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VECTORSTAR (VSA/VSP/VSL) Installation and User`s Manual

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4. 49 S I4INXRODUCGTION n tede tete eee ee ente 49 52 PREVENTATIVE MAINTENANCE e Ritter anes Eee I Te epu efe egest 49 ii VECTORSTAR TABLE OF CONTENTS 52 1 Transient 49 50 5 2 3 Electrical dieti i eit tera 50 5 24 Radio Frequency te 50 5 3 PERIODIC MAINTENANGE ere e tree 50 Sas Ventilation 2 o epit e neon Endo 51 5 3 2 Grounding Inteerity etu tu aet 51 CHAPTER 6 TROUBLESHOOTING iii nien o OU oM Rex 53 Gel INTRODUCTION deett EE ra Qaqa EDO EE EE EAT quedes 53 6 2 SPARE PARIS e RR ER RR tree d ERO RO Rr Qu eet 53 6 21 VECTORS TAR Spare Parts sl ree tere 53 6 22 Spare ote eae wR eats 53 6 2 3 TR e TEGERE AREE IUE 53 6 3 BED STATUS INDICATORS eterne eet SQ te eet e h W ded 54 63 VECTORSTAR EPP EURO EIE EUN oneness 54 6 32 EBD S
5. ctus REL 54 6 4 TEOG ite tar ea PA 55 6 EAE ee Un E Mm 53 6 42 D n ae eto terr re CR ie ed E vete 56 6 4 3 ErTOBHISQOEY bate teet gettin dites Net tt etes 56 6 4 4 Displaying Error Messages ee hie RR I e e Pt D d ta RUE 56 6 4 5 Firmware osse E E t eet E e D edt iC 56 6 5 FACTORY SUPPORT AND REPAIR POLICIES un essere nennen nnne enne tentes 56 CHAPTER 7 SOFTWARE INSTALLATION 57 EE 57 2 COMPUTER REQUIREMENTS petere nu eee ane 57 7 3 INSTALLING MOTIONLINK PLUS 58 TA RUNNING u Su aa 58 7 5 ACCESSING ON LINE HELP IN MOTIONLINK 58 T 6 PROGESSOR MODBS eee P REPE RH eene 58 76 2 1 Interactive estote ott ren RIESGO S hun asan edu 59 4 16 2 2 Run Mode t tds n ded eset 59 7 6 2 3 Monitor des diat ee RU REI reo EE IST C EI een 59 1 0 2 4 Single Step ModE miinan RERO RE I RU us ss 59 16 20 5 Trace Mode one SR k io Ets 60 4 6 2 6 Other Modes aa um e Rd ORI ORI RS 60 CHAPTER 8 GE
6. nnne 83 8 9 MACROIMOVES SSES PSS e tut rto doves en e RT shies ee rl E DER E E SEPA EA 84 8 8 7 1 MCA MCI and MOGO x iiu tende e pec e e d eer Q iH pe rd 84 8 8 7 2 Macro Move Example 1 nennen s 84 8 8 3 Macro Move Example 2 2 2 co a eh eee RH a te diee TES 85 8 8 8 BASED MOVE MRD Command n eene rennen nnne eren nnne 85 8 8 9 Capturing ES 86 8 8 9 1 Enabling Capture CAP and PCAP 4 1 140 20200400102 414 000000000000000000000000000000 86 8 85 92 Capture Direction Ro B eR Fee qi A Tes e re e PA ege I 86 8 8 9 3 Speeding Up Homing Sequences narsa 86 8 5 10 Clamping ec o e Pete eee RENE Ge Rn eaten 87 8 8 10 1 Clamping and Homing saan aaa yau E EA A n aa aquta 87 8 38 11 JOG TO JT amp JOG FROM GE sii Q E ra a hr RE 88 Registration eti Sa M OS au Sua Y Aa SS ERIS 89 8 8 1172 Registration Exainple 5 5 5 e IRURE 89 8 8 11 3 Multiple JE JT Commands nnns 89 8 9 11 4 Changing Profiles During Motion a nenne nnne nens 90 8 5 12 Extermal Inpults eed tice e te diente t roe eset erret e 91 8 8 126 Analog Input 3 2 RUE RP HER
7. 79 8 85 14 STOPS E ertet eerte aree o 79 8 8 1 5 STOP and BREAK with Control X X 79 8 82 Limiting See teni NI RI eritis 80 8821 Hardware Travel tete eU Nee n 80 8 8 2 2 Software Travel Limits PMAX and PMIN nsn 80 8 8 2 3 User Position Trip Points amp 2 nnns 80 8 8 9 Profiles cem tite edt metet accede Marie a cet 80 8 8 3 81 8 8 3 2 Move Absolute MA Command 81 8 8 3 3 Move Incremental MI Command enne nnne nnne nnne 82 8 8 3 4 Incremental Move 1 82 88 3 9 Profile UR 82 8 8 3 6 Multiple Profile Commands 2 40 4 040000060 0000000000000000000000000000000000500 83 8 8 3 7 Profile Final Position droit t epe e evt A vete hose ele tet eee Tn 83 8 8 4 JOG J 4 e tte emet eed iste t ette eiie 83 iv VECTORSTAR TABLE OF CONTENTS 8 8 5 NORMALIZE NORM Command 83 8 8 6 Zero Position Error ZPE Command
8. sese 171 PAFS RS 232 Serial ou Ee ipei qe o aot ve et Ret ie 171 APPENDIX A WARRANTY INFORMATION U Rene an e u Raga 183 APPENDIX B 185 APPENDIX ERROR CODES 197 C INTRODUCTION 197 02 HARDWARE Eu gunu iu GENRE 197 C3 MOTION ERRORS ertt et etd 200 SOFTWARE ERRORS dee E PER P ORIS UON UR PS e He RR he NAR pn 201 APPENDIX D REGIONAL SALES OFFIGE Eon ES eU nien 209 DI INTRODUCTION 15 SOS u D orat Pt ere EO TA beh cu bea av EO paku uapa 209 APPENDIX E ASCGII FABLE cee T 211 viii VECTORSTAR TABLE OF CONTENTS APPENDIX F VARIABLE QUICK REFERENCE GUIDE 215 O EEEE E EAT E 215 E2 STANDARD VARIADBEPES aaa ENERE E E EE 215 E3 INTERNA BLES 220 APPENDIX G SOFTWARE COMMANDS a RR RAM eee 221 G L EXPRESSIONS AND SY MBOBLS inti ot tenete eren es Re 221 02 COMMAND tec e TE PR 222
9. NOLIVNIA H3 L avis SALLOVNI er 4 u oi 56 NOLLVNIWHSLL 56 10 YSA Q3193NNOO LON Nid NOLIVNIWHLL HOS SNIMIS NI 1SV1 NOLLO3NNOO 5 qaad se aq 0 1 00 L0d3G 22 53 OL 3 1d WVX3 000000000000 9999 99 1 5 L Ll 2 avwwas 56 10 MVISHOLOSA anvwaa 592 80 IO3NNOOMWZLNI 685 54 IVIH3S SO TWNINYSL YAWOLSND e WOO 379 33 66 10 HO WVISHOLO3A Figure B 4 C5 Serial Port 189 VECTORSTAR 260286655 TACOW G 3IHSIHH343 3A331S ANATWAINDA HO 260086655 G T3IHSIHH33 dVNS 3A331S 336 VECTORSTAR APPENDIX B DRAWINGS 092 9 ZO YHOLOANNOO WVYOVIG YSA 5 3 01 9 G31V1OSI OQ LIOA vz ONIS 330338 SYAWOLSND ZO Z H3LdVHO 33 AlddNS GALVIOSI NON HOJISIS3H wyo ALOE SVH IVN9IS SIHL STIOA S 1105 303 GAWOS WNOIS Q3ON3H333H NOWINOO V SI HOLINOM I NOWIAOO OL GALOANNOO HOLIOVdVO 390047 V ANY YOLSISSY wyo i V SVH TWNOIS SIHL b 3SIM2079 0001 403 Q31V9S TVN9SIS Q3OoN3aada NONWNOO V SI HOLINOW HOVL SLOWSY 1 310A9 Nanay SWO
10. 2 2 4 004 4000000000000000000000000000000000000000 76 81 3 ee tae ERR DR HR ER 76 8 7 3 1 VCMD VFB VE and 2 2 1 0000 aa A uya a uqa 76 8 7 3 2 Velocity Limits VMAX and VOSPD u n a 76 Bf At Current eto tee dieere ma eee 76 8 142 Current Limits IMAX and see arr ee ette 76 8 7 5 Enabling the Position Loop with PL ener nennen nennen nnne nnns 77 8 7 6 Controlling the Velocity Loop with PROP 77 8 777 Enabling the VEGCTORSTAR ee eR au ER NOR Hte TI 8 7 9 Limiting Motor Current o ee ied OBEN NEN 78 8 7 8 1 Continuous Current ICONT J a g la a a a 78 8 7 82 Foldback Current niet 78 8 7 8 3 Monitoring Current Limits eene trennen nnne nnne eerte rennen nnns 78 8 3 MOTION COMMANDS cete eset ett S uya waqsa 78 8 8 1 Basic Motion Commands 78 8 8 I1 AMAX ACC RR pe aue ded eue eese mia OE 78 8 9 1 2 EIN siot 79 8 8 1 3 Enabling Motion with MOTION
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12. POWER UP Manual Switch Off and Positive Transition Of Cycle Input AUTO 0 500 Manual Switch Run lt LABEL gt Any Error That Breaks Execution Other Tasks BACKGROUNDS Idle Monitor Inputs Prompt Operator for Input Initialize VECTORSTAR for Application Run One Cycle of Auto Program Run Manual Program Continuously General Purpose Programs Gracefully Exit on Error Condition Print Messages to the Screen 140 VECTORSTAR Table 10 5 How to Enable and Disable Multi Tasking How to Enable Multi Tasking Run any label RUN lt label gt Run multitasking Type RUN Include a POWER UP label and power up Execute a Break from your program Enter a Break from the Monitor mode Cause an error that breaks execution 10 8 5 Idling Idling 1 a necessary part of multi tasking So far in our discussion higher priority tasks run until they are complete Actually commands from the highest priority task that is not idle execute For example if an alarm cannot run because it 1s waiting for some condition such as waiting for motion to stop it is idle If a task is running and it becomes idle then a lower priority task can run until the higher priority task 1s no longer idle A task can be idled with pre execution idling and post execution idling 10 8 5 1 Pre Execution Idle A task can be idled by waiting for a condition before execu
13. Figure 4 3 Overdamping 4 3 4 Ringing When you are tuning the VECTORSTAR you may tune it so that the response rings Ringing is caused when you attempt to tune the VECTORSTAR for either too rapid response too high bandwidth or too much stability too much damping or both The only solution is to reduce the bandwidth or the stability or both In Figure 4 4 the graph shows a system that rings 1 60 1 40 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds Figure 4 4 Ringing 4 4 TUNING The TUNE command shakes the motor vigorously Secure the motor before tuning WARNING The VECTORSTAR is usually shipped with a tuning that will work reasonably well with the load inertia between 0 to 4 times the rotor inertia Many applica CHAPTER 4 OPERATION tions have approximately matching inertia If your system does you may not need to adjust the tuning of your VECTORSTAR The following section describes how you can re tune your system N VECTORSTAR quickly You can use K the one letter KILL com NOTE mand to disable your system When tuning a system it may be desirable to disable the The VECTORSTAR provides self tuning Thisisa feature that senses the inertial load of your system and then attempts to set tuning parameters accordingly Note that self tuning is not fool proof You may need to adjust one or two of the tuning param
14. 1 100 2 1000 10 1 USE X10 TO POINT TO X1 P X X10 PRINT WHAT X10 POINTS VECTORSTAR responds CHAPTER 8 GENERAL PROGRAMMING 100 since X X10 X1 100 Now type 10 2 USE X10 TO POINT TO X2 P X X10 PRINT WHAT X10 POINTS VECTORSTAR responds 1000 since X X10 is now X2 which equals 1000 So printing X10 indirect X X10 prints the user variable at which X10 points not X10 itself Indirect user variables are often used to look up data in tables For example they are often used in teach programs programs that remember a large number of positions taught by the operator In this case many user variables are used to remember positions and one variable is used to point at the group Use indirect references with caution since it is easy to make mistakes with them 8 3 11 User Switches User switches are similar to user variables except that they can only take on values of 0 or 1 A user switch can be used in place of a user variable if you only need to store 0 or 1 An example of a good place for a user switch would be to store information for go no go decisions This saves user variables for other places There are 50 user switches ranging from 51 to XS50 For example type 33 1 533 and the VECTORSTAR should respond by printing 1 8 3 12 Special Constants The examples above have used decimal numbers in most ofthe assig
15. esf CD Q 51890 H3MOd 1 Cf THAINHO 1 33S 3SVHd v be ALON 33S MAL M3MOd 4 SLON 33 HLYY 3NIHOVIN OL 8 38 91907 OL ALON 336 3SVHd 319NIS 9 9 H3MOd S SILON 33S N aaivino3asNn IQA 51 SZIOH3N3 OL ZH 09 05 dariddns suawoisno ANO 82 YSA NO 3 I8VTIVAV INANI OV SLIVM SZ GLF OWA OEZ 82 Nv3 NIVW 10 1 N3dO ATIVWHON z 31ON 285 13 LINVA XX S vu Su M LAdLNO ATaWwassy 318vO 21901 109 ASN IV1SOWH3HL IdATOS33 zs W31SAS 1 92 OS Vd HO3 QVO TH3AO dus 4 7 31ON 33S LOVLNOO JI1nv4 YAMOd 5910435 Vd SSAC NOLLONGNI S3IH3S VSA HOLO3NNOO HOJISIS3H N393MW TIVNH31X3 Figure B 2 PA and Motor Connections DC Fan 187 VECTORSTAR APPENDIX B DRAWINGS 1N3 IVAInO3 10 YSA YSA 3AV IS YSA H3 LSVIWN OL 310GON LNdNI 3TALS 22 1 NV 3HIM YSA H3 LSVIN YSA 16 TYNOILdO V NI 133Hs 15
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17. MRD 1000 100 CW MOVE RID TO 1000 ALWAYS CW The above example moves the motor clockwise even if the specified position 1000 is just a few counts counter clockwise The variable DIR has no effect on MRD commands The limit of position is based on the R D converter accuracy as shown in Table 8 8 Table 8 8 RID Converter Accuracy Resolution Maximum Position moves are not buffered They are not allowed when the VECTORSTAR is jogging or if a move is in progress MRD moves can be used to improve the accuracy of homing sequences First use the VECTORSTAR to position the motor as close as possible to the home limit switch trip point Then use the MRD command to move the motor to a specified R D position In this case the limit switch must be accurate only to one half revolution of the motor for the R D moves to be useful 8 8 9 Capturing Position Position capture 15 a feature where the position feedback is captured when a hardware input transitions The VECTORSTAR position capture 1 accurate to 25 microseconds In other words the position that is stored after a capture is equal to the actual position of the motor at the time of the capture within 25 microseconds Capture uses the HOME hardware input as the capture 86 VECTORSTAR trigger 8 8 9 1 Enabling Capture CAP and PCAP The switch CAP controls capture If CAP 15 on then capturing is enabled When capturing is enabled
18. OK You can connect this contact to your controller or to a VECTORSTAR remote inhibit You should inhibit the entire system if a PA fault occurs See Note 2 in Appen dix B 15 CHAPTER 2 INSTALLATION The ratings of this relay are 2 Amps at 28 Volts DC resistive 1 Amp at 120 Volts AC resistive INHIBIT YOUR SYSTEM IF APA FAULT OCCURS YOU MUST WIRE YOUR SYSTEM FOR THIS CAUTION FUNCTION 2 6 3 3 Wiring PA Connector Logic Connector Logic of PA is the Logic Power Supply for the VECTORSTAR Wire the Logic Power Supply from this connector on the PA to Connector C4 of the VECTORSTAR Each logic power supply voltage is connected to two pins so that you can wire from the PA to the nearest VECTORSTAR For example 15 volts appears side by side on Pins 1 and 5 Note that the PA 12 and 20 Amp models can have a maximum of three units axis connected while the 50 and 75 amp models may have six units connected Table 2 2 lists the ratings of the PA logic power supplies Table 2 2 PA Logic Power CURRENT VECTOR PA Connector Connector Logic C4 PIN PER STAR VOLTAGE AXIS 15 VDC 20 0 25 15 20 0 25 8 VDC 20 LOGIC POWER SUPPLY MAXIMUM RATINGS Failure to observe the polarity of the logic power supply will result in damage to the PA and CAUTION VECTORSTAR 2 6 4 Wiring the VECTORSTAR Front Panel Connectors This section will discuss wiring o
19. OT condition is removed prior to the termination of the timer the Motor OT output is turned off and VECTORSTAR operation continues as normal Variables Used MTIMER Used for the delayed termination of the software execution after the motor over temperature condition has been sensed MTIMER is in milliseconds TMR2 Motor Over Temperature timer The time from when the Motor OT I5 input thermostat contact opens until the VECTORSTAR faults terminating application software execution and disabling the motor The timer is initialized by the parameter MTIMER in units of milliseconds The TMR2 timer will decrement from the initialized MTIMER value to 0 Drive Over Temperature The VECTORSTAR senses an internal over temperature condition and reports this condition by energizing the Drive OT I4 output The VECTORSTAR also starts a programmable timer that when exceeded with the OT condition present will terminate application software execution and disable the motor To re enable applica tion software execution the following conditions must be true 1 No OT condition 2 Orient Request 12 input off 3 Toggle the Spindle Reset 16 input on While the OT condition exists and the OT timer is active normal VECTORSTAR operation continues Ifthe OT condition is removed prior to the termination of the timer the Drive OT output is turned off and VECTORSTAR operation continues as normal Variables Used DT DTIMER Used for the del
20. the position feedback 15 the actual position of the motor It is updated every millisecond PFB is in position units Section 8 3 5 Printing Variables explained how to look at PFB and watch it as the motor turns PFB is always active even when the VECTORSTAR is disabled is reset to zero when the VECTORSTAR is powered up 8 7 2 2 Position Error PE amp PEMAX PE is position error sometimes referred to as following error It is the difference between PCMD and PE is zero when the VECTORSTAR is disabled PE is in position units When the magnitude of the position error exceeds the value stored in PEMAX a Position Error Overflow error is generated This 18 a serious error disabling the VECTORSTAR immediately Note that setting PEMAX to some value will not limit the position error The position error depends on the control loop parameters and the application Normally you want to set PEMAX to as low level as will allow the system to run reliably Setting PEMAX too low can generate nuisance errors since the position error has some variation during motion is in position units Position error is limited to protect the system Excessive position error can indicate a fault condition For instance bearings wear out over the life of a motor The increased load from worn bearings can increase the position error during motion In many cases position error is the first indication of wear 8 7 2 3 Positi
21. 1090 938 22108 W3ldvOv 3938 6 0 a YOLOWSY INN A8N3SSV ur sna on e H 291090062 Figure 12 7 High Power VS R L VS R P Block Diagram 178 CHAPTER 12 HIGH POWER VECTORSTAR gt aq 5 58 x lt Tu HE 9g REACTOR L1 P 97335 008 KLR80BTB FUSE FUSES MODEL BLOCK FU2 VSL25 0012 VSP25 0012 VSRL25 012 VSRP25 0012 VSP40 0012 CAPACITOR CARD 96432 CAPACITOR CARD A 96132 A 93715 300 PM200CSA260 CAPACITOR CARD CM300DY 12H 115A 1200 A 84990 012 J LLN 200A 300 P 97345 009 60100 3 JLLS 100A 600V P 97335 001 P 97345001 KLR458TB 602004 97330 100 MG100Q2YS 11 106A 1200 93711 012 97051 J LLN 200A 300V 97335 008 P 97345 009 KLR80BTB 602004 CAPACITOR CARD JLLS 100A 600V P 97335 001 150 120 97345 021 KLR458TB 97337 001 602004C J LLN 200A 300V P 97335 004 150A 800V 9 97345 009 KLRIIOBCB 96354 008 60100 3 JLLS 100A 600 97335 002 P 97345 021 KLR558TB T60100 3C P CAPACITOR CARD A 96132 MG200Q2YS 11 CAPACITOR CARD P 97330 A 96132 CM300DY 12 A 93715 300 T P 106A 1200 93711 012 00 5 660 CAPACITOR CARD P 97338 VSRL4O 00D T602004C J LLN 200A 300V 97335 004 97342 001 P 97345 009
22. When Drive Enable is turned on with the application software executing the Pulse Enable input on and the Orient Request input off the VECTORSTAR will enable and turn on the Drive Ready 4 output Drive Ready The Drive Ready output is the 4 output The Drive Ready output will be on when the VECTORSTAR is ina state to accept and act on a speed command input voltage or an Orient Request input The VECTORSTAR is powered on with the Drive Ready output off The following states must be true to turn the Drive Ready output on 1 Pulse Enable on REMOTE SIGNAL 2 Drive Enable on 3 Orient Request off 4 The VECTORSTAR application software is executing Application software begins executing at power up The software execution could be terminated by several conditions such as a Motor or Drive OT condition that has exceeded the allocated time defined by MTIMER for the motor and DTIMER for the drive 109 CHAPTER 9 SPINDLE PROGRAMMING The Drive Ready O4 output will turn off with any of the following conditions 1 Pulse Enable off 2 Drive Enable off 3 Motor or Drive OT condition has timed out which terminates application software execution 4 An Orient failure which terminates application software execution 5 AVECTORSTAR firmware sensed fault that ter minates application software execution If the Drive Ready output is turned off due to the Pulse Enable input or the Drive Enable input being turned off
23. If PRD does not fall into the range as listed above then either the resolver is improperly wired or the feedback circuitry is not functioning correctly The first step is to check the cable 2 7 10 Checking the Resolver Cable Follow this procedure if you are experiencing problems with the resolver Disconnect the resolver cable at both ends and use an ohm meter to verify the following resolver cable wiring table Table 2 9 The following procedure uses an oscilloscope to measure the amplitude of signals with a frequency of 8 kHz Some digital voltmeters can measure the amplitude of signals at high NOTE frequencies like 8 kHz How ever many meters are designed to read 60 Hz and cannot be relied upon to read 8 kHz signals If the cable is correct check the resolver reference signal Install the resolver cable at both ends Connect an oscilloscope probe to Connector C3 Pin 4 extend the probe with a short length of wire to reach inside the connector housing if necessary and connect the probe ground to common Connector C3 Pin 10 Apply control power 230 VAC The reference signal should be between 11 8 and 12 0 V peak to peak 4 17 and 4 24 V RMS at a frequency of about 8 KHZ If necessary adjust the reference amplitude with potentiometer R237 This potentiometer 15 located between Connectors C2 and C3 and can be adjusted from the front of the unit without disassembly If the reference signal is correct an
24. If you think the cable is correct but you still cannot 26 VECTORSTAR communicate your terminal may not be configured for the data format listed in Section 2 6 5 Check the manual for your terminal or computer virtually all IBM PC compatible computers conform to this format If you are using a terminal be sure your terminal 15 set properly 2 7 INITIAL CHECK OUT This section will discuss the procedure for checking most of the wiring on the system before enabling your VECTORSTAR Communications must be established with your VECTORSTAR before continuing In this section the VECTORSTAR will be used to check wiring to most ofthe VECTORSTAR inputs and outputs You will need to enter some VECTORSTAR commands This section will use a few commands that are described in more detail elsewhere in this manual The first command is the print command You can print the discrete inputs For example after the VECTORSTAR has printed the prompt you can type PLIMIT and the VECTORSTAR will print 1 or 0 1 means that the input is on indicating that the contacts are closed 0 means that the input is off indicating that the contacts are open In this manual instructions that you enter will be shown in italics and surrounded by a double line box The response NOTE from the VECTORSTAR will be in plain upper case letters 2 7 1 Checking Discrete Inputs You can check the state of all of the discrete inpu
25. Ouen 8 GENERAL PROGRAMMING CHAPTER 8 GENERAL PROGRAMMING 8 1 INTRODUCTION This chapter discusses the basics of the VECTORSTAR and its programming language Your VECTORSTAR system should be mounted and wired as described Chapter 2 The AC Line voltage to your PA should not be turned on for examples in this chapter until you are asked to do so Turn on Control Power only and establish communications If the proper connections are not made or the terminal is not commu nicating then see Chapter 2 AC LINE SHOULD NOT BE TURNED ON WARNING 8 2 INSTRUCTIONS The VECTORSTAR can respond to instructions entered from the terminal The format of the instructions is usually a command followed by one or more parameters For example the jog instruction 1s a J followed by one parameter the desired speed The following example would cause the motor to jog at 10 RPM J 10 The command and parameter must be separated by at least one space 8 2 1 Comments Instructions can be followed by comments on the same line A semicolon marks the beginning of a comment The VECTORSTAR ignores everything on the line after the semicolon For example J 10 THIS IS A GOOD COMMENT is a valid instruction Note that a space must separate the semicolon from the last parameter J 10 BAD COMMENT MUST BE PRECEDED BY A SPACE GOOD LINE SPACE NOT REQUIRED WHOLE LINE IS A COMMENT 8
26. The microprocessor cannot pass the checksum self test This fault causes the microprocessor to blink the CPU light three times and then pause The VECTORSTAR will not communicate or run the user program Contact the factory 197 APPENDIX C ERROR CODES VECTORSTAR ERROR 4 SOFTWARE WATCHDOG SEVERITY 4 The microprocessor has failed the software watchdog self test This fault causes the microprocessor to blink the CPU light four times and then pause The VECTORSTAR will not communicate or run the user program Contact the factory ERROR 5 5 VOLTS SEVERITY 4 The 5 volts is too low This fault causes the microprocessor to blink the CPU light five times and then pause The VECTORSTAR will not communicate or run the user program Check the 10 VDC input into the VECTORSTAR Connector Pin 4 or 8 If it is below 6 5 Volts for even a short time this error will occur This happens when the logic supply is loaded too heavily or when the line voltage PA Connector Pins 2 and 3 15 below 98 VAC 115 VAC less 15 C 2 2 VECTORSTAR Faults ERROR 10 REMOTE OFF SEVERITY 2 You attempted to execute an instruction that requires the hardware input REMOTE on the signal connector to be active This error breaks program execution ERROR 11 OVER TEMP SEVERITY 3 The thermostat on the VECTORSTAR heatsink opened indicating overheating Overheating may be caused by exces sive ambient temperature obstructed airflow broken fan etc
27. WARNING Remove the BUS and BUS leads from the PA Power Terminal Block Disconnect Connector C2 from the PA Turn on Control Power to PA Connector C1 and turn on the AC Line to the PA Power Terminal Block L L and L SHOCK HAZARD Large voltages are present on L BUS and BUS very careful when measuring these voltages WARNING Check and record the DC Bus output voltage at BUS with respect to BUS on the PA Power Terminal Block It should be approximately 325 VDC for 230 VAC line voltage or 162 VDC for 115 VAC line voltage Remove the AC line voltage Wait 5 minutes for the DC Bus to discharge Reconnect the BUS and BUS leads to the Power Terminal Block on the PA Be careful to reconnect the leads with the correct polarity Re install Connector C2 on the PA 30 VECTORSTAR OBSERVE POLARITY OF THE DC BUS When interconnecting Industrial Drives GOLDLINE Series Prod ucts connect BUS to BUS and connect BUS to 05 WARNING 2 7 13 Checking the Motor The MOTOR command is provided to ensure that your VECTORSTAR is properly configured for your motor Type MOTOR The VECTORSTAR should respond with something like MOTOR B 204B You can then verify that your motor is 2048 Always check the motor nameplate to verify that you have wired the correct motor to your VECTORSTAR This should agree with the part of your VECTORSTAR model number as described
28. Where is in RPM and 4096 counts per revolution for 12 bit R D mode is assumed The gear ratio is indirectly represented by Vmax in the equation Please see Chapter 10 User Programs for more information Again using the example of 10000 RPM as a maximum input speed command VXNUM VXDEN 104700 1 to obtain the correct reading of VX AVG in PRM with the gear ratio 700 16384 9 6 5 TL Sheet The VECTORSTAR is shipped with a normal TL sheet factory settable parameters and a list of all the program mable variables All the parameters mentioned in this chapter are set to the default values by the factory and are included in the TL sheet 9 6 6 Software Listing The user should be familiar with the VECTORSTAR system and how to program it before attempting to read the code listing of the user program or designing a new program for the VECTORSTAR The following listing is similar though not identical to the one embedded on the EPROM THIS ALARM IS TO SENSE THE RESET INPUT 16 A 16 1 2 5 1214 01050 2 6 1 215 1060 2 1 O4 amp I4 amp I5 amp 1 12 EQ 1 RUN 9 l4EQ0 O51 215 0 0 O6 1 END NITIALIZATION OF THE SYSTEM POWER UP LPF 1 95 PLO RAMP 1 LPF 1 GEARI GEARIO GEARO GEAROO VECTORSTAR VXNUM VXNUMO VXDEN VXDENO 070 GEAR 1 X2 24 NORMAL INPUT PROCESS THE FAULTS AND READ THE INPUT 10 2 O5 EQ 1 GOSUB 50 GO FOR PROCESSING DRIVE OT O6 EQ 1
29. and the VECTORSTAR should respond with 1 5 gt In this case VECTORSTAR executed the print command and displayed the single step prompt indicat ing it is ready for another command Now press the ENTER key repeatedly to step through the program This example shows several characteristics of the Single Step mode 161 CHAPTER 11 DEBUGGING commands preceded by the trace prompt 5 gt Print statements are active in the Single Step mode Notice that the results of the P command are printed normally as they are in the Trace mode Only the executed commands in the IF ELIF ELSE and ENDIF sets are shown Notice that none of the commands following the first print command are shown You can execute commands from the Single Step mode You can also enter the Single Step mode from your program To do this you should include SS ON in your program To exit the Trace mode you can include SS OFF in your program or type it from the single step prompt You can also press the escape key two times 11 2 2 Trace TRC If the error occurs in a section of your program that is not very time critical you can use trace to help track down the error When you execute your program in the Trace mode each command is printed out just before it is executed Use the nested IF example given earlier in this chapter Enter the program set X1 and X2 equal to and turn TRC on ON Then begin execution at la
30. then FOLD is on If IFOLD gt ILIM then FOLD is off then SAT is on then SAT is off If ICMD or IFOLD If ICMD lt and IFOLD ICMD is never gt ILIM ICMD is never gt IFOLD In some cases it may be desirable to know when foldback is just about to limit current below ILIM You can use IFOLD for this if IFOLD is less than the foldback software is limiting current If IFOLD is larger than ILIM but only by 5 or 10 then foldback software is about to limit current 8 8 MOTION COMMANDS This section discusses how to control motion using the VECTORSTAR Basic motion commands are described first Later sections discuss advanced motion control including Macro Moves electronic gearbox and synchronizing motion 8 8 1 Basic Motion Commands 8 8 1 1 AMAX ACC amp DEC The VECTORSTAR controls acceleration with three variables AMAX ACC and DEC is the maximum acceleration allowed for almost all motion commands The only exception is electronic gearbox is the upper limit for the normal acceleration rates ACC and DEC AMAX should always be set below the acceleration level that can damage your machine Errors that stop motion will VECTORSTAR decelerate the motor at therefore your machine 18 subject to deceleration rates of AMAX at any time is in acceleration units which are RPM second as a default AMAX can be changed only when the VECTORSTA
31. 9 25 Sometimes the first digit of a hex number be a letter In this case the number must be preceded with a zero For example X9 FFH ERROR HEX NUMBER MUST BEGIN WITH NUMBER X9 0FFH VALID STATEMENT 70 VECTORSTAR Hex is useful when trying to use general purpose inputs to control the user program See later in this chapter for more information about applying these inputs 8 4 2 Algebraic Functions The VECTORSTAR provides four standard algebraic functions multiplication division addition and subtraction The usual algebraic operators are used Standard algebraic hierarchy 15 observed all multiplications and divisions are done before any additions or subtractions Parentheses are provided to override this precedence Type in the following ex amples 1 2 3 THIS PRINTS 7 NOT 9 IS DONE BEFORE 1 2 3 THIS PRINTS 9 Math expressions must obey the rules listed in Table 8 3 Table 8 3 Rules for Math Expressions No spaces are allowed Any valid variables can be used Any valid constants can be used Indirect user variables can be used Any math operator can be used Parentheses can be nested to 2 levels Integer math is used for all operations Expressions are evaluated left to right Valid math expressions can be substituted for numbers in most instructions A few examples of math expressions in assignment instructions follow 1 50
32. Automatically set by autobaud Nor mally you do not need to set BAUD CAP Enable position Capture mode Set to 0 on power up and normally left at zero for preliminary operation CAPDIR Direction of position capture Set to 1 on power up The value of this variable does not matter if CAP is 0 66 CLAMP DEC DIR FAULT GATEMODE GEAR GEARI GEARO IDEN ILIM INUM VECTORSTAR Enables Clamp mode Set to 0 on power up and normally left at 0 for preliminary operation Deceleration rate initially in RPM Sec and initially set to 100000 Sets VECTORSTAR direction If 1 then positive motion 1s clockwise If 0 then positive motion is counter clock wise This is set to 1 on power up Fault is automatically set and cleared by the VECTORSTAR You can change its state during operation though you do not need to change it during initial operation Enable Gate mode Set to 0 on power up and normally left at zero for preliminary operation Enable electronic gearbox Set to 0 on power up and normally left at 0 for preliminary operation Number of teeth on the input gear for electronic gearbox Initially set to 1 Value of this variable does not matter 1f GEAR is 0 Number of teeth on the output gear for electronic gearbox Initially set to 3 Value of this variable does not matter 1f GEAR is 0 Current units denominator Initially set to 100 for percent Peak current limit The in
33. During the Orient process the motor will be stopped and then commanded to move to the Orient position in less than 1 motor revolution at this specified velocity In the 2 1 application discussed below VORNT also is the speed at which the motor rotates to locate the HOME input VUP Defined band around the speed command in RPM Associated with the Orient software 1s a test that verifies the motor is stopped followed by a test that verifies the motor is at the orient position The in position orient test is executed regularly while the motor is oriented If the test fails the motor will be disabled and application software execution will be halted The application software can be restarted with a power reset of the VECTORSTAR or by toggling the Spindle Reset GP6 input on The Drive Ready section later in this chapter describes the conditions that will allow the VECTORSTAR to enable after a fault The Orient software tests have the following parameters that must be programmed 41 The X41 parameter is added to and sub tracted from the P1 position providing a pass fail band for the orient in position test If the measured PRD motor position is outside the band established by X41 the test will fail X41 is in R D units and there are 4096 units per motor revolution The value of X41 is determined by how far the motor can be from the orient position without causing a machine problem X42 The test that senses the motor has stopped
34. MI 10000 10 SECOND MOVE P SECOND MOVE PROCESSED MI 10000 10 THIRD MOVE P THIRD MOVE PROCESSED B TASK LEVEL 6 BACKGROUND P UPPER TASK IDLED D 250 DWELL 0 25 SEC END Apply DC bus power to your VECTORSTAR and type RUN 1 The result should be FIRST MOVE PROCESSED SECOND MOVE PROCESSED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED THIRD MOVE PROCESSED The first and second moves are processed immediately Then task level 5 is idled while the first move finishes While task level 5 15 idle the background task executes over and over printing the simple message on the screen 141 CHAPTER 10 USER PROGRAMS 10 8 5 2 Post Execution Idle A task also can be idled by waiting for a condition after executing a command This is called post execution idle because the task is idled after executing the command that causes the idle Commands that cause post execution idling are called idling commands There are four idling commands WAIT W DWELL D HOLD For example you can modify the above program to make one move then run the background routine until motion has stopped Use the VECTORSTAR Editor to enter the following program TASK LEVEL 5 1 MAIN PROGRAM EN MI 10000 10 START MOVE P MOVE PROCESSED W 0 WAIT FOR MOVE P ALL MOTION STOPPED B TASK LEVEL 6 BACKGROUND P UPPER TASK IDLED D 250
35. Sec ANUM 4473923 ADEN amp Machine Acceleration In Your Units Table 10 9 Metric Conversion 12 bit RID Only POSITION UNITS PNUM Motor Movement In Radians 0 651 89713 u PDEN amp Machine Movement In Your Units VELOCITY UNITS Motor Velocity In Rad Sec 0 1 0475 y g VDEN amp Machine Velocity In Your Units 4 ACCELERATION UNITS Motor Acceleration Rad Sec Sec 8 ANUM 07120473 ADEN amp Machine Acceleration Your Units CHAPTER 10 USER PROGRAMS procedure to determine PNUM and PDEN is as follows A Select Table 10 8 revolutions or 10 9 radians B Select a convenient amount of motor movement revolutions or radians C Calculate the corresponding machine movement in your user units D Perform the operation indicated in the table under POSITION UNITS and set PNUM PDEN equal to this value E If your R D converter resolution is 14 bits multiply PNUM by 4 Multiply PNUM by 16 for a 16 bit system The procedure to determine VNUM and VDEN is as follows A Select Table 10 8 RPM or 10 9 radians second B Select a convenient amount of motor velocity in RPM or radians second Calculate the corresponding machine velocity in your user units D Perform the operation indicated in the table under VELOCITY UNITS and set VNUM VDEN equal to this value E If your R D convert
36. VECTORSTAR Table 1 3 External Regen Resistor Model Number Scheme LEGEND DEFINITIONS Resistor Rating 4 4 Ohms 1000 W 230V 50 amp 75 Amp Models Only PA 50 75 2 2 Ohms 1000 W 230V 75 Amp Models Only PA 75 PA 85 2 2 Ohms 2000 W 230V 75 Amp Models Only PA 75 PA 85 Options None available at this printing Table 1 4 Environmental Specifications Operating All units fan cooled Storage Temperature Humidity Non Condensing 0 to 45 C 20 C to 70 10 to 90 1 5 THEORY OF OPERATION Figure 1 5 shows a system overview MICROPROCESSOR SYSTEM The VECTORSTAR is a digital positioner and servo drive combined into one unit The velocity loop is 100 digital The VECTORSTAR has battery backup RAM to remember your program and most variables through power down RESOLVER TO DIGITAL CONVERTER The VECTORSTAR is based on a Resolver to Digital R D converter The R D generates a tachometer signal for your convenience However the VECTORSTAR does not use the analog tach signal SERIAL PORT The VECTORSTAR has a serial port for communica tions This port allows you to monitor the operation issue commands and transmit a program DISCRETE INPUTS The VECTORSTAR has 23 discrete inputs including REMOTE ENABLE which is on Connector C2 only Note that two signals HOME and CYCLE can be input to the VECTORSTAR on two connectors C2 and C7 For operation
37. PCMD PRD the results may not be as expected This is because PRD is not stored at the beginning of the command If the motor 18 turning the two references to PRD will produce different results This command takes up to 6 millisec onds to execute and PRD can change several times while this command is executing 8 7 3 Velocity 8 7 3 1 VCMD VFB VE and VAVG VCMD is the commanded velocity Like PCMD it is generated internally from motion commands VCMD is zero when the VECTORSTAR is disabled VCMD is in velocity units VFB is the feedback velocity It is updated every millisecond VFB is always active even when the VECTORSTAR is disabled if you turn the motor shaft by hand and print VFB on the terminal you can see the velocity changing Because VFB is updated very rapidly the speed can appear to vary even when the motor 18 rotating at a fairly constant speed This 18 because the VFB shows the speed averaged over only 1 millisecond The speed from one millisecond to the next 76 VECTORSTAR normally varies a few RPM The long term speed measured over a few seconds normally varies much less about 0 0196 VFB is in velocity units VE is velocity error VE is the difference between VCMD and VFB in velocity units VAVG is the average of VFB over the previous 16 milli seconds Occasionally the normal sample to sample variation of VFB is undesirable In these cases use VAVG 8 7 3 2 Velocity Limits VMAX and V
38. Test Input N N N N N N N N Binary Mask 0 0 0 0 0 0 0 0 Since the mask must be in hex or decimal it can be expressed as 0000000000111001 BINARY equals 39 HEX or 57 DECIMAL which equals 1 8 16 32 DECIMAL Now that the mask is known the condition must be determined The condition 15 formed much like the mask In this case there is a binary 1 for each input that must be on and a binary 0 for each input that is either off or masked VECTORSTAR I O Number 8 I O Input N N N Y Y N N Y Binary 0 0 Number 16 Input N N N N N N N N Binary 0 0 0 0 0 0 0 0 Since the condition must be in hex or decimal it can be expressed as 0000000000011001 BINARY equals 19 HEX or 25 DECIMAL which equals 148 16 DECIMAL Now the mask and the condition can be used in a TIL instruction in the format TIL IN amp mask EQ condition For our example TIL IN amp 39H EQ 19H THIS USES HEX CHAPTER 10 USER PROGRAMS 10 6 1 PRINT P The PRINT P command prints text and variables to the terminal Text and variables may be freely intermixed limited only by the 80 character maximum instruction length The following command prints the speed on the terminal P SPEED VFB RPM Assuming VFB 15 1962 the VECTORSTAR will respond with SPEED 1962 RPM Note that the text must be enclosed by double quotes and that text and or variables must be separated by
