Home

AC Tech SimpleServo Model 94 User Manual

1. B P6 gt 25mm S902 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 4 Installation Perform the minimum system connection Please refer to section 8 1 for minimum connection requirements Observe rules and warnings below WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed The SimpleServo must be mounted vertically for safe operation at the maximum current rating Printed circuit board components are sensitive to electrostatic fields Avoid contact with the printed circuit board directly Hold the SimpleServo by the case only Protect the control from dirt filings airborne particles moisture and accidental contact Provide sufficient room for access to the terminal block Mount the control away from other heat sources Operate within the specified ambient operating temperature range Additional cooling with an external fan may be recommended in certain applications Avoid excessive vibration to prevent intermittent connections DO NOT connect incoming mains power to the output motor terminals U V W Severe damage to
2. Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 9 2 Motor response to gain settings Position Mode 9 2 1 Non optimal P gain D gain relationship P gain 200 D gain 300 Problem Noticeable oscillation Channel 2 Insufficient D gain excess of P gain for this D gain setting Treatment Decrease P gain increase D gain Side effects Decreasing P gain increases position error Increasing D gain lowers bandwidth and increases hi frequency noise E Channel 1 Signal name Motor velocity Scale rococo RPM dkv Offset 0 00 RPM Channel 2 Signs neme Position Error X Scale om Counts div Ofiset 10 00 Counts Time base 20 ms div gt Trigger Auto E N gt i fo 00 F Always on top Single LENE Close S918 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 9 2 2 Optimal P gain D gain relationship Note Oscillation is eliminated Position error is small and only 20 mS long Position regulation bandwidth of the system is 1 20mS 50Hz Channel 1 2550 00 Max 69 01 26 Ba Motor velocity Signal name Scale rococo ReM dw Offset 0 00 a RPM Channel 2 Signal name Postion Error X Scale 150 00 Counts div Offset pu Counts Time base 20 ms drv Trigger msn Options Level fo 00 Close 919 IF Always on top Phone 800 894 0412
3. 150 pF m U Earth grounded conductive mounting plate Encoder Feedback Cable Footprint Filter optional m TI 4 2 2 EMI Protection Electromagnetic interference EMI is an important concern for users of digital servo control systems EMI will cause control systems to behave in unexpected and sometimes dangerous ways Therefore reducing EMI is of primary concern not only for servo control manufacturers such as Lenze but the user as well Proper shielding grounding and installation practices are critical to EMI reduction Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 4 2 3 Enclosure The panel in which the SimpleServo is mounted must be made of metal and must be grounded using the SPG method outlined in section 4 2 1 Proper wire routing inside the panel is critical power and logic leads must be routed in different avenues inside the panel You must ensure that the panel contains sufficient clearance around the drive Refer to Section 3 2 suggested cooling air clearance 4 3 Line filtering In addition to EMI RFI safeguards inherent in the SimpleServo design external filtering may be required High frequency energy can be coupled between the circuits via radiation or conduction The AC power wiring is one of the most important paths for both types of coupling mechanisms In order to comply with EN50081 1 and EN50082 2 an appro
4. menu choose lt Connect Drive gt Click Connect one button type 1 in the address box and press OK to dismiss dialog Drive connects and its icon appears in the left node tree of the MotionView s screen Note MotionView s Connection setup properties need only be configured the first time MotionView is operated or if the port connection is changed Refer to MotionView User s Manual for details how to make a connection to the drive 15 16 17 18 19 20 21 Double click on the drive s icon to expand parameter group s folders Select the motor to be used according to the Section 5 5 Expand the folder Parameters and choose the operating mode for the drive Refer for details to Section 6 3 1 for details on operating modes Click on the Current limit parameter 6 3 3 and enter current limit in Amp RMS per phase appropriate for the motor Click on the appropriate Peak current limit parameter 6 3 4 based on the Drive PWM frequency parameter 6 3 2 used and enter the peak current limit in Amp RMS per phase appropriate for your motor Set up additional parameters suitable for operating mode selected in step 17 After you configure the drive proceed to the tuning procedure if operating in Velocity Position or Velocity limited torque mode Torque mode doesn t require additional tuning or calibration Refer to Section 8 6 for details on tuning Phone 80
5. or in phase with this voltage We can determine which Hall Voltage is in phase with the Vrs Output Voltage by drawing vertical lines at those points where it crosses the horizontal line zero The dashed lines at the zero crossings above indicate that Hall B output is lined up with and in phase with the Vrs Output Voltage 2 Look at the Vst Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall C output is in phase with the Vst Output Voltage 3 Look at the Vtr Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall A output is in phase with the Vtr Output Voltage Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com Note If hall sensors are in phase with corresponding phase voltage but inverted 180 degrees hall sensor waveform edge aligns with phase phase voltage waveform but positive hall sensor cycle matches negative phase phase waveform or visa versa you must check Inverted check box 4 The phases that correspond to the Vrs Vst Vtr voltages are Hall B then Hall C then Hall A or halls number 2 then 3 then 1 Referring to the following table we find that 2 3 1 sequence is Halls Order number 3 We would enter 3 for the Halls Order field in motor dialog HALL ORDER NUMBERS FOR DIFFERENT HALL SEQUENCES Halls Order Hall Sequence 0 1 2
6. regen resistor value P W regen resistor rated power Note If calculation of D is greater than 100 set it to 100 value If calculation of D is less than 10 then resistor power rating is too low Refer to section 5 1 6 for details on braking resistor selection Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 3 15 Encoder repeat source This parameter sets the feedback source signal for the buffered encoder repeat outputs P3 1 6 The source can be the drive s encoder input P4 or an optional feedback module resolver second encoder etc 6 3 16 Master to system ratio This parameter used to set scale between the reference pulse train when operating in position mode and the system feedback device In a single loop configuration the system feedback device is the motor encoder or resolver In a dual loop system the system encoder is the second encoder See sections 8 3 and 8 4 for details 6 3 17 Second to prime encoder ratio This parameter sets ratio between secondary encoder and primary feedback device when the drive is configured to operate in dual loop mode When the primary feedback device is a resolver the pulse count is fixed at 65 536 The resolutions of encoders are post quadrature PPR x 4 See section 8 4 Note Post quadrature pulse count is four times the pulses per revolution PPR of the encoder 6 3 18 Software drive enable Pro
7. P6 2 pin removable terminal block P5 1 dedicated ENABLE 1 programmable 5 24V P3 2 programmable 5 24V 100mA P3 1 differential 10 VDC 16 bit P3 1 single ended 10 VDC 10 bit P3 Standard 25 pin D shell P3 MotionView Windows 98 NT 2000 XP Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 3 Dimensions 3 1 Model 94 Dimensions 38 12 H i mi 127 TT e asl C A S901 Type A mm B mm C mm Weight kg E94S020S1N 67 190 235 1 5 E94S040S1N 69 190 235 1 6 E94S020S2F 67 190 235 1 3 E94S040S2F 69 190 235 1 5 E94S080S2F 95 190 235 1 9 E94S100S2F 115 190 235 2 2 E94S020Y2N 67 190 190 1 3 E94S040Y2N 69 190 190 1 5 E94S080Y2N 95 190 190 1 9 E94S100Y2N 115 190 190 2 2 E94S020T4N 69 190 190 1 5 E94S040T4N 95 190 190 1 9 E94S050T4N 115 190 190 2 2 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 3 2 Clearance for Cooling Air Circulation gt 25mm T hN 3 2 F P2 00 88 of 95 09 F o l 38 P5 P3 T i BR B
8. at AIN and AIN P3 23 and 24 to zero volts and then click this button Any offset voltage at the analog input will be adjusted out and the adjustment value will be stored in the Analog input offset parameter Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 6 Digital I O 6 6 1 Digital input function Digital input IN2 P3 10 is programmable as follows e Not assigned Input not assigned and has no effect on drive operation External fault Input serves as external fault input Servo will stop and indicate fault if this input is activated Stop Rapid In velocity or current mode sets input reference to 0 regardless of voltage on analog input e Reference Reverse Sign of input reference voltage is reversed 6 6 2 Digital output 1 and 2 function Digital outputs OUT1 P3 15 and 16 and OUT2 P3 19 and 20 can be individually assigned to the following functions Not assigned No function has been assigned for the digital output e Zero Speed Motor is at or below the zero speed threshold set by the zero speed parameter in the Velocity Limits Group e In Speed Window Motor shaft RPM is within the speed range as defined in the At speed and Speed Window parameters in the Velocity Limits Group section 6 7 Current Limit Drive current output has exceeded the limit set in the Current Limit parameter in the Drive Parameters Group Run Time Fault A faul
9. equipped with a resolver it needs to be connected to terminal P11 on the resolver option module E94ZARSV1 5 5 2 Motor over temperature protection If using a motor equipped with an encoder and PTC thermal sensor the encoder feedback cable will have flying leads exiting the P4 connector to be wired to the P7 1 T1 and P7 2 T2 terminals If using a motor equipped with a Resolver and a PTC sensor the connector on the Resolver Option Module P11 provides this connection Use parameter Motor PTC cut off resistance see section 6 3 12 to set the resistance which corresponds to maximum motor allowed temperature The parameter Motor temperature sensor must also be set to ENABLE If the motor doesn t have a PTC sensor set this parameter to DISABLE This input will also work with N C thermal switches which have only two states Open or Closed In this case Motor PTC cut off resistance parameter can be set to the default value Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 5 3 Setting Up motor MotionView Motor Group on the left tree shows the currently selected motor You can click CLICK HERE TO CHANGE to view selected motor parameters or select new motor ay Untitled MotionView94 E945040x2x 1 untitled Project Node Tools View Help olslalel x 6 2 E945040x2x 1 untitled Parameter name Value Units E Motor C Paramete
10. input The Analog input velocity scale parameter section 6 3 6 set the scale for this potentiometer the same way it sets it for the analog input The Enable reference sweep check box allows the user to generate a bipolar square wave reference who s period is set by the sweep time and max speed set by the potentiometer This bipolar square wave allows the motor to continually cycle between forward and reverse for easy velocity mode tuning 6 10 2 3 Check Phasing This button activates the Autophasing feature as described in section 5 6 2 However in this panel only the motor phasing is checked the motor data is not modified 6 10 2 4 Enable and Disable buttons These buttons will enable and disable the servo controller in a similar manner as the ENABLE input on P3 17 For the Enable button to function the Software drive enable parameter see section 6 3 19 must be set to enable The Disable button will work regardless of this parameter setting as long as communications with the drive are functioning WARNING Starting of the drive from the MotionView software enable will override the hardware ENABLE P3 17 when in the disable state The operator must ensure that motor and machine are safe to operate prior to enabling the drive Failure to comply could result in damage to equipment and or injury to personnel 6 10 3 Drive info The Firmware build button shows
