital outputs External 5V output 24V power supply Power stage temperature Torque scan state Autotuner state Autotuner tuning state Planner idle flag Encoder position Reference position Encoder velocitv Reference velocitv Reference acceleration STEP frequencv Following error Following error Max Velocitv error Velocitv error Max Encoder errors Mechanical angle encoder Electrical angle encoder Electrical angle HALL DESCRIPTION Drive firmware version Current drive state Alerts Detailed alerts description in menu Tools Show Alerts or after pressing the icon B on the toolbar Warnings Detailed alerts description in menu Tools gt Show Alerts or after pressing the icon B on the toolbar Digital inputs state You can see extended preview after pressing on the toolbar or by selecting Tools gt JOG and I O control from the menu Digital outputs state You can see extended preview after pressing
43. on 8 on our toolbar or Save in flash memory in Settings menu Sometimes we do not want to save the changes e g when we test new settings we can accidentally put the drive out of adjustment If the new settings weren t saved in non volatile memory it s enough to switch the drive power off and on 24V logic power supply and all previous data will be restored If we do any configuration changes after the drive was switched on the icon will blink red B telling us that the changes are not saved in non volatile memory flash gt simDnve AC Servo Drive USER GUIDE 25 Eq CSLAB s c ElectronicLaboratory nicLaboratory 5 3 Parameters Monitor window real time parameters preview During drive configuration it s very useful to have the possibility to watch the parameters and information about them up to date We call the preview window by clicking the icon a on the toolbar or by selecting Tools gt Parameters Monitor from the menu 2 File Tools Configuration Window Help wP 2820 Hose lt z L BD Parameter n Value A Reference Position Monitor Status Firmware Version 2 09 Drive Status Ready Alarm Flags 0x00000000 Warning Flags 0x00000000 Digital Inputs b 00000001 Digital Outputs b 00000010 External 5V Output 4 93 N 24V Power Supply 24 20 V Powerstage Temperature 21 79 C Torque Scan State Initializing Autotuner State Idle Autotuner Tuning State Current Kp 4 Planner Idle flag 1 Mo
44. otor revolution range won t cause damage of a machine axis mechanics and if any other person doesn t work at the axis as a motor will start to rotate in a online CSMID IP sCAN 192 168 8 48 CSMIO P 9140 Node moment l e Click button The motor should start to rotate left and right in one motor revolution range e Current controller tuning o Increase K gain of current controller slowly until you get first symptoms of overshoot buzzing and squealing Next decrease the K slowly by 25 If we get an alarm state during the current controller tuning then you should decrease the gain value by 25 and press Reset and again o Wetune the K parameter of current controller the same way Slowly increase the gain and at first squealing or laud noises decrease the K value by 25 e Velocity controller tuning o Increase K gain of velocity controller slowly until you get first symptoms of overshoot buzzing and squealing Next decrease the K slowly by 25 o We tune the K parameter of velocity controller the same way Slowly increase the gain an at first vibrations decrease the K value by 25 e Position controller tuning o Increase K gain of position controller slowly until you get first symptoms of overshoot buzzing and vibrations Next decrease the K slowly by 20 gt simDnve AC Servo Drive USER GUIDE 37 Es CS LAB S C ElectronicLaboratory In most of cases at this stage of the tuning the procedure
45. our toolbar To assigne a function to an input or an output you should click right mouse button on the nput or the output and select demanded function You can also reverse operation logic each by for input or Change polarization option output selecting CSLAB s c ElectronicLaboratory G E 4 csServoManager 2014 CS Lab s c Calla x File Tools Configuration Window Help RAAN AI J gt n Ho 2 VO Functions Signal select I O Signal Function Inv Inputs a Input 0 Home In y a Inputi Servo On s Input 2 Reset ka Input3 Unused lt Input4 Unused E Stop a Input5 Unused Home In Outputs Reset B OutputO Alarm Servo On Output 1 Home Out Limit gt Output2 Brake FEE Unused Change Polarization 4 III N e online CSMIO IP gt CAN 192 168 8 48 CSMI It s good to clear all current settings first before the configuration For inputs we select O input and we click on 5 input while holding Shift key at the same time Click on all this way selected inputs with right mouse button and select unused We do the same for the outputs If Servo ON function is not assigned to any input then the drive and power output stage is all the time enabled So in this case it is very important to not connect power output stage during first configuration of the drive Otherwise if PID controllers and or motor parameters aren t set properly then the running motor will go into oscillatio