39. The following section discusses how the VECTOR STAR limits motor current 8 7 8 1 Continuous Current ICONT The VECTORSTAR limits current in two ways peak current is limited according to the variable ILIM which was discussed earlier in this chapter continuous that is average current is limited according to the variable ICONT The software that limits the time that motor current is allowed to be above ICONT is called foldback since the current 1 gradually folded back to ICONT ICONT 15 dependent on the VECTORSTAR rating and on the motor ICONT is set at the factory and it is in current units Most VECTORSTAR systems have about 2 1 peak to continuous rating Generally ILIM is 10096 of the maximum current and ICONT is about 5096 The purpose of the foldback software 15 to allow the output current to go above ICONT for a short time generally 2 3 seconds while still protecting the VECTORSTAR from overheating 8 7 8 2 Foldback Current IFOLD There are two current limits ILIM and IFOLD ICMD the commanded current is limited by either ILIM or IFOLD whichever is less You can set ILIM but you cannot set IFOLD IFOLD is controlled by the foldback software IFOLD depends on three things ICONT continuous current rating of the VECTORSTAR IMON current monitor and time When the VECTORSTAR is disabled IFOLD is set to some value well above maximum current IMAX and thus well above ILIM Since current is limited by the les
40. Usually this has the identical effect of issuing a BREAK B command CHAPTER 7 SOFTWARE INSTALLATION As an option you can write an error handling routine beginning at label ERRORS This routine should be short and should end with a BREAK B command The error handler is intended for graceful error recovery For example you can set outputs or print a message It is not intended to continue the program as if the error never occurred 7 6 2 3 Monitor Mode The VECTORSTAR Monitor mode is a unique mode for positioners In this mode the user program is running but commands are accepted from the terminal for immediate execution The Monitor mode allows you to display and change variables during program execution including tuning variables You can print and modify any variable from the Monitor mode The commands that are allowed from the Monitor mode are a subset of the commands allowed from the Interactive mode as shown in Table 7 3 Table 7 3 Monitor Mode Commands In the Monitor mode all print commands from the user program are suppressed and the monitor prompt gt is displayed Print commands typed in from the Monitor mode are executed immediately To enter the Monitor mode press the escape key while a program is running Pressing the escape key again will change modes back to the Run mode STOP BREAK and KILL all return the VECTORSTAR to the Interac tive mode 7 6 2 4 Single Step Mode The Single Step mo
41. be between 32767 GEARO must be between 1 and 32767 If the sign of GEARI is changed then the direction of rotation will be reversed If the master is a motor or encoder calculate GEARI and GEARO with GEARI GEARO REV RESOLUTION Ave RESOLUTION Aster where 91 CHAPTER 8 GENERAL PROGRAMMING master 15 arbitrary number of revolutions of the master motor REV vg is the corresponding number of revolutions of the slave motor RESOLUTION is the resolution of the slave motor in counts revolution and RESOLUTION master is the resolution of the master motor in counts revolution If the master is a pulse train that does correspond to a motor or encoder calculate GEARI and GEARO with where COUNTS is an arbitrary number of counts of the master signal and REV and RESOLUTION as before If the signal is from the analog input A2D 1 the gear ratio will be GEARI GEARO 700 16384 for 10 volts 10000 rpm velocity command Clearly GEARI GEARO 70 16384 will give you 10 volts input 1000 rpm To enable the Gearbox mode type GEAR ON If the ratio is not an integer the VECTORSTAR does not drop pulses VECTORSTAR keeps track of partial pulses to eliminate dropping pulses over time If the number of pulses coming into the VECTORSTAR is at a rate that is too large then ERROR 97 GEAR OVERFLOW will be
42. compares a new motor position with a previously measured motor position When the absolute difference between those values is less than the value in X42 for a given number of consecutive test loops the VECTORSTAR concludes the motor has stopped and the in position test can begin X42 is in R D units and there are 4096 units per motor revolution The value of X42 must be greater than 0 and a value that will sense the motor has stopped Typically allow for a minimum of an I R D unit change so use a minimum of X42 2 VECTORSTAR 43 The maximum loop count ofthe motor stopped software test This parameter prevents the software from staying in the motor stopped test loop if the Orient fails If the loop count were to exceed X43 the VECTORSTAR would be disabled and application software execution would be halted Initially set the value high and orient several times After each orient monitor X36 to capture the number of actual loops of the test Select an X43 value based on X36 that will provide a buffer which will prevent nuisance failures 45 The test that senses the motor has stopped compares a new motor position with a previously measured motor position When the absolute difference between those values is less than the value in X42 for a given number of consecutive test loops as defined by X45 the VECTORSTAR concludes the motor has stopped and the in position test can begin The orient in position test must not start until
43. have failed This is simple to confirm Disable the VECTORSTAR and write a program that continuously prints PRD Rotate the motor slowly by hand and observe PRD to see if it skips several counts do not be concerned if PRD skips a few counts look for skips of 50 counts or more If PRD skips more than 50 counts when the motor is rotating slowly contact the factory If the system works differently on power up than it does after your program starts running remember that many switches are reset on power up Your program may set a switch that is cleared or clear one that is set during the initial cycle After that the program may operate differently You may also be setting or clearing switches In your power up routine that may have the same effect 11 7 ERROR LOG The VECTORSTAR responds to a variety of conditions both internal and external hardware and software which are grouped in a single broad category errors An error indicates that there 15 a problem somewhere More serious errors are grouped as faults 11 7 1 Error Levels The VECTORSTAR s response to an error depends on the error s severity There are four levels of severity listed below in increasing order CHAPTER 11 DEBUGGING Table 11 3 Error Severity Levels and Actions Errors that cause warnings Errors that cause a program break and stop motion in addition to Level 1 Actions Errors that disable the system and set the FAULT LED in addition to Level
44. help debug a large program over the telephone 11 5 SYNCHRONIZING YOUR PROGRAM This section describes the functions and variables that allow you to synchronize the program to events both external and internal 11 5 1 Using the Timers TMR1 4 The general purpose timers TMR1 TMR2 TMR3 and TMR4 are provided for situations where the required timing is too complex for the DWELL command The timers are set in milliseconds and are limited to 2 147 483 647 milliseconds or about 25 days The VECTORSTAR then counts down the timer until it reaches zero Type in this example which continuously reprints a message for 1 second 8 TMR1 1000 TIL TMR1 LE 0 WAITING FOR 1 SECOND DELAY B and type RUN 8 Type in this example showing how multiple waits can be based on one timer setting 163 CHAPTER 11 DEBUGGING 9 1 3000 SET TMR1 TO 3 SECONDS P 3 SECONDS TIL TMR1 LE 2000 P 2 SECONDS TIL TMR1 LE 1000 P 1 SECOND TIL TMR1 EQ 0 B and type RUN 9 11 5 2 Regulation Timer RD Fixed length delays can be added into a program with the DWELL D command In some applications especially those that use profile regulation it is necessary to add a delay with a length that varies with the regulating frequency The DWELL RD command is provided for these occasions When the external input frequency is equal to REGKHZ the delay of the RD command
45. high resolution control Standard VECTORSTAR position repeatability is better than one arc minute bidirectional VECTORSTAR has a 32 bit position word Its position loop completely eliminates the digital dither normally associated with positioning systems Long term speed stability is 0 01 The standard system converter 12 bit provides a resolution of 0 0005 RPM and a maximum speed of 12 000 RPM SELF TUNING VECTORSTAR can tune itself You do not have to be a servo expert to set up a system quickly Just specify the desired bandwidth and let VECTORSTAR do the rest POWERFUL MICROPROCESSOR The heart of the VECTORSTAR system is the 16 bit processor that delivers high performance The result VECTORSTAR can control a motor and execute its motion program faster than a standard positioner can DIGITAL SERVO LOOPS Both the position and velocity loops are totally digital The digital loops give VECTORSTAR features not available in standard velocity drives such as self tuning very low velocity offset and digitally adjustable servo tuning parameters The standard analog input permits you to use VECTORSTAR as an analog velocity drive FEED FORWARD GAIN The digital feed forward gain reduces following error and motion initiation delay thereby increasing machine throughput DIAGNOSTICS VECTORSTAR offers a complete set of error diagnos tics When an error occurs VECTORSTAR displays an English language error message VECTORST
46. rapidly changing technology VECTORSTAR How UsE THIS MANUAL How ro use THIS MANUAL INTRODUCTION This manual is designed to help you properly install and use a VECTORSTAR Spindle Drive or Servo System You do not have to be an expert in motion control to operate the system however this manual does assume you have the fundamental understanding of basic electronics and motion control concepts Many of these are explained in the glossary of this manual VECTORSTAR is a programmable motion control device An understanding of computer programming techniques will be beneficial to all users For applica tions that require complex programs a professional programmer should be consulted RECOMMENDATIONS It is recommended that you read this entire manual before you attempt to install your VECTORSTAR system so you can promptly find any information you need This will also familiarize you with system components and their relationship to one another After installation and before you apply your own application check all system functions and features to insure you have installed your VECTORSTAR properly Proper installation can prevent potential difficulties before they cause harm to your system Be sure to follow all instructions carefully and pay special attention to safety CONVENTIONS To assist you in understanding the material in this manual conventions have been established to enhance reader comprehension Explana
47. the individual inputs or outputs are referenced as the bits of a digital word hence the term Whole Word I O Whole Word references are especially useful when you are trying to set or clear many output bits at once If you are unfamiliar with logical binary math or you plan to use I O one bit at a time you may not be interested in Whole Word However it can save space and execution time when properly used Whole Word I O is done using the variables OUT and IN OUT is an 8 bit digital word representing all of the outputs with O1 as the least significant bit LSB and IN is a 16 bit digital word representing all of the inputs with I1 as the LSB Each bit has a value which depends on its position within the word The value in OUT or IN 18 the sum of the values for each bit that 15 turned on The value for each bit is listed in Table 8 4 71 CHAPTER 8 GENERAL PROGRAMMING Table 8 4 Output 1 8 Decimal Values Out Bits O8 07 06 05 04 03 02 01 Value 128 64 32 16 8 4 2 1 For example if O8 and O4 and all other outputs are off then OUT 128 value of 8 value of O4 136 Many bits can be set or cleared with one instruction For example OUT 7 turns on O2 and while turning all other outputs off One logical math statement can be used to set some bits without affecting others For example O1 ON O2 ON ON can be replaced with OUT OUT 7 SET 3 B
48. then turning both back on with the application software executing will turn on Drive Ready as long as the Orient Request input is off If Drive Ready is turned off due to termination of application software execution or the software is halted while Drive Ready is off a Spindle Reset 16 input will be required to start software execu tion Drive Ready will then turn on after the application software has started when Pulse Enable is on Drive Enable is on and Orient Request is off Pulse Enable The Pulse Enable i e REMOTE VECTORSTAR input works in conjunction with the Drive Enable I7 input to energize the motor and place the motor under VECTORSTAR control Both inputs must be on to enable the VECTORSTAR Ifthe Pulse Enable input is turned off the VECTORSTAR is disabled and the motor will be de energized If the motor is rotating when the Pulse Enable input is lost the motor will coast If both Pulse Enable and Drive Enable 17 inputs lost the motor will be de energized and if the motor was rotating it will coast 9 6 4 Units Review 9 6 4 1 Gear Ratio If you can use the on board A D converter for 10 volt input generating 10000 RPM GEARI GEARO 700 16384 and based on this 70 16384 for 1000 RPM accordingly for 10 volt input 9 6 4 2 VXAVG To obtain a correct VXAVG for the different gear ratios the VXNUM and VXDEN should be calculated by the equation 110 VECTORSTAR VXNUM VXDEN 104700 1 x 10000 V max
49. turn off the OT output if the OT fault condition has been removed i e the OT input has turned on Toggling the Spindle Reset I6 input with the application software executing will have no effect on the VECTORSTAR In the user program an alarm label is used to monitor the RESET input See Chapter 10 User Programs for more information about alarm function programming CHAPTER 9 SPINDLE PROGRAMMING Drive Enable The Drive Enable I7 input works in conjunction with the Pulse Enable dedicated REMOTE VECTORSTAR input to energize the motor and place the motor under VECTORSTAR control Both inputs must be on to enable the VECTORSTAR and to turn on the Drive Ready O4 output If the Drive Enable I7 input is lost with the motor rotating the motor will be commanded to 0 speed After the motor reaches 0 speed the VECTORSTAR will be disabled which de energizes the motor and turns off the Drive Ready 4 output If the Pulse Enable input is turned off the VECTORSTAR is disabled and the motor will be de energized regardless of the state of the Drive Enable I7 input If the motor is rotating when the Pulse Enable input is lost the motor will coast The Drive Enable I7 input and Pulse Enable input being off is not a fault state The VECTORSTAR application software is executing which includes monitoring all VECTORSTAR inputs This is comparable to a fault state in which a Spindle Reset 16 input is required to start program execution
50. 0 n n on Non None 1 1 1 1 1 1 r one one r e e e e e p p n n n n n n n n n on n e e e e e e e e e APPENDIX VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION LSTERR LSTLBL __ Last label oxeowed Anas Nue None None None No Motion POS Pp Position from R D 1 8 FF N UT DF E FB L 217 APPENDIX VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION PROGRAM CONDITION PROP Enable Prop Mode PTRIPI Position Trip Point 1 Always PTRIP2 Position Trip Point 2 PXDEN Exter Pos Denominator Always Noe READY 218 VECTORSTAR UNITS PROGRAM LIMITS POS Long Non e None 12000 None None None None None None None None VECTORSTAR APPENDIX F VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION VDEN VEL Units Denominator Velocity Error Never ve vu EXT Velosty Velocity Feedback ___ se Factory VNUM VEL Units Numerator VOFF Gearbox Velocity Offset VOLTS Drive Voltage VXAVG Averaged VEXT VXDEN External Vel Denominator VXNUM External Vel Numerator WATCH Enable Serial Watchdog WTIME Serial Watchdog Timeout VOSPD Overspeed Setpoi
51. 100 VOSPD 100 The VECTORSTAR converted the 100 to 4095 VECTORSTAR basic units INUM 100 4095 100 x x 4095 100 This sets ILIM to 4095 or 100 of full current When you typed P ILIM the 4095 VECTORSTAR basic units were converted to 100 by multiplying by IDEN and dividing by INUM 10 9 1 2 Other User Units VECTORSTAR basic units for position velocity and acceleration vary with the system resolution The resolution 1s determined by the R D converter which converts the position of the motor into a 12 14 or 16 bit number The system resolution is indicated by the model number Table 10 7 System Resolutions R D Resolution Counts in One Revolution When shipped from the factory the standard VECTORSTAR user units are velocity RPM accel eration in RPM second current in percent of full scale and position in counts The velocity and acceleration units shown on MON USER UNITS above are for the standard 12 bit R D converter For 14 bit resolution multiply VNUM and ANUM by 4 For 16 bit resolution multiply by 16 Do not change VDEN or ADEN 148 When velocity units are in RPM VOSPD would be 100 RPM Then if you change the velocity units to inches minute VOSPD would remain 100 RPM it would just be converted to the equivalent of 100 RPM in inches minute If you change any user units you should reset all programmable variables that depend on
52. 2 Actions Errors that disable almost all VECTOR STAR functions including communications and flash the FAULT LED to indicate the error number These are called firmware errors When any error except a firmware error occurs a message is displayed on the screen The following items are printed the error number the offending entry and an abbreviated error message For example disable the drive and type in a DIS J 100 The VECTORSTAR will respond with ERR 50 J 100 INHIBITED VECTORSTAR The error number 50 the offending entry the whole line and the error message you cannot command a jog when the drive is inhibited are given on one 80 character line The error message starts at character 40 so that if a 40 character display is used the error message will not be printed You can display the line directly either with the Motion Link Editor GOTO A LINE NUMBER selection or Q I or with the VECTORSTAR Editor P command Sometimes only entry 15 bad and not the whole line In this case only the bad entry 15 printed For example PROP 2 generates ERR 83 2 BAD OR OUT OF RANGE 167 CHAPTER 11 DEBUGGING since PROP is switch and cannot be set to 2 If the error comes from the program the line number of the offending entry 18 also printed Use the Editor to enter these lines at the top of the user program 11 PROP 2 B Exit the Edito
53. 2 on OUTA Rotate the motor by hand You should see the 27 CHAPTER 2 INSTALLATION encoder output on your scope Repeat this process for OUTB and OUTB and for OUTZ and OUTZ Note that OUTZ changes state only at one point during a full motor revolution 2 7 6 Checking Encoder Input If you have encoder input connect your encoder to Connector C1 The encoder should not be moving Type PPEXT Now rotate the encoder Type PPEXT PEXT should have changed when you rotated the encoder shaft If the results are not what you expected use an oscilloscope to verify that all four signals are reaching Connector C1 Note that encoder equivalent inputs are not available 1f your system has analog input 2 7 7 Checking Pulse Input Optional If you have a pulse input option connect your pulse input to Connector Stop the pulse train Type PPEXT Now inject a few pulses Type PPEXT PEXT should have changed by the number of pulses you injected If the results are not what you expected make sure that you have set the pulse format switch properly Then use an oscilloscope to verify that all four signals are reaching Connector C1 2 7 8 Checking Analog Input Connect the analog input voltage to Connector C10 Adjust the voltage to zero volts Type P VEXT Wait a few seconds and type 28 VECTORSTAR P VEXT VEXT should no
54. 3 Torque Command In a few applications the VECTORSTAR is given a torque command Actually this is a current command but at lower speeds motor torque is approximately proportional to current In this case VCMD is multi plied by KPROP to form ICMD Note that this differs from the proportional velocity loop only in that VFB is not subtracted from VCMD The switch TQ must be on to select the torque mode and off for all other modes The position loop should be off PL off when the VECTORSTAR is running in Torque command mode The VECTORSTAR will turn PL off when TQ is turned A NOTE When TQ is turned on PL is forced off 8 9 4 Power Up Control Loops The VECTORSTAR has at power up the following settings Position loop enabled or disabled PL on or off depends on the last setting used PL is remembered through power down No feed forward KF 0 Integrating Velocity Loop PROP off TQ off These settings meet the requirements of a large number of applications Figure 8 9 shows each of the five VECTORSTAR controller modes 97 CHAPTER 8 GENERAL PROGRAMMING VECTORSTAR PL 4 0 PROP 0 GEARING amp PROFILE GENERATION POSITION LOOP w INTEGRATION PL 1 0 PROP 1 GEARING amp PROFILE GENERATION POSITION LOOP w o INTEGRATION PL 4 TQ 0 PROP 0 GEARING amp PROFILE GENERATION VELOCITY LOOP w INTEGRATION Figures are correct when PDF 1 Figure 8
55. 3 VARIABLES The VECTORSTAR uses variables to monitor and control virtually all of its processes 63 CHAPTER 8 GENERAL PROGRAMMING 8 3 1 Variable Units Some variables have implicit units associated with their values For example all variables that monitor or control velocity have velocity units In addition there are acceleration units current units and position units Appendix F lists each variable with its units Units are programmable when shipped from the factory the standard settings are as follows Table 8 1 Standard Units of Full Amplifier Current Units Output Position Units Counts Velocity Units RPM External Position Units Counts External Velocity Units RPM This assumes external source is a motor with the same resolution as the VECTORSTAR That is external velocity units are set the same as velocity units With standard units position is expressed in resolver to digital R D converter counts if your VECTORSTAR is configured with the standard 12 bit resolution converter then one revolution is 4096 counts You can change the units to whatever is convenient for your application For example you can select Radians Second instead of RPM Also units can be tailored to a specific machine For example if the VECTORSTAR is driving a lead screw velocity could be programmed in inches minute If you want to change the units see Chapter 9 Machine Specific Units Examples i
56. 8 Printing Control Characters The VECTORSTAR uses the standard ASCII character set as shown in Appendix E There are unprintable characters such as the bell ASCII 7 and carriage return ASCII ODH These characters have an effect on the terminal but do not print anything on the screen Un printable characters range from ASCII 1 to The VECTORSTAR cannot print ASCII 0 As Appendix E shows each unprintable character can be produced with a control sequence For example most terminals will sound a bell when you press lt Control gt G hold down the control key while pressing the G key As Appendix E shows lt Control gt G produces 07 or the ASCII bell You can use the VECTORSTAR to produce unprintable characters by preceding the appropriate character with the carat 7 to signify an unprintable character For example the following VECTORSTAR command will sound the bell on your terminal P AG You can also use the character format to print control characters For example P 07 C 135 CHAPTER 10 USER PROGRAMS also sounds the bell The character format allows you to print variables as ASCII codes However the easiest way to print control characters is normally with the carat One reason for this 15 that control characters can be within text strings For example P BELL lt CONTROL gt G 6 SOUNDS A BELL If you use the carat to specify an invalid control charac ter
57. AND TXD C5 PIN 3 C2 PIN 15 CYCLE ONLY RS 232 5 2 v RDP C2 PIN 9 SEAL 250 DEM 5 ISOLATOR C5 PIN 6 C2 PIN 19 TD OPTICAL C5 PIN 7 ISOLATOR gt TD 120 C2 PIN 8 RS 485 lt OPTICAL CYCLE ISOLATOR RD C5 PIN 8 C2 PIN 18 IN COMMON C5 PIN 9 RD HOME INPUT BUFFERS o 13 PULL UP CYCLE C7 PIN 11 o LIMIT oo MOTION C7 PIN 17 74HC14 GAIE C7 EVEN PINS MICROCOMPUTER SYSTEM C7 STANDARD C8 EVEN PINS C8 PIN 33 4 oo MANUAL C8 PIN 31 4 oo n INPUT BUFFERS INPUT BUFFE MICROPROCESSOR d oo AND PULL UP 12 C8 PIN 27 oo n C8 PIN 25 E 4 o n C8 PIN 23 EM 4 oo E C8 PIN 21 4 oo 16 C8 PIN 19 4 oo C8 PIN 17 EM 4 o C8 PIN 15 EM 7415540 19 C8 PIN 13 d oo 110 C8 PIN 11 MD BACK UP ES gt d 115 C8 PIN 1 oo 116 OPTIONAL DIFF CMD HI ce LT ANALOG TO PULSE C2 PIN 1 DIFF CMD LO l CONVERTER OPTIONAL 945 SN75175 CHA gt ENCODER C1 PIN 10 TO VECTORSTAR SYSTEM OVERVIEW C1 PIN 4 DIGITAL nTYY SN75175 CHB b 8 gt C1 PIN 9 Figure 1 4 VECTORSTAR System Overview VECTORSTAR CHAPTER SYSTEM DESCRIPTION RD TD CARD RESOLVER TO DIGITAL CONVERTER ACTIVE LED SYS L
58. ANUM and ADEN ANUM 447392 ADEN 10000 The VECTORSTAR does not support floating point operations You must use fractional units to make the resolution finer For example if the units for velocity need to be finer than IPM 0 1 IPM could be chosen In this case VDEN would be 100 instead of 10 Then to jog at 1 IPM the command J 10 would be required 10 9 3 Position Rotary Mode ROTARY and PROTARY The VECTORSTAR stores position in a 32 bit number This number 18 large enough to count many revolutions For example the 32 bit number will store the counts from a 12 bit R D converter for about 10 million revolutions before the 32 bit limit is exceeded Nor mally this is sufficient However some applications require the motor to rotate in one direction indefinitely Eventually the 32 bit limit will be exceeded resulting in anerror The Rotary mode allows the VECTORSTAR to support these unidirectional applications The Rotary mode forces all position related variables to roll over after position feedback exceeds specified limit The variables that are rolled over are PFB PCMD and PFNL The rotary distance the specified limit before roll over is stored in PROTARY PROTARY is in position units When ROTARY is on the Rotary mode 15 enabled If PFB is greater than PROTARY then PFB PCMD and PFNL are decremented by PROTARY If PFB is less than zero then PFB PCMD and PFNL are incremented by PROTARY Note that DI
59. APPENDIX H COMMAND TIMINGO ier ice ciu nte asa co chs eet ca se 235 INDEX exar M 237 TABLE CONTENTS VECTORSTAR VECTORSTAR 1 SvsrEM DESCRIPTION 1 1 INTRODUCTION The information in this chapter will enable you to under stand VECTORSTAR s basic functions and features These concepts will allow you to apply them to your own unique applications 1 2 PRODUCT DESCRIPTION VECTORSTAR is a full featured high performance induction spindle and positioning servo in one compact enclosure it isa totally integrated package available to motion control users VECTORSTAR combines a positioner a servo amplifier and an I O interface into one unit VECTORSTAR sets new standards for motion control with its simple BASIC like command structure and sophisticated decision making capability VECTORSTAR provides the outstanding servo performance that you have come to expect from Kollmorgen Using a high perfor mance microprocessor VECTORSTAR does not compro mise on either positioner software or servo performance This single microprocessor closes all servo loops resulting ina truly integrated positioning system VECTORSTAR has the features and performance you need in your next spindle or positioning application CHAPTER SYSTEM DESCRIPTION 1 3 FEATURES VECTORSTAR offers a wide feature set to accommodate real world requirements LOW COST VECTORSTAR is ve
60. BACKGROUND PRINTING ROUTINE HERE END ERROR ERROR HANDLER WRITE YOUR ERROR HANDLER HERE B OF SAMPLE PROGRAM VELOCITY DRIVE SAMPLE PROGRAM DATE NAME POWER UP EXECUTE ON POWER UP PL OFF DISABLE THE POSITION LOOP VNUM 447392 SETS VELOCITY UNITS TO RPM 100 ANUM 447392 SETS ACC UNITS TO RPMISEC ADEN 100000 AMAX 100000 THE MAX ACCEL RATE ACC 1000 THE NORMAL ACCEL LIMIT DEC 1000 THE NORMAL DECEL LIMIT AND DEC ARE RAMP LIMITS FOR GEAR MODE ASSUMING THAT PL IS OFF GEARI 10 THIS SETS THE GEAR MODE FOR 25 GEARO 40 APPROX 10 3000 RPM FOR ANALOG INPUT THE PROPER LEVEL OF GEARI AND GEARO DEPENDS ON THE SYSTEM AND THE INPUT FORMAT THE ADJUSTMENT OF GEARI AND GEARO IS EQUIVALENT TO A DC GAIN ADJUSTMENT OR SCALE FACTOR POT FOUND ON MANY ANALOG DRIVES NOTE THAT ACCIDEC RATES ARE LIMITED BY ACC AND DEC ONLY WHEN PL IS OFF EN ENABLE DRIVE GEAR ON ENABLE ELECTRONIC GEARBOX 158 VECTORSTAR CHAPTER 10 USER PROGRAMS VOFF 0 THIS SETS THE OFFSET VELOCITY VOFF IS SET TO ZERO WHEN GEAR IS TURNED ON THERE IS NEED TO ADJUST FOR VELOCITY DRIFT IN THE INPUT THEN ADJUST VOFF TO THE PROPER LEVEL SO THAT DRIFT STOPS B DRIVE IS NOW IN ELECTRONIC GEARBOX END OF SAMPLE PROGRAM 159 CHAPTER 10 USER PROGRAMS VECTORSTAR 160 VECTORSTAR C une 11 DEBUGGING CHAPTER 11 DEBUG
61. BE TURNED ON WARNING 8 6 1 Firmware Faults Area 1 Area 1 shows how firmware faults are combined Firmware faults are the most serious errors They include checksums to help verify computer memory watchdogs to help verify that the computer is running properly and the 5 volt logic power supply monitor VECTORSTAR These circuits are designed to watch the basic operation of the microprocessor They do not generate error messages because the detected fault affects the micropro cessor directly Instead they just blink the Central Processing Unit CPU LED As shown in Figure 8 1 firmware faults set a latch to turn off communications and blink the CPU LED The CPU LED blinks in cycles consisting of 2 to 8 blinks and a pause The number of blinks corresponds to the error number which you can look up in Appendix C The only way to reset these faults is to power down the VECTORSTAR These faults are serious and you should consult the factory if they occur Do not confuse these faults with autobauding on power up When autobauding the CPU LED blinks at a constant rate about three times per second 8 6 2 Fault Logic Area 2 The large OR gate in Area 2 combines three types of faults hardware software and firmware The circuits that generate these faults are typical of motor controllers and are listed on the drawing These faults are errors that are serious enough to disable the VECTORSTAR as described in Appendix C 8
62. CLAMP is 0 during preliminary operation Position error limit for system This variable 1 initially set to 32767 its upper limit for preliminary operation and can be reduced later PEXT monitors the position of the external master axis Initially this variable is undefined Value of this variable does not matter during initial operation Enable position loop This variable is remembered Enable software travel limits This variable is remembered Positive software travel limit Initially set to 100 If PLIM is 0 the value of this variable does not matter Negative software travel limit Initially set to 100 If is 0 the value of this variable does not matter Set to 1 on power up and almost always left at 1 When set to 0 all prompts such as gt which are normally sent to the screen are not printed This allows you to print customized messages Position units numerator Initially set to 1 Enable proportional velocity loop This 67 CHAPTER 8 GENERAL PROGRAMMING PXDEN PXNUM REGKHZ SCRV SS STATMODE TMRI TMR2 TMR3 TMR4 TRC TRIP TQ 68 variable is set to 0 on power up and usually left at 0 for preliminary opera tion External position units denominator Initially set 1 Value of this variable does not matter during initial operation External position units numerator Initially set to 1 Value of this variable does not matter during initial oper
63. Correct any such condition before resuming operation REMOVE ALL POWER BEFORE CHECKING THIS If everything is functioning properly a drive with a higher current rating may be required This error breaks program execution and disables the VECTORSTAR ERROR 12 OVER CURRENT SEVERITY 3 The VECTORSTAR detected an overcurrent This can be caused by a shorted motor winding a shorted power transistor or a short circuit in the wiring Be sure to check all wiring before resuming operation This error breaks program execution and disables the VECTORSTAR ERROR 13 OVER SPEED SEVERITY 3 The VECTORSTAR determined that the speed of the motor was greater than the variable VOSPD If this occurs occasionally it may be a nuisance fault that should be corrected by raising VOSPD by 5 or 10 This error breaks program execution and disables the VECTORSTAR ERROR 14 POWER BUS SEVERITY 3 The power supply high voltage bus has either an overvoltage fault or an undervoltage fault See Chapter 3 for more information This error breaks program execution and disables the VECTORSTAR ERROR 15 COMP BOARD SEVERITY 3 You attempted to enable the VECTORSTAR with the compensation board removed Replace the compensation board This error breaks program execution ERROR 17 FEEDBACK LOSS SEVERITY 3 The VECTORSTAR has detected that one or more wires to the resolver have been broken or the resolver connector has been removed This error breaks program exe
64. DWELL 0 25 SEC END Apply DC bus power to your VECTORSTAR and type RUN 1 The result should be MOVE PROCESSED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED UPPER TASK IDLED ALL MOTION STOPPED Note that task level 5 immediately processes the move and then is idled until motion stops While task 5 is idled the lower level background task executes continu ously 142 VECTORSTAR 10 8 5 3 Avoiding Idling You can avoid idling the VECTORSTAR by using the TIL command in place of Dwell Wait or Hold For example TIL SEG EQ 0 15 the same as W 0 except the TIL command locks out lower priority tasks since it is not an idling command The Wait command allows lower level tasks to execute since it is an idling command 10 8 6 Alarms Task Levels 1 3 Alarms are the highest priority tasks There are three alarms A B and C A is the highest priority and C is the lowest Normally alarms are used to monitor hardware inputs but they can monitor any user switches XS1 XS50 and MANUAL Using an alarm relieves you of having to write your program so that it checks switches After you define an alarm the VECTORSTAR will watch the switch and automatically execute the code that you specify should the alarm fire Alarms are specified on one line along with the switch that triggers the alarm and the transition For example the A alarm can be defined to fire when
65. END POSITION TO REGISTRATION POSITION OFFSET WAIT FOR MOTION TO STOP TURN ON SAW OUTPUT Figure 10 1 Sample Flowchart 122 VECTORSTAR 10 2 4 Commented Program The following program will work for this application THIS PROGRAM DOES NOT HAVE A HEADER THAT IS THE BEGINNING SECTION WHICH HAS A LOT OF INFORMATION USE THE PROGRAM IN APPENDIX E AS AN EXAMPLE OF A PROGRAM HEADER 1 START OF PROGRAM O1 OFF TURN OFF THE SAW OUTPUT CAPDIR 1 SET REGISTRATION DIR POSITIVE EN ENABLE VECTORSTAR 5 BEGIN LOOP IF 11 EQ 1 15 STOP INPUT GOTO 10 GOTO TO STOP ROUTINE ELSE NORM 0 NORMALIZE TO 0 ACC 1 SET ACC DEC X2 SET DEC CAP ON TURN ON CAPTURE TIL 12 EQ 1 WAIT FOR START 1 TURN OFF SAW OUTPUT J X3 START MOVE TIL CAP WAIT FOR REGISTRATION JT PCAP X4 SET END POSITION TO CAPTURED POSITION PLUS AN OFFSET X4 TIL SEG WAIT FOR MOTION TO STOP O1 ON TURN ON SAW OUTPUT GOTO 5 GO TO TOP OF LOOP ENDIF 10 START OF STOP ROUTINE K DISABLE VECTORSTAR P STOP HAS BEEN ISSUED B 8 EXECUTION CHAPTER 10 USER PROGRAMS 10 2 5 Customer Service If you need help with software or understanding VECTORSTAR functions you can contact the Regional Kollmorgen Sales Office See Appendix D Ask for the Sales Applications Engineer Please observe the following procedure 1 Contact Kollm
66. Exceeding 30 volts could damage this input Observe polarity when connecting CYCLE and CYCLERETURN Note that CYCLE is also available on Connector C7 The CYCLE signal on the Connector C7 is not optically isolated If you use both CYCLE inputs then the VECTORSTAR will sense that CYCLE is on if the CYCLE signal from either Connector C2 or C7 is on REMOTE REMOTERETURN Pins 9 6 REMOTE is on pin 9 REMOTE RETURN is on pin 6 REMOTE is an input that must be activated for the VECTORSTAR to be enabled REMOTE is optically isolated It should be pulled up to between 12 and 30 volts with reference to REMOTE RETURN not common to activate the REMOTE input Exceeding 30 volts could damage this input Observe polarity when connecting REMOTE and REMOTE RETURN HOME HOME RETURN Pins 19 18 HOME is on pin 19 HOME RETURN is on pin 18 HOME is intended to be connected to a home limit switch it can also be used as a general purpose input HOME is optically isolated HOME should be pulled up to between 12 and 30 volts with reference to HOME RETURN not Common to activate the HOME input Exceeding 30 volts could damage this input Observe polarity when connecting HOME and HOME RETURN 19 CHAPTER 2 INSTALLATION Note that HOME is also available on Connector C7 The HOME signal on Connector C7 is not optically isolated If you use both HOME inputs then the VECTORSTAR will sense that HOME is on if the HOME signal from either Connector C2 or C7 i
67. GOSUB 60 GO FOR PROCESSING OT X57IN X5 NE X2 GOSUB 20 GO FOR PROCESSING THE INPUT READY 0 GOSUB 90 DRIVE NOT ENABLED REMOTE amp I7 EQ 0 READY EQ 1 GOSUB 100 REMOTE IS OFF ZERO SPEED X4 VAVG X4 LT 0 X4 0 X4 VZR LT 0 VZR 5 IF X4 LE VZR 011 ELSE O10 ENDIF AT SPEED LT 0 VUP 10 VUPH LT 0 VUPH 10 X10 VXAVG VAVG BETWEEN THE ACTUAL SPEED AND COMMAND X10 LT 0 X10 0 X10 ABSOLUTE VALUE IF X10 LT VUP WITHIN THE BAND O21 ELSE IF X10 GT VUP VUPH OUT OF 2ND BAND O20 ENDIF CHAPTER 9 SPINDLE PROGRAMMING ENDIF GOTO 10 REPEAT LOOP INPUT PROCESS 20 6 5 2 7 5 amp 2 2 5 5 6 7 X5 amp 8 EQ 8 GOSUB 50 DRIVE OT X5 amp 16 16 GOSUB 60 MOTOROT X5 amp 1 EQ 1 GOSUB 30 SPINDLE AXIS X5 amp 2 EQ 2 GOSUB 40 ORIENT RET SPINDLE AXIS 30 GEAR 0 IF 11 EQ 1 GEARI GEARIC SWITCH THE GEAR RATIO VXNUM VXNUMC SWITCH THE SCALE TO VXDEN VXDENC O7 1 RAMP 0 ELSE BACK TO OPEN LOOP GEARI GEARIO VXNUM VXNUMO VXDEN VXDENO RAMP 1 070 ENDIF 2 EQ 0 GEAR 1 RET SPINDLE ORIENT 40 212 0 RET READY EQO RET O7 OFF CONTINUE TURN GEAR JO wo ZPE PL1 MRD P1 VORNT USE MRD TO ORIENT 111 CHAPTER 9 SPINDLE PROGRAMMING wo 011 031 020 TIL 2 0 030 HOLD THE POSITIO
68. If your applica tion does not need software travel limits or if you want to disable software travel limits temporarily type PLIM OFF This error breaks program execution ERROR 24 HARDWARE OVERTRAVEL SEVERITY 3 The VECTORSTAR detected an overtravel condition while it was enabled You can print the state of the overtravel limit switch by typing P LIMIT If LIMIT is 0 then an overtravel condition exists LIMIT should be connected to a limit switch that has contacts that are normally closed but which open where an overtravel condition occurs Hardware overtravel limits cannot be disabled This error breaks program execution and disables the VECTORSTAR ERROR 25 PE OVERFLOW SEVERITY 3 The variable PE the position error exceeded the variable PEMAX This is also called a following error overflow This error breaks program execution and disables the VECTORSTAR ERROR 26 PFB ROLLOVER SEVERITY 3 The variable the position feedback exceeded 2 147 483 647 counts If you are using position units then exceeded the position unit equivalent of 2 147 483 647 counts This can occur if the motor rotates indefinitely in one direction If your application requires this consider using the rotary mode as described in Chapter 10 ERROR 27 RID JUMPERS SEVERITY 3 Either the jumpers on your VECTORSTAR 2 card are incorrectly set or the wrong TL has been loaded Contact the factory 199 APP
69. KLRIIOBCB CAPACITOR CARD A 96432 97334 001 QTY 4 97334 001 QTY 4 97334 001 QTY 6 P 97334 001 QTY 6 Figure 12 8 High Power VS R L VS R P System Matrix Component LIstings 5 1 97337 VSRP40 0012 T60100 3C J LLS 1004 600V 97335 002 97342 002 KLR558TB 2 511 001 1 MG300Q 97731 JLLS 200A 600 KLRIIOBCB 150A 100 97345 026 97345 026 96354 012 602004 97731 001 QTY 3 MG300Q265 11 JLLS 200A 600V KLRIIOBCB 97345 026 602004 MG400Q1US 41 QTY2 JLLS 250A 600V KLRI30BCB 150A 1200 97345 028 97335 005 96354 012 BHOI P MG400Q1US41 97332 001 QTY 6 JLLS 250A 600V KLR130BCB 97345 028 97335 005 BHOI P 179 CHAPTER 12 HIGH POWER IGBT MODEL HEATSINK POWER STAGE REGEN CONTROL AC VOLTS VSL25 0012 VSP25 0012 VSRL25 012 VSRP25 0012 VSP40 0012 8 gt 460 VAC gt CM300DY 12H 230 VAC A 98715 300 RESISTIVE REGEN MG100Q2YS11 P 100 RESISTIVE REGEN 8 gt g gt gt 8 gt et el ejeje s ejeje gt gt gt gt gt 12H A 95144 CONT ROL 460 VAC A 95158 INTERFACE LINE REGEN A 95159 ADAPTER Y IDH 230 VAC 93715 300 RESISTIVE REGEN 12H 8 MG200Q2YS 11 P 97330 RESISTIVE REGEN CM300DY A 95144 CONTROL 230 VAC 93715 300 95158 INTERFACE 95159 MG200Q2YS11 A 95144