11. system The ON ENABLE option clears the fault when the drive is re enabled Choose ON ENABLE if you have a complex servo system with multiple drives connected to an external controller This makes troubleshooting easier since the fault will not be reset until the drive is re enabled Thus a technician can more easily determine which component of a complex servo system has caused the fault 6 3 11 Motor temperature sensor This parameter enables disables motor over temperature detection It must be disabled if the motor PTC sensor is not wired to either P7 1 2 or to the resolver option module P11 6 3 12 Motor PTC cut off resistance This parameter sets resistance of PTC at which motor reaches maximum allowable temperature See section 5 5 2 for details how to connect motor s PTC 6 3 13 Second encoder Disables or enables second encoder Effectively selects single loop or double loop configuration in position mode The second encoder connects to the Encoder Option Module E94ZAENC1 connector P12 Refer to section 8 4 for details on dual loop operation 6 3 14 Regen duty cycle This parameter sets maximum duty cycle for the brake regen resistor This parameter can be used to prevent brake resistor overload Use following formula to set correct value for this parameter D P R Umax 100 where D regen duty cycle Umax V bus voltage at regen conditions Umax 390V for 230VAC drives and 770V for 400 480VAC drives R ohm
12. the SimpleServo will result Do not disconnect any of the motor leads from the SimpleServo unless mains power is removed Opening any one motor lead may cause failure 4 1 Wiring WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing the drive Capacitors retain charge after power is removed Under no circumstances should power and control wiring be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls Refer to section 5 1 1 for Power wiring specifications Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 4 2 Shielding and grounding 4 2 1 General guidelines Lenze recommends the use of single point grounding SPG for panel mounted controls Serial grounding a daisy chain is not recommended The SPG for all enclosures must be tied to earth ground at the same point The system ground and equipment grounds for all panel mounted enclosures must be individually connected to the SPG for that panel using 14 AWG 2 5 mm or larger wire In order to minimize EMI the chassis must be grounded to the mounting Use 14 AWG 2 5 mm or larger wire to join the enclosure t
13. the relationship between Master input and mechanical system movement requires that two parameters be set 1 Master to system ratio sets the ratio between master input pulses and the second encoder pulses system encoder 2 Second to prime encoder ratio sets the ratio between the second and primary motor encoder If the motor is equipped with a resolver connected to the resolver option module E94ZARSV1 the primary encoder resolution of 65536 post quadrature must be used 8 5 Enabling the SimpleServo Regardless of selected operating mode the SimpleServo must be enabled before it can operate A voltage in the range of 5 24 VDC connected between P3 17 and 18 is used to enable the drive Impedance of this input is approximately 700 ohms WARNING Enabling the servo drive allows the motor to operate depending on the reference command The operator must ensure that motor and machine are safe to operate prior to enabling the drive and that moving elements are appropriately guarded Failure to comply could result in damage to equipment and or injury to personnel Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 8 6 Tuning in velocity mode Note In this mode the settings for Position compensation have no effect 1 Make sure that power is applied to the drive and that the drive is connected to a PC running MotionView software 2 Make sure
14. w 913 tcp Function Descrintion Orange LED indicates that the drive is ENABLED running B Regen Yellow LED indicates the drive is in regeneration mode Data Entry Yellow LED will flash when changing Dp Comm Fault Red LED illuminates upon a communication fault Comm Activity Green LED flashes to indicate communication activity 7 3 Faults 7 3 1 FAULT CODES Fault Code Fault Description F_Qy Over voltage Drive bus voltage reached maximum level typically due to motor regeneration _F Feedback error Resolver signal lost or at least one motor hall sensor is inoperable or not connected F_OC Over current Drive exceeded peak current limit F Ok Over temperature Drive heatsink temperature has been reached maximum rating F_EF External fault input Digital input was programmed as external fault input and has activated been activated F_05 Over speed Motor reached velocity above its specified limit F_PE Excess position error Position error exceeded maximum value F bd Bad motor data Motor profile data invalid or no motor is selected F_09 Motor over temperature Optional motor temperature sensor PTC indicates that the motor windings have reached maximum temperature F_ 4 Low Bus Voltage DC Bus voltage has fallen below operating tolerance F_xx Restricted contant Lenze service for any Fault Code not identified Phone 800 894 041
15. 0 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 8 3 Position mode operation gearing In position mode the drive will follow master reference signals at the P3 11 14 inputs The distance the motor shaft rotates per each master pulse is established by the ratio of the master signal pulses to motor encoder pulses in single loop configuration The ratio is set by Master to System ratio parameter see section 6 3 17 Example 1 Problem Setup drive to follow a master encoder output where 1 revolution of the master encoder results in 1 revolutions of the motor Given Master encoder 4000 pulses revolution post quadrature Motor encoder 8000 pulses revolution post quadrature Solution Ratio of Master Encoder to System motor encoder is 4000 8000 1 2 Set parameter Master to system ratio to 1 2 Example 2 Problem Setup drive so motor can follow a master encoder wheel where 1 revolution of the master encoder results in 3 revolutions of the motor Given Master encoder wheel is 1000 pulses revolution post quadrature Motor encoder 4000 pulses revolution post quadrature Desired gear ratio is 1 3 Solution Ratio is master encoder PPR divided by motor encoder PPR times the gear ratio Master PPR Motor PPR 1 3 gt 1000 4000 1 3 gt 1 12 Set parameter Mater to system ratio to 1 12 8 4 Dual loop feedback In dual loop operation position mode only
16. 2 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 7 3 2 Fault Event When drive encounters any fault the following events occur Drive is disabled Internal status is set to Fault Fault number is logged in the drive s internal memory for later interrogation Digital output s if configured for Run Time Fault are asserted Digital output s if configured for READY are de asserted If the display is in the default status mode the LED s display F_XX where XX is current fault code e Enable LED turns OFF 7 3 3 Fault Reset Fault reset is accomplished by disabling or re enabling the drive depending on the setting of the Reset option parameter section 6 3 10 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 8 Operation 8 1 Minimum Connections For the most basic operation connect the SimpleServo 94 to mains line power at terminal P1 the servomotor power at P7 and the motor feedback as appropriate WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed Below is a list of the minimum necessary connections Connect serial
17. 3 1 1 3 2 2 2 1 3 3 2 3 1 4 3 1 2 5 3 2 1 Note Each Hall Voltage will be in phase with one and only one Output Voltage B leads A for CW This is encoder phase relationship for CW CCW shaft rotation When you obtain the diagram for your motor phasing similar to shown above it s assumed by software that motor shaft rotating CW when looking at the mounting face of the motor For that rotation Encoder phase A must lead phase B If it does leave check box unchecked Otherwise if B leads A check B leads A for CW box Note Some manufacturers timing diagrams are CW when viewed from the rear of the motor not from shaft 5 6 3 3 For resolver equipped motors only If parameter Resolver is checked following parameters appear on the form Offset in degree electrical This parameter represents offset between resolver s 0 degree and motor s windings O degree CW for positive This parameter sets the direction for positive angle increment Offset in degree and CW for positive will be set during Auto Phasing of the motor Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 Programmable Features and Parameters All SimpleServo drives are configured through the serial interface The drives have many programmable and configurable features and parameters These features and parameters are accessible via a universal software called Motion
18. 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com i LI LILI LU lt lt CW CCW gt 905 Timing characteristics for Master Encoder signals Input type output compatibility Insulated compatible with Single ended or differential outputs 5 24 VDC Max frequency per input 2 MHz Min pulse width negative or positive 500nS Input impedance 700 approx a 600Q 1009 MA STEP MB DIR M vwk IX 5 6V S906 MA STEP MB DIR Master encoder step and direction input circuit You can connect a single ended or differential signal to the inputs You can also connect sinking or sourcing outputs to these inputs The function of these inputs Master Encoder or Step and Direction is software selectable Use MotionView set up program to choose desirable function 5 2 2 Digital outputs There are two digital outputs OUT1 and OUT2 available on P3 Outputs are fully isolated from the rest of the drive circuits dry contacts See figure below for its electrical diagram Output polarity is programmable i e each output can be programmed for N O or N C operation Each output can be assigned to one of the following functions Zero speed In speed window Current limit Run time fault Ready Brake motor brake release Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrive
19. Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 10 Troubleshooting WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed Before troubleshooting Perform the following steps before starting any procedure in this section Disconnect AC or DC voltage input from the SimpleServo Wait 60 seconds for power to discharge Check the SimpleServo closely for damaged components Check that no foreign material has become lodged on or fallen into the SimpleServo Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the drive s rated phase current and RMS voltage are consistent with the motor ratings For additional assistance contact your local SimpleServo authorized distributor Problem External line fuse blows Possible Cause Line fuses are the wrong size Motor leads or incoming power leads are shorted to ground Nuisance tripping caused by EMI noise spikes caused by poor grounding and or shielding Suggested Solution Check that line fuses are properly sized for the motor being used e Check motor cable and incoming power for s
20. LOCITYmax Vin max 2000 10V 200 RPM Volt value to enter 6 3 7 ACCEL DECEL Limits Velocity mode only The ACCEL setting determines the time the motor takes to ramp to a higher speed The DECEL setting determines the time the motor takes to ramp to a lower speed If the ENABLE ACCEL DECEL LIMITS is set to DISABLE the drive will automatically accelerate and decelerate at maximum acceleration limited only by current limit established by the PEAK CURRENT LIMIT and CURRENT LIMIT settings Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 3 8 Reference Velocity mode only The REFERENCE setting selects the reference signal being used Select Internal only when you using drive s built in digital signal generator MotionView s Run Panel section 6 10 2 2 for tuning purposes Select External for normal operation 6 3 9 Step input type position mode only This parameter sets the type of input for position reference the drive expects to see Signal type can be step and direction S D type or quadrature pulse train Master Encoder Electronic Gearing Refer to section 5 2 1 for details on these inputs 6 3 10 Reset Option RESET OPTION selects the type of action required to reset the drive after a FAULT signal has been generated by the drive ON DISABLE clears the fault when the drive is disabled This is useful if you have a single drive and motor connected in a simple servo