46. output is inactive 5 5 4 Default outputs functions assignment Digital output number Default function 0 1 2 34 Alarm Homing output Brake Default polarization Normal Reversed Normal gt simDrive AC Servo Drive User Guide ES CS LAB X 2 L ADO S C ElectronicLaboratory 5 6 PID controller tuning For beginners it s the hardest stage of the 2 esevoManzger 2014 CS Lab sc File Tools Configuration Window Help configuration but following the manual even they can ama m s tune the PID controller properly and pretty fast Before we enter power output stage HV and we Position Regulator Velocity Regulator switch a servo drive on Servo ON we should first Ko Ko Kd KOK a enter initial low values of the controller to avoid loud motor oscillation right after we turn the motor Open PID tuning window from our menu configuration gt PID tuning or click on the H icon l b b T E E on the toolbar 2000 0 005 0 000 2 500 0 150 0 000 1000 0 250 Max Following Error Current PI Regulator 10000 Pulses ai Bee n D 0 500 online CSMIO IP gt CAN 192 168 8 48 CSMIO I 5 6 1 Initial settings of PID regulator Optimal initial values for various motor types may differ significantly however in the table below there are parameters which should be safe in most of cases they shouldn t cause motor oscillations after it is turned on PID controllertype
47. r We start the servo drive configuration from motor parameters setting Open configuration window from menu Configuration gt Motor parameters or press the icon mQ on the toolbar Z csServoManager 2014 CS Lab s c File Tools Configuration Window Help AEL ALLL 4 Motor Type amp amp Parameters Motor Configuration Feedback INCREMENTAL ENCODER Select Motor Model Pulses Rev All edges x4 aa mo des Reversed Motor Type AC Motor Hall Sensors Rotor Feedback Motor Rated Values Invert Hall signals mm Voltage 220 M Reference Step Dir Speed 5000 RPM Current 280 A Invert Dir Brushless Motor gii Parameters ROS mQ Pole Pairs jtul Se Electronic Gearing X numerator 1 Y denominator Ea L 50 mH Motor Constants Torque Constant 0 12 Nm A MOTOR POS REF POS X Y Voltage Constant 28 0 V 1000RPM online CSMIO IP gt CAN 192 168 8 48 CSMIO IP 9140 Node Adc 5 4 1 Motor type In this group we chose type of the motor we have connected to our simDrive We have to possibilities here e DC Motor DC brushed motor e AC Motor AC or BLDC brushless motor gt simDrive AC Servo Drive USR GUIDE 29 i CS LAB S C ElectronicLaboratory 5 4 2 Motor rated values Here we set three very important parameters Parameter name Description Nominal motor voltage The value is usually placed on a motor Voltage nameplate eid Nominal motor RPM
48. se tuning requires from a user more experience and skill to asses an operations of a motor csTorqueScan tab is available in PID tuning window Scanning and attuning procedure looks as follows 1 Motor scanning e Make sure that any other person doesn t work on a machine and that there are no obstacles for the motor to perform 2 revs e Make sure that PID controllers have already been tuned earlier e Make sure that power outputs stage power supply HV is enable and a drive is ready if it is in alarm state scanning won t start e Set Ampl Slider to 1 value and Phase to O e Click Scan button and wait until the scanning is finished 2 Amplitude and phase tuning the hardest stage that requires a bit of sense e We find at what velocity there is resonance small vibrations of a motor For that we can use JOG function we set small acceleration value and during the acceleration try to hear or even touch a machine touch only in the place where is no risk of crushing e In motion at the resonance velocity we regulate Phase with the slider to get as small vibrations as possible The best way is to test it at both sides motion so the motor rotates alternately right and left you can use Motion planner function in a JOG window e As We have found optimal position of the Phase slider we can try to decrease the amplitude to get the smoothest motion further description next pag