70. Like hex logical math is often used when programming computers With logical functions two numbers are converted to binary representation and compared bit by bit When the numbers are ORed if either bit 15 set the result bit is set With ANDing both bits must be set for the result to be set Type in the following examples P 1 2 THIS IS 3 The VECTORSTAR responds 3 since 00000001 Binary 1 OR 00000010 Binary 2 00000011 Binary 3 P 1 amp 2 THIS IS 0 The VECTORSTAR responds 0 since 00000001 Binary 1 AND 00000010 Binary 2 CHAPTER 8 GENERAL PROGRAMMING 00000000 Binary 0 Logical math is generally used with hex constants Logical math is also useful when trying to use general purpose inputs to control the user program 8 5 GENERAL PURPOSE INPUT OUTPUT The VECTORSTAR provides 16 general purpose inputs and 8 general purpose outputs On power up all outputs are turned off Inputs and outputs can both be referred to individually or collectively I1 I2 116 represent the individual inputs and O1 O2 O8 represent the outputs You can turn the third output on and the sixth off by typing ON TURN ON THE THIRD OUTPUT BIT O6 OFF TURN OFF THE SIXTH OUTPUT BIT To display the fifth input type P I5 Either 1 or 0 will be displayed 8 5 1 Whole Word I O Inputs and outputs can also be referred to collectively In order to do this
71. P for format and examples Allowed from the interactive and monitor modes and the user program Playback recorded points This command prints all the variables that were recorded by the last RECORD command Normally you should use Motion Links PLAYBACK FROM VECTORSTAR command rather than the VECTORSTAR PLAY command Motion Link formats plots and prints data in a much more readable form than does the VECTORSTAR Refresh screen This command is the same as the P command except that no line feed is printed This command can be used to overprint the practice of refreshing the display by printing a line with new values over the same line with old values It is generally used for status updating See P for examples and formats Allowed from the interactive and monitor modes and the user program VECTORSTAR RD RECORD RS RUN APPENDIX G SOFTWARE COMMANDS Delay program execution for a specified period of time but use external clock to time the delay REG need not be on for RD to function properly Allowed only from the user program Format RD Time Example RD 1000 Record 1 4 variables for a specified period of time This command allows you to record most VECTORSTAR variables in real time for later playback You cannot record PE REMOTE TMRI TMR2 TMR3 4 VAVG VXAVG or any user switches Allowed from the user program or from the interactive mode Format RECORD Number Time 1 to 4 Var
72. PA s The thermal overload relay included in the kit was sized for your resistance and power rating the output contacts of the relay must be wired to drop power to the main power contactor in a fault condition as shown in Figure B 1 Do not wire control power PA connector C8 through the main power contactor This is so that control power won t be removed if PA fault contacts open this would turn off any fault LEDs If the VSA uses the optional analog input card VSA the optional encoder inputs in Connector are used Recommended torques for connection to terminal blocks and ground VSA 30 to 55 AMP B ground screw B PA 50to 75 AMP Max torque 20 main power bus connection and ground stud Max torque 12 external regen connection For grounding to machine or earth ground a screw lug should be attached to ground screw or stud Recom mended torque of 12 for ground screws and 20 in Ib for ground studs May also refer to National Electric Code NEC or UL Standard 486B for recommended torques Thermal overload protection is not provided internal to amplifier and must be provided externally Refer to National Electrical Code for proper sizing of overload protection Filter must be provided external to the equipment to meet CE requirements Contact factory for details Motor Cable Power Use Kollmorgen Cable Assembly Example Model No for B 20X motor is GC M2 4 5 xx See Note 9 Ther
73. PHASE B SIN 2 3 2 5 6 7 8 B TOP IGBT 2 C TOP IGBT A BOT IGBT 1 B BOT IGBT C BOT IGBT TO SCR GATES ON DIODE RETURNLUINE RETURN LINE 2 REGEN G2 REGEN E2 MOTOR BRAKE SENSE NOTE 3 CUSTOMER INPUT FROM E STOP 4 HEATSINK THERMOSTAT Sheet 2 based on D 97348 Figure 12 4 VSL VSP Resistive Regen System Diagram Sheet 2 175 CHAPTER 12 HIGH POWER VECTORSTAR VECTORSTAR 38 00 5 08 13 70 Figure 12 5 Outline and Dimensions VSL70 176 DIMENSIONS ARE MM IN 2 Based Dwg 97170 VECTORSTAR CHAPTER 12 POWER 2 gt gt PE see E _ x SEON lt 2 53 O Es D ag Z 7 oz 2 Based Dwg 97177 Figure 12 6 Outline and Dimensions VSL40 177 CHAPTER 12 HIGH POWER OVA 097 2 09 OEZ OVA OEZ 5405856 W319 YIMOd S39vMOVd OF 9 SZ NO 69196 u3ldvQv N3934 CNV 89196 3O0V3H31NI N3938 39V 1d38 3LON AMO MASZ NO 0351 Z ILON 3954 0351 LON 4 310N 81096 SSAA 39115 u3MOd 934 13 22750 7 41 5 41 N3934 xooig HVISHOLO3A 89996 0 uo peseg NES ILON 140 N3934 t9 maam ha 5 10000
74. Pins 15 and 16 The VECTORSTAR is shipped from the factory with this jumper installed GATE Pin17 The GATE input starts precalculated motion profiles It is used to synchronize motion with external events This line may be used as a general purpose input if its primary function is not used 07 08 Pins 19 21 07 and 08 are general purpose outputs CYCLEREADY Pin 23 CYCLE READY is an output that indicates that the VECTORSTAR is ready for the CYCLE line to be activated CYCLE READY is often connected to PLC s or to a lamp on an operator panel 2 6 4 11 Wiring C8 Optional I O C8 is a 50 pin ribbon cable connector as shown in Figure B 7 It provides non isolated 5 volt TTL level inputs and outputs are open collector and directly interfaced to 24 line OPTO 22 compatible I O boards These boards are widely available and use industry standard optical isolation modules This connector is optional It is on top ofthe VECTORSTAR 23 CHAPTER 2 INSTALLATION Note that you must provide a separate power supply when using standard OPTO 22 compatible I O boards This supply must provide 5 volts DC to power the I O modules on the VECTORSTAR side ofthe isolation The common of this supply will normally be connected to the common ofthe VECTORSTAR through the even numbered pins on Connector C7 Do not use the VECTORSTAR 5 VDC power supply to power I O modules Additionally a second power supply may be needed to provide power for those de
75. TO HOME TIL EQ 0 WAIT FOR CAPTURE TO OCCUR 70 8 MOTION 200 RETURN TO APPROXIMATE HOME 1 LOW SPEED HOME CAN BE FOUND TIL HOME EQ 0 ONCE HOME IS CROSSED STOP 70 VECTORSTAR The capture position 1s accurate to 25 microseconds The resulting error is proportional to speed For example for a 12 bit R D converter if the capture were done while the motor was rotating at 5000 RPM the error would be limited to about 1 degree If this is not close enough you can jog the few bits until the switch is tripped or you can use the MRD as discussed above 8 8 10 Clamping Clamping stops VECTORSTAR motion when the position error exceeds a set point This is used to determine that the motor usually through a lead screw has run a part into a mechanical stop The profile stops and the part is held with limited torque This is some times referred to as Feed to Positive Stop The stop 15 detected by watching position error when position error exceeds the variable the part is assumed to have run into a stop When a stop has been detected the VECTORSTAR will hold the current at which should be set to the proper holding current ILIM can be increased or decreased after the stop has been detected To enable clamping turn CLAMP on PECLAMP can be changed at any time In general clamping is done at low speeds with the current limited to
76. The PA and VECTORSTAR are configured at the factory for operation from a 230 volt AC Line The PA and the VECTORSTAR must both have the same voltage rating Operating a PA ora VECTORSTAR with incorrect voltage can damage the units Incorrect motor wiring can cause erratic or runaway motor opera tion Use of factory supplied cable sets is highly recom CAUTION mended 2 6 2 1 Wiring the Motor Connect Pins A B and C of the motor connector through a motor cable to Ma Mb and Mc respectively on the Power Terminal Block located on the front of the VECTORSTAR amplifier Connect Pin D ofthe motor connector through the same motor cable to the VECTORSTAR chassis ground screw located directly beneath the Power Terminal Block Itis very important that you wire the motor properly Brushless permanent magnet motors are not like induc tion motors You cannot simply interchange two phases to reverse the direction of rotation 14 VECTORSTAR Table 2 1 Motor Cable Color Code Motor Wire VECTORSTAR Connector Marker Power Terminal Ma Terminal M4 Terminal Mp Terminal Incorrect motor wiring can cause erratic or runaway motor operation Use of factory sup plied cable sets is highly recom mended WARNING 2 6 2 2 Motor Protection Under normal conditions you do not need to add protection for your motor the VECTORSTAR is nor mally configured to limit the continuous current below the rating of the motor H
77. VECTORSTAR will begin executing the user program at AUTOS and CYCLE READY output will turn off 10 8 8 4 Manual Program MANUAL The following conditions must be met for the VECTORSTAR to execute the MANUAL program When these conditions are met the VECTORSTAR will begin executing label MANUALS Multitasking must be enabled MANUALS must be present in the user program No routines can be executing at task level 5 The MANUAL input must be off Up If these conditions are met the VECTORSTAR will execute the user program at MANUALS You may have noticed that AUTO and MANUAL are very similar The important difference 1s that while the AUTO program begins when CYCLE START turns on the MANUAL program runs continuously 10 8 8 5 Typical AUTO MANUAL Programs Figure 10 2 shows typical AUTO and MANUAL programs This flowchart shows the effects of the MANUAL and CYCLE switches The sample AUTO program causes the motor to rotate one revolution each 145 CHAPTER 10 USER PROGRAMS time the CYCLE switch transitions from offto on The sample MANUAL program is written so that I1 and I2 are JOG and JOG switches So when the MANUAL switch 1s on the VECTORSTAR monitors the jog buttons when MANUAL is off the CYCLE button causes the motor to rotate one revolution Note that both the AUTO and MANUAL programs end with the END command this is the normal way to conclude these programs 10 8 9 Background Task Level 6 The bac
78. X X1 will generate this error This error breaks program execution if the instruction is issued from the user program 203 APPENDIX C ERROR CODES VECTORSTAR ERROR 86 USER PROGRAM FULL SEVERITY 2 You attempted to load a program larger than the VECTORSTAR can hold This occurs with the gt BDS instruction and from the Motion Link communications software Program Transmit T This error breaks program execution ERROR 87 EMBEDDED QUOTE SEVERITY 2 You entered a command with an embedded quote A space must precede an opening quote and follow a closing quote For example P BAD COMMAND has an embedded quote after the P This error breaks program execution if the instruction is issued from the user program ERROR 88 NO CLOSING QUOTE SEVERITY 2 You entered a command with an odd as opposed to even number of quotes This error breaks program execution if the instruction 1 issued from the user program ERROR 89 NOT FOR ALARMIHOLDIRECORD SEVERITY 2 You have specified a switch that is not an allowable switch for an alarm or a hold or record command For example A REMOTE ON ERROR REMOTE NOT ALLOWED FOR ALARMS This line causes Error 89 since REMOTE is not allowed to fire an alarm ERROR 90 TOO MANY POINTS SEVERITY 2 You specified too many points in a RECORD command Only 1000 points total can be recorded For example if you are recording four variables they can be recorded n
79. X1 X2 X2000 They can be displayed and assigned new values like other variables They can store numbers that range from 2 2 147 473 648 to 2 1 2 147 473 647 For example if you want to store PFB the position feedback at a particular time and use it later in a calculation you can assign PFB to a user variable Type the following line on the terminal X1 PFB Now without moving the motor print X1 and PFB by typing P X1 PFB This print statement prints both X1 and PFB on one line and should show them to have approximately the same value Note that when the motor is disabled the position feedback can change slightly so there may be a small difference in the values Turn the motor about one half of a revolution and repeat the print statement from above Notice that X1 has remembered the old position feedback while PFB has changed X1 will not change unless you assign it a new value 8 3 10 1 Indirect User Variables An advanced method of accessing the values stored in user variables is called indirect With indirect user variables the specified user variable points at another user variable Indirect references to variables have the format X Xn where n is between 1 and 250 The value stored in the variable Xn specifies the variable that X Xn refers to This is best illustrated with an example Suppose you want to look at either X1 or X2 when X10 is either 1 or 2 Type this example
80. You can Hold for any switch except REMOTE and user switches 511 850 User switches XS1 XS10 are allowed with the HOLD command 10 7 2 DWELL D Sometimes it is desirable to delay execution for a specified amount of time The DWELL D command is the easiest way to do this The delay is specified in milliseconds For example D 1000 DWELL 1000 MILLISECONDS delays execution for 1000 milliseconds or 1 second The DWELL command can be demonstrated by typing in the following simple program 6 P BEGIN 5 SECOND DWELL D 5000 P END 5 SECOND DWELL B Now exit the Editor and type 138 VECTORSTAR RUN 6 The result should be BEGIN 5 SECOND DWELL END 5SECOND DWELL with 5 seconds between lines being printed Dwells can be up to 2 147 483 647 milliseconds or about 25 days 10 7 3 WAIT W When using MOVE commands it is often necessary to synchronize the execution of your program to motion The WAIT W command can be used to wait for the specified motion segment Examples of the WAIT command are W 0 WAIT FOR MOTION TO STOP W 1 WAIT FOR MOTION COMMAND TO BEGIN W 14 WAIT FOR SEGMENT 14 MACRO MOVE These commands are similar W 0 delays program execution until the last motion command entered has stopped W 1 delays program execution until the last motion command entered has started W 14 waits for segment 14 of the last motion command to begin In
81. a Windows based program designed to most effectively assist the user in setting up and controlling the drive s operation It is highly intuitive in nature and contains an extensive context sensitive on line Help tool press F1 to access The on line Help describes how to use the program in detail and serves as a valuable reference for the drive s variable and command set setup process and troubleshooting techniques Since the software is designed to guide the customer through the operation process of the drive the MotionLink discussion in this section will cover only the installation of the program on the user s computer Once the program is installed the user can then start the program and press the 1 key for extensive detailed help A dumb terminal can also be used to communicate to the drive MotionLink also provides a terminal emula tion feature that contains many useful editing tools for this type of communication The following is recom mended When setting the values of drive variables use the many graphical screens in MotionLink When editing a program use MotionLink s Program Editor screen When running and debugging your program use MotionLink s program Editor screen and the Terminal screen This chapter discusses many Processor Modes and Programming Modes and much of the discussion revolves around how the different modes appear in the terminal interface This is done so for clarity The user m
82. a fault is a safety hazard LATCH THE MOTOR THERMOSTAT DO NOT CONNECT THE THERMO STAT DIRECTLY TO THE VECTORSTAR REMOTE ENABLE OR LIMIT INPUTS The motor thermostat resets closes when the motor cools This can allow the motor to restart operation unexpectedly after a motor thermostat fault unless the thermostat is latched Always latch the thermostat WARNING Some electrical noise from the motor leads will couple capacitively with the thermostat leads This occasionally causes false thermostat trips which means your control ler senses that the thermostat opened even though the thermostat contacts were closed If this occurs you can use the thermostat contacts to energize a relay and then connect the relay contacts to your controller The electrical noise does not normally cause relay contacts to open 2 6 2 4 Wiring the DC Bus Connect the DC Bus from the PA Power Terminal Block BUS BUS to the VECTORSTAR Power Terminal Block BUS BUS You must observe polarity of DC Bus connections always connect BUS to BUS and connect BUS to BUS The PA 50 and 75 can be connected to any combination of 4 VECTORSTARs although no more than 2 units can be on one side of the PA Failure to observe polarity of the DC Bus can result in personal injury WARNING Jury CHAPTER 2 INSTALLATION Failure to observe the polarity of the DC Bus will result in damage to the PA and VECTORSTAR CAUTION 2 6 2 5 Wirin
83. accumulate Allowed from the interactive and monitor modes and the user program Send download a program from the VECTORSTAR Program Memory to the terminal Allowed from the interactive mode and the user program Format lt BDS Receive upload a program from the terminal and store it in VECTORSTAR program memory A password may be specified Ifthe editor password has been set and the password is incorrect or not specified then an error will result and the original program memory will remain Allowed form the interactive mode and the user program Format gt BDS PASS where PASS is the password as set in the editor Example gt BDS SECRET UPLOAD PASSWORD SECRET gt BDS UPLOAD NO PASSWORD 233 APPENDIX G SOFTWARE COMMANDS VECTORSTAR 234 VECTORSTAR APPENDIX H COMMAND TIMINGS 7 2 COMMAND TIMINGS This appendix gives approximate timings of representative commands Command times are difficult to predict because they depend on many factors including whether the VECTORSTAR is enabled whether profile motion has been commanded whether electronic gearbox or profile regulation have been enabled and so on The times listed here are based on these conditions 4 5 The VECTORSTAR is enabled PLIM PL and LPF are on TQ and PROP are off No profiles are being calculated That is the VECTORSTAR is enabled but not in motion GEAR and REG are off Acceleration profiles increase the ex
84. and ends at position 5000 The traverse speed is 200 RPM ACC and DEC are specified independently before the move is commanded VECTORSTAR 200 RPM A DEC CC P O RPM 5000 COUNTS COUNTS Figure 8 2 A Simple Profile 8 8 3 1 S Curves The VECTORSTAR also allows you to specify the type of acceleration you want You can select S curve accelerations for smoothness or straight line accelera tions for quickness The graph in Figure 8 3 shows the profile from Figure 8 2 using S curves instead of straight lines 200 RPM ACC DEC RPM 5000 0 COUNTS COUNTS Figure 8 3 S Curve Profile Notice that ACC and DEC are still independent Notice also that they specify the average acceleration not the peak Since S curves reduce the acceleration rate at the endpoints of the acceleration the acceleration rate the middle must increase Typically when you switch to S curves you must reduce ACC and DEC to stay within the ratings of the motor However since S curves reduce overshoot you may find that you increase the overall acceleration rate when you use them You may need to reduce and DEC when using S curves CHAPTER 8 GENERAL PROGRAMMING For some applications S curves can reduce the average acceleration too much in others straight line accelera tion produces motion that jerks the motor excessively The VECTORSTAR provides different levels of S curves allowing you to make
85. and has 2 alarms then the alarms will be active if you type RUN 55 If your program ends with a Break command then the program will stop executing and multi tasking will be disabled that is the VECTORSTAR will return to the Interactive mode If your program ends with an END command then only the task level that executed the END will stop executing other tasks will continue executing If there are no other tasks that are executing then the VECTORSTAR does not return to the Interac tive mode but instead becomes dormant In this case multi tasking remains enabled For example alarms will continue to be serviced If you want to enable multitasking without running a particular program type RUN without entering a label Table 10 5 shows how to turn multi tasking on and off 139 CHAPTER 10 USER PROGRAMS VECTORSTAR Table 10 4 Multi Tasking Overview How to Typical Uses Task Level Task Name Task Labels Start Task of Task 1 ALARM A Hardware or Highest Priority Software Switch ALARM B ALARM C VARIABLE INPUT BACKGROUND PRINT AND MONITOR Lowest Priority ERRORS POWER UP PROGRAM AUTO PROGRAM 5 MANUAL PROGRAM MANUALS GENERAL PURPOSE PROGRAM USER ERROR HANDLER 6 Hardware or Software Switch Hardware or Software Switch from DEP 01 or V from a PC ora Terminal VARIABLES Power up VECTORSTAR and Establish Communications
86. are convenient The VECTORSTAR allows you to define the units of acceleration current velocity and position for your machine Also if your VECTORSTAR has an external input you can define the units of external position and external velocity 10 9 1 User Units The VECTORSTAR uses internal units called VECTORSTAR basic units which are very inconvenient to use For example velocity is in 1 65 536 counts second User unit constants scale the VECTORSTAR basic units For example if you type VOSPD 1000 the 1000 is multiplied by VNUM VDEN before it 1s stored in the VECTORSTAR memory Your VECTORSTAR is shipped with and VDEN set so that the user velocity units are RPM However with a simple step by step procedure you can redefine the units as inches minutes degrees second or any other units that are convenient for your machine The follow ing table shows some common user units Table 10 6 Common User Units Current Percent INUM 4095 IDEN 100 Amps INUM 4095 IDEN FULL AMPS Position Counts PNUM 1 PDEN 1 Velocity RPM rad sec VNUM 44739 VDEN 10 12 Bit VNUM 42723 VDEN 1 Accel RPM sec ANUM 4474 ADEN 1000 12 Bit rad sec sec 4272 ADEN 100 10 9 1 1 Current Units The VECTORSTAR commands current with a 12 bit digital to analog converter DAC The VECTORSTAR basic current unit is 1 4095th of full scale current Full scale current refers to the peak rating of y
87. are communicating with at all times For example the edit prompt goes from gt to Ae In this way each prompt from each axis is unique Table 10 11 VECTORSTAR Prompts Non multidrop Multidrop ADDR 0 ADDR 65 10 10 6 1 Broadcast You may want to send a command to all VECTORSTARs on the serial line simultaneously This is called a broadcast You can broadcast by sending In this case all VECTORSTARs execute the command During a broadcast none of the VECTORSTARSs can transmit but all will receive and execute the command 10 11 PROGRAM EXAMPLES This section lists a typical application program as well as a sample velocity drive program Use these programs as models for your own This format uses extensive comments The assumption is that you are using Motion Link so that these comments will not be transmitted to the VECTORSTAR as they would normally take an unacceptable amount of space You are encouraged to use comments because they make the program easier to understand and correct For the velocity drive program you must first select whether the input will be analog or digital encoder equivalent Be sure to set GEARI and GEARO for your application 156 VECTORSTAR NAME OF APPLICATION PRETZEL MACHINE DATE A E NEUMAN REVISION HISTORY 8 9 90 ADDED JOG BUTTONS 7 17 90 CORRECTED TEACH BUG ALARM DESCRIPTION A WATCH THERMOSTAT B C 2 VARIABLE SPEED 3 BACKGROUND P
88. as Data Terminal Equipment DTE the usual configuration If your terminal is configured as Data Communications Equipment DCE then interchange Pins 2 and 3 at one end of the cable 21 CHAPTER 2 INSTALLATION Note that handshaking signals CTS DTR etc are not supported Table 2 4 Terminal Wiring WIRING TO MOST RS 232 TERMINALS VECTOR Terminal STAR DB 25 DE 9 Male or Female Female Usually you will only connect the shield at one end Sometimes the shield should be connected at both ends This is system dependent and generally found by trial and error CONNECTING TO A COMPUTER Connect the pins on the DE 9 connector that came with your VECTORSTAR as follows Table 2 5 assumes your PC has an RS 232 serial port that is configured as Data Terminal Equipment DTE the usual configuration If your port is configured as Data Communications Equipment DCE then interchange Pins 2 and 3 at one end of the cable Note that handshaking signals CTS DTR etc are not supported If the PC compatible computer is AC line powered that 18 not battery powered use extreme caution when interconnecting the PC to the VECTORSTAR serial port Both the PC and the VECTORSTAR must share the same power supply common If they do not the voltage difference between the two commons could damage either or both machines Make sure that the computer and VECTORSTAR share the same power supply common Either your computer o
89. at least one blank space If you want to print only one variable from Motion Link P may be omitted 10 6 1 1 Printing Decimal Numbers Variables are normally printed as decimal integers in a field which is 12 characters wide Formatting can be used to adjust the field width or to print decimal points To change the width of the field follow the variable name with the width enclosed in square brackets Referring to the above example CONSTANTS P SPEED VFB 5 RPM will cause the VECTORSTAR to print TIL IN amp 57 EQ 25 THIS USES SPEED Sac REM BOIH If you try to print a number and do not have enough This accomplishes the same function as the TIL instruc tion which refers to inputs one at a time However using the IN word allows the function to be done in a less cumbersome manner 10 6 INTERFACING WITH THE OPERATOR This section covers interfacing via the serial port Connector C5 Often it is necessary to have the VECTORSTAR send information to the operator or ask the operator for information For example it may be useful to output speed and position or ask the operator for a new speed command This is easily accomplished using VECTORSTAR serial I O instructions space in the format for the number then the VECTORSTAR will fill the format width with X s For example P SPEED VFB 3 RPM will result in SPEED XXX RPM again assuming the s
90. can use the SEG to determine when motion is complete since SEG is zero when the VECTOR STAR 18 not commanding a profile The following example continually prints a message until motion stops 46 MA 10000 1000 TIL SEG EQ 0 P MOTION IN PROGRESS B Note that when SEG is zero the VECTORSTAR is not commanding motion However because there is a lag between the command and the response of the motor you may want to insert a short delay after SEG 15 zero 46 MA 10000 1000 TIL SEG EQ 0 P MOTION IN PROGRESS D 100 DWELL 100 MSEC WAIT FOR MOTION TO SETTLE OUT AT THIS POINT MOTION SHOULD BE ZERO B The commands 77L SEG EQ 0 and W 0 are similar since both delay execution until motion profiles are complete However the W 0 command is an idling command and thus allows lower level tasks to execute Also the TIL command can be followed with a statement such as the P command above which is executed continuously until motion stops If you want to synchronize to a segment the SEG variable can be used with the TIL command For example suppose you want to turn on an output after the decel of an MI move begins The following se quence can be used VECTORSTAR CHAPTER 11 DEBUGGING 47 MI 50000 1000 O1 OFF TURN OFF OUTPUT 1 W 4 BUG DELAYS MI 50000 1000 BEGIN THE MOVE UNTIL MOTION TIL SEG EQ 3 WAIT HERE UNTIL STOPS SEGMENT 3 IS STARTED Normally you should use the WAI
91. characters This leads to a problem in the Trace mode because the VECTORSTAR can transmit characters much faster than most PC s can process them This can lead to delays of minutes between when the VECTORSTAR transmits a character and when the computer displays it The best way to cure this problem is to reduce the baud rate from Motion Link use the U command and power the VECTORSTAR down and then up to cause a second autobaud make sure ABAUD is on before powering down Start with 1200 baud and see if the problem 15 cured 11 3 DEBUGGING AND MULTI TASKING If your program uses multi tasking the Trace and Single Step modes show you which level is currently being executed For example enter the program given in Section 10 8 5 2 Turn on the Trace mode and type RUN 1 The result should be something like this VECTORSTAR 15 MAIN PROGRAM T EN T MI 10000 10 START MOVE MOVE PROCESSED MOVE PROCESSED T W 0 WAIT FOR MOVE T BACKGROUND UPPER TASK IDLED UPPER TASK IDLED T D 250 T END DWELL 0 25 SEC T BACKGROUND T P UPPER TASK IDLED UPPER TASK IDLED 0 250 T END DWELL 0 25 SEC AT THIS POINT ASSUME MOTION STOPS AND TASK 515 NOT IDLED ALL MOTION STOPPED ALL MOTION STOPPED Notice that when the example is executing the back ground level task an asterisk is printed Each task level prints out a slightly d
92. contains an extensive checkout procedure because most installation problems are caused by incorrect wiring or poor wiring practices Complete the entire checkout procedure before attempting to put your VECTORSTAR system into operation 2 2 SAFETY INFORMATION The purpose of this section is to alert you to possible safety hazards associated with this equipment and the precautions you can take to reduce the risk of personal injury and damage to the equipment Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installa tion operation or maintenance Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational difficulty WARNING CAUTION NOTE Figure 2 1 Safety Alert Symbols CHAPTER 2 INSTALLATION The safety alert symbols are illustrated in Figure 2 1 When you see these symbols in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols WARNING refers to personal safety They alert you to potential danger or harm Failure to follow warning notices could result in personal injury or death CAUTION directs attention to general precautions which if not followed could result in personal injury and or equipment damage NOTE highlights information critical to your understand ing or use of these product
93. controlling the conveyor continues at full speed and stops the item where the operation will take place The high speed position capture works at all velocities and during accelerations It is accurate to 25 microseconds if Connector C2 Pin 19 is used and therefore will work properly on demanding index to registration applica tions If the OPTO 22 Connector C7 is used with standard industrial OPTO 22 style modules the optical module may add as much as 25 milliseconds of delay so be careful to properly specify the optical coupling to the registration switch To implement index to registration you usually jog the motor at a constant speed capture the position with the registration device connected to the HOME input then use the Jog To command to stop the motor at an endpoint normally a specified distance beyond the registration input 8 8 11 2 Registration Example The following example shows how to program the VECTORSTAR for registration The desired operation of the program is as follows l Set CAPDIR 1 for low to high transition 0 for high to low transition 2 Enable capturing 3 Begin move 4 Wait for the VECTORSTAR to capture 5 Use the captured position to set the endpoint of the move For example the following code segment jogs at 2000 RPM and stops 4000 counts after the registration input transitions from low to high CAPDIR 1 SET CAPDIR FOR LOW TO HIGH CAP ON ENABLE CAPTURE J 2000
94. from the subroutine and begins executing the program one line below the original GOSUB command GOSUB s can be nested up to four levels For example type in the following program 128 VECTORSTAR 4 GOSUB 5 P RETURNED FROM SUBROUTINE 5 B 5 P EXECUTING SUBROUTINE 5 RET Exit the Editor and type RUN 4 The result should be EXECUTING SUBROUTINE 5 RETURNED FROM SUBROUTINE 5 10 4 2 CONDITIONAL COMMANDS The VECTORSTAR provides several conditional commands that allow your program to make decisions Conditional commands include Quick IF TIL IF and ELIF These commands all depend on conditions A condition is an arithmetic comparison of any two numbers variables or expressions The VECTORSTAR supports all 6 common types of arithmetic conditions Note that you should not use the gt or symbols for these conditions Instead you must use the following two character codes Table 10 1 VECTORSTAR Conditions Greater Than Greater Than Or Equal To Less Than Less Than Or Equal To Equal To Not Equal To 10 4 2 1 QUICK IF Command The or Quick IF is a single line command that allows you to specify a condition a command to be executed if the condition is true and another to be executed if the condition is false The format of the command is condition TRUE command FALSE command TRUE command is executed if the condition is true and FALSE command is exe
95. had been recorded since the last time the VECTORSTAR powered up C 4 2 Improper Use of Labels ERROR 70 LABEL NOT FOUND SEVERITY 2 You attempted to branch to a label either from RUN GOSUB or GOTO that does not exist This error breaks program execution ERROR 71 LABEL USED TWICE SEVERITY 2 The user program has a label that is used more than once This error breaks program execution 202 VECTORSTAR APPENDIX C ERROR CODES ERROR 74 ERROR MUST BE LAST SEVERITY 2 The user s error ERRORS must be the last label in the program buffer You cannot have labels after ERRORS nor can you use the GOTO or GOSUB commands when the VECTORSTAR is executing the error handler The error handler is intended to provide a graceful exit during error conditions and cannot be used to restart the program You can use the IF TIL and commands to execute conditional commands in the error handler This error breaks program execution C 4 3 Invalid Instructions or Entries ERROR 79 BAD FORMAT SEVERITY 2 You entered a format that the VECTORSTAR does not recognize For example you may have entered INPUT INPUT X1 X1 3 In this case the decimal point following the is incorrect Pay careful attention to the rules for formats This error breaks program execution if the instruction 1s issued from the user program ERROR 80 INVALID INSTRUCTION SEVERITY 2 You attempted to execute an instruction or change a variable tha
96. if your VECTORSTAR model number is VSA24 0012 2604C 011 then your compensation module model number must be 2604C and your motor must be a V 2604C An example of a 2604C motor model number is V 2604 CN22 VECTORSTAR CAUTION YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR AND VECTORSTAR THE COM PENSATION MODULE CHANGES IF THE AMPLIFIER RATINGS CHANGE EVEN FOR THE SAME MOTOR Failure to install the proper compensation module can cause damage to the VECTORSTAR the motor or both Contact Kollmorgen Application Engineering to size regeneration capability PA VECTORSTAR Power Supply Continuous Current 08 8 Amps 28 28 Amps 50 50 Amps 75 75 Amps 85 85 Amps CHAPTER SYSTEM DESCRIPTION 1 4 5 Molex Assembly Tools VECTORSTAR series electronics use Molex MINI FIT JR series connectors The necessary connectors and pins are included in your VECTORSTAR and PA 50 85 connector kits You can obtain the crimping and extraction tools from your nearest Molex distributor or by contacting Molex at 708 969 4550 Hand Crimping Tool Molex Order 11 01 0122 Extractor Tool Molex Order 11 03 0038 Power supplies have Phoenix screw type connectors 00 Options 00 Standard Figure 1 2 PA Power Supply Model Number Scheme Resistor Rating Options Figure 1 3 External Regen Resistor Model Number Scheme CHAPTER 1 SYSTEM DESCRIPTION
97. initial setting for prelimi nary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary If PI Loop is used PDF 0 15 integrating Gain but with a different value than that for PDF 1 Enables low pass filter The low pass filter is often required to reduce noise or torsional resonance Leave at initial setting for preliminary operation Set to 1 if system is too noisy The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Low pass filter break frequency The low pass filter is often required to reduce noise or torsional resonance Leave at initial setting for preliminary operation Reduce value if system 1s too noisy The initial value 1s listed on the Test and Limits TL sheet which should be enclosed with your system CHAPTER 8 GENERAL PROGRAMMING MULTI 01 8 PDEN PDF PECLAMP PEMAX PEXT PL PLIM PMAX PMIN PROMPT PNUM PROP Enable multi tasking General purpose outputs Reset to 0 on power up These variables are discussed later in this chapter Position units denominator Initially set to 1 1 for PDF control same as BDS5 0 for PI control same as VFS5 special for a spindle When PDF 0 autotune is not available Position error limit for clamping Initially set to 100 Value of this variable does not matter 1f
98. input I1 transi tions from off to on with this command A I1 ON You can follow the alarm definition with the code that you want to execute when the alarm fires For example if I1 turned on it might indicate an error condition In this case you might disable the VECTORSTAR turn off all outputs and break execution The following program would accomplish this using the A alarm A I1 ON DEFINE THE ALARM DIS DISABLE THE VECTORSTAR OUT 0 TURN OFF ALL OUTPUTS B BREAK EXECUTION VECTORSTAR 10 8 6 1 Restrictions of Alarms Alarms have many restrictions 1 You cannot execute GOTO GOSUB or RET commands from an alarm 2 You cannot execute a label 3 You cannot use the REMOTE switch to fire an alarm 4 Alarms must be self contained programs they cannot mix with your program 5 They must be terminated with an END KILL K or BREAK B command 6 Also if all three alarms are present the execution time of your program increases by about 3 Most other commands are allowed for alarms including motion commands and Block IFs 10 8 6 2 Printing with Alarms You must be careful when executing print commands from alarms If you need to print from an alarm task always print after the critical commands have been executed This is necessary because the input command from a lower task will stop any task even a higher priority task from printing The input command stops all printing until th
99. integral brake the flux forcing concept and the brushless motor We developed the electronically commutated electric car motor Kollmorgen pioneered rare earth magnet development for the servo motor industry FOREWORD Between 1974 and 1980 Kollmorgen Drives continued to lead the industry in servo application innovations Our commitment to engineering excellence never waivered In fact that commitment grew stronger with the development of brushless submarine and submersible motors visiting the Titanic graveyard multi axis electronic drives and antenna pedestal drives delivering unprecedented accuracy and revolutionizing the entire industrial automation process The 1980 s brought continued advancements in technol ogy and penetration of new markets requiring precise motion control Already in the fifth generation of brushless products Kollmorgen continues to lead the way with digital servo positioning capability and our newest offering the VECTORSTAR Series Once again we are setting the standards that others only hope to duplicate Recently acknowledged by the Frost and Sullivan Foundation a leading market specialist in the motion control industry Kollmorgen Corporation continues to rank first in servo technology Other achievements Yes too many in fact to mention Each achievement stands as a testimony to the commit ment to quality and excellence in design technology This constancy of purpose is unyielding in an era of
100. interface follows general input and output lines of the drive But if you wish to design a program to implement simple functions simply type LOAD 0 and load your program down to the VECTORSTAR Your program will be executed either by issuing the RUN command from MOTION LINK or automatically at power up by using the SPOWER UP label in your program The following sample program will activate the machine using HOME input and CYCLE input through the C2 connector on the front of the VECTORSTAR First this application checks to see if the system is ready to be enabled then looks at REMOTE input which is the external control for the power stage If REMOTE is 1 the drive will be enabled and wait for either HOME or CYCLE input 1 is active but both cannot be 1 at the same time When HOME input is 1 the motor will run at a constant speed at X1 RPM Assign X1 before running this program The motor can be stopped by turning HOME off reset to zero If CYCLE input is 1 the motor will receive the velocity command from the analog input through the electrical gear function you must set gear ratio GEARI and GEARO before running the program For instance GEARI 560 and GEARO 16384 for 10 volt input 8000 RPM So you can control motor speed by control ling analog input voltage You can switch from analog input to a constant speed by turning CYCLE off and HOME on Note that all the variables stored in the VECTORSTAR will be rememb