21. SIMPLESerVOo MODEL 94 USERS MANUAL Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com Safety Warnings The symbol shown at left indicates an important safety consideration Please read this manual carefully before performing any of the procedures contained herein Failure to follow these instructions may result in equipment damage fire severe injury or fatality Have a qualified electrical maintenance technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment The symbol shown at left indicates additional information shortcuts or tips that do not affect the safe operation of the drive Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure Please ensure that a master switch has been placed in the AC line to stop the drive in an emergency WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power a
22. View Please Refer to the MotionView User s Manual for details on how to make a connection to the drive and change parameter values This chapter covers programmable features and parameters specific to SimpleServo drives in the order they appear in the left tree of the MotionView Programmable parameters are divided into groups Each group holds one or more user s adjustable parameters 6 1 Parameters storage and EPM operation 6 1 1 Parameter s storage All settable parameters are stored in the drive s internal non volatile memory Parameters are saved automatically when they are changed In addition parameters copied to the EPM memory module located on the drive s front panel In the unlikely event of drive failure the EPM can be removed and inserted into the replacement drive thus making an exact copy of the drive being replaced This shortens down time by eliminating the configuration procedure The EPM can also be used for replication of the drive s settings 6 1 2 EPM operation When the drive is powered up it first checks for a blue EPM in the EPM Port If the EPM Port is empty or has a different color EPM inserted no further operation is possible until a blue EPM is installed into the EPM Port The drive will display EP P until a blue EPM is inserted If a blue EPM is detected the drive compares data in the EPM to that in its internal memory In order for the drive to operate the contents of the drive s memory and EPM mu
23. ad a custom motor click OPEN CUSTOM button then select the motor file and click the OPEN button to select or CANCEL to return to the previous dialog box e Click OK to load the motor data and return to the main MotionView menu or Cancel to abandon changes When clicking OK for a custom motor a dialog box will appear asking if you want to execute Autophasing see section 5 6 2 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 6 1 Creating custom motor parameters WARNING Use extreme caution when entering custom parameters Incorrect settings may cause damage to the drive or motor If you are unsure of the settings refer to the materials that were distributed with your motor or contact the motor manufacturer for assistance 1 Enter custom motor data in the motor parameters dialog fields Complete all sections of dialog Electrical Mechanical Feedback See Section 6 8 3 for explanation of motor parameters and how to enter them Note If are unsure of the motor halls order and encoder channels A and B relationship leave B leads A for CW Halls order and inverted fields as they are You can execute autophasing see section 5 6 2 to set them correctly 2 Enter motor model and vendor in the top edit boxes Motor ID cannot be entered this is set to 0 for custom motors 3 Click Save to File button and enter filename without ext
24. are provided to assist you in connecting and commissioning the Model 94 SimpleServo servo controller Important safety instructions are contained in this document which must be observed All persons working on and with the controller must have the Operating Instructions available and must observe the information and notes relevant for their work The Operating Instructions must always be in a complete and perfectly readable state Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 1 2 Scope of Supply Scope of Supply Important 1 Model 94 Servo type E94S After reception of the delivery check immediately whether the scope e 1 Users Manual English of supply matches the accompanying papers Lenze does not accept 1 MotionView CD ROM including any liability for deficiencies claimed subsequently configuration software Claim Documentation Adobe Acrobat e visible transport damage immediately to the forwarder visible deficiencies incompleteness immediately to your Lenze representative 1 3 Legal regulations Identification Nameplate CE Identification Manufacturer Lenze controllers are In compliance with the EC AC Technology Corp unambiguously designated by Low Voltage Directive member of the Lenze Group the contents of the nameplate 630 Douglas Street Uxbridge MA 01569 USA Application as E94S servo controller directed e must only be ope
25. ature Range 0 to 40 C Ambient Storage Temperature Range 10 to 70 C Temperature Drift 0 1 per C rise Humidity 5 90 non condensing Altitude 1500 m 5000 ft derate by 1 per 300m 1000 ft above 1500m 5000 ft Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 2 3 Operating Modes Torque Reference Torque Range Current Loop Bandwidth Velocity Reference Regulation Velocity Loop Bandwidth Speed Range Position Reference Minimum Pulse Width Loop Bandwidth Accuracy 10 VDC 16 bit scalable 100 1 Up to 3 kHz 10 VDC or 0 10 VDC scalable 1 RPM Up to 400 Hz 5000 1 with 5000 ppr encoder 0 2 MHz Step and Direction or 2 channels quadrature input scalable 500 nanoseconds Up to 200 Hz 1 encoder count 2 4 Connections and I O RS232 serial interface Encoder Feedback primary Standard 9 pin D shell DCE P2 Standard 15 pin D shell P4 Encoder Feedback secondary Option module with standard 9 pin D shell P12 Resolver feedback Encoder buffered repeat Mains Power Motor Power Regen and Bus Power Keep Alive 24VDC Power Digital Inputs Digital Outputs Analog Input Analog Output I O Controller Windows Software Option module with standard 9 pin D shell P11 In 25 pin D shell controller connector P3 4 pin removable terminal block P1 6 pin pin removable terminal block P7 5 pin removable terminal block
26. cable between SimpleServo s P2 and your PC serial port using a straight through 9 pin RS232 cable available as EWLCOO3BA1NA Connect mains power to terminal P1 Mains power must be as defined on the drive s data label see section 2 1 If motor is equipped with an encoder connect the encoder cable to SimpleServo feedback connector P4 If motor is equipped with a resolver install the Resolver option module E94ZARSV1 in the lower option bay and connect resolver cable to P11 Connect motor windings U V W sometimes called R S T to terminal P7 according to Section 5 1 1 Make sure that motor cable shield is connected as described in section 4 2 Provide an Enable switch according to Section 8 5 Perform drive configuration as described in the next section Note You must configure the drive before it can operate Proceed to Section 8 2 8 2 Configuration of the SimpleServo Regardless of the mode in which you wish to operate you must first configure the SimpleServo for your particular motor mode of operation and additional features if used Drive configuration consists of following steps Motor Selection Mode of operation selection Drive parameters i e current limit acceleration deceleration setup Operational limits velocity or position limits setup Input Output I O setup Velocity position compensator gains setup Optionally store drive settings in a PC file and exit the Motio
27. city mode the motor runs away Possible Cause e Hall sensors or encoder miswired e SimpleServo not programmed for motor connected Suggested Solution Check Hall sensor and encoder connections e Check that the proper motor is selected Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com
28. ction hall sensor connection or resolver connection MotionView will respond with an error message Common problems are with power shield and ground terminations or an improper cable is being used Correct the wiring problem s and repeat steps 1 6 If the error message repeats exchange motor phases U and V R and S and repeat If problems persist contact the factory 7 If autophasing is completed with no error then MotionView will return to the motor dialog box For motors with incremental encoders the parameter field Hall order and the check boxes inverted B leads A for CW will be filled in with correct values For resolver equipped motors fields Offset and CW for positive will be correctly set 8 Click Save File to save the completed motor file you can use the same filename as you use to save initial data in step 1 and click OK to load the motor data to the drive 5 6 3 Custom Motor Data Entry The Motor Parameters dialog has three sections frames dividing motor parameters into groups Electrical constants Mechanical constants and Feedback When creating a custom motor you must supply all parameters listed in these sections All entries are mandatory except the motor inertia Jm parameter A value of 0 may be entered for the motor inertia if the actual value is unknown 5 6 3 1 Electrical constants Motor Torque Constant Kt Enter the value and select proper units from th
29. d at a fixed resolution of 65 536 counts per motor revolution 6 8 2 MAX ERROR TIME Specifies maximum allowable time in mS during which a position error can exceed the value set for the Position error parameter before a Position Error Excess fault is generated 6 8 3 SECOND ENCODER POSITION ERROR Specifies the maximum allowable error of the second encoder in post quadrature encoder counts before enabling the Second encoder max error time clock described next 6 8 4 SECOND ENCODER MAX ERROR TIME Specifies maximum allowable time in mS during which the second encoder s position error can exceed the value set for the Second encoder position error parameter before a Position Error Excess fault is generated Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 9 Compensation group 6 9 1 Velocity P gain Proportional Proportional gain adjusts the system s overall response to a velocity error The velocity error is the difference between the commanded velocity of a motor shaft and the actual shaft velocity as measured by the primary feedback device By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal 6 9 2 Velocity I gain Integral The output of the velocity integral gain compensator is proportional to the accumulative error o
30. des The SimpleServo has 6 operating mode selections Torque Velocity Position Velocity limited torque CAN Torque and CAN Velocity the latter two selections are described in the CAN documentation found in the MotionView help Product Manuals For Torque and Velocity modes the drive will accept an analog input voltage on the AIN and AIN pins of P3 see section 5 3 1 This voltage is used to provide a torque or speed reference For Position mode the drive will accept step and direction logic signals or a quadrature pulse train on pins P3 11 14 6 3 1 1 Torque mode In torque mode the SimpleServo control provides a current output proportional to the analog input signal up to the maximum output current rating of the drive Set Current current the drive will try to provide is calculated using formula Set Current A Vinput Volt x Iscale A Volt where e Vinput is voltage at analog input AIN and AIN e Iscale is current scale factor input sensitivity set by the Analog input Current Scale parameter section 6 3 5 6 3 1 2 Velocity mode In velocity mode the servo controller regulates motor shaft speed velocity proportional to analog input voltage Target speed set speed is calculated using formula Set Velocity RPM Vinput Volt x Vscale RPM Volt where e Vinput is voltage at analog input AIN and AIN e Vscale is velocity scale factor input sensitivity set by the Analog input Velocity scale pa