49. stepper motors which are we can say controlled blindly servo drives work in so called closed loop so when they control a motor they check if its position is compliant with the set position If actual rotor position differs from the expected one there is a current correction entered to overcome the existing error If the motor overtook the ENCODER position that was set it just slows down or speeds up to catch up if the set position overtook the actual position It is just like driving a car we would like to catch up another car next to us If it is running away we step on the gas and speed up and if we are too far we let up on the gas to slow down What happens if the car we want to align with doesn t make it any easier and every moment speeds up or slows down moreover we are already nervous and we overreact stepping on the gas or brake to the limit time and time again As a result we will still pass the chased car being most of the time far away from it As a result we will still pass the chased car being most of the time far away from it Translating this analogy to a CNC machine it would appear that axes do not follow the set motion path and a lot of machining inaccuracies would arise Servo drives require fast and precise correction to the position error Going back to the cars comparison the point is that the driver from the chasing car should be as experienced as possible so he could predict behavior of the second running awa
50. t 100 The example above shows that even a small error may cause large offset correction value if it lasts for longer time In practice we deal not with seconds but with fraction of seconds because the PID controllers work from a few hundred to several thousand times per second Matching the P and lI terms we get a controller which immediately reacts on large error values P and some other deviations it corrects with small delay 1 So it all starts to work pretty well 9 2 3 The Derivative term D After reading descriptions of P and T terms we can come to conclusion that we do not need nothing more In many situations that is true and very often in practice the derivative gain D is set to 0 what cause it is skipped However sometimes there is necessity to add some stabilization element as sharply tuned P and Y may cause unwanted vibrations near the set point Here the derivative term D will be helpful which works as a dumper prevents sudden rapid movements The D reacts the stronger the faster a position error changes If the error increases fast the D control will react towards strongly If the error decreases quickly then the D control will strongly react towards 9 2 4 The sixth sense the mysterious Kvrr parameter Where this parameter comes from if we described all the terms of PID controller Actually it is not another PID controller term it is rather an element w
51. tartuj P Czekam 8 1 csServoManager utility update csServoManager utility update comes down to an installer launching section 5 1 2 csServoManager utility software installation 8 2 simDrive firmware update simDrive firmware update requires simDriveUploader exe launching First make a copy of your servo drive settings and save them in csServoManager Update procedure looks as follows 1 Make sure that simDrive servo driver is connected through RS232 COM port updates through CAN bus is not supported Select your language and press Start Wait until the uploader will detect the connected drive Select the file with new firmware Wait until the update process ends ee ee 9 Close the uploader AN Only control system fitter installer should perform the update because after update to newer firmware version there can some new additional functions appear which need to be set Update performed by unqualified staff can lead to incorrect drive operation so it may even be not able to use till it will finally be set correctly E simDrive servo drive firmware must be compatible with csServoManager version In other case connection will not be possible Always update csServoManager and simDrive firmware as well gt simDnve AC Servo Drive USER GUIDE 45 E CSLAB s c ElectronicLaboratory 9 Baddition What is PID controller regulator 9 1 What is PID controller As opposed to
52. ter Mi Du as ansassasqisaqtasqaawasqapaawqaqauspkaqsqsswkasauaakaqaqaasqaqaayasuapasshaqkasqin 48 9 2 4 The sixth sense the mysterious K yep parameter 48 10 C addition Slave AXIS i iii iii as dai 49 11 D addition Diagnostics via Mach3 software 50 gt simDnve AC Servo Drive USER GUIDE 3 Es CS LAB S C ElectronicLaboratory 1 Introduction 1 1 Signs used in this guide Useful information tips Warning failure to complv with these warnings mav lead to inappropriate functioning or damage of the device Potential danger and or possible injury risk 1 2 Standards compliance simDrive servo drives were designed and made in accordance with the national and international standards for industrial control systems based on electronic components EN 61800 5 1 EN 61800 3 EN 61000 6 2 EN 61000 6 4 EN 61000 3 2 EN 61000 3 3 Adjustable speed electrical power drive systems Safety requirements Electrical thermal and energy Adjustable speed electrical power drives systems EMC requirements and specific test methods Electromagnetic compatibility EMC Generic standards Immunity for industrial environments Electromagnetic compatibility EMC Generic standards Emission standard for industrial environments Electromagnetic compatibility EMC Limits for harmonic c