101. is being used for a velocity com mand as 18 the case for electronic gearbox applications then you must be careful to connect the encoder input for the correct direction of rotation If the VECTORSTAR is being used as a velocity drive and another controller is closing a position loop reversing the encoder inputs can cause VECTORSTAR to run away or oscillate Be careful to connect the encoder pulse input so that the direction is correct Phase the Encoder Equivalent Input correctly Incorrect phas ing of the encoder input can cause excursions oscillations or runaways WARNING 2 6 4 3 Pulse Input OPT2 Card As an option you can also purchase your VECTORSTAR with a Pulse Input option This option allows you to 1 Control the VECTORSTAR from a stepper motor controller For this function configure the VECTORSTAR as an electronic gearbox and select the format that is compatible with your controller 18 VECTORSTAR 2 Inputasingle phase clock from your computer There are occasions when you want to control the VECTORSTAR with a unidirectional clock for example feedrate override The Pulse Input option accepts a single phase clock such as would be generated from an electronic timer counter chip The Pulse Input Option board VECTORSTAR OPT2 is mounted inside the VECTORSTAR unit This board accepts pulse inputs in three formats count direction up down or single phase Use the toggle switch on the board to
102. is in milliseconds just like D command However when the external input frequency decreases the regulated dwell time lengthens so that the DWELL is proportional to the inverse of the external frequency For example 45 REGKHZ 100 SET REGKHZ TO 100 KHZ RD 2000 REG DOES NEED TO BE ON FOR RD TO OPERATE P DELAY COMPLETE B In this case the RD command causes a 2 second dwell when the external input frequency 1s 100 KHz and a 4 second dwell when the frequency is 50 KHz Note that MACRO DWELLS MCD are regulated by the external input when REG 15 on RD delays are always regulated by the external frequency even when REG is off 11 5 3 Motion Segments moves and jogs occur in segments Normal jogs have two segments accel decel and traverse Simple moves MRD MI and MA have three segments accel traverse and decel Position dependent jogs have three segments traverse to position accel decel and traverse The following table shows the different segments for 164 VECTORSTAR VECTORSTAR moves Table 11 2 Segments for Different Moves Accel Accel Decel Traverse Accel Decel Traverse Traverse Decel N A Traverse Macro moves have up to 30 segments where each accel decel traverse and dwell counts as a segment In each case every move begins with the variable SEG equal to 1 As the move progresses SEG is incremented When all moves are complete SEG is set to zero You
103. line with EDITOR will be found If you do not want to use the default string from the last Find command type in the word or words you want to find this time Pressing the escape key will abort the F command If the Editor cannot find the specified word it will respond with FOUND and return to the edit mode NOT FOUND gt 10 3 2 6 The Change command is similar to the Find com mand However Change allows you to change the string you found Also Change only searches the current line Use the P command to go to line 1 and print the line you typed from the previous discussion of the Insert com mand Type P1 The VECTORSTAR should respond 1 TEST LINE FOR LEARNING ABOUT THE EDITOR Now use the C command to change EDITOR to VECTORSTAR EDITOR Type VECTORSTAR will respond with CHANGE WHAT EDITOR gt Again EDITOR from the Find command is the default input Press the return key to accept the default and the VECTORSTAR will respond with CHANGE TO WHAT gt Now type 126 VECTORSTAR VECTORSTAR EDITOR The VECTORSTAR will change the line to read 1 TESTLINEFORLEARNING ABOUT THE VECTORSTAR EDITOR C has defaults for both the CHANGE WHAT and the CHANGE TO WHAT This allows you to step through memory changing each occurrence of one string to another string with minimal keystroke
104. means the table moves 0 1 inch per motor revolution The R D resolution is 12 bits The user units for table motion you desire are CHAPTER 10 USER PROGRAMS Position Units mils 1 mil 0 001 inch Velocity Units inches minute IPM Acceleration Units inches minute second IPM second Objective Find PNUM and PDEN Find VNUM and VDEN Find ANUM and ADEN Solution Find PNUM and PDEN A Select Table 10 8 B Select a motor movement of 1 revolution C 1 revolution of the 0 1 pitch lead screw translates to 0 1 inch or 100 mils of table movement D Refer to Table 10 10 under POSITION UNITS for the formula PNUM PDEN 4096 1 100 40 96 Select PNUM and PDEN PNUM 4096 PDEN 100 E Since a 12 bit R D converter is used calculations in step E are not needed Find VNUM and VDEN A Select Table 10 8 B Select 10 RPM motor velocity C 10 RPM of the 0 1 pitch lead screw translates to 1 IPM of table velocity D Referto Table 10 11 under VELOCITY UNITS for the formula VNUM VDEN 4473 92 10 1 44739 2 Select VNUM and VDEN VNUM 447392 VDEN 10 Find ANUM and ADEN 151 CHAPTER 10 USER PROGRAMS A Refer to Table 10 8 B Select 10 RPM second motor acceleration C 10 RPM second acceleration of the 0 1 pitch lead screw translates to 1 IPM second of table acceleration D Refer to Table 10 8 under ACCELERATION UNITS for the formula ANUM ADEN 4 47392 10 1 44 7392 Select
105. motor may move a small amount but PRD should remain in the zero position Type P PRD If the motor rotates to the zero position then type CHAPTER 2 INSTALLATION DIS ZERO OFF and continue to the next section If the motor rotated to the wrong position then you must stop and correct this problem Either the resolver is improperly wired the motor is improperly wired the motor is not functioning properly or the resolver 15 not functioning properly In most cases the wiring 15 the problem Check your motor and resolver wiring carefully Follow the procedure in Checking the Resolver Cable in section 2 7 10 If you have wired the motor through motor overload relays verify that the relay 1s closed Contact the factory 1f your motor does not rotate to the Zero position and you can not correct the problem DO NOT PROCEED IF YOUR 15 NOT ZEROING PROPERLY WARNING 31 CHAPTER 2 INSTALLATION VECTORSTAR Figure 2 5 VectorStar Pinout Information Relay Outputs Interface Customer Interface Connector 127 Pim Assignment 1 Spare IN15 2 Tach IN14 3 Shld IN13 4 1 Monitor IN12 5 15 IN11 6 Remote Rtn IN10 7 Cycle Rtn IN9 8 Cycle IN8 Remote IN7 O1 Hi IN6 Spare IN5 Com INA Shld IN3 Com IN2 Com IN1 Relay Contact Manual Relay Contact Status Home Rtn O6 Home O5 O1 Lo 04 Relay 02 01 Pin Assignment Motor OT Meter Out Not available on VS
106. no way to use MA or MI to accomplish this profile so Macro moves must be used The following sequence will generate the move shown in Figure 8 4 20000 DEC 20000 MCI 10000 1000 200 MOVE 10000 COUNTS TRAVERSE AT 1000 RPM AND END AT 200 RPM 1000 MORE COUNTS TRAVERSING AT 200 RPM THE FINAL SPEED OF THE PREVIOUS MOVE AND END AT 0 RPM BEGIN MOTION MCI 1000 0 MCGO Every subsequent MCGO will generate a similar move 11000 counts long 8 8 7 3 Macro Move Example 2 The profile can be made slightly more complex by adding a 0 5 second dwell and a return to the original position on the end This profile is demonstrated in Figure 8 5 Note that this diagram is a shorthand schematic of motion This curve is plotted as velocity versus time for forward motion the first 5 segments and for the dwell However return motion is shown as negative motion returning to the origination time Obviously time does not go backwards This method of diagramming motion is commonly used because it is simple 1f not in all respects accurate and conveys the necessary information CHAPTER 8 GENERAL PROGRAMMING 200 1000 5 SEC 10000 COUNTS 11000 COUNTS 1000 RPM Figure 8 5 Macro Move Example 2 The above sequence should be modified as follows Note that here the profile is converted to Absolute rather than Incremental this is a matter of con
107. of electromagnetic noise Run signal leads in separate conduit from power leads Shields are recommended for signal leads 2 Minimize lead lengths 4 Connect the VECTORSTAR system according to the System Wiring Diagram Figures B 1 B 8 pay close attention to the grounding scheme and notes 2 6 1 Wiring the Ground Two ground terminals are located on the front of the VECTORSTAR and PA These ground screws are directly below the Power Terminal Block of each unit To prevent shock hazard and to ensure proper operation of the system the VECTORSTAR PA and the motor must be grounded GROUND YOUR VECTORSTAR PA and motor PROPERLY Failure to provide proper grounding can result in a WARNING shock hazard One of the ground screws on the should be con nected to Earth Ground or Machine Ground The other should be connected to the adjacent VECTORSTAR ground screw along with the ground wire from the motor 13 CHAPTER 2 INSTALLATION The other ground screw on the VECTORSTAR chassis should then be connected to the next VECTORSTAR etc Use 10 AWG or larger wire for grounding between VECTORSTARSs and PAs and from PA to Earth Ground or Machine Ground 2 6 2 Wiring the Power Connections This section discusses how to wire the PA and VECTORSTAR power connections To prevent equipment damage the AC Line and the DC bus must be connected as indicated by the System Wiring Diagram Figures CAUTION B 1 B 8
108. on the screen The following items are printed the error number the offending entry and an abbreviated error message For example disable the drive and type in a Jog CHAPTER 6 TROUBLESHOOTING DIS J 100 The VECTORSTAR will respond with ERR 50 J 100 VECTORSTAR INHIBITED The error number 50 the offending entry the whole line and the error message you cannot command a jog when the drive is inhibited are given on one 80 character line The error message starts at character 40 so that if a 40 character display is used the error message will not be printed You can display the line directly either with the Motion Link editor GOTO A LINE NUMBER selection or QT or with the VECTORSTAR Editor P command Sometimes only an entry 15 bad and not the whole line In this case only the bad entry 18 printed For example PROP 2 generates ERR 83 2 BAD OR OUT OF RANGE since PROP is a switch and cannot be set to 2 If the error comes from the program the line number of the offending entry is also printed Use the Editor to enter these lines at the top of the user program 11 PROP 2 B Exit the Editor and type RUN 11 and the response should be ERR 83 LINE2 2 BAD OR OUT OF RANGE This message shows that the error occurred on line 2 You can enter the Editor and type P2 and the following line will be displayed 55 C
109. parameters and user program may be checked and modified The RS 232 can also be used to monitor the system working states To do this you must use the BDS5 Motion Link software and a PC Compensation parameters VCMD Voltage command should be 345 on 240 VAC systems or 690 on 480 VAC systems KVI KPROP NOTE CHAPTER 12 HIGH POWER Proportional gain for the DC bus voltage regulation Set to 10 30 Integrating gain for the DC bus voltage regulation Set to 1 4 DC bus over voltage Set to 900 950 400 430 volts If the DC bus voltage is greater than this the unit will shut down automati cally Line Regen Unit hardware overvoltage protection trips around 420 volts DC ILIM Current limit In units of percentage of rated peak current with a range of 1 100 The following parameters show the unit working states V VP ICMD IMON DC bus voltage actual volt V 2 3 for 230 V system Line peak voltage Actual line rms volt VP 10 for 230 V system Current command in units of percentage of rated peak current Actual rms line current same units as ICMD 171 6 5 6 uo peseg O6dMSA 04dMSA 0Z THSA 5 OVTUSA SZdUSA SCTHSA ST3QOW luo syun 06 pue 02 Uo 9 VECTORSTAR
110. print the state of the REMOTE input P REMOTE REMOTE SHOULD BE 1 SHOCK HAZARD Large voltages from the AC Line and the DC Bus can cause injury Ensure that the wiring is correct See Chapter 2 WARNING CHAPTER 8 GENERAL PROGRAMMING THE MOTOR MAY MOVE UNEXPECTEDLY BE PREPARED TO DISABLE THE VECTORSTAR You should have completed Initial Check Out in the Chapter 2 If not complete that section before proceeding WARNING This section will enable the VECTORSTAR The system may be unstable The motor may begin oscillating or run away Be prepared to disable the VECTORSTAR quickly You can disable the VECTORSTAR by turning off opening the contacts of LIMIT or REMOTE To enable the VECTORSTAR turn on the AC Line and enter the enable command EN The VECTORSTAR should turn on To verify that it did turn on print ACTIVE If ACTIVE is 1 then the VECTORSTAR is enabled otherwise it is disabled To disable the VECTORSTAR enter the disable command DIS As an alternative you can disable the VECTORSTAR with the one letter kill command by typing K ENABLE DISABLE and KILL are examples of VECTORSTAR commands All ofthe VECTORSTAR commands are listed with their formats and syntax in Appendix G N NOTE Appendix G is a quick reference for all VECTORSTAR commands 77 CHAPTER 8 GENERAL PROGRAMMING 8 7 8 Limiting Motor Current
111. programs and the user error handler These labels are letters or words followed by a dollar sign For example is the A Alarm label Dedicated labels cannot be used by the RUN GOTO or GOSUB commands These labels are discussed with multi tasking later in this chapter 10 4 1 2 RUN The RUN command is used to start the program from the Interactive mode For example type RUN 3 If there are no errors and if label 3 is in the user pro gram then program execution begins at label 3 The RUN command can execute all valid general purpose labels If the label 15 not in the program an error is generated and no part of the program is executed You cannot use the RUN command for dedicated labels Before the program is run the VECTORSTAR searches the entire program for some types of errors If after you enter a RUN command an error is detected the VECTORSTAR will display the appropriate error message together with the offending line Also RUN verifies that the program has not changed since the last edit If the program has changed a PROGRAM CORRUPT error is generated The program corrupt error can be cleared though this requires that the entire program be erased with the Editor NEW command or the gt BDS command Ifa Program Corrupt error occurs and it was not caused by losing power while you were editing this may indicate a serious condition Contact the factory 10 4 1 3 Break B The Break B command
112. the example below the WAIT command is used to delay the calculations of the third move until the second move has begun The use of W 1 here allows the third move to be calculated while the second is being ex ecuted Do not type in the following example it 15 meant to run as a part of the user program MI 10000 100 BEGIN THE FIRST CALCULATE THE SECOND MOVE WHILE THE FIRST IS IN PROGRESS W 1 DELAY PROGRAM EXECUTION UNTIL THE SECOND HAS STARTED CALCULATE THE THIRD MOVE AND PREPARE IT FOR EXECUTION MI 10000 200 MI 10000 300 VECTORSTAR The WAIT W command and synchronization will be discussed in more detail later in this chapter 10 8 MULTI TASKING Multi tasking 1s an important feature of the VECTORSTAR Multi tasking allows you to write separate fasks that run concurrently which means more than one task executes at the same time For example you can write a program with two separate tasks one to ask the operator questions and another to command motion These two tasks can run independently so that while the operator is answering questions the motion continues Each task has a priority level The VECTORSTAR has 6 different task levels as detailed in Table 10 4 High priority means that 1f two tasks both need to run at the same time then the commands from the task with highest priority will execute first For example Alarm A has the highest priority If Alarm and A
113. the motor has stopped X45 defines the number of times the motor position must be captured and not change outside the X42 parameter window A typical value is less than 5 9 6 3 2 2 1 Application The VECTORSTAR can be used in an application in which two revolutions of the motor result in one revolu tion ofthe spindle 1 e 2 1 application In this applica tion the speed of the motor will be twice the speed of the spindle and the feedback resolution of the spindle will be twice that of the motor with the feedback transducer remaining in the motor One concern is that the motor orients on the correct revolution so that the spindle is aligned in the correct position If the motor was oriented on the other revolution the spindle would be 180 degrees from the orient position When the VECTORSTAR receives an Orient Request I2 input the externally commanded speed is captured The VECTORSTAR then assumes control of the motor maintaining the externally captured command speed The motor is then commanded to rotate in the direction the motor was rotating when the Orient Request was received and at the speed defined by the parameter named VORNT The VECTORSTAR then monitors the dedicated HOME input The input must go off or be off and then on at which time the VECTORSTAR brings the motor to a stop at a random motor position prior to moving the motor to the orient position in less than one revolution CHAPTER 9 SPINDLE PROGRAMMING The X46 p
114. the performance of a system a VECTORSTAR and a motor connected to a load to a three part criterion Noise Susceptibility Response Stability Tuning is normally a laborious procedure requiring an experienced person However the VECTORSTAR provides many tools to aid tuning making it a much simpler process In a broad sense the performance of a system is charac terized by its noise susceptibility response and stability These quantities tend to be mutually exclusive The system designer must decide what noise susceptibility in the form of a busy motor is acceptable Busyness is random activity in the motor and can often be felt on the motor shaft Busyness in a motor should not be confused with PWM noise PWM noise is high pitched relatively constant noise and cannot be felt on the motor shaft Response is a measure of the system s quickness Response can also be characterized by bandwidth and by rise time in response to a step command Normally designers want high bandwidth though sometimes the response is purposely degraded to reduce stress on mechanical components This is called detuning Typical velocity loop bandwidths range from 20 to 60 Hz Typical position loop bandwidths range from 0 1 to 0 2 times the velocity loop bandwidth Stability measures how controlled the system is Stabil ity can be measured with damping ratio or with over shoot in response to a step command A discussion of different lev
115. the position loop gain and KF the position loop feed forward gain The position loop calculates the position error PE as the difference of PCMD and PFB As a secondary command source PCMD is differentiated d dt PCMD The position loop then performs the following calcula tions VCMD KP_PE KF_ d dt PCMD The position loop is optional If the switch PL is on then the position loop is enabled if it is off then the position loop is bypassed PL is turned on at power up VECTORSTAR The feed forward gain reduces position error at high speed Without feed forward the velocity command is generated only from position error a large position error 18 required to command a high speed If KF is large enough then a high velocity command can be generated with little or no position error The VECTORSTAR scales KF so that unity feed forward occurs when KF equals 16384 In other words if KF is 16384 no position error 1s required to generate the velocity command in steady state running conditions KF should never be larger than 16384 In addition larger KF makes the system more responsive to commands Unfortunately large values of KF cause overshoot KP must be reduced to reduce overshoot If you need to minimize position error when the motor is turning you will need to optimize KF and KP Typically KF ranges from 2000 to 10000 TQ should be off when PL is turned on The system becomes unstable when PL and TQ are both on If you do
116. the speed com mand in RPM VUPH A second hysteresis parameter to provide a new band around the speed command after the motor speed entered into the first band in percentage of RPM Before using this function make sure VXNUM and VXDEN are correct for the current gear ratio Spindle Axis C Axis Open Loop Modes The Spindle Sxis mode also called C axis mode is used by the higher level controller to control both the angular position and the speed of the motor The higher level controller can use the motor position information to close the loop The spindle motor is used as a servo motor in this mode This feature develops a technique known as rigid tapping allowing operators more precise depth and torque control during tapping The velocity command can be scaled by the gear ratio i e GEARI and GEARO In the Open Loop mode GEARI and GEARO are programmed by the variables GEARIO and GEAROO While in the spindle axis mode GEARIC and GEAROC are used for the new gear ratio Once the maximum RPM for the Open Loop mode is specified the GEARI and GEARO values can be calcu lated Load the required GEARI value in GEARIO and the GEARO value in GEAROO The VECTORSTAR will accept a analog DC voltage over the range of 10 to 10 VDC as a speed command input in the Spindle Axis i e Closed Loop mode or the Open Loop mode The VECTORSTAR converts the VECTORSTAR analog voltage input into a bi directional speed com mand W
117. the trade off There are five levels that are selected by setting the variable SCRV to either 1 2 3 4 or 5 For more information on S curves see KMTG application note B101 Acceleration Profiles Table 8 7 S Curve Acceleration Chart 1 2 3 4 5 For this acceleration Straight Line Modified Polynomial Polynomial Modified Sinusoid Sinusoid 8 8 3 2 Move Absolute MA Command There are two kinds of simple moves absolute and incremental With absolute moves you specify the end position with incremental moves you specify the total distance of the move The MA command allows you to command absolute moves by specifying the end position ACC DEC and SCRV are all in effect for MA moves option you can specify the traverse speed The following example moves to position 50000 at a peak speed of 1000 RPM MA 50000 1000 The variable VDEFAULT is the default velocity for MA and MI commands If you enter an MA command without specifying a speed the traverse speed will be VDEFAULT MA 100000 The above example would move the motor so that PFB is equal to 100000 it would assume a traverse speed of VDEFAULT If you do not specify the speed in MA commands it reduces the execution time This normally means less delay between when the command is entered and when the motor begins turning Appendix H lists the execution times of a few simple moves 81 CHAPTER 8 GENERAL PROGR
118. transmit anything until a command has been entered The only exception is if you program the VECTORSTAR to print a gt from a PRINT or INPUT command The VECTORSTAR will allow gt in print statements though this is considered a poor practice if you are using a computer to communicate with the VECTORSTAR Similarly the VECTORSTAR will not accept input unless a gt has been issued The INPUT command is the only exception to this rule This rule can be awkward if you are using the VECTORSTAR from a terminal if an error occurs during the interactive or monitor modes after the gt has been displayed the VECTORSTAR will not print the error message until a carriage return or escape has been entered The prompt for each mode is listed below The only exception is the Run mode This mode does not have a prompt since input is not accepted from the serial port Notice that the trace prompt does not end with gt This is because the trace prompt does not indicate that the VECTORSTAR is waiting for input If the VECTORSTAR is communicating within a multidrop communication line then the prompt is modified to include a prefix which indicates the axis address Table 7 2 shows the prompts in both the single and multidrop configurations Note that the multidrop address is 65 ASCII A VECTORSTAR Table 7 2 VECTORSTAR Prompts Mode Non multidrop Multidrop ADDR 0 ADDR 65 Interactive Monitor Single s
119. used in accordance with this installation and service manual in order to prevent possible interference with radio communications or other electronic equipment 5 3 PERIODIC MAINTENANCE Periodically you will need to inspect your equipment for possible problems to ensure ongoing safe and efficient operation Periodic maintenance should be performed at scheduled intervals to insure proper equipment perfor mance It must be performed by qualified personnel familiar with the construction operation and hazards involved with the VECTORSTAR and its application Power should be disconnected during all maintenance procedures VECTORSTAR CHAPTER 5 MAINTENANCE 5 3 1 Ventilation The PA and VECTORSTAR should be mounted verti cally to allow maximum ventilation of the components This configuration allows the heat generated by the components to vent through the top and draft in cooler air through the bottom The top and bottom of the components are vented to allow this drafting to occur These ventilation passages should be kept open If the PA requires auxiliary cooling with fans inspect the fans on a regular basis 5 3 2 Grounding Integrity The method employed for grounding or insulating the equipment from ground should be checked to assure its integrity on a regular basis This check should be performed with the power off and the testing equipment grounded 51 CHAPTER 5 MAINTENANCE VECTORSTAR 52 VECTORSTAR C rh 6 TROUB
120. v8z SNOLLOSNNOO 6 1015 SNOILOSNNOO S YOLOW sna 16 1 07826 081 5 Z S31OH ONILNNOW 82 0 2 HOLO3NNOO NOILdO 3181550 0 0 Figure B 10 VSA 24 28 Outline and D 196 VECTORSTAR APPENDIX C ERROR CODES ERROR CopEs C 1 INTRODUCTION The VECTORSTAR s response to an error depends on the error s severity There are four levels of severity listed below in increasing order Errors that cause warnings Errors that cause a program break and stop motion in addition to Level 1 actions Errors that cause the system to disable and set the FAULT Hardware Output in addition to Level 2 actions Errors that disable almost all VECTORSTAR functions including communications and flash the CPU LED to indicate the error number These are called firmware errors Je See Chapter 6 for more information about error severity The following is a complete list of errors generated by the VECTORSTAR C 2 HARDWARE FAULTS C 2 1 Firmware Faults ERROR 2 HARDWARE U P FAIL SEVERITY 4 The microprocessor cannot pass self test This fault causes the microprocessor to blink the CPU light twice and then pause The VECTORSTAR will not communicate or run the user program Contact the factory ERROR 3 HARDWARE CHECKSUM SEVERITY 4
121. within a Block IF even if you have another Block IF in that subroutine In this case the IF in the subroutine is like a nested IF However be careful to return from the subroutine after 131 CHAPTER 10 USER PROGRAMS you have executed the ENDIF You should never return from a subroutine from between IF and ENDIF Finally you may use a GOTO to jump completely out of an IF THEN ELSE control structure When a GOTO is executed after an IF has been executed but before an ENDIF has been executed all ENDIF s are automati cally executed This means that you cannot jump to a label within any IF THEN ELSE structure Note that jumping out of a control structure in such a manner is a poor programming practice and should be avoided Also you may not jump to a label within an IF THEN ELSE from outside the structure an IF ENDIF set You should N never execute a RET from NOTE between an IF and ENDIF You cannot GOTO the middle of 10 5 USING THE GENERAL PURPOSE INPUTS General purpose inputs can be used to control the program From Chapter 8 you may recall that these inputs can be referred to one at a time using variables I1 I16 or collectively IN If the program must wait for a particular input to be on or off before continuing execution the TIL command can be used TIL 15 0 If this statement is executed from the program the program will delay execution until I5 is 0 If the program must wait for m
122. ya 0 v vi blank List Of Tables te ee Or eae de s 0 vii viii blank IastotfDr wings c oue par 0 1 1 1 16 Text Pages cse OG GEHT ETE Ne NER oy E EUER 0 2 1 2 26 TEXT METRE 0 3 1 3 10 Text Pages tasa ted EE ES FO t reg etre d odes 0 4 1 4 4 TextJPages a ED kausaspa 0 5 1 5 6 pe A ane RR 0 1 A 2 blank Appendix Warranty Information sns 0 B 1 B 22 Appendix B Drawings o eR RE he Ur Meat 0 C 1 12 Appendix C Error Codes E eed A aa A eee 0 D 1 0 2 Appendix D Regional Sales Offices sss 0 E 1 E 2 blank Appendix E On line Reference Guide sese 0 Glossary i xiv Si c c 0 Index i iv Tyas ou m m Sw a u stesse fo dudo aede 0 Zero in this column indicates an original page CONFIGURATION TABLE INSTALLATION AND User s MANUAL MVSOOOH RECORD OF REVISIONS ISSUE NO DATE CHANGED PAGES BRIEF DESCRIPTION OF CHANGE CHANGE NO Revised December 19 1996 Original Release 1 13 June 97 Replaces issue dated 19 December 96
123. 0 1 5 100 1 5000 10 1 7 3 28 22 set X1 to 500 Furthermore variables be used in the following expression which fills X3 with 600 1 20 2 30 1 2 VECTORSTAR operations are done with integer math Fractional results from division are rounded to the nearest integer Also expressions are evaluated from left to right These two conditions can cause unexpected results Consider the following expressions P 53 100 280 THIS PRINTS 280 P 280 100 53 THIS PRINTS 159 P 280 53 100 THIS PRINTS 148 Mathematically these three expressions are equivalent they calculate 53 of 280 which is exactly 148 4 However with integer math the first expression is evaluated as 280 This 15 because 53 100 is evaluated first The result 0 53 is rounded to the nearest integer 1 which is multiplied by 280 Likewise in the second expression the 280 100 is evaluated as 3 which is multiplied by 53 to get the result 159 Only the third expression gives the expected result 148 In this example round off error is minimized by performing the multiplication first 8 4 3 Logical Functions AND OR Two logical math functions AND and OR can also be used in math expressions ANDing is indicated by amp operator and ORing 15 indicated by operator When evaluating an expression AND has the same level of precedence as multiplication and OR has the same level as addition
124. 0 731 0847 FAX 540 875 3743 TWX 6 3 LED STATUS INDICATORS 6 3 1 VECTORSTAR LED s The VECTORSTAR provides LED s for diagnostics These LED s are on the front panel of the VECTORSTAR When the VECTORSTAR is powered up all LED s on the front panel turn on to verify they are operational The states on or off of each LED are listed below ACTIVE This LED shows whether the VECTORSTAR is active Active means that the VECTORSTAR 15 enabled and the REMOTE input switch is on This LED is on when the VECTORSTAR is active and off when it is not active SYS OK This LED indicates the state of the hardware watchdog protection circuit It should be on during normal operation However it is off during autobauding If SYS OK turns off take the VECTORSTAR out of service and contact the factory CPU This LED indicates the state of the software watchdog protection circuit It is on during normal operation and blinks for the most serious errors This LED also blinks during autobauding FAULT This LED indicates that a fault has occurred fault is an error that is serious enough to disable the VECTORSTAR You can turn the FAULT LED on or off from your program The FAULT LED is turned off when you enable the VECTORSTAR 54 VECTORSTAR RELAY This LED indicates the status ofthe VECTORSTAR relay It is on when the relay contacts are closed and off otherwise 6 3 2 PA Series LED s The PA Series power supply has 3 in
125. 000 SET ACCEL AND DECEL RATES DEC 100000 NORM 0 NORMALIZE TO ZERO POSITION J 100 TO 100 RPM JT 20000 400 ERROR SHOULD DELAY TIL SPEED REACHES 100 RPM BEFORE EXECUTING JT COMMAND 89 CHAPTER 8 GENERAL PROGRAMMING JT 30000 0 ERROR SHOULD DELAY TIL SPEED REACHES 400 RPM BEFORE EXECUTING JF COMMAND DIS B You might think the motor will first jog to 100 RPM then to 400 RPM at 20000 counts and finally come to rest at 30000 counts Actually the motor will jog to about 40 RPM and continue at that speed until it comes to rest at 30000 counts This 18 because the JF JT commands cause the motion profile to hold the velocity command constant even if an acceleration is com manded from the previous motion command The solution is to insert delays to force the program to wait until the motor reaches the final speed from the previous motion command For example the above program can be modified as follows 55 EN ENABLE VECTORSTAR ACC 100000 ACCEL AND DECEL RATES DEC 100000 NORM 0 NORMALIZE TO ZERO POSITION J 100 TO 100 RPM TIL VCMD EQ 100 WAIT TIL SPEED REACHES 100 RPM JT 20000 400 EXECUTE JT COMMAND TIL VCMD EQ 400 WAIT TIL SPEED REACHES 400 RPM JT 30000 0 EXECUTE JT COMMAND DIS B Although delays with the TIL command work delays usually should be inserted with the WAIT W command The WAIT W command takes less space
126. 1 PFB 64 69 75 80 96 PFNL 83 84 Phase Adjustment 92 PL 77 93 96 97 PLAY Command 44 PLC Interface 145 PLIM 80 83 PMAX 80 83 PMIN 80 83 PNUM 148 Position Capture 86 Command 75 Error 44 75 Feedback 75 R D 75 Resetting 83 Position Dependent Jogs 88 165 Position Error 97 Minimized 97 Overflow 75 199 Zeroing 83 87 Position Feedback 64 Position Loop 77 96 Position Loop Gain 96 Position Loop Tuning 43 Position Units 75 Power Bus Error 38 Power Up Condition 66 Power Up Control Loops 97 POWER UP 59 145 153 PRD 75 87 Ranges 75 148 Preventative Maintenance 49 Print ASCII 135 242 VECTORSTAR Binary 134 Control Characters 135 Decimal Point 133 Expressions 135 Formatting 133 Hexadecimal 134 Ignored 59 Status 136 Switches 134 Print P Command 127 Print P command 133 Print Status PS Command 136 Printing 64 Processor Modes 58 Profile Pre Calculation 165 Profile Regulation 16 Profile Regulation 91 93 164 Profile Regulation and Counting Backwards 94 Profiles 80 Profiles and Gearbox 92 Program Control 127 Program Corrupt Error 127 Program Dump 154 Programming 101 119 Programming Conditions 65 Programs 119 PROMPT 153 Prompts 58 153 List 58 156 Rules 58 PROP 77 97 102 Proportional Velocity Loop 97 PROTARY 152 PTRIPI PTRIP2 80 Pulse Input 16 Pulse Input OPT2 Card 7 18 PWM Noise 40 PXDEN 148 151 PXNUM 148 151 Q Quick If Command 128 R R D Based Move MRD 85 87 94 R
127. 110 9 6 7 Sample Application Program for the VECTORSTAR 2 22 1 21 20 4 40 2 01100200000000000000000000000004 113 CHAPTER 10 USER PROGRAMS i re en 119 10 1 INTRODUCTION eie chere Pie e Hh ee eee e ER e eH RH 119 10 2 PROGRAMMING TECHNIQUES eese ttn 119 10 2 1 Example ice ene E EA ARRESE eae ERE e EGER e Eee ede 120 10 2 2 oe ne sayay aya e e e eed 121 10 2 3 Application Flowchart ied eee nte edt ee eed en eet erede 121 10 2 4 123 10 2 5 Customer 8 esee bee a d c te e d ce a tae eros ped SA 123 TOS EDITING Qusa ayna ss A O 124 10 3 1 Motion Link Editot ee B pete edere ER e BRIDE eR erg 124 10 3 2 VECTORSTAR Resident Editor 2 2 2 4 2 4 1000 124 10 3 2 1 Editor Print P tee pe P REED M Pee e 124 10 3 2 2 Next Line nete e Ue b E eur en d nte neon 125 10 3 2 3 Password PASS eee eed de e WO e 125 10 32 4 Insert shoe etu ht eet e erit eee iod le er edet Pi be co edet 125 103 2 5 Find P ctt tert mec ee tera rie te pee ta e e ge PI elec bee te a gene 125 10 3 2 6 Change C e
128. 15 being executed This reduces inter index delay the delay between successive moves almost to zero When you are commanding motion from the Interactive mode gt be careful not to type in two move commands while another is executing motion from the original command is not complete This generates an error If you are com manding motion from your program the VECTORSTAR automatically pauses before calculating a third motion profile thus stopping this error from occurring 8 8 3 7 Profile Final Position PFNL If you want to keep track of the end position of the present move the variable PFNL Position Final 15 provided This variable contains the final position of a move The variable can be used to compute the distance remaining by combining it with Position Feed back P DISTANCE TO GO PFNL PFB PRINT THE AMOUNT OF POSITION TO GO TO FINISH THE MOVE CHAPTER 8 GENERAL PROGRAMMING 8 8 5 NORMALIZE NORM Command NORM the NORMALIZE command is required 1f you want to reset the VECTORSTAR position feedback PFB Often you may want to set the position feedback to some known value For example on power up the position feedback 15 set to zero After a homing se quence you may need to reset the position register This 15 done using NORM The following example sets position feedback as well as PCMD POSITION command to 10000 in position units NORM 10000 As an alternative yo
129. 2 14 Aug 97 Replaces issue dated 13 June 97 3 5Feb 99 Replaces issue dated 14 August 97 VECTORSTAR oreworp Commitment to quality at Kollmorgen is our first priority In all aspects of our business research development product design and customer service we strive to guarantee total quality This pledge 15 founded on a solid history of innovative technological achieve ments dating back to 1948 One of the finest tributes to that achievement 15 now on display at the Smithsonian the first stellar inertial navigation system developed by Dr Charles Stark Draper This system contains the first models of torque motors built by the founding organiza tion of Kollmorgen During the period of 1948 to 1960 our firsts in the industry numbered more than a dozen they ranged from the simple but invaluable such as the direct drive DC torque motor and movie theater projec tion motors to the exotic submarine periscope drive motors for the U S Navy electric drives Curtis Wright electric brake coils and numerous other innovations For more than a decade Kollmorgen has continued to enhance its sophisticated engineering solutions to pioneer new product development The results of these and other efforts have encouraged some of the most significant innovations in the servo industry We developed the application of servo motors and drives in the Machine Tool market We were the first with water cooled servos the
130. 2 is restricted to one transmitter per serial line otherwise the devices will work with RS 485 devices You should specify the communication standard that you want when you order your VECTORSTAR When choosing between RS 232 and RS 485 there are a number of factors to take into consideration RS 232 is much more common than RS 485 Most terminals and computer serial ports are RS 232 however RS 485 15 becoming more widely available on personal computers RS 485 1s differential RS 232 15 single ended To illustrate this RS 232 transmits one output TxD Alternatively RS 485 simultaneously transmits TxD and VECTORSTAR TxD the logical inverse of TxD Logical inverse means that if TxD 1 then TxD 0 RS 232 transmitters typically have series terminated outputs while RS 485 transmitters do not All this makes RS 485 less suscep tible to noise and able to transmit over much longer distances On the other hand RS 232 is easier to use and much less susceptible to transmission line effects RS 232 is also less expensive A major advantage of RS 485 is that it allows multidrop communication where many axes can be connected on one serial line Table 2 3 Communication Requirements To Communicate With Your VECTORSTAR You Will Need RS 232 Terminal IBM PC Compatible with Communication Software RS 485 Terminal and Connector for Your Terminal DE 9S Connector Provided with VECTORSTAR 3 Wire with Shiel
131. 3 CYCLE READY 24 COM 25 SPARE 26 COM 43 A Acca O Q00 CON CO OUT 07121 OUT 08119 J221 8 129 09 010 011 012 013 014 015 016 O Q P OO N JFAN NOTE 7 11 DC 21 c VFS5 INTERFACE A 95140 COM 5 UNREG NAA AWN COONMDNRWN O OVER TEMP OVER CURRENT OVER VOLTS UNDER VOLTS BIT 0 BIT 1 BIT 2 3 2 5V CON JBUS JPOW L1 1 s 21 BONES Ls SINTER HEN A 95125 TO 15V CONTROL COM 2 COM J1 CO 00 OTI 5V 22 SPARE SPARE 15V 15V COM IA COM IC J10 TACH MONITOR SHIELD I MONITOR 15 RELAY CONTACT RELAY CONTACT HOME RTN 00 4 COO O01 0N O NO J13 RESOLVER REF HI NOA ANWOUNOW ANOL N OQO 4 COND gt Noo zi io 00 0 014 COND X CO O0 4 OD 01 I COND X91 BRAKE 1 BRAKE 12 5 3 STOP 14 THERM 1 1 JINT2 THERM 212 COM IB COMP SWITCH FAST LIMIT 2 PHASE A SINE