31. e drop down list Note Round the calculated result to 3 significant places Motor Voltage Constant Ke The program expects Ke to be entered as a phase to phase Peak voltage If you have Ke as an RMS value multiply this value by 1 414 for the correct Ke Peak value Phase to phase winding Resistance R in Ohms Q This is also listed as the terminal resistance Rt The phase to phase winding Resistance R will typically be between 0 05 and 200 Ohms Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com Phase to phase winding Inductance L This must be set in millihenries mH The phase to phase winding Inductance L will typically be between 0 1 and 200 0 mH Note If the units for the phase to phase winding Inductance L are given in micro henries uH then divide by 1000 to get mH Nominal phase current RMS Amps Nominal continuous phase current rating In in Amps RMS Do not use the peak current rating Note Sometimes the phase current rating will not be given The equation below may be used to obtain the nominal continuous phase to phase winding current from other variables In Continuous Stall Torque Motor Torque Constant Kt The same force x distance units must be used in the numerator and denominator in the equation above If torque T is expressed in units of pound inches Ib in then Kt must be expressed in pound inches p
32. e representation of different signals inside the SimpleServo drive and is helpful when debugging and tuning drives Operation of oscilloscope tool is described in more detail in the MotionView Software User s Manual Following are the signals that can be observed with the oscilloscope tool Phase Current RMS Motor phase current Phase Current Peak Motor peak current Ig Current Measures the motor Ig torque producing current Motor Velocity Actual motor speed in RPM Commanded Velocity Desired motor speed in RPM velocity mode only Velocity Error Difference in RPM between actual and commanded motor speed Position Error Difference between actual and commanded position Step amp Direction mode only Bus voltage DC bus voltage Analog input Voltage at drive s analog input Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 10 2 Run Panels 6 10 2 1 Drive and motor monitor This button activates a separate window that displays the status of the motor mounted encoder position and halls status or resolver position The second encoder and master encoder positions if connected are also shown This window also allows viewing of the commanded position of the motor and allows comparison with the actual position 6 10 2 2 Run Panel Run Panel is active in velocity mode only It replicates an analog slider style potentiometer as if it were connected to the analog reference
33. ension Default extension cmt will be given when you click OK on file dialog box Note Saving the file is necessary even if you are going to use the autophasing feature and still don t know all of the final parameters After autophasing is completed you will have a chance to save the corrected motor file again before loading it to memory Click OK to exit from the Motor Parameters dialog MotionView will ask if you want to autophase your custom motor If you answer No the motor data will be loaded immediately to the drive s memory If you answer Yes the motor dialog will be dismissed and the drive will start the autophasing sequence Refer to section 5 6 2 for autophasing information 6 If you answered Yes for autophasing you will be returned to the same motor selection dialog box after autophasing is complete For motors with incremental encoders the fields B leads A for CW Halls order and inverted will be assigned correct values For motors with resolvers the fields Offset in degree and CW for positive will be assigned correct values 7 Click Save File to save the custom motor file and then OK to exit the dialog box and load the data to the drive 5 6 2 Autophasing The Autophasing feature determines important motor parameters when using a motor that is not in MotionView s database For motors equipped with incremental encoders Autophasing will determine
34. er Amp Ib in A Likewise if T is expressed in units of Newton meters N m then units for Kt must be expressed in Newton meters per Amp N m A Example Suppose that the nominal continuous phase to phase winding current In is not given Instead we look up and obtain the following Continuous stall torgue T 3 0 Ib in Motor torque constant Kt 0 69 Ib in A Dividing we obtain In 3 0 Ib in 0 69 Ib in A 4 35 A Our entry for In would be 4 35 Note that the pound inch Ib in units cancelled in the equation above leaving only Amps A We would have to use another conversion factor if the numerator and denominator had different force x distance units Nominal Bus Voltage Vbus The Nominal Bus Voltage can be calculated by multiplying the Nominal AC mains voltage supplied by 1 41 When using a model with the suffix S1N where the mains are wired to the Doubler connection the Nominal Bus Voltage will be doubled Example If the mains voltage is 230VAC Vbus 230 x 1 41 325V This value is the initial voltage for the drive and the correct voltage will be calculated dynamically depending on the drive s incoming voltage value Rotor Moment of Inertia Jm From motor manufacturer or nameplate Note Round the calculated result to 3 significant places Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com Maximum Motor Speed in RPM This is also li
35. erence voltage as seen by the drive is the voltage difference between AIN and AIN If used in single ended mode one of the inputs must be connected to a voltage source while the other one must be connected to Analog Common AG If used in differential mode the voltage source is connected across AIN and AIN and the driving circuit common if any needs to be connected to the drive Analog Common AG terminal Reference as seen by drive Vref AIN AIN and 10V lt Vref lt 10V Reference Source Reference Source 909 Single ended Differential 5 3 2 Analog output AO P3 21 Analog output is a single ended signal with reference to Analog Common AG which can represent the following Motor data RMS Phase Current e Peak Phase Current Motor Velocity Phase U Current Phase V Current Phase W Current MotionView Setup program can be used to select the signal source for the analog output as well as its scaling Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 4 Communication interfaces 5 4 1 RS232 interface standard SimpleServo drives are equipped with RS232 communication interface as a standard for programming and diagnostics from MotionView Software The E94S family of drives support the following baud rates 9600 19 200 and 38 400 Drives are addressable with up to 32 addresses from 0 31 Communication speed and address are set from the drive s fr
36. ffset 0 00 Amps Channel 2 Signal name Motor velocity X Scale 1300 00 RPM div Ofiset 0 00 RPM Time base Trigger Auto G Level 2 00 I Always on top Single Run Close S914 9 1 2 Correct P gain P gain 500 I gain 0 Current reaches maximum value Lx Channel 1 Signa name Phase current RMS Scale 4 00 Amps div Offset 0 00 Amps Channel 2 Signal neme Motor velocity X Scale 300 00 RPM div Ofiset 0 00 RPM Time base Trigger AN Options I Always on top Single Level 2 00 ane 915 Y Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 9 1 3 I gain too high P gain 500 I gain 300 Notice the high velocity overshoot Channel 1 Signal name Commanded velocity hd Scale foo BPM diw Offset po o S RPM Channel 2 Signal name Motorvelocity Scale bow S REPM div Offset po RPM IF Always ontop Single S t 2 00 Close 9 1 4 Correct P gain and I gain P gain 500 I gain 100 Notice a very low velocity overshoot and very close matching of the waveforms I Always on top Single Time base 50 ms div Trager Auto v Opler S916 Channel 1 Signal name Commanded velocity v Scale 300 00 RPM div Offset 0 00 BPM Channel 2 Signal name Motor velocity X Scale bow BPM div Offset 10 00 RPM Time base 50 ms div v Trigger Auto Options T Close S917
37. gital input IN1 P3 17 to compensate for bouncing of switch or relay contacts 6 7 Velocity Limits Group These parameters are active in Velocity Mode Only 6 7 1 ZERO SPEED Specifies the upper threshold for motor zero speed in RPM When motor shaft speed is at or below the specified value the zero speed condition is set to true in the internal controller logic The zero speed condition can also trigger a programmable digital output if selected see section 6 6 2 6 7 2 SPEED WINDOW Specifies the speed window width used with the In speed window output section 6 6 2 6 7 3 AT SPEED Specifies the speed window center used with the In speed window output section 6 6 2 These last two parameters specify speed limits If motor the shaft speed is within these limits then the condition AT SPEED is set to TRUE in the internal controller logic The AT SPEED condition can also trigger a programmable digital output if selected For example if AT SPEED is set for 1000 RPM and the SPEED WINDOW is set for 100 then AT SPEED will be true when the motor velocity is between 950 1050 RPM 6 8 Position limits 6 8 1 POSITION ERROR Specifies the maximum allowable position error in the primary motor mounted feedback device before enabling the Max error time clock described next When using an encoder the position error is in post quadrature encoder counts When using a resolver position error is measure
38. horts e Check that you follow recommendation for shielding and grounding listed in section shielding and grounding early in this manual Problem Ready LED is on but motor does not run Suggested Solution If in torque or velocity mode Reference voltage input signal is not applied Reference signal is not connected to the SimpleServo input properly connections are open In MotionView program check lt Parameters gt lt Reference gt set to lt External gt For Velocity mode only n MotionView check lt Parameters gt lt Compensation gt lt Velocity loop filter gt P gain must be set to value more then 0 in order to run Without load motor will run with P gain set as low as 20 but under load might not If P gain is set to O motor will not run at all In step and direction mode Step and Direction inputs are not wired correctly In MotionView program check lt Parameters gt lt Step input type gt is set for lt S D gt if you use a step and direction indexer output and lt Master Encoder gt if you use quadrature type output from a master motor encoder or indexer Position loop P gain set to 0 Set P gain to 100 and D gain to 200 If in PIVFF mode or if in P V mode P gain to 10 and D gain for 5 and Velocity P gain 50 and I gain 20 initially to get motion Tune them afterwards for best performance Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com Problem In velo
39. in and continue to increase D gain until oscillation stops The ratio between P gain and D gain is now set and if P gain needs adjustment in the next steps the D gain will need to be adjusted accordingly to maintain the ratio The goal is to minimize position error by increasing P gain and at the same time avoid oscillation and instability by increasing D gain There could be a case when increasing P gain breaks the system into oscillation and audible noise can be heard and increasing D gain does not fix the situation At this point lower P gain and possibly lower D gain as well to the level where noise and instabilities disappear 12 Finally set motor velocity to a steady speed of 200 RPM and adjust Position I gain and Position I limit to obtain desirable result in steady state 13 Stop indexer and disable drive Note Remember that these are only initial settings for your system Your application will likely require fine tuning To optimize settings you will need to experiment with combinations of all gains P D and and IL limit settings Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 9 Sample Motor Responses to Gain Settings 9 1 Motor response to gain settings Velocity mode 9 1 1 Low P gain P gain 100 I gain 0 Current didn t reach maximum possible value x Channel 1 Signal name Phase current RMS Y Scale 4 00 Amps div O
40. ing direction 11 Select Compensation from node tree Set Velocity regulation window to 6 for encoder feedback motors or to 8 for resolver feedback motors Set Velocity P gain to 2000 and Velocity I gain to 100 12 Slowly increase the Velocity P gain until the current waveform grows to a maximum value when velocity changes from negative to positive or visa versa See sample waveforms in Section 9 1 13 Slowly increase Velocity I gain and watch for overshoot on motor velocity waveform Leave it at a level where overshoot just starts to happening or is very narrow less then 5mS or less then 3 5 If fast acceleration deceleration in your servo system is not an objective but stiffness at low velocity or stall torque is Velocity I gain can be increased allowing overshoot up to approximately 15 20 14 Finally check the motor Ig current Set oscilloscope Channel 1 source to Ig current Observe current waveform and insuring that there is no significant oscillation 15 On the Run panel click the Set to Zero button to stop the motor Disable the drive 16 Optionally select Parameters from node tree then set Reference parameter to External so next time that the drive is enabled it will use analog input for reference Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 8 7 Tuning in position mode Note In th