53. ty the positioning is worst but oscillations are less likely to happen The autotuning procedure requires a motor to be in motion and mechanically mounted on a machine so you need to be careful and verify if there is enough space for the motion by default a motor Turing autotuning rotate by 0 5 of a rev and also if no one else works on the machine at the moment You should be ready to turn off the drive immediately as well To keep your changes saved after power is off press 8 icon after autotuning is finished i During the autotuning you can notice knocking squeaks vibrations etc It is normal If these symptoms last constantly longer than 5 sec then you should stop the autotuning by pressing Stop button 40 l gt simDrive AC Servo Drive User Guide ElectronicLaboratory 5 7 Torque scan function csTorqueScan Some motors have large torque ripple in a rev angle a Wine function simDrive servo drive enables a measurement Of H manzirunna IA auto Tuning V Stones Control amp Tuning gt Start these ripples and lets for proper compensation entering in sa l a a real time It makes positioning is more precise and g ar vibrations are suppressed without the compensation the stensenerawcha momentuobr malang Motor torque ripple vibrations would occur at some velocity ranges This function is designed for rather more advanced users as preci
54. u will get information about incompatible version you should update your csServoManager and simDrive firmware Always up to date software you will find on http www cs lab eu You can read more about software update in chapter Addition A Firmware update 20 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 5 2 2 CAN bus connection TERMINATOR AT The principle of simDrive and CSMIO IP controller connection through CAN bus The most convenient way of connection is connection via CAN bus and CSMIO IP controller You only have to set drives addresses first The addresses range is 104 109 we recommend keeping the order with axis signs so 104 for X axis 105 for Y axis and so on The new drive has by default 96 address If two or more drives on the CAN bus will have the same address the communication won t be possible The main problem then to set the CAN addresses is that you need to be connected first There are two solutions we consider it basing on three drives on X Y Z axes 1 Recommended Following addresses setting e Asadrive default address is 104 X axis drive doesn t require any address change e Y axis drive address change into 105 o Switch off power supply 24V of X and Z axes drives and click Scan in csServoManager software window In the list you will see one drive Y with its address 104 Select drive from the list and click Connect o In the software Co
55. uration in non volatile memory with button close the connection in csServoManager Y and switch off the 24V power supply for min 5s Next switch it on and connect with the drive w Open PID regulators tuning window and ensure that the needed values in there are safe for the first run look at chapter 5 6 1 Initial settings of PID regulator Enable power output stage voltage HV and open JOG I O control window Next click Reset The drive should change its status into Ready next click A the drive should change its status into Running gt Test the motion on low revs about 50 100 rev min few revs left and right If a motor x doesn t move or it jerks and or it reports an error then verify connection and settings again especially motor parameters configuration Ifyou want to use automatic PID regulators tuning function skip this point In JOG I O Control go to Motion planner tab Set speed to 150RPM 3000 RPM s k J acceleration and relative motion as pulses number per encoder rev it s range of 1 motor rev Next start cyclic motion a Launch automatic PID regulator tuning in PID regulator tuning window ful on Automatic y tuning tab or tune the regulators manually as following e current regulator e speed regulator e position regulator Save the configuration in non volatile memory gt and click Y to disconnect the drive Verify if the drive works properly w
56. urrent emissions Electromagnetic compatibility EMC Limitation of voltage changes voltage fluctuations and flicker in public low voltage supplv svstems The product was made in lead free technology RoHS compliant The simDrive servo drive is a high voltage device that can be hazardous to your health and life Before you start any installation turn off the power of the device and wait min 10 minutes it is lead free the time needed to discharge a capacitor l gt simDrive AC Servo Drive User Guide sel CS LAB S L ElectronicLaboratory 1 3 Technical data sheet PARAMETER M4 HO75K Model M4 HO40K Model M4 L075K Model M4 L040K Model Power supply voltage of a power output stage Maximum output 325 VDC 155 VDC 12A 6A 20 A 10A current Maximum output 2 3 0 kW 1 2 kW 2 2 kW 1 2 kW power Recommended motor powerBtgd Nie kon 750 kW 400 W 750 W 400 W zdefiniowano zaktadki Motor types supported DC BLDC AC Synchronous HALL rowel i Aga Short circuit overload overvoltage and thermal protection Digital inputs number 6 Digital outputs number 3 Encoder inputs number 1 Logic supplv voltage 24VDC 10 Power consumption 24V ae Maximal permissible 30VDC voltage on I O lines Maximal load on an SOMA output line Signal type of STEP DIR position speed defining Differential signal Max STEP signal 4 MHz frequency Max encoder signal 8 MHz frequencv Encoder tvpe incremental TTL En