132. 32 I O 2 same as 1 with line filters and hp meter driver Input 0 Encoder input 1 Analog input standard 2 Pulse input kW Rating Communication 08 8kW Continuous 0 RS232 12 12 kW 1 5485 24 24 kW 28 28 kW Mechanical 40 40 kW 0 Standard configuration 70 70 kw 4 With screw terminal 90 2 90 kW connector boards 5 Gasket blower Option available on amp L package only 6 D C fan Figure 1 1 VECTORSTAR Model Number Scheme CHAPTER SYSTEM DESCRIPTION VECTORSTAR Table 1 1 VECTORSTAR Description Low Power VSA24 0012 75 AMP Replaces VFS5 275 VSA28 0012 85 AMP Replaces VFS5 285 PA8500 ServoStar 85 AMP P S Table 1 2 VECTORSTAR Description High Power VSR40 0012 Line Regen 460V 40 HP VSR70 0012 Line Regen 460V 75 HP VSR90 0012 Line Regen 460V 100 HP VSL40 0012 Resist Regen 230V 40 HP aa VSRP25 0012 Line Regen 460V 30 HP A partial model number is printed on a gold and black tag on the front of the compensation module the gray plastic box secured by two screws to the front of your VECTORSTAR See Figure 1 2 for the descriptions of the model number that is what ABB and HHHH mean The model number is as follows The compensation module depends on your motor and the voltage and current rating of your VECTORSTAR It is important that the motor the VECTORSTAR and the compensation module model numbers all agree For example
133. 6 3 Fault Latch Area 3 The latch in Area 3 turns on the FAULT LED the FAULT software switch and the FAULT output on Connector C8 Any fault sets this latch you can also write your program to turn it on if you detect a fault condition The fault latch can be reset by 1 Turning FAULT off 2 Typing the enable command EN or 3 Powering down the VECTORSTAR 8 6 4 Ready Latch Area 4 Area 4 shows the logic required to make the drive ready If there are no faults the EN command sets the ready latch This turns the READY software switch on This latch is reset with the KILL K command the DISABLE DIS command or a fault These turn READY off 8 6 5 ACTIVE Area 5 Area 5 shows that ACTIVE will be on if both READY and REMOTE are on This turns on the ACTIVE LED It also allows the VECTORSTAR to actively control the motor CHAPTER 8 GENERAL PROGRAMMING REMOTE Remote Enable is an isolated input that 15 accessed from Connector C2 on the front of the drive You can print REMOTE with the P command It must be 1 to activate the VECTORSTAR If you cannot turn REMOTE on see the Chapter 2 Note that some faults hide the value of the REMOTE input from the VECTORSTAR microprocessor This does not normally matter because all faults must be cleared before the drive will enable If this condition exists the VECTORSTAR will print REMOTE as 1 8 6 6 Relay and STATUS Control Area 6 Area 6 shows how software switch ST
134. 77 L ALON 33s 3HVHS SVSA dl ZO HOLO3NNOO HONOSHL SI SIH1 GALOANNOO 38 150 SVSA 3AV IS H3 SVW SNOWWOO YSA 3AV IS ANY H3JSVIN YSA 3AV IS 2 L33HS NO TL ALON 935 JVWNOILdO NI LO HOLO3NNOO ONIDNIY OL YOLSISAY 2 1 wyo 021 V HLIM YSA SHL GSLVNINYAL 38 LSNW SLAdLNO YAGOONA AHL ATIVNOISVO9DO OL FINGOW 2 31416 22 0440 NV HDNOYHL SHIM IVWNOILdO V NI IVNOILdO 8 NI NOWWOS NOWMWOO YSA OL dal 38 LSNW AlddNS dO NONWOO lt Alddns YY S Figure C1 Encoder Equivalent 188 APPENDIX DRAWINGS 1304 Tvlt13S 90 YSA boooooooooooQ 59996049994 90 dsz aa 0 0 00 0 3 SNIH LS SIXV YSA 1SV1 aasn aa SN3dWhf TIVLSNI AINO AV arava ozi Noga v 13349 NVHLSS31 o 9 aowvisig 1499335 01 2 Tr 8 l1HOHS 404 SIXV YSA HOV3 5 4 NOLIVNIWHA L 31VIS SALLOVNI 9 3ONVO3dMI 56 0 ssag se 30 1v Wgl GO OL QUINO 687 54 IVINAS 66 10 YSA 56 10 YSA a vwWad4 56 10 9508 LOANNOOYALNI 987 54 IVIH3S SO YAWOLSND alr rar se 30 ssag
135. 8 8 4 Manual Program MANUAL 145 10 8 8 5 Typical AUTO MANUAL Programs 2 21211 2 2 02 200410000000000000000000000000000000000000 145 10 8 9 Background Task Level 6 estet Re d etin ie e 146 10 8 9 1 Restrictions of Background etie tees aede Rede AI INN IGI 146 UNET S 146 10 91 User Units tp oet ic OE 146 10911 Current Units te 146 10 91 27 Other User Units 12 2 teri tti terea neta et e a Ee Pa e 148 10 9 1 3 external Units a rh reet HR dee Pe Ea Qha 148 10 9 3 Position Rotary Mode ROTARY and PROTARY nennen enne enne 152 10 9 3 1 Choosing PROTARY PNUM and PDEN nn nennen nennen nne 152 10 9 3 2 Rotary Mode and Absolute Moves n ens 153 10 10 SERIAL COMMUNICATIONS U S S K Oka Q a O A ASA Saa A aS 153 tobauding 5 OR D RERBA 153 10 10 1 1 Setting the VECTORSTAR to Autobaud sse eene 153 10 10 1 2 Autobauding and MOTION sse a A E 153 10 10 1 3 Enabling Autobaud with ABAUD nnne ens 153 10 10 1 4 Baud Rate BAUD u u y S Sus
136. 83 153 Motion 23 Enabling 79 Error 79 Gating 165 Limits 79 Macro 84 Stopping 79 Motion Commands 78 Motion Link 124 162 Motion Link Editor 124 Motor Noisy 40 Motor Brake 73 Motor Disturbance 46 Motor Protection 14 Motor Thermostat 14 Mounting 12 INDEX Mounting the External Regen Resistor 13 Mounting the PSR4 5 12 Mounting the VECTORSTAR 12 Move Absolute MA 81 92 94 153 165 Move Incremental MI 82 92 94 165 Moves Buffering 86 Incremental 82 Triangular 82 MRD Command 85 87 200 MSLIP 102 MTIMER 102 106 108 MULTI 139 144 Multi Tasking 139 Debugging 162 Multidrop 58 155 205 Multiple JF JT Commands 89 Multiple Profiles 83 N N 69 Nesting 129 131 Noise Susceptibility 40 96 Noisy Motor 40 Non Linear Mechanics 45 Normalize NORM 83 96 Note 11 Numeric Expression 135 O 20 O1 8 71 132 OFF 69 OK2EN 38 ON 69 Operating Temperature 12 Operation 37 OR 71 Orient 105 OUT 71 132 Output Relay 75 Outputs General Purpose 132 Masking 132 Overdamping 40 OVERLOAD LED 54 Overloading the Motor 44 Overshoot 81 97 Overspeed 76 P 1 102 106 P2 102 PA 50 75 241 INDEX Mounting Hole Patter 194 Outline and Dimensions 195 Parameters 63 Parentheses 70 204 Parity 24 Part Nunber Description 3 Password 125 password 154 PC Wiring 22 PC Scope 44 PCAP 86 PCMD 75 96 PDEN 148 PDF 102 PE 75 96 PECLAMP 87 PEMAX 75 83 199 Periodic Maintenance 50 PEXT 76 9
137. 9 VECTORSTAR Control Modes 98 VECTORSTAR GEARING amp PROFILE GENERATION GEARING amp PROFILE GENERATION GEARING amp PROFILE GENERATION EXTERNAL ENCODER INPUT Encoder resolution must be equal to RDRES 4096 counts standard and must be mounted directly on to motor CHAPTER 8 GENERAL PROGRAMMING PL 1 TQ 0 PROP 1 VELOCITY LOOP w o INTEGRATION PL 1 0 PROP 1 OPEN LOOP TORQUE CURRENT PL 4 0 PROP 0 EXTERNAL POSITION LOOP w INTEGRATION EXTLOOP 1 99 CHAPTER 8 GENERAL PROGRAMMING VECTORSTAR 100 VECTORSTAR asics 9 SPINDLE PROGRAMMING CHAPTER 9 SPINDLE PROGRAMMING 9 1 INTRODUCTION Induction motors produce torque from the mutual interaction between the rotor current and the stator magnetization current The rotor current of induction motors is induced from the stator current The objective of vector control is to supply stator current so that its two current components the rotor current and the magnetizing current are exactly supplied to the motor as commanded from a controller The vector control condition can be met if the controller is programmed to read the exact orientation of the rotor magnetic axis which can be estimated via the speed detector and the amount of slip frequency 9 2 SYSTEM COMPENSATION VARIABLES The following variables for system compensation are unique for the induction motor All are set at the fa
138. A Common 4 Ref Hi Max potential 28V 1 Amp Common 10 Ref Lo Even pins common 7 Sine Hi 1 Sieto Connector C1 J7 3 Cos Lo Pins 9 Cos Hi Spare 5 Shld Tach 8 Shld Shld 2 Shld Monitor 11 Shld 15 6 Remote Rtn 12 Spare Cycle Rtn Cycle Note Remote C Low power unit O1 Hi Connector C10 J250 High power unit Spare Com Shld Com 32 VECTORSTAR C us 3 Quick START CHAPTER 3 QUICK START 3 1 INTRODUCTION Here we assume that you are experienced with servo drives and their installation The safety precautions are not included in this chapter However all safety measures should be properly followed before permanently installing this equipment 3 2 QUICK INSTALLATION FOR LOW POWER UNIT For the following instructions refer to Figure 3 1 on page 35 and Figures B 1 and B 2 in Appendix B For more information on each step please refer to the section listed parentheses 1 Mount the drive and power supply 2 5 1 and 2 5 2 2 Wire the external regen resistor to the power supply 2 5 3 3 Connect DC bus between the power supply and drive 2 6 2 4 4 Connect motor power Ma Mb and Mc phase must be correct 2 6 2 1 and resolver cables 2 6 4 6 5 Wire the ground drive power supply and motor 2 6 1 Wire the 3 phase AC line input 2 6 2 5 Connect 230 volt to Control Input of PA28 50 70 85 pins 1 and 3 2 6 3 1 Connector C6 of the drive 1s for the cool
139. AMMING AN NOTE time Not specifying the speed in MA commands reduces execution 8 8 3 3 Move Incremental MI Command The MI command allows you to command incremental moves by specifying the total distance of the move ACC DEC and SCRV are all in effect for MI moves Like MA if you enter an MI command without specify ing a speed the traverse speed will be VDEFAULT For example the following command causes the motor to move 5000 counts at a peak speed of 200 RPM MI 5000 200 The profiles that were shown earlier as SIMPLE PROFILE or S CURVE PROFILE could have been generated from this example As with the MA command MI 25000 causes the motor to move 25000 counts with the peak speed at the speed VDEFAULT For both the MI and MA commands not specifying speed reduces execution time and program size Not specifying the speed in MI N une commands reduces execution NOTE 8 8 3 4 Incremental Move Example SHOCK HAZARD Large voltages from the AC line and the DC bus can cause injury Wire the VECTORSTAR as described in Chapter 2 WARNING 82 VECTORSTAR THE MOTOR MAY MOVE UNEXPECTEDLY BE PREPARED TO DISABLE THE VECTORSTAR You should complet Initial Check Out in the Chapter 2 before proceeding This section will enable the VECTORSTAR The system may be unstable The motor may begin oscillating or run away Be prepared to disable the V
140. AMP off if you are not certain If it is CLAMP try raising the clamp limit PECLAMP somewhat If that does not help turn CLAMP off If you now get PE OVERFLOW errors it may be because the motor is undersized See the hints for PE OVERFLOW errors below Imake sure REG is not preventing motion turn REG off if you are not certain If REG is on you may not be feeding in the master encoder signal properly Remember it must always count up Check VEXT It should be greater than zero for profile regulation to work 166 VECTORSTAR make sure ZERO is off make sure all tuning constants are well above zero Check KP KV KVI and KPROP Each should be at least one hundred generally they are above one thousand make sure ILIM is not too small If ILIM is below 1095 the motor may not be able to overcome frictional load Imake sure you are commanding a speed that you see The VECTORSTAR can command speeds as low as 0004 RPM or about one revolution every three days depending on how you program velocity units If you have changed VNUM or VDEN from the factory setting temporarily restore them to see if the problem goes away If the motor moves and you get OVERFLOW error ERROR 25 the error occurs occasionally it may be because you have the limit PEMAX set too low Raise it by 20 and see if the problem is corrected use the VECTORSTAR RECORD function to record ICMD when a
141. AR remembers the last 20 errors even through power loss In addition VECTORSTAR lets you write your own error handler During a fault condition you can use the error handler to set outputs alert an operator and shut down your process smoothly VECTORSTAR offers trace and single step modes so that you can debug your program VECTORSTAR has complete fault monitor ing including travel limit switches feedback loss and software position limits as well as hardware safety circuits watchdogs and checksums for more reliable and safer operation VECTORSTAR IO VECTORSTAR has up to 32 I O sections that you connect via ribbon cable to standard OPTO 22 compat Ible I O boards or to our own I O 32 The I O 32 provides either fixed 24 volt or removable industry standard optically isolated I O SERIAL COMMUNICATIONS VECTORSTAR s serial communications provide powerful link to other popular factory automation devices such as PLC s process control computers and smart terminals VECTORSTAR offers RS 232 for most terminals and RS 422 RS 485 for multidrop communica tions With multidrop you can put up to 26 axes on one serial line VECTORSTAR can autobaud from 300 baud to 19 2k baud eliminating the need to set dip switches to start communicating MOTIONLINK Kollmorgen also offers MotionLink Plus a powerful windows based communications package for your IBM PC c compatible computer With this package VECTORSTAR s programs
142. ATUS and the relay work You can configure STATUS to indicate either drive READY but not necessarily ACTIVE or drive ACTIVE The difference is in how you want to use STATUS For example if STATUS is used for an interlock you want STATUS to indicate drive ACTIVE If the VECTORSTAR becomes inactive for any reason including the REMOTE input turning off then STA TUS will turn off As an alternative you can use STATUS to indicate that the VECTORSTAR is ready for the REMOTE input to turn on That is if REMOTE turns on the VECTORSTAR will be ACTIVE In this case you want STATUS to indicate drive READY The software switch STATMODE controls which state STATUS will indicate If STATMODE is on then STATUS will indicate drive READY If STATMODE is off then STATUS will indicate drive ACTIVE The operation of STATUS is shown by the AND gate and OR gate in Area 6 If STATMODE is on then READY will turn on STATUS through the AND gate If STATMODE is off then only ACTIVE from Area 5 will turn on STATUS through the other leg of the OR gate The STATUS output on optional Connector C8 Pin 35 is always the same as the STATUS software switch Note however that the state of the STATUS output is undefined for 25 milliseconds after power up STATUS may turn on for up to 25 milliseconds during power up WARNING 8 6 7 Motor Brake Kollmorgen motors can be purchased with an optional brake The brake is fail safe in that if no current
143. BEGIN MOVE TIL CAP EQ 0 WAIT FOR POSITION CAPTURE JT 4000 0 CHAPTER 8 GENERAL PROGRAMMING Note that the motor comes to rest 4000 counts after the position that was captured not 4000 counts after the JT command is executed If 4000 counts was not enough distance ERROR 42 MOVE W O TIME would be generated This means that the commanded speed change cannot be accomplished given DEC the decel eration limit Note also that you must leave an additional 10 15 milliseconds for the TIL and JT commands to be executed The JT command example given here brings the system to rest As an alternative you can change the speed to any value the motor can run as long as you do not attempt to change direction with one JT command For example the following command replaces the above JT command when you want to change speed to 100 RPM at 4000 counts past PCAP JT 4000 100 CHANGE SPEED TO 100 RPM BEGIN DECEL SO THE SPEED IS JUST REACHING 100 RPM WHEN THE POSITION IS 4000 COUNTS PAST REGISTRATION MARK For more information about registration see KMTG application note Cut to Length 8 8 11 3 Multiple JF JT Commands Many applications require that multiple Jog From JF and Jog To JT commands be executed sequentially In most cases you will have to insert a delay in your program between JT and JF commands For example if you enter 55 EN ENABLE VECTORSTAR ACC 100
144. CODES ERROR 46 MCI ACTIVE SEVERITY 2 You attempted to insert an MCI segment after an MCA segment in a macro move This error breaks program execution ERROR 47 TOO COMPLEX SEVERITY 2 You attempted to execute a macro move that required too many segments This error breaks program execution ERROR 48 MCA MCI RUNNING SEVERITY 2 You attempted to build a macro move while another macro move was running This error breaks program execution C 4 SOFTWARE ERRORS C 4 1 Programming Modes or Motion Modes ERROR 50 DRIVE INHIBITED SEVERITY 2 You attempted to execute an instruction that required the VECTORSTAR to be enabled while it was inhibited This error will break program execution if the instruction is issued from the user program ERROR 51 DRIVE ENABLED SEVERITY 2 You attempted to execute an instruction that required the VECTORSTAR to be inhibited while it was enabled This error will break program execution if the instruction is issued from the user program ERROR 52 NOT FROM TERMINAL SEVERITY 1 You attempted to execute an instruction from the terminal that is not allowed from the terminal This error generates no action ERROR 53 NOT FROM PROGRAM SEVERITY 1 You attempted to execute an instruction from the program that is not allowed from the program This error breaks program execution ERROR 54 NOT FROM MONITOR SEVERITY 1 You attempted to execute an instruction while in the Monitor mod
145. CONTROL 460 VAC P 97330 A 95158 INTERFACE LINE REGEN A 95159 ADAPTER MG300Q2YS 11 460 VAC P 97331 001 RESISTIVE REGEN A 95144 CONTROL 460 VAC A 95117 GATE DRIVE LINE REGEN 97330 CM300DY A 95144 CONTROL 230 VAC 93715 300 A 95158 INTERFACE LINE REGEN A 95159 ADAPTER 460 VAC RESISTIVE REGEN A 95144 CONTROL 460 VAC A 95117 GATE DRIVE LINE REGEN Figure 12 8 Continued High Power VS R L VS R P System Matrix Component LIstings 180 VECTORSTAR VECTORSTAR CHAPTER 12 HIGH POWER 8 o 2 u 2 BE 9 Y roo lt 26 T D 5 d 50 Bs Z lt 8 rus a gt 0 lt lt T lt m ALL CABLES EXIT BOTTOM OF UNIT FEE ATEEE 9 gt 000 lt lt lt ENCODER EQUIV OUTPUT 10 PIN BOTTOM BOARD LOCATION J7 CUSTOMER INTERFACE 20 PIN BOTTOM BOARD LOCATION J9 RESOLVER FEEDBACK 12 PIN BOTTOM BOARD LOCATION J13 PASS INPUT POWER LEADS THROUGH GROMMETS RS232 INPUT 9 PIN SERIAL TOP BOARD LOCATION 210 50 PIN BOTTOM BOARD LOCATION J12 Figure 12 9 VS R L VS R P Connector Locations 181 CHAPTER 12 HIGH POWER VECTORSTAR 182 VECTORSTAR WARRANTY INFORMATION Corporatio
146. CTORSTAR D C BUS This green LED is on when AC Line Voltage is applied REGEN This yellow LED turns on when the PA regen circuit 1s active FAULT This red LED indicates an overtemperature fault It turns on when the PA thermostat opens It turns off when the thermostat closes If this fault occurs it means that the regen resistor is on too often or for too long If you get this fault you may need to increase the power rating of your regen resistor and the PA may need to be modified at the factory Contact the factory 6 4 ERROR LOG The VECTORSTAR responds to a variety of conditions both internal and external hardware and software which are grouped in a single broad category errors An error indicates that there 15 a problem somewhere More serious errors are grouped as faults 6 4 1 Error Levels The VECTORSTAR s response to an error depends on the error s severity There are four levels of severity listed below increasing order Table 6 1 Error Severity Levels and Actions Errors that cause warnings Errors that cause a program break and stop motion in addition to Level 1 Actions Errors that disable the system and set the FAULT LED in addition to Level 2 Actions Errors that disable almost all VECTOR STAR functions including communications and flash the CPU LED to indicate the error number These are called firmware errors When any error except a firmware error occurs a message is displayed
147. CTORSTAR or PA EXTERNAL REGEN RESISTORS ARE SHOCK HAZARD Mount these resistors properly Enclose these resistors to protect personnel and equipment WARNING EXTERNAL REGEN RESISTORS GET HOT If you are using external regen resistors allow sufficient clear ance around the resistors Enclosures must provide ventila tion CAUTION 2 6 WIRING The customer is responsible for providing proper circuit breaker or fuse protection The customer is responsible for providing proper wire gauge and insulation rating for all wiring including motor AC line DC bus and External Regen Resistor connections The customer is responsible for making sure that all system wiring and electrical protection comply with all applicable national and local electric codes CHAPTER 2 INSTALLATION Figures B 1 B 8 in Appendix B and Figure 3 1 in Chapter 3 illustrate the System Wiring Diagram Carefully read all 9 figures before wiring your VECTORSTAR system including all of the notes following Figure B 8 Before wiring your VECTOR STAR system carefully study all eight pages of Figure B 1 B 8 in Appendix B including ALL of the notes following Figure B 8 and Figure 3 1 WARNING When wiring your VECTORSTAR system observe the following guidelines 1 Twist all AC leads to minimize electromagnetic emissions noise 2 Avoid running signal leads in close proximity to power leads motor stator leads or other sources
148. D Resolution 28 75 148 Radio Frequency Energy 50 RAMP 93 RD Command 164 202 READY 73 RECORD Command 44 reflection 16 Refresh R Command 136 Refresh Status RS 136 VECTORSTAR REG 93 164 REGEN LED 54 Registration 89 Registration input 23 REGKHZ 93 164 Relay 19 73 RELAY LED 7 54 RELAY LED 73 REMOTE 19 27 73 77 Remote Enable 73 REMOTE RETURN 19 Removing Code 163 Required Data Format 24 Resident Editor 124 Resistor 193 Resolution R D 28 75 148 Resolver Cable 29 Resolver Wiring 28 30 Resolver to Digital Converter 6 Resonance 45 Response 40 Return RET Command 128 131 206 Ringing 41 ringing 16 ROTARY 152 RS 232 20 21 RS 485 20 155 RUN Command 59 127 Run Mode 59 S S curve 81 Safety information 11 safety alert symbols 11 SAT 78 SCRV 81 83 84 88 SEG 87 164 Segments 82 164 SERIAL 137 serial busy 137 Serial Communications 153 Serial Port 6 57 Serial Watchdog 154 Shield 19 Single phase AC line 15 Single Step 59 161 SLIP 101 SLIPLIM 102 SLOPE 101 Software Gearbox 16 Software Gearbox 91 205 Software Installation 58 Software Listing 110 Software Travel Limits 80 INDEX Software Watchdog 72 198 Spare Parts 53 Ordering Information 53 Spare Parts List 53 Special Constants 69 spindle axis mode 104 spindle functions 103 SS 59 161 Stability 40 96 Standard Units 148 static sensitive 11 STATMODE 73 STATUS 73 Status 24 Stop S Command 79 127 Stop Bits 24 St
149. Drive must be disabled Format DUMP Dump variables and program DUMP VERSION Dump firmware version Delay program execution for a specified amount of time up to 2 147 483 647 milliseconds or 25 days D 15 idling command that is 1f you are using multi tasking D suspends the task but lets other tasks proceed Allowed only from the user program Format D Time Example 223 APPENDIX SOFTWARE COMMANDS VECTORSTAR DIS ED ELIF ELSE EN 224 D 1000 DWELL FOR 1 SECOND Disable the VECTORSTAR This command turns off the variable READY Refer to Draw ing C 84732 for more information Allowed from the interactive mode monitor mode and user program Format DIS Edit the user program Allowed only from the interactive mode Format ED Editor Commands DEL Delete a line F Find string C Change String I Enter insert mode P Go to a line and print it NEW Clear user program SIZE Show remaining program memory PASS Change password Empty Line Go to the next line and print Escape Key Exit the insert mode editor Part of block if Conditionally begins block execution Allowed from the user program See the IF command Format ELIF lt gt Logical lt Expr gt Example ELIF PFB GT 100 lt Expr gt Logical lt Expr gt is the condition Part of block if Begins last block execution Allowed from the user program See the IF command Format ELSE Ena
150. EAR must be on Advanced functions for the VECTORSTAR are described in detail through out this manual 3 4 QUICK TEST FOR SPINDLE FUNCTIONS If you want to test the spindle functions built into the drive and the drive has been connected to a CNC these instructions may help you quickly test the system 1 Make sure the connections between the drive and the CNC are correct see the table in Figure 3 1 note I4 and I5 are negative logic 2 Make sure LOAD 1 3 Using Motion Link check the input status by pressing the Esc key first to get the prompt gt and typing IN you should get a reading of 24 You can check each input by typing P I1 P I2 P I3 P I7 4 If everything is okay the motor should be enabled by giving 17 1 from the CNC 5 Check the motor speed by giving an analog signal to the drive and typing VEXT to check if the drive receives the input 6 You may repeat the test of adjusting the deadband of analog input by changing Z0 CHAPTER 3 QUICK START VECTORSTAR
151. ECTORSTAR quickly by either turning off opening the contacts of LIMIT or REMOTE WARNING Turn on the AC line voltage Type in the following example EN ACC 1000 DEC 1000 MI 4000 100 This should cause the motor to rotate 4000 counts with a traverse speed of 100 RPM With the next example the motor will repeat the move Type VDEFAULT 100 MI 4000 Notice that the motor again moves 4000 counts To bring the motor back to the original position type MI 8000 8 8 3 5 Profile Limits With both the MA and MI commands if the traverse speed cannot be reached because ACC or DEC is too small for the specified move then the VECTORSTAR reduces the maximum speed so that the move for all practical purposes is triangular Actually there is a very short less than 5 milliseconds traverse segment so that the move still has three segments VECTORSTAR The maximum time for an entire move is not limited However the time for each acceleration or deceleration is limited to 30 seconds If the acceleration rate is so low that this limit is exceeded then the VECTORSTAR generates an error explaining that either ACC or DEC is too low This error is issued before the motion command begins In this case ACC or DEC must be increased or the peak speed of the move must be decreased 8 8 3 6 Multiple Profile Commands The VECTORSTAR allows one succeeding move to be calculated while the present move
152. ED HARDWARE WATCHDOG C2 PIN 17 C2 PIN 16 RELAY C IV C2 PIN 10 24 VOLT 01 OPTICAL C SIN 20 ISOLATOR 01LO C8 PIN 35 STATUS OUTPUT BUFFERS C8 PIN 47 WITH OPEN COLLECTORS 8 45 i C8 PIN 43 03 C8 PIN 41 04 C8 PIN 39 05 C amp PIN 37 06 ULN2803A C8 OPTIONAL 07 C7 PIN 19 08 C7 PIN 23 CYCLE C7 STANDARD READY BUS BUS 2 2 ABSOLUTE doi VALUE 5 VOLTS FULL SCAI C2 PIN 4 L CIRCUIT LESE gt MONITOR C2 PIN 14 gt COMMON CURRENT 92 Ma SAMPLE 2 PWM B PHASE POWER CURRENT STAGE CURRENT SAMPLE i S LOOP GBHASE CURRENT CURRENT SAMPLE 2 1 e MOTOR GND 1 0K C2 PIN 2 TACH MONITOR C3 PIN 4 REF HI TACH SCALING 1000 RPM V 4700pf 2 COMMON C3 PIN 10 REFLO C1 PIN 1 f CHA OUTA C3 PIN 7 SIN HI gt 75174 C1 PIN 6 OUTA C3 PIN 1 SINLO C1 PIN 2 C3 PIN 9 COS HI POTAE p gt 75174 C1 PIN7 ENCODER C3 PIN 3 Cos LO Oure C1 PIN 3 CHZ a 0072 75174 C1 PIN8 6 gt gt CHAPTER 1 SYSTEM DESCRIPTION VECTORSTAR VECTORSTAR Cac 2 INSTALLATION 2 1 INTRODUCTION The information in this chapter will familiarize you with safety information unpacking and inspection installation requirements mounting procedures and wiring for install ing the VECTORSTAR PA unit and or External Regen Resistors Read the entire chapter carefully The chapter
153. EEDED MINIMUM O1 OFF GOTO 20 DONE GO TO END 11 GET HERE IF WITHIN RANGE O1 ON P PFB WITHIN RANGE 20 END OF BLOCK You can choose whether to use or the IF command when you are writing your program You should choose the command that results in the most readable form For example if multiple commands are to be executed the IF command s block structure sets off the commands and avoids the use of a GOTO and a label On the other hand if a single instruction 1s to be executed the may be more readable Usually one form results in less program space or faster execution and this may dictate which to use However if space or timing are not critical use the most readable form 10 4 2 6 Nesting IF commands You can nest IF commands For example the following program shows two levels of nesting 55 IF X1 GT 0 IF X2 GT 0 P BOTH X1 AND X2 0 ELSE P ONLY X1 GT 0 ENDIF ELSE IF X2 GT 0 P ONLY X2 GT 0 ELSE P NEITHER X1 NOR X2 0 ENDIF ENDIF B You can nest IF commands indefinitely You should be careful to include all of the ENDIF s to close each level of nested IF All of the restrictions and options that were listed earlier as applying to IF commands also apply to nested IF s The indentation shown above is not required but is present to make the program more readable The VECTORSTAR ignores the indentation 10 4 2 7 IF s with GOTO and GOSUB You can use the GOSUB command from
154. ENDIX C ERROR CODES VECTORSTAR C 3 MOTION ERRORS C 3 1 Position Calculation Errors ERROR 30 MANY MOVES SEVERITY 2 You typed in too many move commands MA MI MCGO from the interactive mode You can have one move execut ing and the other pending The error does not occur when move commands are executed from the user program because the VECTORSTAR sees that the motion buffer 1 full and delays execution to prevent the error This error breaks program execution ERROR 31 MANY MRD MOVES SEVERITY 2 You attempted to execute a motion instruction that required the profile buffer to be empty This occurs when two instructions are active at once You should use a synchronizer to delay the execution of the instruction that caused the error This error breaks program execution ERROR 32 ACCIDEC TOO LOW SEVERITY 2 You entered a motion command that calculated a motion profile where either the acceleration or deceleration segment was more than 30 seconds long You must increase ACC or DEC or reduce the speed change of the move This error breaks program execution ERROR 33 VEL OUT OF BOUNDS SEVERITY 2 You entered a motion command where the commanded velocity was out of the allowable range The range for Jog J commands is VMAX The range for other motion commands is 0 to This error breaks program execution C 3 2 Macro Move JT JF Errors ERROR 40 CHANGED DIRECTION SEVERITY 2 You attempt
155. ENERAL PROGRAMMING Most control variables and all user variables are stored in non volatile their values are not lost when the VECTORSTAR is powered down In general control variables are remembered except the switches Table 8 2 shows the state of all VECTORSTAR programmable switches on power up The output word OUT 15 set to zero shortly after power up 8 3 9 Initial Settings of Control and User Variables This section briefly discusses the standard initial and power up settings for all control and user variables The learning process is simplified by using the standard settings which disable certain functions Note that here initial means as shipped from the factory However initial does not imply factory settable you can change values that are set initially at the factory but you cannot change factory settable variables A2D Switch from analog input to the gear encoder input Remembered through power down ABAUD Enable autobauding Initially set to 1 and left at 1 for preliminary operation ACC Acceleration rate initially in RPM Sec and set to 100000 ADDR Address for multidrop applications Initially set to 0 for non multidrop ADEN Acceleration units denominator Initially set to 1000 for RPM Sec Limits DEC and ACC acceleration and deceleration rates Initially in RPM Sec and set to 100000 ANUM Acceleration units numerator Initially set to 4474 for RPM Sec BAUD Baud rate for serial communications
156. ER A TOP IGBT BUS L1 4 12 L3 4 5 E 6 FOR 7 EXTERNAL 9 USE 10 11 TO DC FAN 12 VFS5 MC3 J43 J20 STAT1 COM REF MOTOR TEMP COM 4 COGO CN C OUT 07121 OUT 08 19 J221 SPARE 18 COM J29 SPARE 09 COM SPARE COM HOME COM LIMIT COM CYCLE COM MOTION COM GATE COM COM COM CYCLE READY COM SPARE COM c 255 95140 5 a CONDUBWNH NN AAA 00 AWN OVER VOLTS UNDER VOLTS J10 1 MOTOR 21RTO J3 SPARE SPARE SWITCH COMP SWITCH FAST LIMIT 2 PHASE A SINE OOOI NO TACH MONITOR 19 I MONITOR EN REV ENI 12 REMOTE RTN CYCLE RTN J12 CYCLE NOTE 1 REMOTE 01 HI OUT 1 SPARE 01 COM SHIELD COM OUT2 COM 02 RELAY CONTACT RELAY CONTACT OUT 3 03 Naa BOON RON c 5 4 OUT 4 04 OUT 5 05 O OO N NO gt J13 RESOLVER REF HI NM NOUNOWANOL a X91 BRAKE 11 12 STOP 3 STOP 14 THERM 1 1 JINT2 THERM 212 COM COMP SWITCH HORT CIRCUIT PHASE B SINE PHASE C SINE N CONMUBWNH 1 c ap SHT CIRC E STOP BRAKE NOT USED L PHASE A SIN
157. ESPONSE 2 INCREASE 10 20 DECREASE 10 20 DECREASE 10 20 LPF ON LPFHZ 500 REDUCE LPFHZ Figure 4 5 Velocity Loop Tuning flow Chart CHAPTER 4 OPERATION 47 CHAPTER 4 OPERATION VECTORSTAR 48 VECTORSTAR CG s 5 MAINTENANCE 5 1 INTRODUCTION The information in this chapter will enable you to maintain the system s components ensuring smooth efficient operation of the motor Preventative maintenance of the equipment is also specified along with periodic mainte nance Follow these practices when operating your servo system 5 2 PREVENTATIVE MAINTENANCE Preventative maintenance can help you prevent situations that will damage your equipment Four types of preventa tive maintenance are presented below Following each of the procedures can reduce problems with and add life to your equipment Preventative maintenance to this equipment must be performed by qualified personnel familiar with the construction operation and hazards involved with the applica tion CAUTION CHAPTER 5 MAINTENANCE Electronic components in this amplifier are static sensitive Use proper procedures when handling CAUTION component boards Preventative maintenance should be performed with the VECTORSTAR system out of operation and disconnected from all sources of power 5 2 1 Transient Voltages All transient producing devices must be properly suppr
158. FH Two s complement notation is used when printing in hex This means that printing negative hex values requires the full field width of 9 characters When printing in hex format the field must be wide enough to Include the appended H 10 6 1 4 Printing Binary Numbers To print a variable in binary format follow the variable name with a B enclosed in square brackets B The variable will be printed in a field 33 characters wide including an appended B indicating binary All of the leading zeros will be printed The default field width of 33 can be reduced by following the B with the desired field width For example X2 127 2 X2 B 2 X2 B10 P SPEED VFB 5 3 1 KRPM This command would produce SPEED 1 9 KRPM So the general order for decimal format is OVERALL WIDTH DECIMAL POSITION PRINTABLE DIGITS For the example above 5 3 1 the overall width was 5 the decimal position was 3 and the number of printable digits after the decimal was 1 You can leave off any of these three specifications The overall width defaults to 12 the decimal position to zero and the printable digits to the value of the decimal position 10 6 1 3 Printing Hex Numbers To print a variable in hexadecimal follow the variable name with an H enclosed in square brackets The variable will be printed in a field 9 characters wide including an appended H indicating hex The def
159. Figure 2 2 Master VECTORSTAR and Slave VECTORSTAR CHANNEL A OUTA OUT B OUT Z CHANNEL B IN B Standard IN A Standard OUTA OUTB OUTZ IN B Standard IN A Standard Figure 2 4 VECTORSTAR C1 CHANNEL Z Figure 2 3 Encoder Phasing for Clockwise Rotation 17 CHAPTER 2 INSTALLATION inputs are Channel A Pins 5 10 and Channel B Pins 4 9 The outputs are Channel A Pins 1 6 Channel B Pins 2 7 and the marker channel Channel Z Pins 3 8 There is no input Channel Z though this signal often would be connected to HOME see Chapter 8 Refer to Figure 2 3 fora phasing diagram The logic power supply common is not available on Connector If you are wiring from one VECTORSTAR to another VECTORSTAR on the same PA then you need not connect common as the commons of the two drives will be connected through the logic power supply connector C4 If you need to connect to common you must obtain it from Connector C2 or C4 Be sure that the common ofthe VECTORSTAR and of the encoder power supply are electrically connected to each other 2 6 4 2 Encoder Equivalent Input The encoder and pulse inputs are for signals from a master encoder for example an encoder on another motor or the encoder output of another VECTORSTAR The VECTORSTAR can also use an encoder for feed back in some cases The encoder equivalent input 18 not available when pulse input OPT2 Card is installed If the encoder input
160. GING 11 1 INTRODUCTION The information in this chapter will enable you to rectify problems you may have while programming the VECTORSTAR When you write programs you may inadvertently include a few errors or bugs The best step you can take to correct errors is to prevent them by following the programming practices provided in this manual Every effort has been made to make the VECTORSTAR language as simple as possible with BASIC like commands algebraic math and a variety of conditional commands Still some bugs are almost certain to surface in a new program The VECTORSTAR provides two execution modes to help you debug your program Trace and Single Step 11 2 DEBUGGING MODES 11 2 1 Single Step SS If the error occurs in a section of your program that Is not time critical you can use single stepping to help track down the error When you execute your program in the Single Step mode each command is printed out The VECTORSTAR waits for you to press the ENTER key before executing the com mand Use the nested IF example given in Chapter 10 Enter the program set X1 and X2 equal to 1 and turn SS on by typing SS ON Then begin execution at label 55 by typing RUN 55 The following line should be displayed 55 5 gt Press the ENTER key and the response should be IF X1 GT 0 5 gt You can probe the VECTORSTAR variables from the Single Step mode without stopping your program For example type P X1
161. H 9 SLOWSY YAWOLSND 20 HOLO3NNOO od NOWNWOO qT3IHS V S uvds lt NOWWOO HOLINOW HOVL TEn NOWWOO SNILOANNOO NAHM 3AH3S80 LSNW NOA OCA 06 SdWV 6270 Q31V3 341 ANOS V SI LI LAdLNO GALVIOSI NV SI LO N lt LSNW AVIS N OVA SLOVLNOD AV HALSIS3H dV 01 JAINA NYO SIOVINOO AV HH 3uvMquvH o o o o aq o 5 5 u 019 HOLO3NNOO q 3lHS 5 WONWIXVIW A0L I 1 SO IVNV 190 APPENDIX DRAWINGS VECTORSTAR 1 22 WVHSVIG YSA aanaans 5 Alddns NOWWOD YSA AHL OL GALOANNOO 38 LON LSNW Qa1v 1OSI SIHL dO NOWNWOO 3H L qariadns s3Wolsno Alddns SNId Q3 338WnN d 18VO NO8SI HONOYHL NONWNOO YSA OL GALOANNOO SI SLIOA S SIHL dO NOWWOO 3H qm LNATIAINDA HO 13GON 584 38 OL SQ33N dWV19 318gISSOd SV WalarTdWv OL 35012 SV 38 OL SAJAN L SALON NOILISOd 8 22 0140 L 31ON 335 318V9
162. HAPTER 6 TROUBLESHOOTING PROP 2 6 4 2 DEP If your VECTORSTAR prints to a Data Entry Panel DEP 01 or any other 40 character wide display the standard error messages will not print properly The problem 15 that error messages are based on an 80 character wide display and the DEP 01 15 only 40 characters wide To correct this problem the VECTORSTAR provides the DEP switch which when turned on cuts all error messages down to 40 characters If your VECTORSTAR prints to a DEP 01 type DEP ON 6 4 3 Error History The VECTORSTAR stores the twenty most recent errors in the Error History To display the entire Error History type ERR HIST This causes the Error History to be sent to the terminal with the most recent error sent first When the VECTORSTAR is powered up a DRIVE POWERED UP message is inserted into Error History even though this is not an actual error To clear the Error History type ERR CLR Error History remains intact even through power down 6 4 4 Displaying Error Messages The ERR command can also be used to display an abbreviated description of the error For example type ERR 50 The VECTORSTAR responds with ERR 50 VECTORSTAR INHIBITED You may display messages for errors from through 999 If you type in an error number that the VECTORSTAR does not recognize it will respond with 56 VECTORSTAR ERROR NOT FOUND A description o
163. I O pinouts These can be used for spindle functions such as C axis Command Zero Speed output etc If you are using the spindle function provided by our user program you must assign the general purpose I O 9 5 3 Application Code A user application code can be embedded into the PROM for permanent storage At power up the VECTORSTAR will load this code to the RAM and execute it immediately if LOAD is 1 Autobaud must be disabled on power up so that the application software can be executed without waiting for the establishment of communications which is expected by the CNC If the you want to run a program other than the embed ded one enter LOAD 0 and load the user program The new program will reside in RAM and be ready to run At power up the new program will run rather than the embedded program 9 6 TYPICAL APPLICATION PROGRAM FOR VECTORSTAR This section provides details for a user program for a typical spindle application If you think the program is suitable to your application contact the factory for embedding the code into EPROM The following application software implements general spindle drive functions which may interface with a higher level controller through the GENERAL PURPOSE I O connectors provided by the VECTORSTAR Note that this example may NOT work for your applica tions Very often modifications are necessary under different circumstances The user variables X1 to X55 and XS1 to XS15 are rese