41. is mode the Velocity gains should be set first 1 Perform velocity loop tuning as per section 8 6 2 Make sure that the drive is disabled and d 5 is displayed on the drive 3 Set up the external indexer to perform the following move e Move forward N steps where N number of steps to perform one full motor shaft revolution e Move backward N steps where N number of steps to perform one full motor shaft revolution 4 Set Accel limit and Decel limit to the maximum the application requires or that the system allows 5 Select Tools then Oscilloscope tool from node tree 6 On the Oscilloscope tool select e Motor Velocity as source for Channel 1 e Position error as source for Channel 2 e Timebase 50ms div e Trigger Channel 1 Rising 7 Set the Drive mode to Position and Step input type as appropriate Ensure Master to system ratio is properly set as described in section 6 3 17 and section 8 3 8 Select Compensation from node tree Set Position P gain to 100 and Position D gain to 200 Set Position I gain to 0 and Position I limit to 0 9 Enable the drive 10 Run indexer and observe position error waveform 11 Slowly increase simultaneously P gain and D gain and watch for Position error waveform Continue to increase both gains until noticeable oscillation on flat portion of waveform is observed At this point stop increasing P ga
42. l B 5 BZ Buffered Encoder Output Channel Z 6 BZ Buffered Encoder Output Channel Z 0 7 GND Drive Logic Common 8 SHLD Shield 9 5V 5V output max 300mA 10 IN2 Digital Input 2 Programmable 11 MA Step Master Encoder A Steps input 2 12 MA Step Master Encoder A Step input 13 MB Dir Master Encoder B Direction input 14 MB Dir Master Encoder B Direction input 15 OUT1 C Programmable output 1 Collector 16 OUT1 E Programmable output 1 Emitter 17 IN1 Digital Input 1 Enable 18 IN_COM Digital Input Common amp 19 OUT2 C Programmable output 2 Collector 20 OUT2 E Programmable output 2 Emitter 21 AO Programmable analog output 10V use with AG 22 GND Drive logic common 23 AIN Positive of Analog signal input 24 AIN Negative of Analog signal input 25 AG Analog Common 0 See Note 1 Section 5 1 7 Connector and Wiring Notes 2 See Note 2 Section 5 1 7 Connector and Wiring Notes 2 See Note 3 Section 5 1 7 Connector and Wiring Notes Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 1 4 P4 Motor Feedback second loop encoder input P4 is a 15 pin DB connector that contains connections for hall effect sensors and incremental encoder feedback Refer to the P4 pin assignments table for the connector pin assignments Encoder inputs on P4 have 26LS32 or compatible differential receivers for increased noise im
43. le for another device on the network The same will happen if a command is received over the RS485 interface all devices whose addresses do not match will repeat the command on their RS232 ports This feature is useful when you need to access drives on an RS485 network using an RS232 interface Typically a PC is not equipped with an RS485 interface as standard Using the above described feature a PC can be used to communicate to an RS485 network of SimpleServo drives by connecting the PC s RS232 port to one of the drives in the network 5 4 4 MODBUS RTU support As a default the RS232 and RS485 interfaces are configured to support MotionView program operation In addition the RS485 interface can be configured to support the MODBUS RTU slave protocol The interface can be configured through the MotionView program When configured for MODBUS operation the baud rate for RS485 is set by the parameter Modbus baud rate in MotionView while the RS232 baud rate is set on the drive s front panel Thus RS485 and RS232 can have different speeds at the same time if RS485 is configured for MODBUS operation Please note that if RS485 is configured for MODBUS operation the command repeat function see 5 4 3 is unavailable even if baud rates are set the same for both interfaces The Modbus RTU slave interface protocol definitions can be found in the MotionView help menu under Product Manuals Phone 800 894 0412 Fax 888 723 4773 Web ww
44. munity Inputs have all necessary filtering and line balancing components so no external noise suppression networks are needed All conductors must be enclosed in one shield and jacket around them Lenze recommends that each and every pair for example EA and EA be twisted In order to satisfy CE requirements use of an OEM cable is recommended Contact your SimpleServo representative for assistance The SimpleServo buffers encoder feedback from P4 to P3 Encoder Feedback channel A on P4 for example is Buffered Encoder Output channel A on P3 The Hall sensors from the motor must be wired to the 15 pin connector P4 WARNING Use only 5 VDC encoders Do not connect any other type of encoder to the SimpleServo reference voltage terminals When using a front end controller it is critical that the 5 VDC supply on the front end controller NOT be connected to the 5 VDC supply on the SimpleServo as this will result in damage to the SimpleServo Note e SimpleServo encoder inputs are designed to accept differentially driven hall signals Single ended or open collector type hall signals are also acceptable by connecting HA HB HC and leaving HA HB HC inputs unconnected You do not need to supply pull up resistors for open collector hall sensors The necessary pull up circuits are already provided by the SimpleServo amplifier Encoder connections A B and Z must be full differential SimpleServo doe
45. nView program Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com To configure drive 1 pw oP eve 11 12 13 14 Ensure that the control is properly installed and mounted Refer to Section 4 for installation instructions Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements Connect drive serial port P2 to your PC serial port Make sure that the drive is disabled Apply power to the drive and wait until d 15 shows on the display For anything other then this refer to the chart below before proceeding Drive display Meaning EP P EPM missing Refer to 6 1 2 d E EPM data Refer to 6 1 2 E d EPM data Refer to 6 1 2 Sidr No valid firmware Monitor mode Using drive s keypad and display check that baud rate is set to 38 4 kbps Using drive s keypad and display check that address is 1 Set if necessary Launch MotionView software on your computer From the MotionView menu select lt Project gt lt Connection setup gt Select UPPP over RS 485 RS 232 then select lt Properties gt and select computer s serial port drive connected to e Select the Comm port that matches the serial port of the computer used for this connection e Set baud rate at 38400 and rest of the parameters at default Click lt OK gt twice to dismiss both dialog boxes From lt Node gt
46. nd wait 60 seconds before servicing drive Capacitors retain charge after power is removed Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 1 General Information The SimpleServo line of advanced general purpose servo drives utilize the latest technology in power semiconductors and packaging SimpleServo uses Field Oriented control to enable high quality motion The SimpleServo Model 94 is available in four mains input power configurations 1 400 480V nominal three phase input An external input mains line filter is available These drives have the suffix TAN 2 120 240V nominal Single Phase input with integrated input mains line filter Actual input voltage can range from 80VAC to 264VAC The maximum output voltage is approximately equal to the input voltage These drives have the suffix S2F 3 120 240V nominal Single or Three Phase input Actual input voltage can range from 80VAC to 264VAC The maximum output voltage is approximately egual to the input voltage An external input mains line filter is available These drives have the suffix Y2N 4 120V or 240V nominal single phase input When wired for Doubler mode L1 N the input is for 120V nominal only and can range from 45VAC to 132 VAC and the maximum output voltage is double the input voltage When wired to terminals L1 L2 N the input can range from 80 VAC to 264 VAC and the maximum outpu
47. nect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed DO NOT connect incoming power to the output motor terminals U V W Severe damage to the SimpleServo will result All conductors must be enclosed in one shield and jacket around them The shield on the drive end of the motor power cable should be terminated to the conductive machine panel using screen clamps as shown in section 4 2 The other end should be properly terminated at the motor shield Feedback cable shields should be terminated in a like manner Lenze recommends SimpleServo cables for both the motor power and feedback These are available with appropriate connectors and in various lengths Contact your SimpleServo representative for assistance Wire size 1 lt 8A 16 AWG 1 5 mm or 14 AWG 2 5 mm 8A lt l lt 12A 14 AWG 2 5 mm or 12 AWG 4 0 mm gt 12A 12 AWG 4 0 mm P1 TERMINAL ASSIGNMENTS INPUT POWER Standard Models Doubler Models Terminal Function Terminal Function PE Protective Earth Ground PE Protective Earth Ground L1 AC Power in N AC Power Neutral 120V Doubler only L2 AC Power in L1 AC Power in L3 AC Power in 3 models only L2 N AC Power in non doubler operation Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com P7 TERMINAL ASSIGNMENTS OUTPUT POWER Terminal Function PE Protective Earth Chassi
48. nt Current Current Current E94S020Y2N 5 0 3 0 2 0 6 E94S040Y2N 120 240V 2 8 6 5 0 4 0 12 1 or 3 E94S080Y2N 80 V 0 264 V 0 15 0 8 7 8 0 24 E94S100Y2N 18 8 10 9 10 0 30 E94S020T4N 2 7 2 0 6 400 480V E94S040TAN 3 5 5 4 0 12 320 V 0 528 V 0 E94S050TAN 6 9 5 0 15 Mains voltage for operation on 50 60 Hz AC supplies 48 Hz 0 62Hz 0 Connection of 120VAC 45 V 132 V to input power terminals L1 and N on these models doubles the voltage on motor output terminals U V W for use with 230VAC motors 3 Connection of 240VAC or 120VAC to input power terminals L1 and L2 on these models delivers an equal voltage as maximum to motor output terminals U V W allowing operation with either 120VAC or 230VAC motors 4 Drive rated at 8kHz Carrier Frequency Derate Continuous current by 17 at 16kHz Peak RMS current allowed for up to 2 seconds Peak current rated at 8kHz Derate by 17 at 16kHz Applies to all models Acceleration Time Range Zero to Max Speed 0 1 5x109 RPM sec Deceleration Time Range Max Speed to Zero 0 1 5x109 RPM sec Speed Regulation typical 1 RPM Input Impedance AIN to COM and AIN to AIN 47 KQ Power Device Carrier Frequency sinusoidal commutation 8 16 kHz Encoder power supply max 5 VDC 300 mA Maximum encoder feedback frequency 2 1 MHz per channel 2 2 Environment Vibration 2 g 10 2000 Hz Ambient Operating Temper
49. nt sets Motor RMS phase current that is allowed for up to 2 Seconds After this two second limit the current limit will be reduced to the value set in the Current Limit parameter When the motor current drops below nominal current for two seconds the drive will automatically re enable the peak current level This technique allows for high peak torque on demanding fast moves and fast start stop operations with high regulation bandwidth The control will use only the Peak current limit parameter for the carrier frequency selected 6 3 5 Analog input scale Current scale This parameter sets analog input sensitivity for current reference used when drive operates in Torque mode Units for this parameter are A Volt To calculate this value use the following formula Iscale Imax Vin max Imax maximum desired output current motor phase current RMS Vin max max voltage fed to analog input at Imax Example Imax 5A phase RMS Vin max 10V Iscale Imax Vin max 5A 10V 0 5 A Volt gt value to enter 6 3 6 Analog input scale Velocity scale This parameter sets analog input sensitivity for velocity reference used when the drive operates in Velocity mode Units for this parameter are RPM Volt To calculate this value use the following formula Vscale VELOCITYmax Vin max VELOCITYmax maximum desired velocity in RPM Vin max max voltage fed to analog input at Velocitymax Example VELOCITYmax 2000 RPM Vin max 10V Vscale VE