57. y car and to react precisely as the situation evolves In servo drives PID controller is the driver The controller is a mathematical algorithm that is responsible for motor reaction on deviations from set position The PID name derives from the following terms of the controller Proportional Integral e Derivative ens 46 gt simDrive AC Servo Drive User Guide ES CSLAB s c ElectronicLaboratory 9 2 PID controller terms parameters operation There are like tens of thousands descriptions of PID controller work in the Internet but for most of people putting it mildly they are rather vague and actually do not say anything In this section we present the PID controller blocks described in a few words so you could get the logic of their operation 9 2 1 The proportional term P It is the easiest part of the controller It makes that correction is greater the larger position error is The error is calculated in the following way Perr P Penc Where Par position error P current set position P onc actual position of an encoder An output of the proportional term is calculated by the formula OUT Kp Perr Where OUT output of proportional term Ko Proportional gain Par Position error Let s assume that the set position 0 Kp 10 and analyze the situation for a few different actual positions of a motor e Motor position 0 Error is zero so the P term has also zero output so
58. y on yet Install the csServoManager software and possibly the controller to the USB RS232 converter if you connect with the drive through RS232 port Turn on the 24V logic power supply for the time being do not turn on the HV power output stage power supply yet Now We are connecting with the drive If you connect with the drive via CSMIO IP controller and you have more than one drive on the CAN bus then you have to set addresses for the drives read chapter 5 2 2 Connection through the CAN bus If the motor supplier is CS Lab s c company load configuration template for the particular model available on www cs lab eu and save the configuration in non volatile memory by pressing 8 icon Open parameters monitor window a and select Position Encoder from the list Turn a motor shaft left and right Counter should count alternately up and down depending on motor shaft rev direction If the counter doesn t change the value or it skips only between 1 up to 1 then verify encoder connection In the parameters monitor window select HALL sensors state from the list Turn the motor shaft and watch indications The sensors state should change in one of the following sequences depending on revs direction e C CB_ B BA A C A C etc e C C A _A BA B CB C etc If the sequence is incorrect or the state is or ABC then verify HALL sensors connection Open JOG I O control 2 and verify I O signals op
59. you have easy access to them gt csServoManager 2014 CS Lab s c File Tools Configuration Window Help wn 20208 Hose online CSMIO IP gt CAN 192 168 8 48 CSMIO IP 9140 The icons have the following functions assigned from the left ICON Corresponding menu function FI File Load Parameters B File gt Save Parameters ki Configuration gt Save to flash memory Q Tools gt Parameters monitor E Tools gt Fast scope p3 Tools gt JOG I O control Description Disconnection connection with a drive If e g we have finished configuration of one drive and we want to start another then we click the icon to disconnect Then we plug in a wire to another drive and click the icon again to connect Loading settings from a file It s worth to save drive configuration after it s set In breakdown situation and replacement necessity we can use the configuration we saved in a file Save settings to a file IMPORTANT Settings file save in non volatile memory You should click the icon after you make changed the drive s configuration If you don t then previous drive s settings will show up after its power supply will be off Real time preview of drive parameters After clicking on the icon a window with a list of all the important settings will show up We can see them as a graph as well It s very useful tool during configuration and drive tuning Function of high speed oscilloscope available with
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