164. IF ELIF condition 2 ELIF block 2 ELSE ELSE block ENDIF The above example shows two ELIF commands You can have any number of ELIF commands The operation of this example IF command is as follows 130 VECTORSTAR If the IF condition is TRUE All commands in the Block IF are executed No other blocks are executed even if some or all of the other conditions are true Program execution continues after the ENDIF command Otherwise if ELIF condition 1 is TRUE All commands in ELIF block 1 are executed No other blocks are executed even if the conditions that follow are true Program execution continues after the ENDIF command Otherwise if ELIF condition 2 is TRUE All commands in ELIF block 2 are executed No other blocks are executed even if the conditions that follow are true Program execution continues after the ENDIF command Otherwise All commands in ELSE block are executed Program execution continues after the ENDIF command Note that only the first block with a true condition is executed The IF ELIF ELSE and ENDIF commands have several restrictions and options Each IF ELIF ELSE ENDIF set must have one and only one IF may have any number of ELIFs need not have any ELIFs may have one ELSE Need not have an ELSE must have one and only one ENDIF 10 4 2 5 IF vs You can use in place of IF commands For example clamping applications make decisio
165. INSERT MODE The VECTORSTAR will respond with gt CHAPTER 10 USER PROGRAMS indicating that you are in the Insert mode Now type TEST LINE FOR LEARNING ABOUT THE EDITOR Press the escape key to exit the insert mode Type P1 The VECTORSTAR should respond with 1 TEST LINE FOR LEARNING ABOUT THE EDITOR You can specify the line you want to insert directly For example 5 enters the Insert mode The next line you type is entered directly into the program as the new line 5 Subsequent lines 6 7 and so on follow line 5 10 3 2 5 Find F The Find F command will search down through the program memory for a particular word letter or string of characters For example the Find command can be used to find the word EDITOR from the Insert command above From the Editor type USE P TO GO TO TOP AND SEARCH F The VECTORSTAR should respond with FIND WHAT gt then type EDITOR The Find command will find line 1 since the word EDITOR occurs in that line Now F can be used to find the next line with EDITOR Type F and the VECTORSTAR should respond with 125 CHAPTER 10 USER PROGRAMS FIND WHAT EDITOR gt In this example Find command has a default FIND WHAT string The default is the find string from the last Find command If you enter an empty line the next
166. ITS WITH LOGICAL OR which turns on O1 O2 and O3 without affecting O4 08 The logical AND can be used to turn off several bits OUT OUT amp 7 CLEAR 5 BITS WITH LOGICAL AND turns off 04 08 and does not affect O1 O3 Note that the hex representation can be especially useful when setting the higher bits O4 ON O7 ON O8 ON 16 the same as OUT OUT 0C8H IN is formed with 11 16 in the same way OUT is formed with O1 8 72 VECTORSTAR Table 8 5 Input 1 16 Decimal Values 32768 16384 8192 4096 For example if IN were equal to 5010 that would mean I2 I5 I8 I9 I10 and I13 were on and all others were off because 5010 is the sum of those bits 5010 2 16 128 256 512 4096 8 6 ENABLE AND FAULT LOGIC This section covers how to enable the VECTORSTAR and how faults affect the operation This discussion will center around Figure 8 1 This drawing has six areas each of which is labeled with a circled number 1 6 Note that this drawing 1s a functional diagram it does not directly represent the actual hardware and software used to implement these functions Your VECTORSTAR system should be mounted and wired as described in the Chapter 2 The AC Line to your PA should not be turned on for examples in this chapter until you are asked to do so If the proper connections are not made or the terminal is not commu nicating see Chapter 2 AC LINE SHOULD NOT
167. LESHOOTING CHAPTER 6 TROUBLESHOOTING 6 1 INTRODUCTION The information in this chapter will enable you to order spare parts and isolate and resolve common system hardware problems The VECTORSTAR aids in diagnostic evaluation through its LED Status Indicators and the VECTORSTAR Error Log Both of these features are explained to assist you in finding solutions As another part of Kollmorgen s obligation to its customers Factory Support and Repair is also defined 6 2 SPARE PARTS There are no user serviceable parts on the VECTORSTAR There are several fuses that are user serviceable on the PA Remember the PA can be damaged by ESD Electro static discharge Observe proper ESD protec tion practices The PA can be damaged by ESD electro static discharge Observe proper ESD protection CAUTION practices 6 2 1 VECTORSTAR Spare Parts List Connector Kit for 20 Amp VECTORSTARs VECTORSTAR x20 X VECTORSTARC 101 6 2 2 PA Spare Parts List Connector Kit PSR4C 100 Regen Fuses 8 8 Ohms External Regen 230 Volt Units PA 2xx xx01 12 Amp Fuse A 80552 002 6 2 3 Ordering Information If you need to order parts for the VECTORSTAR and or PA you can order them through your local distributor For a complete list of Kollmorgen representatives contact us directly at 53 CHAPTER 6 TROUBLESHOOTING Kollmorgen Motion Technologies Group 201 Rock Road Radford VA 24141 U S A Telephone 540 639 2495 54
168. MING PRD each time It turns out that the average value of PRD 15 1500 counts Then use the following command MRD 150042048 200 CCW MOVE TO 1 2 REVOLUTION FROM 1500 COUNTS You must specify the direction CW or CCW so that the VECTORSTAR always backs away from the stop Remember that for example J 1000 1s not necessarily clockwise since the direction of jog rotation is controlled by the variable DIR You should be aware that if you replace your motor you must repeat this process since the relationship of PRD to the motor shaft position is different for each motor 8 8 11 JOG TO JT amp JOG FROM If you replace your motor repeat this process In some applications JOG commands need to be synchronized with position feedback With J the standard JOG command the speed changes when the command is entered Position dependent jogs Jog To and Jog From delay the speed change until a specified position is reached You specify the position at which the change in speed begins with the Jog From JF command Similarly you specify the position at which the change in speed ends with the Jog To JT command With position dependent jogs you must specify a position and the new speed ACC DEC and SCRV are in effect Position dependent jogs are always Absolute moves not incremental The following graph shows the effect of a JF command This example assumes that the speed 15 alread
169. Motion Technologies Group VECTORSTAR VSA VSP VSL Installation and User s Manual Manual MVS000H February 1999 VECTORSTAR VSA VSP VSL Installation and User s Manual MVS000H Copyright 1996 Motion Technologies Group All rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Kollmorgen except under written agreement rights reserved No part of this book shall be reproduced stored in a retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Kollmorgen Motion Technologies Group furnished for customer use ONLY No other uses are authorized without written permission of Kollmorgen Information in this document 15 subject to change without notice and does not represent a commitment on the part of Kollmorgen Motion Technologies Group Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to former issues IBM PC is a trademark of International Business Machines Corporation OPTO 22 is
170. N UNTIL 1220 PLO RET DRIVE OVER TEMPERATURE 50 IF 14 EQ 0 2 O5 0 TMR1 DTIMER 051 TMR1 EQ 0 GOTO 80 ELSE 050 TMR1 0 2 2 8 ENDIF RET OVER TEMPERATURE 60 IFISEQO 06 EQ 0 TMR2 MTIMER 061 TMR2 EQ 0 80 ELSE O6 0 2 0 X2 X2 16 ENDIF RET APPLICATION FAULT EXIT EXECUTION 80 040 CONTINUE 2 REMOTE EQ 1 2 READY EQ1J0 wo DIS 070 03 0 020 PLO END 112 VECTORSTAR ENABLE THE DRIVE WITH REMOTE 1 READY 1 AND WITHOUT ORIENT 90 14 amp 1 05 EQ 0 GOSUB 50 15 amp 1 06 EQ 0 GOSUB 60 amp 17 amp 1 12 EQ 0 RET 2 2 amp 65533 1 041 REMOTE z0 OR DRIVE ENABLE 0 AFTER THE DRIVE WAS ENABLED 100 IF I7 0 2 REMOTE EQ 1 J 0 W0 DIS O40 O30 PLO ELIF REMOTE EQ 0 040 03 0 PLO GEAR 0 ENDIF 04 EQ 0 REMOTE EQ 0 GOSUB 110 RET WAIT FOR REMOTE 1 110 14 amp 1 05 EQ 0 GOSUB 50 15 amp 1 06 EQ 0 GOSUB 60 7 EQ 0 DIS I7 EQ 0 RET 2 REMOTE amp I7 amp 1 12 EQ 0 110 2 2 amp 65533 1 041 510 DO THESE AFTER A VFS5 ERROR OCCURS ERROR O20 070 040 030 VECTORSTAR PLO GEAR 0 DIS END 9 6 7 A Sample Application Program for the VECTORSTAR As mentioned earlier the VECTORSTAR can have a set of spindle functions built in the drive which meets higher controller or CNC requirements The
171. NERAL PROGRAMMING nennen nnne nnn u 63 INTRODUCTION RE e eo etel vi os 63 8 21 Comments ER 63 89 VARIABLES E REO ERE OF er E 63 92321 s 64 8 3 2 Three Types of asc eee Ee aS 64 8 33 Variable Limits a eet tata in a REA e n ERE a ire Bevan EA 64 Bid Ay Switches tutte ien edi tette mte Sete Re MS 64 Q SS Printing Vatiables e Sete ip domna distent ius 64 83 6 Ch ngmg Variable 3 ee den i ede nette t bim cs 65 8 3 7 RH IRR e RS 65 8 3 8 Power up and Control Variables nan 65 8 3 9 Initial Settings of Control and User Variables sss 66 823210 User Variables ee oe etd nO ROB UD ies t ens 69 8 3 10 1 Indirect User Vatrables u aa un ee ek 69 iii VECTORSTAR S3 LT User Switelies ma to e did entere re i PERRO 69 8 312 Special Constants ce s m ERR ERU QE HEY e RR S UG RES WI 69 ies se tote tty tte Non 70 8 41 Hexadecimal 3
172. NI NOLLdIHOS3Q 1 33V SLNdLNO SLNANI INOS SALON Figure 3 1 System Wiring VSA 35 CHAPTER 3 QUICK START VECTORSTAR 36 VECTORSTAR C unen 4 OPERATION CHAPTER 4 OPERATION 4 1 INTRODUCTION The information in this chapter will introduce you to the system components and their dependence upon one another Also it will help you ensure each component is configured and functions properly At this point all safety stops and other precautions should be in place and working properly Be prepared to stop the machine if necessary In addition this chapter will enable you to compensate your motor for load conditions Tuning is an important step in setting up and maintaining your VECTORSTAR servo system This chapter defines and explains tuning in detail A flowchart 1 also provided for easy step by step instructions to tune the servo system 4 2 START UP AND CHECKOUT You should now be ready to supply power to test the servo systems functions and features Work with only one axis section at a time Confirm all other VECTORSTAR amplifiers are inhibited meaning the enable circuits are open high Appropriate precautions should be taken to stop the machine if necessary Limit switches and safety devices should be in place WARNING THE MOTOR MAY MOVE UNEXPECTEDLY BE PREPARED TO DISABLE THE VECTORSTAR Commands in this section will enable
173. OFF to turn the Rotary mode off This error breaks execution if the instruction was issued from the program ERROR 60 OUTSIDE PROTARY SEVERITY 2 You attempted to make an absolute move either MA or MCA beyond PROTARY For example if PROTARY 15 1000 and you typed MA 2000 Use incremental moves MI and MCI if you want to move beyond the rotary limit This error breaks execution if the instruction was issued from the program ERROR 61 NORMALIZE FIRST SEVERITY 2 You attempted to turn on the Rotary mode when PFB was less than zero or greater than PROTARY Use the NORM command to normalize the position to between 0 and PROTARY This error breaks execution if the instruction was Issued from the program ERROR 62 RD ALREADY IN USE SEVERITY 2 You attempted to execute RD when RD was in use from some other task This error occurs when two task levels attempt to simultaneously use the RD command This error breaks program execution ERROR 63 NOT AT THIS LEVEL SEVERITY 2 You attempted to execute a command that is not allowed at the present task level For example GOSUB and GOTO are not allowed from within an alarm This error breaks program execution ERROR 64 BACKWARD REGULATION SEVERITY 3 The external input counted backwards more than 30 000 counts when REG was on This error breaks program execution and disables the VECTORSTAR ERROR 65 RECORD NOT READY SEVERITY 3 You entered a PLAY command when nothing
174. OK CPU FAULT RELAY CURRENT LOOP COMPENSATION The VECTORSTAR has analog current loops The current loop compensation components are all contained in the compensation module located on the front of the VECTORSTAR The current loop compensation changes when you change the motor model You must install the correct compensation module when changing motor models YOU MUST HAVE THE PROPER COMPENSATION MODULE INSTALLED FOR YOUR MOTOR Failure to install the proper compensation module can cause damage to the VECTORSTAR the motor or both CAUTION 1 6 VECTOR CONTROL OF INDUCTION MOTORS Included in the VECTORSTAR series is a line of vector controlled induction motor drives for spindle applications This line of drives is also user program mable to fit many applications The motors used with these drives are designed for machine tool duty and have bearings and special balance for high speed operation Operation of the VSA Spindle Drive is identical to that of the standard VECTORSTAR system The control software 1s designed to control induction motors such as machine tool spindle applications CHAPTER SYSTEM DESCRIPTION The VSA units have an efficient bonded fin heatsink a fan shroud that channels all the air from the fan over the heatsink and an externally mounted fan This allows the unit to have a contiuous duty rating of 75 85 AMPS VSA units use an EXT1 card which has filtered channels for the externa
175. OSPD VMAX is the VECTORSTAR maximum velocity It depends on the motor and the resolution of the R D converter For standard systems with 12 bit R D converters VMAX is less than or equal to 12000 RPM For 14 bit systems VMAX is limited to 3000 RPM 16 bit systems are limited to 750 RPM VMAX is set at the factory and VMAX is in velocity units VOSPD is the maximum velocity for your system The VECTORSTAR generates an overspeed fault if VFB is ever greater than VOSPD You can set VOSPD to any level below 1 2 times the VMAX value This allows you to limit the speed of your system to any level below VMAX When an overspeed occurs the VECTORSTAR is disabled immediately You should set VOSPD to at least 10 or 15 above your system s maximum speed to avoid nuisance overspeed faults You can change VOSPD only when the VECTORSTAR is disabled VOSPD is in velocity units 8 7 4 Current 8 7 4 1 Motor Current ICMD and IMON ICMD is commanded motor current ICMD like PCMD and VCMD is generated internally from motion com mands ICMD is in current units IMON is the output of the current monitor circuit and it represents the magnitude of the motor current IMON is always positive and it is in current units IMON is the digital conversion of the analog signal I Monitor on Connector C2 8 7 4 2 Current Limits IMAX and ILIM IMAX is the maximum level of current that the VECTORSTAR can output It is set at the factory its value depends o
176. P until the motor is performing appropriately 4 6 2 Tuning the Position Loop Once the velocity loop is tuned you can tune the position loop Break program execution and stop motion by typing S Type in the following commands The drive will be enabled and the motor will turn Make sure the motor is secured WARNING PEMAX 30000 ZPE ZERO POSITION ERROR TO AVOID POSITION ERROR OVERFLOW WHEN ENABLING POSITION LOOP PL ON KF 0 RUN 80 The motor should again begin turning Now adjust KP until the motor is performing appropriately Table 4 2 shows the relationship between a properly tuned position loop that is the highest setting for KP and velocity loop bandwidth Note that the position loop bandwidth will be substantially lower than the velocity loop bandwidth usually by a factor of 5 to 10 Table 4 2 Velocity Loop Bandwidth vs KP VELOCITY LOOP BANDWIDTH 500 43 CHAPTER 4 OPERATION If you want to eliminate some or all of the following error you can raise KF as high as unity feed forward Unity is defined as 16384 However the larger you make KF the more you must reduce KP to eliminate overshoot and thus reduce the position loop performance If you cannot get the desired performance from the position loop then try reducing ACC and DEC to reduce overshoot This can be a good way to limit overshoot in the position loop and you may be able to raise KP slight
177. PE overflow occurs If ICMD is saturating equal to ILIM for more than a few milliseconds you are commanding motion that your motor cannot perform See hints on motor loading ILIM ACC DEC and PEMAX below If the overflow occurs at high speeds and with low ICMD below ILIM see the hint about speed problem sure that the load does not exceed the capability of the motor make sure that is set high enough you get the error during acceleration or deceleration make sure ACC and DEC are not set too high If they are too high the commanded profile will exceed the capability of the motor if you get the error during constant speed verify that the AC line voltage is large enough Chapter 1 lists the VECTORSTAR model numbers If the voltage you apply to the VECTORSTAR 15 lower than the specified voltage the motor will not operate properly at high speed VECTORSTAR If you get overspeed errors ERROR 13 if the error occurs occasionally it may be because you have the limit VOSPD set too low Raise it by 20 or as high as 120 of VMAX and see if the problem is corrected if it happens on acceleration it may be because your motor is not tuned properly Is your motor overshooting orringing Retuning the motor should correct the problem 1f it happens when the motor is rotating very slowly so that you are sure that the speed 15 not near VOSPD your resolver or R D converter may
178. PLUS Win 95 98 Select Start gt KMTG Motion Suite gt MotionLink Plus Windows 3 1 double click the MotionLink Plus icon in the KMTG Motion Suite program group 7 5 ACCESSING ON LINE HELP IN MOTIONLINK PLUS Once you have started MotionLink pressing the F1 key at any time will give you access to on line context sensitive help It is recommended that you make extensive use of MotionLink s on line help file It explains the operation of the program and how to get the most out of it in minute detail 7 6 PROCESSOR MODES 7 6 1 Prompts The VECTORSTAR provides several modes of opera tion Each mode is distinguished by a unique prompt the short series of characters that the VECTORSTAR writes to the screen requesting input For example the interactive prompt is gt The VECTORSTAR is designed to receive commands from a terminal or a computer through a serial port In order to support computer communications the follow ing conventions are observed 58 VECTORSTAR Table 7 1 VECTORSTAR Rules for Prompts Prompts are 3 or 4 characters long Prompts end with a greater than symbol gt Each mode has a unique prompt Once the VECTORSTAR displays a prompt it stops transmitting until a new instruction and or a carriage return is received The last rule ensures that there is never a question about which device is transmitting If a gt has been issued from the VECTORSTAR then the VECTORSTAR will not
179. PTER 9 SPINDLE PROGRAMMING VXNUMO VXNUM for Open Loop Mode X47 Open Loop KPROP value X48 Open Loop KVI value X49 Open Loop LPFHZ value X50 C axis Loop KPROP value 51 C axis Loop KVI value 52 C axis Loop LPFHZ value VXDENO and VXNUMO are used to convert the internal value to RPM for a specific gear ratio so Zero Speed and At Speed can work in both modes Orient The VECTORSTAR assumes speed and position control of the motor during Orient and rotates the spindle motor to a desired programmable position An Orient cycle is initiated by the Orient Request I2 input After the motor 18 oriented the VECTORSTAR energizes the Orient Complete O3 output The Orient Request I2 input must remain on to complete the Orient and to hold the motor in the Orient position After the Orient Request I2 input 18 turned off the VECTORSTAR decodes the state of the Spindle Axis Open Loop I1 input and assumes the state of the selected mode The Orient Request is received from GENERAL PUR POSE connector I2 The software is so designed that I2 must be maintained in order to complete the Orient and hold the motor in the Orient position Orient Request I2 must be turned off when the Drive Ready O4 output is turned off because the VECTOR STAR will inhibit the Drive Ready output from turning on if the Orient Request input is on After the Orient Request has been removed from I2 12 0 the user must issue the Drive Enable again so that the softwar
180. R 0 does not work well with the Rotary mode as PCMD PFB and PFNL are always less than zero You cannot change PNUM PDEN or PROTARY when ROTARY 15 ON In addition you must normalize 152 VECTORSTAR so that 0 lt PROTARY before turning ROTARY ON Enable the Rotary mode by typing ROTARY ON 10 9 3 1 Choosing PROTARY PNUM and PDEN If you have a rotary application such as a printing drum set PROTARY in position user units to be the exact equivalent of one revolution of the drum PROTARY must be exact or position error will accumulate over many revolutions For example suppose the motor of an application is connected through a 5 3 gearbox For convenience assume the user units are in degrees of the table PROTARY would be one revolution of the table or 360 degrees How do you select PNUM PDEN and PROTARY The key is selecting PNUM and PDEN so that PROTARY can be represented exactly as an integer This does not mean that PROTARY must be an integer number of counts In fact it normally will not be Returning to the example a motor movement of 5 revolutions would cause 3 revolutions of machine table rotation or 1080 user units degrees Returning to Table 10 9 PNUM 4096 5 PDEN 360 3 thus PROTARY would be 360 Notice that PROTARY 15 not exact in counts it 1s 5 3 of a revolution or 6826 and 2 3 counts However it is exact in user units Therefore error will not accumulate
181. R is disabled Set AMAX below the maximum acceleration rate that your machine can experience without damage NOTE ACC is the acceleration rate for most moves ACC is in acceleration units ACC can be changed at any time although it must be less than AMAX Attempting to set ACC to a value greater than AMAX will generate an error DEC is the deceleration rate for most moves DEC is also in acceleration units DEC can be changed at any time Attempting to set DEC to a value greater than AMAX will generate an error 8 8 1 2 EN Before any motion can take place the VECTORSTAR must be enabled Type EN 8 8 1 3 Enabling Motion with MOTION MOTION is a hardware input that enables or inhibits motion If MOTION is on motion is enabled if MOTION is off motion is inhibited You can enable the VECTORSTAR if MOTION is off but commanding motion will generate an error If you do not need to connect MOTION for your application you must hardwire MOTION on See Chapter 2 for instructions on how to hardwire MOTION Before continuing make sure that MOTION is on Type the following command to print the state of the MOTION input P MOTION MOTION SHOULD BE 1 Many times the MOTION input is controlled by the normally closed contacts of a push button This push button is often called STOP since pressing the button opens the MOTION input and forces the motor to stop Emergency Stop should not be implemented w
182. REN EI 91 8 85 13 Electroni Gear DOR x 91 8 8 13 1 Gear Ratio GEARI amp 1 1 m aS s SA 91 8 8 13 2 Gearbox Example it t S 92 8 8 13 3 Gearbox Ex mple 2 o E GR i 92 8 5 13 4 Profiles tid Gearbox tnde De ERA Oe ter tat 92 8 83 Velocity Offset Z uu ee ns ORE CX EU 93 8 8 13 6 Gearbox ACC DEC and Jogs 93 8 8 14 Profile Regulation ite tus 93 88 2 e be bata fodere i re ed ee ER eee 93 8 8 14 2 Profile Regulation and Counting Backwards sss 94 8 3 14 3 Repulation Example a u eei Bene REDI 94 8 8 15 Encoder Feedback e ieioea es ER OPER 94 8 8 16 CONTINUE ttr E ER EE ERE 96 8 9 CONTROL OOPS ssi citer iere trt e EO Rr TERR ERROR 96 8 01 Position d ERI I 96 9 9 2 1 Proportional Veloctty LE00p u u e etas dee ate ERR pe OO Gu sana us 97 8 9 2 2 Integrating Velocity enne enne a E 97 8 9 3 Torque Command 5 5 oS e D Rd tese abes bee ind D HUE RIS 97 8 0 4 Power
183. RINTING NOT USED FILL X1 WITH BACKGROUND DESCRIPTIONS GENERAL PURPOSE INPUTS n JOG PUSH BUTTON I2 JOG PUSH BUTTON 13 TEACH POSITION PUSH BUTTON 4 CONTACTOR INTERLOCK SWITCH j I5 PLC INTERFACE I6 HOME REQUEST PUSH BUTTON I7 THERMOSTAT GENERAL PURPOSE OUTPUT j O1 COOLING FLUID PUMP O2 SPINDLE MOTOR CONTACTOR PLC INTERFACE DEDICATED I O CYCLE CONNECTED TO PLC VECTORSTAR CHAPTER 10 USER PROGRAMS GATE NOT USED HOME CONNECTED TO HOME LIMIT SWITCH LIMIT CONNECTED TO OVERTRAVEL LIMIT SWITCH MANUAL NOT USED MOTION CONNECTED TO STOP PUSH BUTTON READY CONNECT TO PLC STATUS NOT USED USER VARIABLES X1 STORE NUMBER OF CYCLES RUN X2 STORE LAST POSITION RUN TO X3 INTERMEDIATE CALCULATION 4 LOOP COUNTER X5 LOOP COUNTER X6 X250 NOT USED USER SWITCHES XS1 XS50 NOT USED N W w W 4 w w w w 4 w w w w w w 3 APPLICATION PROGRAM POWER UP POWER UP LABEL PLIM OFF SOFTWARE LIMITS NOT USED HERE CONTINUE YOUR POWER UP PROGRAM HERE END 17 OFF P THERMOSTAT INPUT I7 OPENED P PROCESS BEING CLOSED DOWN DIS DISABLE THE VECTORSTAR B BREAK PROGRAM EXECUTION VARIABLE INPUT ENTER NEW SPEED X1 END AUTO AUTO LABEL WRITE YOUR AUTO PROGRAM HERE END MANUAL MANUAL LABEL WRITE YOUR MANUAL PROGRAM HERE END WRITE MORE OF YOUR PROGRAMS HERE 157 CHAPTER 10 USER PROGRAMS VECTORSTAR END BACKGROUND WRITE YOUR
184. ROP 2000 KVI 500 PROTECTED VARIABLES ANGLD 0 BSLIP 3500 FOLDD 100 FOLDR 900 FOLDT 200 ICONT 50 100 1 IZERO 25 MADV 0 MANG 165 MSLIP 0 POLES 512 SGOOSE 0 SLOPE 30 VADVTBL 12500 2500 12000 720 15000 117 CHAPTER 9 SPINDLE PROGRAMMING VECTORSTAR 118 VECTORSTAR S rh 10 USER PROGRAMS CHAPTER 10 USER PROGRAMS 10 1 INTRODUCTION The information in this chapter will enable you to understand the capabilities of the system You will also explore important considerations that must be addressed before you implement your own application Examples of programming techniques will aid you in developing your own applications 10 2 PROGRAMMING TECHNIQUES User programs are combinations of the commands stored in the VECTORSTAR memory These programs are stored in non volatile RAM they are not lost when the VECTORSTAR is powered down User programs composed mainly of the commands that have been described in earlier chapters In addition there are commands necessary for controlling the way the program executes these commands are covered in this chapter The first section describes the VECTORSTAR Editor which allows you to enter and modify programs from the terminal If you have not already done so read Chapter 8 before proceeding This manual is written to be read sequentially Do not attempt to save time by skipping ahead to this chapt
185. RSTAR High voltage will be on DC bus at all times unless the three phase line voltage is removed CAUTION 12 4 4 Operating the Line Regen In normal operation no adjustment is necessary and the unit is always ready to operate without any special settings The LED will indicate the unit status error message and a reset button can be used to reset the unit The three phase input voltage must be higher than 195 V rms line to line to operate the unit After turning on the main power to the Line Regen Unit the unit will be in a soft start procedure The soft start procedure ends when the contactor closes High voltage will be on DC bus immediately after main power is applied CAUTION About 1 5 seconds after the contactor is closed the unit will start to regulate the DC bus voltage and enter the normal working state An E Enabled will be shown on the LED 12 4 4 1 Error Message on the LED and Possible Reasons Over voltage Bus voltage cannot be held regen you may have tried to regen too hard 1 Over current or over temperature L Phase loss of line voltage 12 4 4 2 RS 232 Serial Port Normally communication with the Line Regen Unit is not recommended The statement here 15 only for troubleshooting The Line Regen Unit is programmable and has an RS 232 serial port for the user to communi cate with the unit RS 232 communication allows the compensation to be adjusted if required Also the system
186. S 5 et a fuses IU pep suu s N RES 1 1 4 PART NUMBER DESCRIPTIONS lu za eene E tnter trennen 3 1 4 5 Molex AsSseribly Tools 2 4 Ree tt teet be e e pO meten de Ee e deen e EE 5 1 55 THEORYOB OPERATION a tin ue Fe ere ia 6 1 6 VECTOR CONTROL OF INDUCTION MOTORS u netten tnter nennen 7 CHAPTER 2 INSTALLATION Merc E 11 225 INTERODUGCTION en 11 22 lt Suwa ene RD 23 UNPACKING AND INSPECTION Sa a SSO a naa A kya 11 2 4 INSTAEEATION REOUIREMBNY IS Xun ettet teet t tt eter bap 12 2 4 1 Environmental trente 12 2 4 2 BHClOSULeS D ENEE 12 2 5 MOUN EING ede bead RD A e RE TE HS 12 2 5 1 Mounting the VECTORSTAR E uyu u e e e aaepe P e RE Eee 12 2 3 2 Mounting the PA e Eno pen ueteri tete Be E diat 12 2 5 3 Mounting the External Regen Resistor a aqna naq enne enne enne enne 13 ZG WIRING AE S IAN E AE A O EE 13 2 6 1 Waring the Ground i ssh adeo dn 13 2 6 2
187. S is generated when the VECTORSTAR detects either an undervoltage or an overvoltage If the VECTORSTAR cannot be enabled because ERROR 14 continually reoccurs it is probably because of undervoltage Return to Checking the AC Line Voltage and Checking the DC BUS Voltage beginning in section 2 7 11 to ensure that the DC Bus is present If this error occurs only when the system is powered up it is probably because your program attempts to enable the VECTORSTAR before bus voltage is present 2 1 a switch that is ON when your VECTORSTAR can be enabled without generating a fault You can delay enabling the VECTORSTAR until bus voltage is present by modifying your program to wait for OK2EN to be ON TIL 2 EQ ON EN If the error occurs occasionally it could be overvoltage or undervoltage Overvoltage is usually caused by regenerative energy from a deceleration which forces the DC BUS voltage to rise above the VECTORSTAR overvoltage level about 200 VDC for 115 VAC line voltage systems and about 400 VDC for 230 If the error occurs only during deceleration it is probably an 38 VECTORSTAR overvoltage error This can be corrected by reducing the deceleration rate although often it must be reduced dramatically or by adding increased regeneration capability Contact Kollmorgen Application Engineering to add regeneration capability Undervoltage is caused by the loss of the AC Line The und
188. S 1 IN HEX IS 1 H P 1 IS THE RESULT OF ADDING X1 AND X3 P SENSE OF DIRECTION IS DIR 2 1 2 P DISTANCE GO IS PFNL PFB 3 INCHES HIGH BYTE OF IN IS IN amp OFOH 10H H3 10 6 1 7 Printing ASCII Characters The VECTORSTAR will also convert numbers to ASCII format before printing You can do this by following the variable or expression with bracketed C C This will cause the VECTORSTAR to print out the character for which the number is an ASCII code For example X6 65 P NUMBER X6 2 IS THE ASCII CODE FOR X6 C will result in THE NUMBER 65 IS THE ASCII CODE FOR A CHAPTER 10 USER PROGRAMS If the number is greater than 127 that is the eighth bit 15 set the VECTORSTAR removes the eighth bit before transmitting the character For example P 65 C 15 THE SAME AS 128 65 C since the VECTORSTAR removes the eighth bit of the expression on the right which has the end effect of reducing the number by 128 If the number 15 larger than 255 the VECTORSTAR divides the variable or expres sion into four bytes and prints them out separately For example X2 256 256 256 65 256 256 65 256 65 65 P X2 C prints AAAA since the number stored in X2 15 equivalent to 4 bytes of 65 The default field width of the character format is 4 and you can change the field width by following the C with the desired format 10 6 1
189. S OK LED on the front ofthe VECTOR STAR should turn on and remain on at all times after power up and autobauding The gt means that your VECTORSTAR is in the interactive mode and is ready to accept commands 2 6 5 4 If You Can t Communicate If the VECTORSTAR does not respond then check to be sure that Connector C5 is wired properly A common mistake is that of having the transmit and receive lines swapped Also make sure that none of the wires in the cable are broken Ifthe CPU LED has stopped blinking 25 CHAPTER 2 INSTALLATION the VECTORSTAR has established communications However the transmission from the VECTORSTAR is not being displayed on your terminal Check carefully for miswired cable broken wires or possibly a shorted transmit line from the VECTORSTAR to your terminal Ifthe CPU LED is still blinking the VECTORSTAR has not established communications You can determine that your terminal is working by disconnecting the serial cable at your terminal Then temporarily connect the transmit and receive pins to each other usually Pins 2 and 3 on a 25 Pin DB 25 connector and press a few keys The characters that you type should appear on the terminal screen If they do not then your terminal is not functioning properly If your terminal 15 functioning properly the serial communications cable may have open circuits broken or missing wires or may not be connected to the proper pin
190. SHORT CIRCUIT PHASE B SINE PHASE C SINE SHT CIRC E STOP BRAKE NOT USED PHASE A SIN PHASE B SIN Figure 12 2 Line Regen System Diagram Sheet 2 2 A TOP IGBT 2 _ B TOP IGBT 2 C TOP IGBT 2_ A BOT IGBT 2 B BOT IGBT 4 2 C BOT IGBT RETURN LINE RETURN LINE RETURN LINE REGEN G2 REGEN E2 TO SCR GATES ON DIODE MODULES MOTOR BRAKE SENSE NOTE 3 CUSTOMER INPUT FROM E STOP NOTE4 HEATSINK THERMOSTAT Sheet 2 based on D 97349 173 CHAPTER 12 HIGH POWER 6 Buymeiq uo peseg YAMOd o 06dSA OZdSA 0 16 OrdSA OPISA SCdSA SZ1SA STSGON 1 lt 21901 2 SZL v GZL winwixey Ex pJeo 7 Mari SALON 24 oez o oez lend 080 7 sng co 50 HOLOIN 8507 end a 21 1 VSO ls bf 7 sna zv AlddNs H3MOd NO il 9 29 co 19 YOLOVAY ASVLS Figure 12 3 VSL VSP Resistive Regen System Diagram Sheet 1 174 VECTORSTAR CHAPTER 12 HIGH POW
191. STAR Figure 10 3 MasterlSlave Block Diagram 150 VECTORSTAR For external inputs PEXT and VEXT the procedure for calculating the conversion constants PXNUM PXDEN VXNUM and VXDEN is similar It differs in that the external inputs are not functions of the motor position or R D resolution Table 10 10 has been provided to assist in calculating the conversion constants Table 10 10 External Units Conversion EXTERNAL POSITION UNITS PXNUM External Input In Counts amp Machine Movement In Your Units 4 EXTERNAL VELOCITY UNITS a 65 535 VXDEN s External Input In Counts Sec 0 amp Machine Velocity Your Units The procedure to determine PXNUM and PXDEN is as follows A Select a convenient number of counts on the external input B Calculate the corresponding machine movement in your user units C Perform the operation indicated in Table 10 10 under EXTERNAL POSITION UNITS and set PXNUM PXNUM equal to this value The procedure to determine VXNUM and VXDEN is as follows A Select a convenient number of counts per second on the external input B Calculate the corresponding machine velocity in your user units C Perform the operation indicated in Table 10 10 under EXTERNAL VELOCITY UNITS and set VXNUM VXNUM equal to this value Example A machine has a motor coupled to a 0 1 inch pitch lead screw which drives a table A 0 1 inch pitch lead screw
192. STAR e G APPENDIX G SOFTWARE COMMANDS SOFTWARE COMMANDS G 1 EXPRESSIONS AND SYMBOLS lt Label gt lt Time gt lt Logical gt lt Expr gt X1 X2 X3 lt Position gt lt Velocity gt lt Traverse gt lt End gt One or two digits followed by a dollar sign When using GOSUB or GOTO a user variable can be used as lt Label gt if its value is between 0 and 99 Specifies time in milliseconds Must be between 0 and 2 147 483 647 about 25 days One of the following GT GE LT LE EQ or NE for greater than greater than or equal to less than less than or equal to equal to or not equal to respectively Any valid math expression Valid math expressions include user variables indirect references to user variables constants algebraic and logical math operations parenthesis Examples of valid expressions are X2 VFB IVOFF X1 amp 07FH PFB PCMD TMR11100 X1 X2 X1 X2 X3 Any valid expression for position The result is assumed to be in position units The range is 2 147 483 647 counts If your system has position units then the limits are the position unit equivalent of 2 147 483 647 Any valid expression for velocity The results is assumed to be in velocity units Any valid expression for velocity The result is assumed to be in velocity units Traverse is used in macro moves as the middle speed for three speed moves Any valid expression for velocity The result is ass
193. T command when you Er ON TURN ON OUTPUT 1 are synchronizing motion to program execution It is an 11 5 4 WAIT W The WAIT W command can also be used for synchro nization The WAIT command is followed by the segment for which you want the program to wait or a 0 If you want the program to wait for motion to stop WAIT 18 provided in addition to the TIL command because it takes less space in your program For example W 3 performs a similar function to TIL SEG EQ 3 The WAIT command provides a few special features needed for motion synchronization For example in the following program the Wait delays execution until segment 2 of the second move MI 50000 1000 BEGIN THE FIRST MOVE CALCULATE THE SECOND MOVE 2 WAIT FOR SEG 2 THE SECOND 50000 1000 If TIL SEG 2 were used in place of W 2 then execution would delay until segment 2 of the first move Since you normally want to wait for the specified segment of the last move calculated the WAIT command always applies to the last move The WAIT command never waits when motion has stopped For example if you entered the following program the TIL command would delay execution indefinitely because SEG would never equal 4 MI 50000 1000 TIL SEG EQ 4 BUG DELAYS INDEFINITELY However the following program only delays until motion stops because the WAIT command does not delay program execution when m
194. TIXNY 340 ATIVWHON 310N 33s S1OV1NOO LT0V3 L 90 ALON 339 SLINN 98 9 SZ 06 Vd is ees A qwesse ejqeo esf aNnouo HO 3NIHOVIN ALON 33S qajvino3sNn 8 qajvino93sNn 91 062 IOVINOO Nyva dus 4 7 AON3S33NW3 d SON 385 cL 5 91535 01515 34 IVNH3IX3 97970 HO LOW vl 1 33S 33OHO 3SVHd IVNIWHAL H3MOd 4 31ON 33 1 OL 79 HO1O3NNOO 31ON 33S 9 7 29 3 18vO 3NI13109 3sn IVLSOWYSHL WALSAS YOLOW O YOLOANNOD SAAC NOILONGNI 91535 YSA Figure B 1 PA and Motor Connections AC Fan 186 APPENDIX DRAWINGS VECTORSTAR 66 2 ABH SNOLLO3NNOO HOLOW 8 Vd 3 20 YSA 39Vd 1571 NO SALON 33S 99v 29 adi SALON 33s lt 3SVHd 319NIS ASWHd sasnd YO gt IE 30199109 ae 30 SLOVINOS vL ILON 33s Har 3SVHd YAWOLSND HONOYHL HO TIVNHSLEX3 A quiesse ejqeo
195. TOR DATA MODEL V 2031EN MAXIMUM SPEED 12000 RPM CONTINUOUS TORQUE 35 LB FT ROTOR INERTIA 0 014 LB FT SEC LOAD INERTIA RANGE 0 015 LB FT SEC BASE SPEED 1500 RPM AMPLIFIER DATA MODEL VSA 12 TACH MONITOR 1750 RPM VOLT C2 PIN2 CURRENT MONITOR 16 AMPS RMS VOLT C2 PIN 4 CONTINUOUS CURRENT 40 AMPS RMS PHASE OR 50 80 AMPS RMS PHASE OR 100 NOM SYSTEM VOLTS 230 VOLTS RMS MAX SYSTEM SPEED 12000 RPM AT NOM SYSTEM VOLTS AMPLIFIER COMPENSATION CURRENT LOOP A PHASE R7 499K C8 3300pf 9 OPEN B PHASE R4 499K C5 3300pf C6 OPEN C PHASE R1 499K C2 3300pf C3 OPEN The following variables are listed in the UNPROTECTED VARIABLES section POSITION LOOP PL SOFWARE SWITCH KP GAIN KF FEED FORWARD GAIN VELOCITY LOOP KPROP PROPORTIONAL GAIN KVI INTEGRATING GAIN PROP SET 1 TO DISABLE INTEGRAL ACTION LOW PASS FILTERS SOFTWARE SWITCH LPFHZ HERTZ x SYSTEM SPEED Q VOSPD OVERSPEED is a user changeable variable up to 120 of VMAX S VMAX MAXIMUM SYSTEM SPEED This is a PROTECTED VARIABLE m 115 CHAPTER 9 SPINDLE PROGRAMMING VECTORSTAR TL VSA12 2031E12 ISSUE 1 SH20F5 TEST LIMITS AND MODIFICATION DATA VSA COMP 1 FORM REV B RESOLVER CODING RESOLVER RESOLUTION 12 Label VSA COMP 1 in the box provided with amplifier current rating and motor compensation EXAMPLE REV NO 1 ADDENDUM Attached to this TL SHEET please find a listing o
196. Timer ee Pann eiu 164 LL tenebit e t eei atleta ete eee E 164 TH WATE Wy r 165 11 5 5 Gating Motion with GATE 165 T1 6 FINDS ces m PERIERE ER BR ER RE RE QN QUU EE a 166 1 me tob ea RU TR e ette 167 11 7 1 Errot Levels is usan i e ete ee step 167 I7 2 DEP see tc e re Ode eu ende do FAIR 168 168 11 7 4 Displaying Error Messages u z asqa apasha A 168 uie e RR RH De a eet e ae e E asua iq n ce Seas 168 CHAPTER 12 HIGH POWER S S EIE ND waka 169 127 L INTRODUGTLTION etr SEM rete 169 TA VSA DRIVES 169 19 221 Powsr Supply aseo d oi ua ama ES 170 12 35 E P SERTES PUERO EP a sau usu a 170 12 4 INSTRUCTION FOR THE LINE REGENERATION 170 12 41 General Description 170 12 42 Performance 5 etes e eat 170 12 43 Fault Relay 2 5 here te BE Eee e T sq se ect ae 170 12 4 4 Operating the Line Regen Gashi nnne nennen 171 12 4 4 1 Error Message on the LED and Possible Reasons