50. o earth ground A lock washer must be installed between the enclosure and ground terminal To ensure maximum contact between the terminal and enclosure remove paint in a minimum radius of 0 25 in 6 mm around the screw hole of the enclosure Lenze recommends the use of the special SimpleServo cables provided by Lenze If you specify cables other than those provided by Lenze please make sure all cables are shielded and properly grounded It may be necessary to earth ground the shielded cable Ground the shield at the SimpleServo end and at the motor end If the SimpleServo continues to pick up noise after grounding the shield it may be necessary to add an AC line filtering device and or an output filter between drive and servo motor EMC Compliance with EN 61800 3 A11 This is a product of the restricted sales distribution class according to IEC 61800 3 In a domestic environment this product may cause radio interference in which the user may be required to take adequate measures Noise emission Installation according to Drive Models ending in the suffix 2F are in EMC Requirements compliance with class A limits according to EN 55011 if installed in a control cabinet and the motor cable length does not exceed 10m Models ending in N will require an appropriate line filter A Screen clamps Control cable W C Low capacitance motor cable core core lt 75 pF m core screen lt
51. ont panel display 5 4 2 P8 RS485 interface module Option Bay 1 SimpleServo drives can be equipped with an RS485 communication interface option module E94ZARS41 which is optically isolated from the rest of the drive s circuitry This option module can be used for two functions drive programming and diagnostics using MotionView from a PC with RS485 port or as a Modbus RTU slave The E94S family of drives support the following baud rates 9600 19 200 and 38 400 Drives are addressable with up to 32 addresses from 0 31 The factory setting for the baud rate is 38 400 with a node address of 1 The drives address must be set from the front panel display of the drive When used with MotionView software the communication speed is also set from the front panel display Please note that baud rate and address are applied to both RS232 and RS485 interfaces in this case If used for Modbus RTU communications the Modbus baud rate is set as a parameter within the MotionView P8 TERMINAL ASSIGNMENTS RS485 interface ICOM Isolated Common Transmit A Transmit B 5 4 3 Using RS232 and RS485 interfaces simultaneously If a MotionView command is received by the drive and doesn t matched the drive s address the drive resends this command over the other interface For example if the drive receives the command over RS232 and the address does not match the drive will resend this command over the RS485 interface thus making it availab
52. or operation If a non Lenze motor is used the encoder connections are made as follows P12 PIN ASSIGNMENTS Second Encoder Feedback Pin Name Function Second Encoder Channel B Input Second Encoder Channel A Input Second Encoder Channel A Input Supply voltage for Second Encoder Supply common Second Encoder Channel Z Input Second Encoder Channel Z Input No Connection 1 2 3 4 5 6 7 8 9 Second Encoder Channel B Input The second encoder needs to be enabled using MotionView software See section Dual loop feedback Section 8 4 for details WARNING Use only 5 VDC encoders Do not connect any other type of encoder to the option module otherwise damage to drive s circuitry may result 5 2 Digital I O details 5 2 1 Step amp Direction Master Encoder Inputs P3 pins 11 14 You can connect a master encoder with quadrature outputs or a step and direction pair of signals to control position in step direction operating mode stepper motor emulation These inputs are optically isolated from the rest of the drive circuits and from each other Both inputs can operate from any voltage source in the range of 5 to 24 VDC and do not require additional series resistors for normal operation See figure below STEP DIRECTION CW CCW 904 Timing characteristics for Step And Direction signals Phone 800
53. osition error measured in the previous servo cycle D gain decreases bandwidth and increases overall system stability It is responsible for removing oscillations caused by load inertia and acts similar to a shock absorber in a car 6 9 6 Position I limit The Position I limit will clamp the Position I gain compensator to prevent excessive torque overshooting caused by an over accumulation of the I gain It is defined in terms of percent of maximum drive velocity This is especially helpful when position error is integrated over a long period of time 6 9 7 Second encoder I gain Integral This parameter sets second encoder position I gain when the drive is in a dual loop configuration Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 9 8 Velocity regulation window Sets total velocity loop gain multiplier en where n is the velocity regulation window If during motor tuning the velocity gains become too small or too large use this parameter to adjust loop sensitivity If the velocity gains are too small decrease the total loop gain value by deceasing this value If gains are at their maximum setting and you need to increase them even more use a larger value for this parameter 6 9 9 Tune gains button This command button opens a window with all gains configured as sliders for more convenient set up 6 10 Tools Group 6 10 1 Oscilloscope tool Oscilloscope tool gives real tim
54. priate filter must be installed within 20cm of the drive power inputs Line filters should be placed inside the shielded panel Connect the filter to the incoming power lines immediately after the safety mains and before any critical control components Wire the AC line filter as close as possible to the SimpleServo If you add separate fuses add them after the AC line filter Note The ground connection from the filter must be wired to solid earth ground not machine ground If the end user is using a CE approved motor the AC filter combined with the recommended SimpleServo motor and encoder cables is all that is necessary to meet the EMC directives listed herein The end user must use the compatible filter to comply with CE specifications The OEM may choose to provide alternative filtering that encompasses the SimpleServo and other electronics within the same panel The OEM has this liberty because CE is a machinery directive 4 4 Heat sinking SimpleServos contain sufficient heat sinking within the specified ambient operating temperature in their basic configuration There is no need for additional heat sinking However you must ensure that there is sufficient clearance to circulate air As a minimum you must allow an air gap of 25 mm above and below the drive 4 5 Line Mains fusing External line fuses must be installed on all SimpleServo drives Connect the external line fuse in series with the AC line voltage input Use fa
55. rameter section 6 3 6 6 3 1 3 Position mode In this mode the drive reference is a pulse train applied to P3 11 14 terminals Input can be configured for two types of signals step and direction and Master encoder quadrature signal Refer to section 5 2 1 for details on these inputs connections Refer to section 8 3 for details about positioning and gearing 6 3 1 4 Velocity limited torque mode This mode is identical to Torque Mode described in 6 3 1 2 except that speed will be restricted to the value set in the Velocity limit parameter section 6 3 20 Upon reaching the velocity limit the drive will maintain speed rather than torque The Velocity P gain and Velocity I gain parameters section 6 9 must be correctly set in order to maintain normal operation and stability when speeds are close to the Velocity limit Velocity I gain must be greater than 10 for this mode to operate correctly Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 3 2 Drive PWM frequency This Parameter sets the PWM carrier frequency Frequency can be changed only when drive is disabled Maximum overload current is 300 of drive rated current when the carrier is set to 8KHZ it is limited to 250 at 16KHZ 6 3 3 Current Limit The CURRENT LIMIT setting determines the nominal current in amps RMS per phase 6 3 4 8 KHZ Peak current limit and 16 KHZ Peak current limit Peak curre
56. rated under the conditions prescribed in these Instructions are components for closed loop control of variable speed and torque applications with PM synchronous motors for installation in a machine for assembly with other components to form a machine e are electric units for the installation into control cabinets or similar enclosed operating housing comply with the requirements of the Low Voltage Directive are not machines for the purpose of the Machinery Directive are not to be used as domestic appliances but only for industrial purposes Drive systems with E94S servo inverters comply with the EMC Directive if they are installed according to the guidelines of CE typical drive systems e can be used for operation on public and non public mains for operation in industrial premises and residential areas The user is responsible for the compliance of his application with the EC directives Any other use shall be deemed as inappropriate Liability The information data and notes in these instructions met the state of the art at the time of publication Claims on modifications referring to controllers which have already been supplied cannot be derived from the information illustrations and descriptions The specifications processes and circuitry described in these instructions are for guidance only and must be adapted to your own specific application Lenze does not take responsibility for the s
57. re already configured for operation If a non Lenze motor is used the resolver connections are made as follows P11 PIN ASSIGNMENTS Resolver Feedback Function Resolver reference connection No Connection Resolver Cosine connections Resolver Sine connections Thermal sensor ololalola lRlelw WARNING Use only 10 V peak to peak or less resolvers Use of higher voltage resolvers may result in feedback failure and damage to the resolver option module Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 1 9 P12 Second encoder interface module Option Bay 2 SimpleServo drives can support a second incremental encoder interface for dual loop systems Depending on the motor primary feedback type encoder or resolver a second encoder can be connected as follows e If the primary motor feedback is an encoder connected to P4 the second encoder interfaces through the encoder option module E94ZAENC1 at P12 on Option Bay 2 If the motor primary feedback is a resolver connected to the resolver option module E94ZARSV1 at P11 on Option Bay 2 the second encoder connects to the P4 connector on the drive In this case the hall inputs on P4 are not used The 2nd Encoder Option Module includes a 9 pin D shell male connector When using a Lenze motor with encoder feedback and a Lenze encoder cable the pins are already configured f
58. rmware revision ex F1 10 OPEr Operating mode to set POS position mode UEL velocity mode tarf torque mode LAnU CANBUS velocity mode CAnt CANBUS torque mode E UL velocity limited torque mode bAUd RS232 RS485 normal mode baud rate to set QO selects 38 4 19 2 9 6 kbps baudrate Adr Drive s address to set QO sets 0 31 drive s address FLES Stored fault s history amp to view QQ scroll through stored faults FOXX to F7XX where XX is the fault code section 7 3 2 HE Heatsink temperature amp to view Shows heatsink temperature in C if greater than 40 C Otherwise shows LO low EnC Encoder activity amp to view Shows primary encoder counts for encoder diagnostics activity HALL Displays motor s hall sensor states to view Shows motor hall states in form XXX where X is 1 or 0 sensor logic states buUS Displays drive DC bus voltage to view Shows DC bus voltage value Curr Displays motor s phase current RMS Shows current value if drive is enabled otherwise shows d 5 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 7 2 Diagnostic LED s The SimpleServo has five diagnostic LEDs mounted on the periphery of the front panel display as shown in the drawing below These LEDs are designed to help monitor system status and activity as well as troubleshoot any faults c A W g w w
59. rs Motor ID 519 E Communication Motor model 520 10 200 10 Motor vendor AC TECH SIMPLESERVO Limits Torque constant 0 15 Voltage constant 8 80 Inductance phase phase 1 81 Resistance phase phase 2 22 Max phase current 2 88 Terminal voltage max 325 Rotor moment of inertia 0 000016 Max velocity 6000 Hall code 3 Number of poles 4 Encoder E Compensation Tools Faults For Help press F1 Ln 2000 Col 200 Off line MotionView s Motor Group folder and its contents sane Note If drive is ENABLED a new motor cannot be set You can only set a new motor when the drive is DISABLED To View selected motor parameters or make a new motor selection e Click CLICK HERE TO CHANGE Selection dialog opens see figure above If you are just viewing motor parameters click Cancel on Motor Parameters dialog when done to dismiss the dialog box e Select motor Vendor from the right list box and desired motor from the left list box e If you will be using a custom motor not listed in our motor database go to Using a custom motor topic in the next section Finally click OK button to dismiss dialog and return to MotionView main program 5 6 Using a custom motor You can load a custom motor from a file or you can create a new custom motor To create a custom motor click CREATE CUSTOM and follow the instructions in the next section Creating custom motor parameters e To lo
60. s Ground Ww Motor Power Out V Motor Power Out U Motor Power Out T2 Thermistor PTC Input T1 Thermistor PTC Input 5 1 2 P2 Serial Communications Port P2 is a 9 pin D sub connector that is used to communicate with a host computer via standard RS 232 interface using a proprietary Point to Point Protocol PPP This port is present on all SimpleServo drives All levels must be RS 232C compliant P2 PIN ASSIGNMENTS COMMUNICATIONS Pin Name Function 1 RESERVED 2 TX RS 232 transmit 3 RX RS 232 receive 4 RESERVED 5 GND Common 6 RESERVED 7 RESERVED 8 RESERVED 9 RESERVED WARNING Do not make any connection to Reserved pins Note If you purchase serial cables from a third party you must use a pass through cable not Null Modem not crossover Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 1 3 P3 Controller Interface P3 is a 25 pin DB connector for interfacing to front end controllers It is strongly recommended that you use OEM cables to aid in satisfying CE requirements Contact your SimpleServo representative for assistance P3 PIN ASSIGNMENTS CONTROLLER INTERFACE Pin Name Function 1 BA Buffered Encoder Output Channel A 2 BA Buffered Encoder Output Channel A 3 BB Buffered Encoder Output Channel B 4 BB Buffered Encoder Output Channe
61. s com Digital outputs electrical characteristics Circuit type Isolated Open Collector Digital outputs load capability 100mA Digital outputs Collector Emitter max voltage 30V Yek So OUT1 E 90 ourec Yek lt 2 OyT2E 50 ouric S907 Digital outputs circuit 5 2 3 Digital inputs IN1 and IN2 P3 10 17 and 18 Optically isolated inputs Inputs IN1 and IN2 are compatible with a 5 24V voltage source No additional series resistor is needed for circuit operation Both inputs share COM terminal IN_COM Input IN1 is dedicated for Drive Enable function while IN2 is programmable Choices are e External fault e Stop rapid e Reverse reference In addition both inputs have separate software adjustable de bounce time 47 1 6kQ IN1 O ENABLE AN AZ 1 6 KQ 10 IN2 O PROGAMMABLE AN AZ kK N com ob S908 Digital inputs circuit Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 3 Analog I O details 5 3 1 Analog reference input AIN AIN P3 23 and P3 24 The analog reference input can accept up to a 10V analog signal across AIN and AIN The maximum limit with respect to analog common AG on each input is 18VDC The analog signal will be converted to a digital value with 16 bit resolution 15 bit plus sign This input is used to control speed or torque of the motor in velocity or torque mode The total ref
62. sn t support single ended or open collector type outputs from the encoder An encoder resolution of 2000 PPR pre guadrature or higher is recommended Using P4 as second encoder input for dual loop operation P4 can be used as a second loop encoder input in situations where the motor is equipped with a resolver as the primary feedback If such a motor is used the drive must have a resolver feedback option module E94ZARSV1 installed A second encoder can then be connected to the A and B lines of the P4 connector for dual loop operation See Dual loop feedback operation for details Section 8 4 Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com P4 PIN ASSIGNMENTS ENCODER Pin Name Function 1 EA Encoder Channel A Input 2 EA Encoder Channel A Input 3 EB Encoder Channel B Input 4 EB Encoder Channel B Input 5 EZ Encoder Channel Z Input 6 EZ Encoder Channel Z Input 7 GND Drive Logic Common Encoder Ground 8 SHLD Shield 9 PWR Encoder supply 5VDC 10 HA Hall Sensor A Input 11 HA Hall Sensor A Input 12 HB Hall Sensor B Input 13 HC Hall Sensor C Input 14 HB Hall Sensor B Input 15 HC Hall Sensor C Input 0 See Note 1 Section 5 1 7 Connector and Wiring Notes 5 1 5 P5 24 VDC Back up Power Input P5 is a 2 pin quick connect terminal block that can be used with an external 24 VDC 2 amp power suppl
63. solution on P3 21 The signal is scaled to 10V The analog output can be assigned to following functions Not Assigned Phase current RMS Phase current Peak Motor Velocity Phase R current Phase S current Phase T current Iq current Torque component Id current Direct component 6 5 2 Analog output current scale Volt amps Applies scaling to all functions representing CURRENT values 6 5 3 Analog output velocity scale mV RPM Applies scaling to all functions representing VELOCITY values Note that mV RPM scaling units are numerically equivalent to volts kRPM 6 5 4 Analog input dead band Allows the setting of a voltage window in mV at the reference input AIN and AIN P3 23 and 24 such that any voltage within that window will be treated as zero volts This is useful if the analog input voltage drifts resulting in motor rotation when commanded to zero 6 5 5 Analog input offset parameter Allows you to adjust the offset voltage at AIN and AIN P3 23 and P3 24 This functions as the equivalent to the balance trim potentiometer found in analog drives Lenze recommends that this adjustment be made automatically using the Adjust analog voltage offset button while the external analog reference signal commands zero speed 6 5 6 Adjust analog voltage offset This control button is useful to allow the drive to automatically adjust analog input voltage offset To use it command the external reference source input
64. st acting fuses rated for 250 VAC or 600 VAC depending on model and approximately 200 of the maximum RMS phase current Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 SimpleServo Connections The standard SimpleServo control contains seven connectors four quick connect terminal blocks and three subminiature type D connectors These connectors provide power communications and external feedback to the motor SimpleServo control and host controller Prefabricated cable assemblies may be purchased from Lenze to facilitate wiring the control motor and host computer Contact your SimpleServo Sales Representative for assistance As this manual makes reference to specific pins on specific connectors we will use the convention PX Y where X is the connector number and Y is the pin number 5 1 External Connectors 5 1 1 P1 amp P7 Input Power and Output Power Connections P1 is a 3 or 4 pin quick connect terminal block used for input mains power P7 is a 6 pin quick connect terminal block used for output power to the motor P7 also has a thermistor PTC input for motor over temperature protection The tables below identify connector pin assignments WARNING Hazard of electrical shock Circuit potentials are up to 480 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Discon
65. st be the same If the contents are different then two behaviors are possible Case 1 EPM data is valid but different from the drive s memory Drive display allow one of the two copy operations E d EPM to drive or d E drive to EPM You can choose the operation by pressing the arrow amp button Pressing the Enter button executes the copy making the drive ready to operate Case 2 EPM is not formatted with drives format In this case there is only d E drive to EPM copy operation possible Pressing the Enter button copies drive s memory contents to EPM making the drive ready to operate Note If the EPM contains any data from an inverter drive data will be overwritten during this procedure 6 1 3 EPM fault If the EPM fails during operation or the EPM is removed from the EPM Port the drive will generate a fault and will disable if enabled The fault is logged to the memory Further operation is not possible until the EPM is replaced inserted and the drive s power is cycled The fault log on the display shows F EP fault Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 2 Motor Group The motor group shows the data for the currently selected motor Refer to Section 5 5 for details on how to select another motor from the motor database or to configure a custom motor 6 3 Parameters Group 6 3 1 Drive operating mo
66. sted as Speed V motor speed at the terminal voltage rating The maximum motor speed will typically be a round even value between 1000 and 6000 RPM Number of Poles This is a positive integer number that represents the number of motor poles which is normally 2 4 6 or 8 5 6 3 2 For motors equipped with incremental encoders only Encoder Line Count The Encoders for servomotors normally have Line Counts of 1000 1024 2000 2048 4000 or 4096 The Encoder Line Count must be a positive integer and must be pre quadrature Index pulse offset Enter 0 zero Index marker pulse position This field is reserved for backward compatibility All SimpleServo drives determine actual marker pulse position automatically Halls Order Each hall signal is in phase with one of the three phase phase voltages from the motor windings Hall order number defines which hall sensor matches which phase phase voltage Motor phases are usually called R S T or U V W or A B C Phase Phase voltages are called Vrs Vst Vtr Halls are usually called HALL A HALL B HALL C or just Halls 1 2 3 A motor s phase diagram is supplied by motor vendor and usually can be found in the motor data sheet or by making a request to the motor manufacturer A sample phase diagram is shown below Ve e Vst m A Vir m The Halls Order is obtained as follows 1 By looking at the Vrs Output Voltage determine which Hall Voltage is lined up with
67. t has occurred Refer to Section 7 3 for details on faults Ready Drive is enabled Brake Command for the holding brake option E94ZAFFD1 for control of a motor mounted brake This output is active 10ms after the drive is enabled and deactivates 10ms before the drive is diabled 6 6 3 Digital input polarity Parameter sets logic polarity for digital input active low or active high Note The active high state asserts the defined function when current is flowing through the input circuit The active low state de asserts the defined function when current is flowing through the input circuit 6 6 4 Digital output 1 and 2 polarity Parameter sets polarity Normally Closed or Normally Open of the digital outputs Note The normal condition is the state of an output is when the condition for its defined action has not been met Example Output is to be on until the a fault has occurred Program OUT1 for Run time fault and polarity for Normally Closed 6 6 5 Digital input de bounce time Sets de bounce time for the digital input IN2 P3 10 to compensate for bouncing of switch or relay contacts This is the time during an input transition that the signal must be stable before it is recognized by the drive Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 6 6 Enable input de bounce time Sets de bounce time for the ENABLE input di