197. ULT 1000 2 52 msec calc time only 2 84 msec calc time only 2 98 msec 2 61 msec VDEFAULT 1000 3 16 msec 2 84 msec 2 61 msec VDEFAULT 1000 3 14 msec MRD 1000 100 CW NORM 0 O1 ON O1 OFF OUT OUT 0C8H 1 ON GEAR ON P P 18 1 TIL 1 EQ 0 X1 X2 X1 X2 1 X1 X2 1 1 2 100 1 2 100 X1 X2 1 GEAR ON ZPE NOTE Drive is enabled EN for all timing tests VECTORSTAR 1 71 msec 1 29 msec 0 95 msec 0 96 msec 1 41 msec 0 99 msec 2 09 msec 2 09 msec 2 53 msec 1 46 msec 1 27 msec 0 85 msec 1 07 msec 1 07 msec 1 16 msec 1 18 msec 1 12 msec 1 27 msec ACC DEC 100 000 and SCRV 2 VECTORSTAR INDEX Symbols lt BDS Command 154 gt BDS Command 127 154 205 Command 128 V 143 X 79 24 28 AMP Outline and Dimensions 196 A AS 142 ABAUD 153 205 AC Fan PA and Motor Connections 186 AC Line Voltages 29 ACC 78 80 81 83 84 88 93 Acceleration 80 Limit 78 ACTIVE 73 ACTIVE LED 7 54 ACTIVE LED 73 ADDR 153 155 205 ADEN 148 Alarms 142 Algebraic Functions 70 AMAX 78 79 AMPS 206 Analog Input 18 Analog Input 91 93 Analog Input OPTI Card 6 Analog input 193 AND 71 ANUM 148 application code 103 Application Flowchart 121 Application Software 156 Application Specification 121 ASCII 135 At Speed 104 AUTOS 145 Autobauding 7 23 25 54 59 139 145 153 Disabling 153 autobauding 25 autotransformers 50 A
198. Up Control Loops a A M ieu 97 CHAPTER 9 SPINDLE PROGRAMMING reir ro RAGA eels 101 9 T INTRODUGTION u RR RE 101 9 2 SYSTEM COMPENSATION VARIABLES u uuu a 101 9 3 COMMANDS FOR INDUCTION DRIVE 102 9 4 DEDICATED VARIABLES SA Eu S tror tote oreet ine a Pre RR Eee ORE Hoa enel on Ere 102 a SPINDLE FUNCTION EP ERN PERF Ee UE RAO 102 9 5 Power Meter Output eere te b E re 102 9 5 2 General Purpose Input Output Pin Assignments nennen nnns 103 953 Application Code 5 ise te eme diia 103 9 6 TYPICAL APPLICATION PROGRAM FOR 103 9 6 l Eeatutes iiu t tg et te pr s u esa atahay s etudes spa 103 9 6 2 VECTORSTAR General Purpose Input Output Definition essere 103 9 6 3 Software Function Description 104 9 6 3 T 1 Application etti ees S Su u S d Suede 106 9 6 3 2 21 nentes tenendi Pei SH EDU Hd titres 107 TABLE CONTENTS VECTORSTAR 9 6 4 Units Review eit bod trea DER GU ERE ERE IER 110 9 641 Gear re qe e Re ria e E et ere p e E Dh eres canes ds 110 9642 QVCE 110 PROMUS RT RN 110 9 6 6 Software
199. Wiring the Power Connections nerne u qusaqa nennen enne enne innen tenen enne 14 2 62 L Wiring the aee ER A E RA AREE ES 14 2 6 2 2 Motor Protection s ded e eoe e de a d a e ER 14 2 6 2 3 Motor Thermostat ie E eate pete 14 2 6 2 4 Waring the Ote vere PO vitet eis iuto 15 2 06 25 Wiring the AG Lire sone tede te tn bte Casi e ERR en 15 2 6 2 6 Wiring the Regen 5150 15 2 6 3 Wiring the PA Front Panel Connectors n 15 2 6 3 1 Wiring the Control Power to 15 2 6 3 2 Wiring to the PA Fault Output on Bus OK 15 2 6 3 3 Wiring PA Connector 1 nennen enne enne ennt rre nnne entere nnne nnns 16 2 6 4 Wiring the VECTORSTAR Front Panel Connectors sess 16 2 6 4 1 Wiring Encoder Equivalent esses eene nnne nennen nnns 16 2 60 42 Encoder Equivalent Input u au nie e et RR NETTE NA Tage eds 18 2 6 4 3 Pulse Input OPT2 Card 4 45 eate eene e rete Gene EE RO OE 18 264 4 Encoder Equivalent Output zen sete dece ea av dete eene ee 18 2 6 4 5 Wiring C2 and C10 Customer and Analog Input sss 18 2 6 4 6 Wiring C3 Resolver uu n a au 20 2 6 4 7 Wiring C4 Logic Power Su
200. a S t irap 153 10 103 Watchdog uide ettet e ne uie eei tidie 154 10 10 4 Lransmit Recetve Progr nis Een e RIORUM R 154 10 10 4 1 lt BDS Command Receiving from the VECTORSTAR 154 10 10 4 2 The gt BDS Command Transmitting to the VECTORSTAR sese 154 10 10 System Dump e e h D e n eo PERI e EE ete 155 10 10 51 Version e e eee er te e e o tae OR 155 10 10 6 Multidrop Communications sessi 155 10 10 61 Broadcast pte tte 156 I0 H PROGRAM EXAMBDLBES he Hte qusaqa ashpa Pe E e etna 156 vii TABLE CONTENTS VECTORSTAR CHAPTER 11 DEBUGGING eee HM 161 ERINI RKRODPUCTION 22 he Re eU e ad 161 11 2 DEBUGGING MODES Sie petet r RI e ovre A pe ee e aetas iege 161 11221 SinglesStepASS un 161 race CER GC PEE 162 11 2 2 1 Motion Link eene 162 11 3 DEBUGGING AND MULTI TASKING l l N a T asa 162 REMOVING CODES 4 N CREER 163 11 5 SYNCHRONIZING YOUR PROGRAM creia 163 14 81 Using the Timers edd eere ria I e a 163 11 52 Regulation
201. a trademark of the OPTO 22 Company U L is a trademark of Underwriters Laboratories N E C is a trademark of the National Electric Code VECTORSTAR VFS Series VSA VSP VSL SERVOSTAR PA Series MotionLink MotionLink Plus PC Scope and Macro Moves are trademarks of Kollmorgen Corporation Dangerous voltages currents temperatures and energy levels exist in this product and in the associated servo motor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt WARNING to install set up and operate this equipment Ensure that the motor drive and the end user assembly are all properly grounded per NEC requirements INDUSTRIAL DRIVES 201 Rock Road Radford VA 24141 Motion Technologies Group Phone 540 639 2495 Fax 540 731 0847 TECHNICAL MANUAL CONFIGURATION INSTALLATION AND User s MANUAL MVSOOOH PAGE NO DESCRIPTION ISSUE NO mE Title Page c etie uu UU uu RH S 0 Ma V Technical Manual Configuration sss 0 teamed Configuration Table o ee e sts 0 l Customer RESPONSE aiio eset ee FREE YT ERE e Or au 0 E e DRM Copyright ear eh a oan EE 0 Ede EOFGWOEG t ott tet tet treo titio pepe tectum edente areae 0 How to Use This Mantal uu ette tete e E E 0 Sonde eR Table of Contents ees eie ere e ad e d ete UI 0 iii iv blank Last Of Figures uo epe eI PER
202. age Temperature 20 C to 70 C Humidity 1096 to 90 Non Condensing 2 4 2 Enclosures Itis suggested that the VECTORSTAR and PA unit be mounted in a cabinet or other suitable enclosure to protect them from physical and environmental damage Refer to specifications for complete system dimensions Allow sufficient clearance for the large regenerative heat producing resistor s mounted at the upper edge of the PA unit and the externally mounted regen shunt regulator power resistor s CAUTION 12 VECTORSTAR 2 5 MOUNTING The VECTORSTAR Series and Series power supply should be mounted in a cabinet or other suitable enclosure to protect them from physical and environmen tal damage The PA power supply and the VECTORSTAR are outfitted with protective guards over the power terminal blocks After wiring 18 complete always replace the protective guards to reduce shock hazard REPLACE THE POWER TERMINAL GUARDS AFTER WIRING THE SYSTEM WARNING 2 5 1 Mounting the VECTORSTAR Refer to Figure B10 in Appendix B for mounting dimen sions The VECTORSTAR and PA should be mounted in the vertical position Since these units are convection cooled there should be a minimum of 25 millimeters 1 inch of unobstructed space above and below the units In addition there should be a minimum of 20 millimeters 0 8 inch between units to ensure proper airflow for these convection cooled units 2 5 2 Mounting t
203. akes the line a comment so that when the line is re transmitted it has no effect If the semicolon were not there re transmitting the dump information would generate an error when a protected variable was changed Every line of the user program is preceded with a semicolon for the same reason 10 10 5 1 Version Dump Your VECTORSTAR will print out its firmware version at any time with the DUMP VERSION command DUMP VERSION 10 10 6 Multidrop Communications This function is not available for the RS 232 option CHAPTER 10 USER PROGRAMS Multidrop communication allows you to have many up to 32 axes on one serial line This is only supported with RS 485 When the VECTORSTAR is in Multidrop mode each axis must have a unique address This address 15 a prefix on all communications to and from the VECTORSTAR The address is stored in variable ADDR ADDR is set to 0 for standard single drop communications Valid addresses are 48 ASCII 0 through 57 ASCII 9 and 65 ASCII A through 90 ASCII Z see Appendix B Note that the address must be set before multiple units are connected to the same serial line When the VECTORSTAR powers up in Multidrop mode it is asleep When asleep the VECTORSTAR continues to execute programs and control the motor properly but it does not communicate over the serial line The VECTORSTAR executes commands which normally print to the seri
204. al port P PS R RS INPUT and errors except that the output is not sent to the serial transmitter The delays incurred by printing are still present If you have print statements that delay the program when the axis is awake you will have the same delays when it is asleep even though no characters are being transmitted When you transmit its address the VECTORSTAR wakes up and communicates The address is a backslash followed by the ASCII character represented by ADDR For example if your VECTORSTAR has the RS 485 option type ADDR 65 ADDRESS 65 ASCII A UP A P THIS IS AXIS ADDR PRINT ADDR ADDR 0 RESET DRIVE TO SINGLE DROP This example sets the address to upper case A NOTE Setting ADDR to 65 makes this axis address and automatically puts the VECTORSTAR in Multidrop mode This axis then waits for the VA After this VECTORSTAR is awakened and it remains awake until it receives a backslash 1 A backslash puts ALL drives on the serial line to sleep If you select an axis in multidrop only that axis transmits and receives 155 CHAPTER 10 USER PROGRAMS During multidrop the prompts are changed If you typed in the example from above you would have noticed the prompt going from gt to gt after you typed in the second line All prompts in a multidrop system have the axis address as the first character of the prompt This tells you which axis you
205. ambients above 45 C consult the Applications Group at Industrial Drives Connector C2 provides these three signals with optical isolation Connector C7 expects non isolated TTL signals on a 26 pin ribbon cable connector Optional Connector C8 expects non isolated TTL signals on a 50 pin ribbon cable connector DISCRETE OUTPUTS The VECTORSTAR has 10 discrete outputs Notice that O1 appears both on Connector C2 with optical isolation and on Connector C8 ENCODER INPUT The VECTORSTAR accepts external inputs in encoder format This can come from a master motor in a master slave system Note that you must use a resolver even if you use a feedback encoder with the VECTORSTAR ENCODER EQUIVALENT OUTPUT The VECTORSTAR provides encoder format output derived from the R D converter ANALOG INPUT The VECTORSTAR can accept a 10 volt analog input This input 18 converted to digital format by the VECTORSTAR Gain and offset adjustments are made digitally inside the VECTORSTAR not with potentiometers VECTORSTAR PULSE INPUT OPT2 CARD The VECTORSTAR can accept special pulse inputs The standard VECTORSTAR can accept signals directly from encoders or encoder like devices As an option the VECTORSTAR can accept other pulse formats such as count direction or up down LED S The VECTORSTAR provides LED s for diagnostics These LED s are on the front panel of the VECTORSTAR The LED s are listed below ACTIVE SYS
206. and The INPUT command causes the VECTORSTAR to print a message to the terminal and wait for a response VECTORSTAR from the operator The input information can be stored in any programmable variable This allows the operator to change or enter information without making any changes to the program itself You can only execute the INPUT command from the user program Type in the following example INPUT instruction INPUT ENTER NEW SPEED X2 This causes the VECTORSTAR to print ENTER NEW SPEED Type the new speed into the terminal After you are prompted enter a number and press the enter key The number you enter is stored in the variable X2 If you press the enter key without entering a number the variable X2 is left unchanged Use the Print command to display the new value of X2 2 10 6 3 1 INPUT Limits You can also specify an upper and lower limit for the operator entry If the above INPUT instruction were written as INPUT ENTER NEW SPEED X2 10 100 the VECTORSTAR would force the operator to input a value between the specified low limit 10 and high limit 100 If the input is invalid or outside the range an error message is sent and the operator is prompted again The limits can be constants as shown above as well as any valid numerical expression Ifthe limits are outside the variable s normal range they are ignored If they are not specified at all the varia
207. and variables be retrieved from or saved to a disk drive Also on line help and a full screen editor are built into MOTION LINK VSRA gt VS Series dis vector controlled AC Regen Line Regen Package Volts A Modular 230 vac P Integral Supply 460 vac L Integral Supply 230 vac CHAPTER SYSTEM DESCRIPTION MENU DRIVEN SOFTWARE VECTORSTAR s programming language allows you to write operator friendly menu driven software By incorporating an Kollmorgen Data Entry Panel or any other serial communications device the operator can be prompted for specific process data MONITOR MODE VECTORSTAR provides interactive communications and permits all system variables and parameters to be examined and modified at any time even during actual program execution or while the motor is running 1 4 PART NUMBER DESCRIPTIONS A model number is printed on a gold and black tag on the front of your VECTORSTAR PA Series Compensa tion Card and External Regen Resistor modules The model number identifies how the equipment is config ured Each component is described to explain what the model configurations are You should verify that the model numbers represent the equipment desired for your application Also verify the compatibility between components of the servo system The model numbers are as follows 2 00 1 2 2034C 2 xxx Compensation factory designated y o 1 Standard
208. and works better with multi tasking a subject discussed in Chap ter 9 For our example the first TIL command can be replaced with W 2 and the second can be replaced with W 3 8 9 11 4 Changing Profiles During Motion Position dependent jogs can also be used to change the speed or endpoints of an MA MI MCI or MCA command that is already in progress For example 90 VECTORSTAR suppose you want to change the speed of a profile depending on an input You could write the following program to reduce the speed when is 1 X1 10000 1 STORES THE ENDPOINT MA X1 5000 BEGIN AT 5000 RPM TIL SEG EQ 0 GOSUB 25 25 WATCHES CHANGE SPEED B 25 11 EQ 0 RET CHANGE ONLY IF 1 21 J 1000 REDUCE SPEED TO 1000 RPM TIL SEG EQ 2 WAIT UNTIL SPEED IS 1000 RPM JT X1 0 JT TO GET TO ORIGINAL ENDPOINT AT NEW SPEED TIL SEG EQ 0 WAIT FOR MOTION TO STOP B DONE You must be careful not to begin the motion too late in the profile For example suppose I1 became 1 after the profile was well into deceleration and the speed was say 200 RPM In this case the JT command would generate an error because by the time it was executed the motor position would be past X1 the original endpoint This is because the unit would accelerate up to 1000 RPM before the JT command was executed In general you must limit the time during which you are looking for the speed change After this point t
209. ant to print the current line then do not specify a line For example to print the current line type P If you attempt to print a line that 1 not in the program such as line 100 of a 10 line program the Editor will issue an error such as BAD ENTRY 10 3 2 2 Next Line If you enter an empty line then the VECTORSTAR goes down one line in the program and prints that line The empty line is entered by pressing the enter key This makes it easy to move down through the program 10 3 2 3 Password PASS The VECTORSTAR Editor has password protection The password allows you to prevent the user program from being changed If the password is set the program cannot be changed but it can still be displayed The password can be up to six characters long The default setting of the password is null i e empty which means there is no password protection From the Editor type PASS The VECTORSTAR will ask you for the new password If you do not want password protection enter an empty line Note that the NEW command discussed later also clears the password 10 3 2 4 Insert 1 Entering the Insert I command causes the Editor to enter the Insert mode When you are in the Insert mode everything you type 1 put directly into the program memory Exit the Insert mode by pressing the escape key or entering an empty line For example type P BEG GO TO THE BEGINNING OF THE PROGRAM ENTER THE
210. any inputs to be on or off then the TIL command can be expanded For example if inputs 1 4 5 and 6 must all be on either of the following TIL instructions can be used TIL 11 14 15 16 EQ 4 THIS USES ALGEBRAIC MATH TIL I1 amp I4 amp I5 amp I6 EQ 1 THIS USES LOGICAL MATH BOTH WORK Itis slightly more complicated if the program must wait for some inputs to be and others off For example if inputs 1 4 and 5 must be on and input 6 must be off the following TIL instructions can be used 132 VECTORSTAR TIL 11 14 15 1 16 EQ 4 ALGEBRAIC MATH TIL 118148158 1 16 EQ 1 LOGICAL MATH Notice the use of 1 16 This is a logical NOT because if I6 equals 1 then 1 16 is 0 and if 16 equals 0 1 16 is 1 The logical NOT is useful when checking to see if inputs are off If more than a few inputs must be tested then referenc ing them one at a time can be cumbersome As an alternative IN can be used This can be demonstrated with the example above If the program must wait for inputs 1 4 and 5 to be on and input 6 to be off logical math can be used to mask the inputs that are not sup posed to be tested inputs 2 3 and 7 16 A mask isa binary word with a 0 for each input that is not tested and a 1 for each that is In this example the mask would be Input Number 8 7 6 5 4 3 2 1 Test Input N N Y Y Y N N Y Binary Mask 0 0 1 1 1 0 0 1 Input Number l 6 15 14 13 12 11 10 9
211. apacitance of the interconnecting cable is small enough Capacitance increases with cable length which implies that the transmitter OUT s and receivers IN s should be as close to each other as is practical You should use 120 ohm cable For longer distances over a 100 feet consider using reduced capacitance cables such as those available from Black Box Pitts burgh PA The cable should be run from point to point as opposed to branching out from a single point Branches could cause reflections a transmission line effect that can interfere with the signals If the cable is very long ringing also a transmission line effect may occur If this happens you should connect a 120 ohm resistor across each signal and its logical inverse at both ends of the cable The Encoder Equivalent Connector uses RS 485 compat ible 75174 line drivers and 75175 line receivers which are available from many IC manufacturers including Texas Instruments The VECTORSTAR uses the same phasing for the encoder inputs and outputs for clockwise rotation Channel A leads Channel B For standard systems the VECTORSTAR CHAPTER 2 INSTALLATION CONNECTOR C1 COMMONS OF MASTER SLAVE VSA s MUST s BE CONNECTED THIS IS ACCOMPLISHED THROUGH CONNECTOR C7 IF VSA s SHARE ONE PA SEE NOTE 13 LAST SHEET 6 SLAVE VSA MASTER YSA WIRE THROUGH AN OPTO 22 STYLE DC INPUT MODULE TO CONNECTOR C7 PIN 9
212. arameter defines the amount of time in milliseconds the VECTORSTAR will allow to sense the HOME input running or being off and then turning on If the X46 time frame is exceeded the VECTORSTAR will stop the motor disable the drive and halt application software execution The Orient position is defined by the parameter P1 and is in R D units with a range of 0 to 4095 The speed at which the motor moves to the orient position from the random stopped position is controlled by the parameter VORNT in RPM VORNT thus controls the speed of the motor in searching for the HOME input and also in determining the speed of the motor during the Orient move from the random stopped motor position to the orient position The 2 1 application is selected by making MORNT equal to 3 The spindle has a cam that will activate the HOME input over the half of the spindle revolution in which the orient position exists The orient position must be centered on the cam and the cam can not exceed one half of the spindle revolution or there is a chance the spindle could be oriented 180 degrees from the desired position After the motor is moved to the orient position the motor stopped test is executed followed by the orient in position test When both tests are complete the VECTORSTAR energizes the Orient Complete O3 output if the HOME input is active The orient in position test will continue to be executed while the Orient Request GP2 input is on While the motor is ori
213. as a maximum main power input current of 85 AMPS RMS The actual application may require less current Use 600 VAC insulated wire and refer to local electrical codes for proper wire size for the currents listed above Fuses for main power should be U L rated time delay type such as Bus FRN R Series The power bus between a PA and VSA should use the following wire gauge with 600 VAC insulation PA 50 bus bars supplied with unit or 8 AWG or larger wire PA 75 bus bars supplied with unit or 8 AWG or larger wire 5 signals and control wires to be 22 18 AWG wire The crimp terminals for 22 18 AWG wire are supplied for use with VSA Connectors C2 C3 C4 C6 and PA connectors C6 and C7 and C2 For 16 AWG wire use Molex 39 00 0078 terminals 6 AC lines should be twisted cables 7 The total number of axes allowed per PA depends on the PA model and combination of VSA s and or SR s PA 50 A maximum of 4 VSA s or 3 SR s PA 75 A maximum of 4 VSA s or 3 SR s Axis expansion on the PA 50 75 and 85 AMP units are also limited to a maximum of 4 VSA s or 3 SR s on either side of the PA 10 11 12 13 14 15 The is configured at the factory for either RS 232 RS 485 XX in the cable number stands for cable length in meters Cable length is available from 3 to 75 meters in incre ments of 3 meters A thermal overload relay is supplied in the regen resistor kit for the 50 75 and 85 AMP
214. as the table rotates The incorrect way to choose PNUM PDEN and PROTARY would be to select PNUM and PDEN so that PROTARY could not be represented as an integer For example we could have stated that 5 3 revolution of the motor would cause one revolution of the machine Then PNUM 4096 5 3 or about 6827 PDEN 360 In this case PROTARY would not be exactly 360 degrees actually it would be 359 98 degrees so that error would accumulate as the table turned Remember PROTARY must be an integer in user units though it can have fractional counts VECTORSTAR 10 9 3 2 Rotary Mode and Absolute Moves When the VECTORSTAR is in the Rotary mode you must limit the final position of all absolute moves to between 0 and PROTARY If you want to move more than PROTARY you can use incremental moves For example MI 50 PROTARY is a legal command 10 10 SERIAL COMMUNICATIONS This section discusses details of VECTORSTAR serial communications This includes autobauding multidrop connections and transferring your program to and from the VECTORSTAR If you are using Motion Link the Kollmorgen software package for the VECTORSTAR you do not need to read the sections on transmitting and receiving your program or on system dump Motion Link provides facilities for these functions 10 10 1 Autobauding It is not necessary to set the baud rate on the VECTORSTAR directly Once the VECTORSTAR is properly connected it can
215. ation Enable Profile Regulation mode Set to 0 on power up and normally left at zero for preliminary operation Profile regulation frequency Initially set to 1000 Value of this variable does not matter if REG is 0 Set S curve level Initially set to 2 Enable Single Step mode Set to 0 on power up and normally left at 0 for preliminary operation Set mode of STATUS output Set to 0 on power up and normally left at 0 for preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Software timer Set to 0 on power up Value of this variable does not matter during preliminary operation Enable Trace mode for debugging Set to 0 on power up and normally left at 0 for preliminary operation Enable position trip points Enable torque loop which disables velocity loop This variable is set to 0 on power up and left at 0 for prelimi nary operation VDEN VDEFAULT VNUM VOFF VOSPD VXDEN VXNUM WATCH WTIME X1 X2000 51 550 20 VECTORSTAR Velocity units denominator Initially set to 10 for RPM Default velocity for MI and MA com mands Initially set to 1 RPM Velocity units numerato
216. ault field width of 9 can be changed by following the H with the desired field width For example 134 will cause the VECTORSTAR to print X2 0000000000000000000000001111111B X2 001111111B 10 6 1 5 Printing Switches Formatted printing can also be used to display switches any variable with a value of 0 or 1 either as Y or N or as on or off This allows you to communicate with the operator better than just printing 0 or 1 The switch format on or off is printed with a bracketed S S following the variable XS1 21 P USER SWITCH 1 IS XS1 S These commands would result in USER SWITCH 1 15 ON Similarly VECTORSTAR 51 0 P USER SWITCH 1 IS XS1 S results in USER SWITCH 1 15 OFF In addition you can print a switch as Y or N if you follow the switch with a bracketed Y Y For ex ample P XS1 Y will print either Y or depending on whether XSI is 1 or 0 respectively This format is useful with the input command which we will discuss later The input command allows the operator to respond with Y or N and stores 1 or 0 VECTORSTAR variable This print format allows you to print the previous answer on the screen the way it was entered 10 6 1 6 Printing Expressions The P instruction 15 not restricted to printing only variables In general any numeric expression can be formatted and printed the following examples are valid P MINU
217. ay choose to operate in MotionLink s graphical screens or from its terminal interface whichever is more appropriate and more comfortable 7 2 COMPUTER REQUIREMENTS MotionLink requires an IBM PC or compatible com puter with the following features IBM PC XT AT 386 486 PS 2 or compatible computer running Windows 3 1 or Windows 95 98 3 5 Floppy Drive Standard Video Adapter CGA MDA EGA MCGA and VGA Serial Port for communication link with SERVOSTAR The serial communications port may be COM1 COM2 COM3 COM4 is the normal configuration 57 CHAPTER 7 SOFTWARE INSTALLATION COMI Address 3F8h Interrupt Request 4 COM2 Address 2F8h Interrupt Request 3 COM3 Address 3E8h Interrupt Request 4 Address 2E8h Interrupt Request 3 7 3 INSTALLING MOTIONLINK PLUS Insert the MotionLink Plus for Windows diskette 1 into a 3 5 floppy drive From the desktop Win 95 98 select Start Run For Windows 3 1 select File Run Type A setup exe and hit the Enter key Once Setup Screen is displayed click on OK to start installation Select the destination directory The user may install MotionLink Plus for Windows in any directory or drive but the default that is presented during installation is highly recommended Click on to begin installation Click on to create a KMTG Motion Suite Program Group in Program Manager 7 4 RUNNING MOTIONLINK
218. ayed termination of the software execution after the drive over temperature condition has been sensed VECTORSTAR DTIMER is in milliseconds and a maximum of 10 to 15 minutes is recom mended Drive Over Temperature timer The time from when the Drive OT 14 input thermostat contact opens until the VECTORSTAR faults terminating application software execution and disabling the motor The timer is initialized by the parameter DTIMER in units of milliseconds The timer will decrement from the initialized DTIMER value to 0 Spindle Reset The Spindle Reset I6 input 15 used to reset the VECTORSTAR application software execution after a fault has been detected The VECTORSTAR will halt application software disable the motor and remove the Drive Ready O4 output after a fault has been detected To start application software execution the following conditions must occur 1 The Spindle Reset I6 input must be toggled off to on 2 TheDrive OT I4 input must be in a non fault state or on 3 The Motor OT I5 input must be in a non fault state or on 4 The Orient Request I2 input must be off A Spindle Reset will only start application software execution The Drive Ready O4 output will then turn on when the REMOTE input is on the Drive Enable O7 input is on and the Orient Request I2 output is off If an OT fault terminated application software execution the Spindle Reset I6 input must be toggled off to on to
219. baud when it 1s powered up or reset provided that the multidrop address ADDR is 0 After a successful autobaud the baud rate will be stored in BAUD If you do not want your VECTORSTAR to autobaud when the unit is powered up then turn ABAUD off This 1s important if you want the VECTORSTAR to run the Power Up Label POWER UP because if ABAUD is on the VECTORSTAR will not execute the program until communications have been established 10 10 1 4 Baud Rate BAUD If the MOTION input is on ADDR is zero and ABAUD 18 off then the system will check the variable BAUD for the desired baud rate If it is not a valid baud rate the VECTORSTAR will autobaud After a successful autobaud an error is generated indicating that the baud rate was out of range on power up 10 10 2 Prompts The VECTORSTAR issues a prompt when it is ready to receive a new command Prompts are discussed in Chapter 8 The VECTORSTAR allows you to suppress the prompt characters by typing PROMPT OFF PROMPT is turned on at power up Prompts are particularly important when communicating with computers since the computer that is transmitting to the VECTORSTAR must wait for a prompt before begin ning a new line After the prompt is received the computer can transmit at the full baud rate without inserting delays 153 CHAPTER 10 USER PROGRAMS 10 10 3 Serial Watchdog The VECTORSTAR provides a serial watchdog timer for applications where a co
220. be connected through gearboxes lead screws or any other mechanical device 3 You must turn the switch EXTLOOP on This switch configures the VECTORSTAR to close the position loop with feedback from the external input rather than from the resolver When EXTLOOP is on PE the position error is the difference of PCMD and PEXT rather than the differ ence of PCMD and PFB The ZPE command zero s the difference of PCMD and PEXT Also the NORM command normalizes both PEXT and PFB simulta neously 8 8 16 CONTINUE The CONTINUE command is provided as a controlled way to turn off master slave position control The CONTINUE command tells the VECTORSTAR to keep the motor going at its present speed while simultaneously turning off REG and GEAR One use of this command 18 to cause a controlled deceleration to 200 RPM for example when the electronic gearbox 15 enabled If you just typed J 200 it would have the effect of adding 200 RPM to the command from the gearbox However if you typed CONTINUE J 200 CONTINUE would disable the electronic gearbox while commanding the motor to continue at whatever speed it was going when the command was executed Then the J 200 command would bring about a controlled decelera tion to 200 RPM CONTINUE normally looks at the velocity command for 1 millisecond Ifthe velocity command is generated 96 VECTORSTAR from the electronic gearbox or a regulated profile the
221. be limited by ACC and DEC type is turned on VOFF is set to zero when GEAR RAMP ON ACC AND DEC WHEN PL IS OFF 8 8 14 Profile Regulation This section describes profile regulation one of the VECTORSTAR Master Slave modes Profile regulation allows you to synchronize the rate of profile execution according to the external input This modifies the velocity and acceleration of move commands without affecting the final position of the move The rate of the move is dependent on the frequency of an external clock which is connected to the external input in addition to the normal limits of the move ACC DEC and the velocity are set in the move command itself The CHAPTER 8 GENERAL PROGRAMMING external input may be a master motor to which all moves must be synchronized such as a conveyor belt motor or it may be a signal that you generate electronically As an option an analog signal can be fed directly to the VECTORSTAR where it is converted to a pulse train and can be used as the external input Profile regulation works with MA and MI as well as Macro moves profile regulation is based an accumulation of counts from the external input during the move Ifthe external frequency changes during a move the velocity of that move will be proportional to the changing clock frequency In fact if the external input frequency goes to zero then motion will stop Note that if the external input chang
222. bel 55 RUN 55 and the following lines should be displayed T 55 T IF X1 GT 0 T IF X2 GT 0 T P BOTH X1 AND X2 gt 0 BOTH X1 AND X2 gt 0 ELSE ENDIF ELSE ENDIF gt This example shows several characteristics of the Trace mode commands are preceded by the trace prefix 162 VECTORSTAR Print statements are active in the Trace mode Notice that the results of the P command are printed just below where the print command is displayed Only the executed commands in IF ELIF ELSE and ENDIF sets are shown Notice that none of the commands following the first print command are shown This helps you debug your program by only showing the commands that are executing You cannot type in commands from your terminal while the VECTORSTAR is executing in the Trace mode You can also enter the Trace mode from your program To do this you should include ON in your program To exit the Trace mode you can include OFF in your program or you can press the escape key two times 11 2 2 1 Motion Link and Trace Motion Link is the software communications package provided for the IBM PC and compatibles IBM PC and compatibles can communicate at 9600 baud only in that they can receive and transmit a character at that fre quency However they cannot receive an indefinite number of characters at that rate because the computers are not fast enough to process the
223. bi directional power converter In rectifier mode the unit converts the three phase line voltage to a DC voltage This is the same function as a full bridge rectifier but with a sinusoidal current taken from the line and a DC bus voltage that 15 regulated higher than a bridge rectifier can achieve The regenerative mode occurs when the DC bus voltage is higher than the rectifier mode A good example 15 when a motor acts as a generator The unit sends power back to the three phase line input in this mode The unit senses the phase of the input line voltage and tries to make the power factor as close as possible to unity regardless of the load If the line current is within the rating of the unit for both directions the DC bus voltage will be a constant value 12 4 2 Performance System rating 100 A rms continuous and 200 rms peak line current for both rectifier and line regeneration modes DC bus regulation 345 volts 5 on 240 VAC Input 690 volts 5 on 480 VAC Input Drive Protection Overvoltage for DC bus and undervoltage for line overcurrent phase loss and over temperature A relay will be dropped out if any of the above faults occurs THD harmonic distortion 4 5 6 5 with a constant load 12 4 3 Fault Relay Before operating the unit connect the relay of the line regen pins and 2 of J6 to the drive REMOTE input In this way the drive will be disabled when there is a fault from the line regen VECTO
224. ble s normal range is used as the limit For example the limits on ACC are 0 and AMAX Type in this command X1 ACC STORE INPUT ENTER NEW ACC 1000 1000 The VECTORSTAR knows that the lower limit on ACC 18 0 so that no negative numbers will be accepted If AMAX is less than 1000 AMAX will be the upper limit Otherwise 1000 will be the upper limit If you specify limits that are outside the variable s program limits the VECTORSTAR uses the program limits Appendix F lists all variables and their program limits CHAPTER 10 USER PROGRAMS 10 6 3 2 INPUT and Decimal Point You can use the INPUT to prompt the operator for values that include a decimal point You must specify the number of characters after the decimal point This is the only way you can enter numbers having a fractional part into the VECTORSTAR For example suppose your user position units are mils 0 001 inches You can prompt the operator for any position in inches with the INPUT The following example stores the results of the INPUT command in X1 Enter this short program in your VECTORSTAR then type RUN 44 44 INPUT ENTER NEW POSITION X1 3 P NEW POSITION X1 3 P ACTUALLY X12 X1 B Notice the bracketed 3 following X1 in the INPUT command This causes the operator input to be multi plied by 1000 103 before it is stored in X1 The print statements that follow display X1 in inches as the opera
225. ble the VECTORSTAR This command turns on the variable READY Refer to Drawing C 84732 for more information Allowed from the interactive mode monitor mode and user program Format EN VECTORSTAR END ENDIF ERR GOSUB GOTO APPENDIX G SOFTWARE COMMANDS Enda task If you are using multi tasking END ends that task If there are no special labels present in the program except POWER UPS then END is equivalent to Break B If there are special labels the VECTORSTAR becomes inactive waiting for a task to resume execu tion Format END Part of block if Ends block if Allowed from the user program See the IF command Format ENDIF Display an error message display the error history or clear the error history Allowed from the interactive and monitor modes and user program Format ERR Error Number ERR Option Where Error Number is a valid error number and Option can be HIST or CLR Example ERR 25 DISPLAY MESSAGE FOR ERR 25 ERR HIST DISPLAY ERROR HISTORY ERR CLR CLEAR ERROR HISTORY Go to a subroutine Allowed only from the user program Format GOSUB lt Label gt Example GOSUB 25 GOSUB X3 Go to a program label Allowed only from the user program Format GOTO Label Example GOTO 25 GOTO X5 225 APPENDIX SOFTWARE COMMANDS VECTORSTAR H IF INPUT 226 Delay Hold up execution of a task until a switch is in the spec
226. cessary Reduce the bandwidth of the system Shorten the length and increase the diameter of shafts and lead screws 4 9 5 Low Pass Filters The LPF switch enables the low pass filter It can be turned on and off when the drive is operating The frequency of the low pass filter is stored in LPFHZ in Hz It can also be changed when the drive is operating For example if LPFHZ is 200 and LPF is on then a 200 Hz low pass filter is run in the VECTORSTAR The filter can be modeled as two cascaded low pass single pole filters both with a 3 dB frequency of 200 Hz LPFHZ should be set as high as possible since it degrades the system performance For example the following sequence sets the low pass filter to 250 Hz and enables the drive LPF ON ENABLE LOW PASS FILTER LPFHZ 250 SET BREAK FREQ TO 250 HZ well If the low pass filter is on the TUNE command may not work NOTE 46 VECTORSTAR VECTORSTAR USE EDITOR TO INSTALL USE PROGRAM SHOW AT RIGHT USER PROGRAM 80 X1 500 81 100000 JX1 1000 DEC AMAX 10 PL ODD D 1000 TQ OFF GOTO 81 LPF OFF ILIN 100 KV 100 KVI 0 INCREASE KV FOR STABILITY INCREASE KVI FOR IMPROVED RESPONSE MONITOR TACHOMETER WITH OSCILLOSCOPE SIGNAL C2 PIN2 GND C2 PIN14 TYPE EN TUNE 252 RUN 80 press lt 5 gt UNDERDAMPED T INCREASE KV FOR PROPER DAMPING TOO SLOW SYSTEM TOO FAST R
227. ck 78 Following Error 44 75 199 Formatting 133 Full duplex 24 Fuses 193 G GATE 23 165 Gate 23 GATEMODE 165 Gating Motion 165 GEAR 91 205 Gear Ratio 110 GEARI 91 105 GEARIC 102 105 GEARIO 102 105 GEARO 91 105 GEAROC 102 105 GEAROO 102 105 General Purpose I O 132 General Purpose Input Output 71 General Purpose Timers 163 GIMAGF 102 GOSUB Command 128 131 206 GOTO Command 127 131 Grounding 13 Grounding Integrity 51 H Hardware Errors 55 167 Hardware Travel Limit 80 239 INDEX Hardware Watchdog 72 Hexadecimal 70 134 Hold H Command 138 HOME 19 23 86 Home 23 HOME RETURN 19 Homing 86 87 Humidity 12 I I Monitor 19 I O DC 20 I Monitor 44 76 I1 16 71 132 IBASE 101 ICMD 76 ICONT 78 IDEN 146 Idling Commands 137 IF Command 130 205 IFOLD 78 ILIM 42 64 77 78 87 148 IMAG 101 IMAX 76 IMON 76 IN 71 72 132 in position orient test 106 IND 101 Indirection 69 203 Induction motors 101 Inertia Matching 41 INITIAL CHECK OUT 26 Initial Settings 66 initial START UP 37 Initiation 145 INPUT Command 136 Input Output 71 Inputs General Purpose 132 Masking 132 Installation 11 Installation Requirements 12 Instruction Format 63 Instructions 63 Integrating Velocity Loop 97 Integrating Velocity loop 77 Interactive Mode 59 INTERFACING WITH THE OPERATOR 133 INUM 146 J Configuration Jumper 24 Jog J Command 63 79 83 92 94 240 VECTORSTAR Jog From JF C