68. t voltage is equal to the input voltage These drives have the suffix S N The SimpleServo will accept feedback from an incremental encoder that includes Hall channel information or from a resolver It accepts commands from a variety of sources including analog voltage RS485 interface PPP and Modbus RTU CANopen interface digital pulse train and master encoder reference The control will operate in current torque velocity or position step and direction master encoder modes The SimpleServo s built in RS 232 serial communications port and SimpleServo control program MotionView make programming extremely simple In fact you could be up and running in less than thirty minutes MotionView s real time oscilloscope tool with a sweep time of 1mS 500mS allows the display of critical data including current and velocity profiles in graphic form for analyses and optimum tuning The EPM Electronic Programming Module stores all drive setup and tuning information This module can be removed from the drive and reinstalled making field replacement of the SimpleServo extremely easy SimpleServo controls support Point to Point PPP and Modbus RTU over RS485 and CANopen DS301 communication protocols SimpleServo supports incremental quadrature encoder or resolver feedback devices A second encoder can also be supported in position and velocity modes 1 1 About these Operating Instructions These Operating Instructions
69. that the drive is disabled and d 5 is displayed on the drive 3 Select the Parameters folder from the node tree Click on Reference parameter and change it to Internal This will tell drive to use internally generated reference controlled by Run panel tool 4 Make sure that Enable Accel Decel limits is set to Disable 5 Select Tools then Run Panels then Run Panel from the node tree to bring up the run panel control window 6 Select Oscilloscope tool from node tree to engage oscilloscope Check checkbox Always on top so MotionView main window doesn t cover oscilloscope tool 7 On the Scope tool select Phase current RMS as source for Channel 1 e Motor Velocity as source for Channel 2 Timebase 50ms div Trigger Channel 2 Rising e Trigger level O Rom 8 Enable the drive 9 Set the Reference slider in the Run panel to a motor test speed If the motor s maximum speed is less than 5000 RPM set the slider to approximately 250 RPM If the motors maximum speed is greater than 5000 RPM set the slider to approximately 500 RPM After setting the slider to the appropriate test speed the motor should begin to run 10 Set reference sweep to 200 mS The sweep range is 10 1000 milliseconds msec Check the Enable Reference Sweep box By enabling reference sweep a bi polar square wave signal is generated which allows monitoring of the motor s behavior when chang
70. the Hall order sequence Hall sensor polarity and encoder channel relationship B leads A or A leads B for CW rotation For motors equipped with resolvers Autophasing will determine resolver angle offset and angle increment direction CW for positive YL To perform autophasing 1 Complete the steps in the previous section Setting custom motor parameters If the motor file you are trying to autophase already exists simply load it as described under Using a custom motor at the beginning of this section Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 2 Make sure that the motor s shaft is not connected to any mechanical load and can freely rotate WARNING Autophasing will energize the motor and will rotate the shaft Make sure that the motor s shaft is not connected to any mechanical load and can freely and safely rotate 3 Make sure that the drive is not enabled 4 Itis not necessary to edit the field Hall order and check boxes inverted and B leads A for CW as these values are ignored for autophasing 5 Click OK to dismiss motor selection dialog MotionView responds with the question Do you want to perform autophasing 6 Click OK A safety reminder dialog appears Verify that it is safe to run the motor then click Proceed and wait until autophasing is completed Note If there was a problem with the motor conne
71. the drive firmware version 6 11 Faults Group Faults Group loads fault history from the drive The 8 most recent faults are displayed with newer faults replacing older faults in a first in first out manner In all cases fault 0 is the most recent fault To clear faults history from the drive s memory click on Reset Fault history button Each fault has its code and explanation of the fault See section 7 3 for details on faults Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 7 Display and Diagnostics 7 1 Diagnostic display SimpleServo drives are equipped with a diagnostic LED display and 3 push buttons to select displayed information and to edit a limited set of parameter values Parameters can be scrolled by using UP and DOWN Q buttons To view a value press Enter To return back to scroll mode press Enter again After pressing the Enter button on editable parameters the yellow LED C see figure in the next section will blink indicating that parameter value can be changed Use UP and DOWN buttons to change the value Press Enter to store new setting and return back to scroll mode Display Description SERE current drive status to view run drive running d 5 drive disabled F_XX drive fault Where XX is the fault code section 7 3 2 Hx xx Hardware revision ex H1 01 FX xx Fi
72. these pins can be reprogrammed to be a buffered pass through of the signals from a feedback option card This can be either the second encoder option module E94ZAENC1 or an encoder emulation of the resolver connected to the resolver option module E94ZARSV1 Note 2 An external pulse train signal step supplied by an external device such as a PLC or stepper indexer can control the speed and position of the servomotor The speed of the motor is controlled by the frequency of the step signal while the number of pulses that are supplied to the SimpleServo determines the position of the servomotor DIR input controls direction of the motion Note 3 The ENABLE pin IN1 P3 17 must be wired through a switch or an output on a front end controller to digital input common IN COM P3 18 If a controller is present it should supervise the enable function on the SimpleServo The SimpleServo ENABLE circuit will accept 5 24V control voltage 5 1 8 P11 Resolver interface module Option Bay 2 SimpleServo drives can operate motors equipped with resolvers Resolver connections are made to a 9 pin D shell female connector P11 on the resolver option module E94ZARSV1 When the motor profile is loaded from the motor database or from a custom motor file the drive will select the primary feedback source based on the motor data entry When using a Lenze motor with resolver feedback and a Lenze resolver cable the pins a
73. uitability of the process and circuit proposals The specifications in these Instructions describe the product features without guaranteeing them Lenze does not accept any liability for damage and operating interference caused by Disregarding the operating instructions Unauthorized modifications to the controller Operating errors Improper working on and with the controller Warranty e Warranty conditions see Sales and Delivery Conditions of Lenze Drive Systems GmbH e Warranty claims must be made to Lenze immediately after detecting the deficiency or fault The warranty is void in all cases where liability claims cannot be made Disposal Material recycle dispose Metal Plastic Assembled PCB s Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 2 Specifications 2 1 Electrical Characteristics Single Phase Models 1 Mains 1 Mains Current Current Rated Output Peak Output Type Mains Voltage doubler Std Current Current E94S020S1N 9 7 5 0 2 0 6 120V or 240V E94S040S1N 16 8 8 6 4 0 12 E94S020S2F 5 0 2 0 6 E94S040S2F 120 240V 8 6 4 0 12 E94S080S2F 80 V 0 264 V 0 15 0 8 0 24 E94S100S2F 18 8 10 0 30 Single Three Phase Models 1 Mains 3 Mains Rated Output Peak Output Type Mains Voltage Curre
74. ver cycle time with I gain controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in velocity Note The following four position gain settings are only active if the drive is operating in Position mode They have no effect in Velocity or Torque modes 6 9 3 Position P gain Proportional Position P gain adjusts the system s overall response to position error Position error is the difference between the commanded position of the motor shaft and the actual shaft position By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal 6 9 4 Position I gain Integral The output of the Position I gain compensator is proportional to accumulative error over cycle time with I gain controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in position 6 9 5 Position D gain Differential The output of the Position D gain compensator is proportional to difference between current position error and the p
75. vides a dialog box that allows the drive to be enabled through MotionView in conjunction with the ENABLE input on the drive This parameter does not enable the drive but rather only allows the use of the enable button in MotionView s Tools Run Panels folder see section 6 10 2 4 Unlike other parameters this parameter always initializes to disable when the drive is powered up regardless of how it was left in the previous session 6 3 19 Velocity limit This parameter sets the maximum speed that the motor will be allowed to reach when in velocity limited torque mode 6 4 Communication 6 4 1 RS 485 configuration This parameter sets how the optional RS485 interface will function The RS485 interface can be configured for normal operation programming and diagnostics using MotionView software or as a Modbus RTU slave See section 5 4 for details on communication interfaces 6 4 2 Modbus baud rate This parameter sets baud rate for RS485 interface in Modbus RTU mode When drive is operating in normal mode baud rate is set to the same as for RS232 interface 6 4 3 Modbus reply delay This parameter sets time delay between drive reply to Modbus RTU master This delay is needed for some types of Modbus masters to function correctly Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 6 5 Analog I O Group 6 5 1 Analog output SimpleServo has one analog output with 10 bit re
76. w actechdrives com Email info actechdrives com 5 4 5 P9 CAN bus interface module Option Bay 1 CANopen interface is available as an option module E94ZACAN1 The CANopen interface support documentation can be found in the MotionView help menu under Product Manuals P9 TERMINAL ASSIGNMENTS CAN bus interface ICOM Isolated Common CANL CAN bus Low Can bus High 5 5 Motor Selection SimpleServo drives are compatible with many 3 phase AC synchronous servo motors both Lenze motors and motors from the other manufacturers We have tested many motors with the SimpleServo and put their parameters in a database for customer convenience If your motor is in the database you do not need to provide any motor data to set it up However if your motor is not in the database it can still be used but some electrical and mechanical data will need to be provided to create a custom motor profile The auto phasing feature of the SimpleServo allows you to correctly determine the relationship between phase voltage and hall sensor signals eliminating the need to use a multi channel oscilloscope 5 5 1 Motor connection Motor phase U V W or R S T are connected to terminal P7 It is very important that motor cable shield is connected to Earth ground terminal PE or the drive s case The motor feedback cable must be connected to encoder terminal P4 if the motor is equipped with an incremental encoder If the motor is
77. y to provide Keep Alive capability during a power loss the logic and communications will remain active Applied voltage must be greater than 20VDC P5 TERMINAL ASSIGNMENTS BACK UP POWER Terminal Function 24 VDC Positive 24 VDC Input Return 24V power supply return WARNING Hazard of unintended operation The Keep Alive circuit will restart the motor upon restoration of mains power when the enable input remains asserted If this action is not desired the the enable input must be removed prior to reapplication of input power 5 1 6 P6 Braking Resistor and DC Bus P6 is 5 pin quick connect terminal block that can be used with an external braking resistor the SimpleServo has the regen circuitry built in The Brake Resistor connects between the Positive DC Bus either P6 1 or 2 and P6 3 P6 TERMINAL ASSIGNMENTS BRAKE RESISTOR AND DC BUS Terminal Function B Positive DC Bus Brake Resistor B BR Brake Resistor B Negative DC Bus B Phone 800 894 0412 Fax 888 723 4773 Web www actechdrives com Email info actechdrives com 5 1 7 Connectors and Wiring Notes Note 1 Each of the encoder output pins on P3 is a buffered pass through of the corresponding input signal on P4 This can be either from a motor mounted primary feedback encoder or from an auxiliary encoder when a resolver is the primary feedback device on the motor Via software

AC Tech SimpleServo Model 94 User Manual

Contents

Download Pdf Manuals

Related Search

Related Contents