228. com 209 APPENDIX D CUSTOMER SUPPORT VECTORSTAR 210 VECTORSTAR APPENDIX E ASCII TABLE ASCII TABLE The chart on the following pages is an ASCII Code and Hexadecimal conversion chart The VECTORSTAR does not support extended ASCII 128 255 211 APPENDIX E ASCII TABLE VECTORSTAR ASCII CODE AND HEX CONVERSION CHART ES gt zx e S gt gt 3 gt gt o AW Tm a gt gt gt gt gt gt 9 O18 212 VECTORSTAR APPENDIX E ASCII TABLE ASCII CODE AND HEX CONVERSION CHART CONTD This side of the table is provided for Decimal to Hex Conversion The VECTORSTAR does no support extended ASCII 128 255 Decimal to Hex Conversion 213 APPENDIX E ASCII TABLE VECTORSTAR 214 VECTORSTAR APPENDIX F VARIABLE QUICK REFERENCE e F VARIABLE Quick REFERENCE GUIDE F 1 INTRODUCTION This appendix lists all the variables on the VECTORSTAR variables are shown with the required programming conditions For example ABAUD has the programming condition ALWAYS This means ABAUD can be changed at any time Other variables require the VECTORSTAR to be enabled or disabled Others such as feedback variables are never programmable FACTORY variables can only be changed at the factory Factory variables program the VECTORSTAR for the particular motor it wil
229. command When the move is completely specified the Macro Go MCGO can be used to execute the move MCGO can be executed as many times as desired once calculations for the entire move are complete Both Macro Absolute and Macro Incremental moves are specified in a similar manner You must specify either the end position for Absolute moves or the distance for Incremental moves You also can specify up to two velocities If two velocities are specified then the first is the traverse speed and the second is the ending speed If one velocity is specified then it is assumed to be the ending speed In this case the VECTORSTAR uses the larger speed either the beginning or ending speed for the traverse speed velocities are specified greater than zero The VECTORSTAR determines the direc tion based on the specified position If no velocities are specified then the VECTORSTAR continues the Macro section at the beginning speed until the specified position is reached 84 VECTORSTAR If you want to include a dwell in the middle of a Macro move use the Macro Dwell MCD command In this command you specify the time of the dwell in millisec onds The following example specifies a 100 millisecond dwell MCD 100 3100 MSEC DWELL Macro dwells are only allowed at the beginning of a Macro move and when the previous section has ended at zero speed After all motion sections have been specified with the final motion e
230. command inside another For example suppose you want to break program execution if X1 is less than 100 and greater than 100 You could use X1 LT 100 GOTO 20 X1 GT 100 GOTO 20 B 20 However those four commands can be replaced by just one nested command X1 LT 100 X1 GT 100 B Nesting two commands is the same as ANDing the two conditions The example above only executes the B command if both lt 100 and gt 100 Nesting of commands is limited by the number of entries and the maximum length of a line VECTORSTAR commands are limited to 15 entries the example above has 9 entries X1 LT 100 X1 GT 100 and B Since each level of command nesting requires 4 entries you cannot have more than three levels of nesting Also command must be less than 80 characters long since it must fit on a single line 10 4 2 3 TIL Command The TIL is a single line command that allows you to specify a condition and a command to be executed repeatedly until that condition 15 true The TIL com mand has the following format TIL condition FALSE command FALSE command 18 repeatedly executed as long as the condition is false If the condition 15 true at the begin ning of the TIL command then FALSE command is never executed In this case program execution contin ues to the next step An example of the TIL command would be to print a line to the operator continuously until th
231. ctive mode after power up then end the power up routine with the Break command 10 8 8 2 Error Handler ERROR When a serious error occurs the VECTORSTAR breaks execution of your program and checks your program to see if you entered ERRORS If you did the error handler the routine that follows the ERRORS is executed All multi tasking is suspended including alarms when the error handler is being executed CHAPTER 10 USER PROGRAMS 10 8 8 3 Auto Routine AUTOS If you want to start a program from an external switch you should use the auto routine You can use the auto routine to interface to simple operator panels or to programmable logic controllers PLCs CYCLE Connector C7 Pin 13 is a hardware input that under the proper conditions will cause the VECTORSTAR to begin executing one cycle of the auto program The AUTO program begins at AUTOS CYCLE READY is a hardware output that indicates the VECTORSTAR is ready to run another cycle of the AUTO program The following conditions must be met for the VECTORSTAR to execute the AUTO program When these conditions are met the CYCLE READY output Connector C7 Pin 23 will turn on Multitasking must be enabled AUTOS must be present in the user program No routines can be executing at task level 5 The MANUAL input must be off The CYCLE input must be low Cn am t If these conditions are met the CYCLE READY output will turn on Then when CYCLE turns on the
232. ctory IND This switch must be ON IND 1 to configure your VECTORSTAR for an induction motor IMAG Magnetization Current Unit is in percent of IMAX Normally this current should be close to the no load current of the motor at rated voltage and base frequency The optimal IMAG value should be set at the factory VBASE BSLIP IBASE SLOPE VADVTBL SLIP Magnetization current is now reduced automatically during field weakening operation Magnetization current set by the IMAG variable is maintained at speeds below base speed At speeds higher than the base speed magnetization current will be inversely proportional to the speed Base speed is set at the factory and is generally determined by the start of the constant horsepower point of the curve Base speed RPM Field weakening starts here Expected Slip frequency when IBASE current is supplied to the motor BSLIP 524 corresponds to Hz of slip frequency Stator Current that produces BSLIP at VBASE Unit is in percent of IMAX When in field weakening region slip per current must be increased This is the maximum speed of the slip table Set the same as VMAX if possible Not programmable Current Slip is dis played using this command In this representation Hz slip corresponds to SLIP 524 To obtain optimal parameters for a specified motor the two following 101 CHAPTER 9 SPINDLE PROGRAMMING variables help determine the optimal ope
233. cuted if the condition 15 false VECTORSTAR Both TRUE command and FALSE command are optional although at least one must be present Some examples of the command are GT 5 P X155 P 1 lt 5 2 VFB GT 3000 P HIGH SPEED P LOW SPEED 2 X2 5 LE 1 100 GOSUB 40 2 1 2 2 EQ X1 5 5 IF X1 IS EVEN DO NOTHING X1 IS ODD 14 1 J 2000 IMIS JOG BUTTON Note that each condition has an exact opposite EQ amp NE LE amp GT and LT amp GE are all pairs of opposites Since the command allows both TRUE command and FALSE command you have your choice of which command to use in the condition For example the two commands that follow have exactly the same effect 2 EQ 10 B P X1 OK BREAK IF X1 10 X1 NE 10 P X10K B BREAK IF X1 10 The command can be used to make a loop counter Suppose you want to go to subroutine 25 twenty times You could just write GOSUB 25 twenty times but it would probably be better to use a program loop The following statements show how the command can be used to control that program loop X302 1 30 IS THE LOOP COUNTER 12 THE LOOP BEGINS AT 12 GO TO SUBROUTINE 325 INCREMENT THE LOOP COUNTER X30 LE 20 GOTO 12 EXECUTE LOOP 20 TIMES CONTINUE PROGRAM GOSUB 25 X30 X30 1 CHAPTER 10 USER PROGRAMS 10 4 2 2 Nesting Commands You can nest one
234. cution ERROR 18 BAD TL SEVERITY 3 The VECTORSTAR has two boards a small MC board and a larger IBD board Both boards have the current and voltage rating encoded and they must match If this error occurs because you exchanged the MC card then you should replace the original card If it occurs for some other reason contact the factory This error breaks program execution 198 VECTORSTAR APPENDIX C ERROR CODES ERROR 19 MOTION HDWR LINE SEVERITY 2 The MOTION input was off at the beginning of a motion instruction or it turned off during a motion instruction This signal comes from the optional I O card This error breaks program execution ERROR 20 TUNE FAILED SEVERITY 3 The TUNE command failed Either the inertia on the motor 15 too large for the desired bandwidth the motor 15 not functioning properly the bus voltage is too low or the VECTORSTAR is not functioning properly Try reducing the desired bandwidth to correct this problem Make sure REMOTE is on If this does not work attempt to tune the system by hand as described in Chapter 4 ERROR 21 NOT wIPI SEVERITY 3 Auto tune is not available for PI control PDF 0 ERROR 22 12 VOLTS SEVERITY 3 The 12 volts is out of tolerance Contact the factory This error breaks program execution C 2 3 Positioner Faults ERROR 23 SOFTWARE OVERTRAVEL SEVERITY 2 Software travel limits are enabled and either PMAX or PMIN the software limits have been exceeded
235. d This manual is written for use with Motion Link For more information on Motion Link refer to Chapter 7 2 6 5 1 Required Data Format The VECTORSTAR and your terminal must use the same format for serial data RS 232 C and RS 485 describe hardware only There are other specifications left to up to the user full or half duplex the number of bits per character whether or not parity is used the number of stop bits and the baud rate Full duplex means both the terminal and the VECTORSTAR can send and receive at the same time Half duplex means only one system can talk ata time Bits per character refers to the number of actual data bits sent at one time The parity is a bit sent for error detection The number of start and stop bits sets a minimum delay between characters The baud rate 18 the rate at which bits are transmitted and received The VECTORSTAR requirements are Full duplex 8 bits per character No parity 1 start bit 1 Stop bit Baud rates equal 300 600 1200 2400 4800 9600 or 19200 Most terminals and computers will allow you to set these options with little difficulty Motion Link sets these requirements automatically 2 6 5 2 First Transmission Before you attempt to establish communications you must 1 Mount the VECTORSTAR and PA system as described earlier in this chapter 2 Make all connections as described in the earlier sections of this chapter especially connecting the VECTORSTAR serial con
236. d Cable 5 232 5 Wire with Shield Cable RS 485 Use one of the conductors to connect the power supply commons The shield should not be used for this connection but should connect to earth ground If you have an RS 232 terminal or computer and you want to use RS 485 either for multidrop or for noise immunity then you can purchase an RS 232 to RS 485 converter For example Anaheim Automation Anaheim CA produces Model DC 2170 for this purpose The RS 232 serial input and outputs connect to 75155 line driver receivers The RS 485 serial input and outputs connect to 75176B line driver receivers These chips are available from many IC manufacturers includ ing Texas Instruments LINE TERMINATION The VECTORSTAR provides line termination for RS 485 An RS 485 line may need to be terminated to reduce ringing on long cables In this section Line refers specifically to the RxD RxD pair or the TxD TxD pair A line is terminated by connecting a resistor from RxD to RxD or TxD to TxD Terminating resistors are provided inside the VECTORSTAR These resistors are CHAPTER 2 INSTALLATION connected by installing jumpers across Pins 3 and 4 and across Pins 7 and 8 J1 on the front of the VECTORSTAR The lines should only be terminated at the end of the communication cable For example if you are using several VECTORSTARs in multidrop then you should install the jumpers only on the units at the ends of the seria
237. d D 3NOH ANY 3ALLSIS3 dlAV OL dn Nuri 38 31038 91 8 AVI SAIC NYO SLOWLNOO AY TH 330339 SHAWOLSND E JHL ZO Z dvHO 385 44 OC O I Adans 33 MOd Q31v TOS NON 4 015 3ALLOV STGNIdS 40 pS Sa 1 duas 0 sae 8 90 C SH VS m 0 18588 VINAS A z E S0 So 0 SI 5 z 0 cun am 0 INIT HOLSISSY 0 _ 2125 zd HO Ld el J WHOM YNOS SIHI SHOAS TAANI SONY 1 15 NOS 55 64 V SI IOLINOWI K Nowwoo aads 20 _________ __ 0 4001 WE 48395 0482 0 56 39 ssaa NOWWOO OL Q3193NNOO 3d 007v v ANIT NI YOLSISIY lt WHO JL Y SVH TVN IS SIHL 1 S1ndino 20702 0001 Q3 VOS Nowwoo STONIdS SHOW OL 3333 NOLLVIAHO
238. d PEXT The frequency of the external input 15 provided in VEXT VEXT is in external velocity units VXNUM and VXDEN PEXT 18 the accumulation of counts from the external input PEXT can be set to any value from the terminal or from your program at any time this is equivalent to normaliz ing the external position PEXT is in external position units PXNUM and PXDEN If the external input comes from a motor VEXT and PEXT represent the master motor s velocity and position although you must properly calculate the external velocity and position units In this way the master position is similar to PFB the slave position Likewise VEXT is similar to VFB If the master motor has the same resolution as the slave then set PXNUM PXDEN VXNUM and VXDEN equal to PNUM PDEN VNUM and VDEN respectively Otherwise see Chapter 9 for more information on calculating the units VXAVG is the average of VEXT over the previous 16 milliseconds Occasionally the normal sample to sample variation of VEXT is undesirable In these cases use VXAVG in place of VEXT 8 8 12 1 Analog Input Also the VECTORSTAR provides an analog external input Note however that you cannot have both types of inputs at the same time The VECTORSTAR features an on board A D 12 bit converter The analog input is on CHAPTER 8 GENERAL PROGRAMMING connector C10 pin 5 HI and pin 6 LO Connector C2 can also be used as analog input if the opti
239. d the feedback circuitry is not working your VECTORSTAR may be malfunctioning Contact the factory CHAPTER 2 INSTALLATION Table 2 9 Goldline Resolver Cable Wiring ECTORSTAR Resolver C3 Connector Sine Low B Shield No Connect Cosine Low C Reference High Shield No Connect Not Used No Connect Sine High A Shield No Connect Cosine High Reference Low Shield Connect Not Used No Connect Thermostat Black T Thermostat Black U Optional Brake Blue N Optional Brake Blue P R S Flying Lead Flying Lead Flying Lead Flying Lead Flying Lead Optional Tach Black Optional Tach White Flying Lead 2 7 11 Checking the AC Line Voltages SHOCK HAZARD Large voltages are present on the AC Line Be very careful WARNING when measuring these voltages 29 CHAPTER 2 INSTALLATION Open the circuit breaker or remove the fuses in the AC Line Turn on the AC Line Use an AC voltmeter to check and record the 1 or 3 phase line to line voltage at the circuit breaker or fuse holders Turn offthe AC Line Note the model number ofthe VECTORSTAR unit and refer to the Model Number Figures in Chapter 1 to confirm correct AC Line voltage 2 7 12 Checking the DC Bus Voltage Remove the AC Line Wait 5 MINUTES for the DC BUS to discharge WAIT 5 MINUTES FOR THE DC BUS TO DISCHARGE The DC Bus is connected to large capacitors inside the PA These capacitors can store a lot of energy
240. de is provided for debugging and it allows you to execute a program one step at a time The single step prompt s gt is printed out followed by the line that is about to be executed the next command Any command allowed from the terminal in the Monitor mode is also allowed from the terminal in the Single Step mode These commands allow you to probe the VECTORSTAR variables while debugging your program If you press the enter key without a command entered then the next command in the user program is executed To stop the program enter the S B or K command To turn off the Single Step mode and allow the program to execute normally press the escape key twice once to get into the Monitor mode and again to get into the Run mode or type SS OFF 59 CHAPTER 7 SOFTWARE INSTALLATION Single Step mode is enabled by turning SS on either from the program from the Interactive mode before running the program or from the Monitor mode After SS is on the VECTORSTAR will enter the Single Step mode when the user program is executed SS can also be turned and off from the program This is useful if there are certain sections that you want to single step through Turning SS off from the program returns the VECTORSTAR to the Run mode 7 6 2 5 Trace Mode The Trace mode is provided for debugging When in Trace the VECTORSTAR prints statements before they are executed The trace prompt t is printed out followed by the line that i
241. determine the terminal s baud rate then set its own baud rate accordingly This is called autobauding After the VECTORSTAR deter mines the correct baud rate it will store this rate away in BAUD The VECTORSTAR will flash the CPU light to indicate that it is autobauding In order for the VECTORSTAR to determine the baud rate setting on your terminal you must press the enter key several times Press only the enter key otherwise the VECTORSTAR will not autobaud correctly The system will only autobaud during power up 10 10 1 1 Setting the VECTORSTAR to Autobaud There are three ways to set the VECTORSTAR to autobaud at power up 1 Powering up with the MOTION input off 2 Turning the switch ABAUD on before the next power up 3 Setting the value of the variable BAUD to an invalid value 1000 for example CHAPTER 10 USER PROGRAMS 10 10 1 2 Autobauding and MOTION If the MOTION input is off during power up the VECTORSTAR will autobaud Note that this also sets ADDR to zero This allows you to command autobaud without being able to communicate with the VECTORSTAR The other ways to start autobauding require that communications be set up first See the section on ADDR and multidrop communication later in this chapter for more information 10 10 1 3 Enabling Autobaud with ABAUD The autobaud software switch ABAUD is the usual way to tell the VECTORSTAR to autobaud on power up If ABAUD is on then the system will auto
242. dication LED s except low current versions which have 2 D C BUS This green LED is on when AC Line Voltage is applied REGEN This yellow LED turns on when the PA regen circuit is active OVERLOAD This red LED indicates a fault It turns on when the PA circuitry detects that the regen resistor has absorbed too much energy It is turned off when power 18 removed and then reapplied Normally this is caused when the motor decelerates too rapidly or too often If you get this fault you may need to increase the power rating of your regen resistor and the PA may need to be modified at the factory If your system has an internal regen resistor you will need a new PA power supply designed for external regen Contact the factory BLOWN FUSE This red LED indicates a fault It turns on when the fuse that protects the regen resistor has absorbed too much energy You must remove power and replace the fuse The spare parts list at the beginning of this chapter provides ordering information for this fuse If the fuse blows during normal operation see the section above on OVERLOAD because similar conditions cause both faults and similar actions must be taken to correct the conditions If you replace the fuse and it blows within a few seconds of applying power then the regen transistor is probably shorted The PA must be returned to the factory for repair The PA X50 and PA X75 50 and 75 Amp versions have 3 indication LED s VE
243. dix C Note that we have omitted the power supply relay connection and motor thermostat connection We also assume that you do not need encoder input encoder output or general I O for the moment For quick start purposes the REMOTE input is temporarily using a non isolated power supply directly from the drive pins 5 and 15 of C2 MOTION and LIMIT also must be connected where needed 3 3 ANALOG INPUT CONTROL If you want to try the analog input control follow these steps 1 Connect analog voltage input to pins 5 and 6 of C10 on the drive top 2 pins on the left column 2 Type VSCALE 10000 to scale analog input to 10000 RPM 10 volts As an alternative from Motion Link check the values of GEARI and GEARO by typing P GEARI and P GEARO GEARO should be 16384 and GEARI should be 700 for a system of 10 volts input 10000 RPM or 420 for a system with 10 volts input 6000 RPM 3 Type A2D 1 to turn on analog input Type GEAR 1 to turn on Gear function 4 Give zero volt input and enable the drive by typing 34 VECTORSTAR 5 If there is a drift you may increase the value of Z0 which is the deadband 1 equals 620 micro volts 6 If the analog input is 1 volt the motor should run at 1000 RPM for a 10000 RPM system or 600 RPM for a 6000 RPM system At this point you have completed this quick start section by performing two of the simplest operations JOG and analog input G
244. e The VSA 28 is available with 24 VDC fans NOTE VECTORSTAR 2 6 4 10 Wiring C7 Standard C7 is a 26 pin ribbon cable connector It provides non isolated 5 volt TTL level inputs Open collector outputs are directly interfaced to 8 OPTO 22 compatible I O boards These boards are widely available and use industry standard optical isolation modules available from several companies including Potter and Brumfield Grayhill Gordos OPTO 22 and Crydom This connector is on top ofthe VECTORSTAR Note that you must provide a separate power supply when using standard OPTO 22 compatible I O boards This supply must provide 5 volts DC to power the I O modules on the VECTORSTAR side ofthe isolation The common of this supply will normally be connected to the common ofthe VECTORSTAR through the even numbered pins on Connector C7 Do not use the VECTORSTAR 5 VDC power supply to power I O modules Additionally a second power supply may be needed to provide power for those devices which are isolated from the VECTORSTAR by the I O modules The common of this supply should not be connected to the VECTORSTAR common You must provide an additional power supply for the modules NOTE HOME Pin9 HOME is the input for the home limit switch Itis also the registration input If your application has both a home limit switch and a registration input use HOME for the registration input and connect the home limit swi
245. e can go back to the state of Spindle Axis or Open Loop defined by I1 N NOTE Input 2 must be turned off when Drive Ready O4 is off The orient positional units are in R D resolver to digital bits rev VECTORSTAR has 4096 bits in revolution ofthe motor The orient position 1s stored in the variable named P1 The range of values for P1 is 0 to 4095 To capture the P1 orient position place the motor in Tram mode i e disable the motor such that the motor can be rotated by hand Position the motor to the orient position Using the VECTORSTAR communication device perform the command P PRD The number 105 CHAPTER 9 SPINDLE PROGRAMMING returned is the number that is loaded in terminal mode into P1 representing the orient position 9 6 3 1 1 1 Application The VECTORSTAR can be used in an application in which one revolution of the motor results in one revolu tion of the spindle 1 1 application When the VECTORSTAR receives an Orient Request I2 input the externally commanded speed is captured The VECTORSTAR then assumes control of the motor maintaining the externally captured command speed The Orient command then brings the motor to a complete stop at a random position prior to moving the motor to the orient position in less than one revolution The speed at which the motor moves from the random stopped position to the orient position is controlled by the parameter named VORNT in units of RPM Various modes
246. e of these problems does occur it can go undetected indefinitely If personal safety is involved always hardwire the function Programming errors can damage your equipment Use caution when programming equipment CAUTION protection functions 120 USE CAUTION WHEN PROGRAMMING EQUIPMENT PROTECTION FUNCTIONS Sometimes you can hardwire equipment protec tion functions but other times this is impractical and you must program the functions If this 1 the case be very careful Remember if your program has an error it can result in damage to your equipment For example suppose you want to wire your motor thermostat so that when a fault occurs the present machine cycle continues until complete In this case you must program the function hardwiring the thermostat would result in motion stopping the moment a thermostat fault is encountered Carefully test these functions WRITE A SIMPLE SPECIFICATION FOR YOUR APPLICATION Write an outline of all the functions your applica tion will require before you start programming This will serve as a specification Everyone who is involved with your system customers supervi sors co workers operators should agree on the specification While last minute requests for program changes will still occur this is a reason able step towards reducing the incidence of such requests VECTORSTAR 4 WRITE A FLOWCHART OF YOUR PRO GRAM People new to programming often have a natura
247. e operator responds with a new value For example write your program like this B HOME ON FIRE ALARM WITH HOME 0 TURN OFF OUTPUTS DIS DISABLE DRIVE P MESSAGE NOW PRINT A MESSAGE B Do not print before you turn outputs off or disable the VECTORSTAR Otherwise an INPUT command from another task may idle the alarm indefinitely 10 8 7 Variable Input Task Level 4 The variable input task is the next highest priority Normally the variable input task is used to prompt the operator for input while still allowing the main section of the program to continue For example the operator could be entering a new distance while the main program continues executing the program using the old distance The variable input task 1s similar to an alarm except that it is fired upon receiving a special character from the terminal or computer which is V control V or ASCII 16H The button on the Kollmorgen DEP 01 Data Entry Panel also transmits a V to fire the variable input task The variable input task begins with VARIABLES You can then follow that label with various statements CHAPTER 10 USER PROGRAMS usually printing and input commands For example enter the following program TASK LEVEL 4 VARIABLE P X1 IS X1 INPUT INPUT NEW VALUE OF X2 X2 P X1 IS NOW X1 B END EXECUTION TASK LEVEL 5 10 X1 0 11 1 1 1 11 Now you can enable mul
248. e that is not allowed from the Monitor mode This error generates no action ERROR 55 NOT FROM RECOVERY SEVERITY 2 You attempted to execute an instruction from the error recovery user s error handler or ERRORS that is not allowed This includes attempting to enable the VECTORSTAR GOSUB and GOTO This error breaks execution ERROR 56 NOT wIGEAR SEVERITY 2 You attempted to execute an instruction when the Gear mode was enabled that is not allowed with the Gear mode For example MRD MA JT and JF are not allowed with the Gear mode on This error breaks execution if the instruction was issued from the program ERROR 57 NOT w PROFILE SEVERITY 2 You attempted to execute an instruction that is not allowed while the VECTORSTAR is profiling Profiling occurs when move instructions MA MI MRD or macro moves are executing Other examples of this are the traverse segment before the accel decel portion of position dependent jogs JT JF and the accel decel portions of all jogs J JT JF This error breaks execution 201 APPENDIX C ERROR CODES VECTORSTAR ERROR 58 NOT wIJOGGING SEVERITY 2 You attempted to execute an instruction that 15 not allowed when the VECTORSTAR is jogging This error breaks execution if the instruction was issued from the program ERROR 59 NOT wIROTARY SEVERITY 2 You attempted to execute an instruction that is not allowed when the VECTORSTAR is in the Rotary mode Type ROTARY
249. e variable KC which is normally set to 200 This value of KC produces suffi ciently smooth low speed performance for almost all applications However if your application is very demanding you may want to adjust KC somewhat It is rare for this procedure to be required l Turn PL off by typing PL OFF 2 Twist the motor shaft back and forth lightly at about 1 or 2 twists per second You should feel very slight graininess This graininess is similar to the feel of anti backlash gears If you want to make the graininess more pronounced so that you can feel it set KC to zero Type 0 3 Adjust KC so that the graininess is minimized The best way to do this 1s by attaching a mirror to the motor shaft and shining a laser onto the mirror and observing the reflected dot about 10 20 feet from the motor You can attempt to feel the graininess but that measurement is so coarse that you should probably just set KC to 200 and skip this procedure The normal range for KC 1 between 175 and 225 This adjustment must be repeated when either the motor or the amplifier is changed out 4 Restore PL Type PL ON This completes the initial check out 39 CHAPTER 4 OPERATION 4 3 SYSTEM COMPENSATION Feedback systems like a motor controller require tuning to attain high performance Tuning 15 the process whereby the position and velocity loop gains are set attempting to optimize
250. e variable PFB is greater than 10000 This statement delays program execution until the condition is true and also refreshes the display while the program waits TIL PFB GT 10000 P WAITING FOR PFB 10000 The TIL command can be used to simply delay your program because the statement that follows the condi tion is optional For example this statement delays execution but does not refresh the display 129 CHAPTER 10 USER PROGRAMS TIL PFB GT 10000 AN NOTE The TIL can be used to delay program execution More examples of the TIL command are TIL EQ DELAY EXECUTION TIL 11 EQ ON P PRESS INPUT 1 TIL SEG EQ 0 DELAY UNTIL MOTION STOPS TIL SEG EQ 0 P PFB PRINT UNTIL MOTION STOPS 10 4 2 4 IF ELIF ELSE and ENDIF Commands The IF command together with ELIF ELSE and ENDIF will allow you to conditionally execute large blocks of commands These commands are provided because the command which is limited to a single line does not provide the most efficient means to control blocks of commands You can use the IF command to write more readable less error prone programs The format of the IF ELIF ELSE and ENDIF com mands follows Note that the conditions have the same format as the conditions for the TIL and commands Note also that block can indicate any number of com mands IF IF condition Block IF ELIF ELIF condition 1 ELIF block 1 EL
251. ecution time by 4096 5096 If the GEAR mode is enabled increase execution time by 1096 to 2096 Profile regulation increases execution time by as much as 2096 As you can see if either gear or profile regulation is enabled and the VECTORSTAR is executing the acceleration or deceleration portion of a motion profile then the times can be 6096 greater than those shown here These commands are not meant to represent the worst case but are only provided as an estimate of the execution times l These times are based on tests run at Industrial Drives Electronic Lab Reference Test 67 of May 21 1990 235 APPENDIX COMMAND TIMINGS 1 EQ 1 OI 20 10 amp 10 10 amp 108 GOSUB 120 amp 120 IF 1 EQ 0 1 1 1 0 1 2 ELSE X1 3 ENDIF J 1000 JF 40960 1000 JT 40960 1000 40960 MA 40960 1000 MCGO MCI 1000 1000 200 MCI 1000 0 MI 40960 MI 40960 1000 MI 40960 1000 GATEMODE ON MI 40960 1000 GEAR ON MI 40960 GEAR ON MI 40960 1000 GEAR ON amp In Motion MI 40960 1000 REG ON MI 40960 REG ON MI 40960 1000 REG ON amp In Motion 236 1 93 msec 0 72 msec 0 84 msec 0 84 msec 1 46 msec 4 88 msec 1 37 msec calc time only 2 46 msec calc time only 2 46 msec calc time only 1 96 msec calc time only VDEFAULT 1000 2 52 msec calc time only 5 50 msec calc time only 1 96 msec calc time only VDEFA
252. ed to change direction with an instruction that does not allow direction to change These instructions include JT JF and macro moves This error breaks program execution ERROR 41 MOVE NEEDS MOTION SEVERITY 2 You attempted to execute an instruction that requires the motor to be in motion These instructions include JT JF and MCI MCA with no velocity parameter specified This error breaks program execution ERROR 42 MOVE TIME SEVERITY 2 You attempted to execute a move that required more time than was available For example you attempted a JT or macro segment where the final position could not be reached because of acceleration limits You may have attempted a JT or JF when you were already well beyond the specified position This error breaks program execution ERROR 43 MACRO NOT READY SEVERITY 2 You attempted to execute a macro move with the MCGO instruction in which the last segment of the move did not end at zero speed or the macro move memory is empty The macro move memory is cleared every time the VECTORSTAR 18 turned on This error breaks program execution ERROR 44 MCD wIMACRO MOVING SEVERITY 2 You attempted to insert a macro move dwell when the previous macro move segment ended at a speed other than zero This error breaks program execution ERROR 45 MCA ACTIVE SEVERITY 2 You attempted to insert an MCA segment after an MCI segment This error breaks program execution 200 VECTORSTAR APPENDIX C ERROR
253. els of stability follows 4 3 1 Critical Damping Generally the most desirable amount of damping is Critical Damping Critically damped systems respond as fast as possible with little or no overshoot In Figure 4 1 the graph shows the response of a TACH signal on Connector C2 Pin 2 to a square wave input when the system 15 critically damped 40 VECTORSTAR 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds Figure 4 1 Critical Damping 4 3 2 Underdamping Sometimes the system is tuned for critical damping and the system is still too slow In these cases you may be willing to accept less than critical damping For applications that can work properly with a slightly underdamped system you may reduce the stability to improve the response The graph in Figure 4 2 shows a slightly underdamped system 1 40 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds Figure 4 2 Underdamping 4 3 3 Overdamping An overdamped system is very stable but has a longer response time than critically damped or underdamped systems Also overdamped systems are noisier than less damped systems with the same response rate The graph in Figure 4 3 shows an overdamped system VECTORSTAR 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds
254. ented all inputs are monitored The Zero Speed feature is active and the Zero Speed O1 output will be on The At Speed feature 15 active and the At Speed O2 output will be controlled by the value of the analog command voltage Since the motor is being maintained at the Orient position a command voltage of 0 will activate the At Speed output The Over Tempera ture inputs are included in the monitoring The Spindle Reset I6 input will not have any affect After Orient is complete command P PRD can be used to check the Orient results The designed input channel for Orient is I2 Variables used 2 Desired orient positions units VECTORSTAR currently uses 12 bit mode and these are per resolution The programmable Orient position can be assigned from 0 to 4095 VORNT Desired motor orient speed in RPM The motor will move to the P1 or P2 in less than 1 revolution at this speed If the motor moves only a short distance the VORNT may not be reached before the stop at the Orient position 107 CHAPTER 9 SPINDLE PROGRAMMING MORNT Orient mode selection 0 the random stopped position in the direction the motor was rotating when the Orient Request input was received 1 same mode 0 but in CCW direction see from non shaft end of motor 2 same as mode 0 but in CW direction 4 same as mode 0 but in the shorter direction X41 A pass fail band for the orient in position test X42 Must be great
255. er READ THIS ENTIRE SECTION CAREFULLY This section discusses programming practices The VECTORSTAR has a flexible language You must follow proper programming principles to ensure that the flexibility does not lead to overly complex programs If you follow good programming practices you will be able to modify programs when the application changes have fewer programming errors have an easier time fixing the programming errors that do occur and be able to get help with errors you cannot fix People who are new to programming often disregard good programming practices because they have not experienced the problems that result from poor program ming practices Save yourself the misery of having to re write your entire program Follow these steps Always hardwire personal safety functions Never program these functions WARNING 119 CHAPTER 10 USER PROGRAMS l DO NOT PROGRAM SAFETY FUNCTIONS Always hardwire safety functions This includes EMERGENCY STOP or ESTOP You should not depend on your program for safety functions because of three potential problems 1 You can easily make programming errors software problem 2 A function on the VECTORSTAR may not work in exactly the way you expect it to in every condition firmware problem and 3 A critical component in your system may fail and prevent the function from working hardware problem Remember safety functions are rarely exercised so that if on
256. er resolution is 14 bits multiply VNUM by 4 Multiply VNUM by 16 for a 16 bit system The procedure to determine ANUM and ADEN is as follows A Select Table 10 8 RPM sec or 10 9 radians second second B Select a convenient amount of motor acceleration C Calculate the corresponding machine acceleration D Perform the operation indicated in the table under ACCELERATION UNITS and set ANUM ADEN equal to this value E If your R D converter resolution is 14 bits multiply ANUM by 4 Multiply ANUM by 16 for a 16 bit system 149 CHAPTER 10 USER PROGRAMS VECTORSTAR COUNTS FROM MASTER RESOLVER TO DIGITAL CONVERTER PFS PNUM CONNECTOR INTERNAL _ ENCODER a FEEDBACK X VDEN ues 65 536 NUM MICROPROCESSOR MASTER VECTORSTAR m MASTER O ENCODER l mi um m sac SSE SS mm mms mE COUNTS FROM MASTER RESOLVER TO DIGITAL CONVERTER INTERNAL PNUM FEEDBACK X VDEN m 65 536 UNUM gt Nes PEXT AG PXNUM x4 EXTERNAL C1 DECODER FEEDBACK k x VXDEN VERE SEE VXNUM MICRO PROCESSOR SLAVE VECTOR
257. er than 0 and is used to sense the motor has stopped by compar ing X42 with the movement of the motor within one sampling period X43 A maximum loop count of the software test for motor being stopped If the test has been done more than X43 times the VECTORSTAR will conclude the test has failed X45 Defines the number of times the motor position must be captured and not change outside the X42 parameter window Normally set to 3 All X variables are in PRD units 4090 counts per revolution for 12 bit resolution of R D Motor Over Temperature The VECTORSTAR senses a motor over temperature OT condition and reports this condition by energizing the Motor OT 16 output It senses the OT condition when the Motor OT 15 input goes to a logical 0 turns off The VECTORSTAR also starts a programmable timer When this timer is exceeded with the OT condition present the current application job will be terminated and the motor will be disabled The Motor OT timer is programmed by the variable MTIMER in milliseconds Normally MTIMER should not be greater than 120 minutes The designed input channel for Motor Over Temperature is 15 To re enable application software execution the follow ing conditions must be true 1 condition 2 Orient Request I2 input off 108 VECTORSTAR 3 Toggle the Spindle Reset I6 input on While the OT condition exists and the OT timer is active normal VECTORSTAR operation continues If
258. ered through power down PROGRAMLIST POWER UP START PROGRAM HERE AT POWER UP GEAR 0 NOT RECEIVING CHAPTER 9 SPINDLE PROGRAMMING VELOCITY COMMAND FROM ANALOG ABAUD 0 AUTO BAUD TIL 2 EQ 1 WAIT FOR SYSTEM READY 5 REMOTE EQ1 WAIT FOR REMOTE INPUT IS 1 EN ENABLE THE DRIVE 10 IF REMOTE amp HOME EQ 1 CHECK BOTH REMOTE AND HOME ARE 1 GEAR 0 NOT RECEIVING VELOCITY COMMAND FROM ANALOG INPUT J X1 RUN A CONSTANT SPEED AS X1 WHICH HAS BEEN GIVEN BY USER MAY BE FROM LAST OPERATION TIL HOME EQ 0 POLLING THE HOME INPUT JO 8 THE MOTOR IF HOME 0 W0 WAIT FOR ZERO SPEED D 500 WAIT HALF SECOND FOR MOTOR STOP COMPLETELY ENDIF 30 IF REMOTE amp CYCLE EQ 1 WAIT UNTIL BOTH REMOTE AND CYCLE INPUT ARE 1 GEAR 1 READY TO RECEIVE VELOCITY COMMAND FROM ANALOG INPUT ENDIF TIL CYCLE EQO CONTINUE JO W o0 D 500 GOTO 10 LOOP BACK FROM 10 ERROR START THIS ROUTINE ONLY IF AN ERROR OCCURS 113 CHAPTER 9 SPINDLE PROGRAMMING VECTORSTAR IF LSTERR EQ 14 ERROR 15 POWER BUS WAIT UNTIL SYSTEM IS READY TIL OK2EN EQ 1 RUN 5 SYSTEM IS OK RUN FROM 5 ENDIF B OTHERWISE QUIT 114 VECTORSTAR CHAPTER 9 SPINDLE PROGRAMMING Motion Technologies Group TL VSA12 2031E12 ISSUE 1 SH 1 OF 5 WRITTEN BY T CONNER 6 4 97 TEST LIMITS AND MODIFICATION DATA VSA COMP1 FORM REV B MO
259. errors and their severity 8 8 1 5 STOP and BREAK with Control X X You can execute a stop and break command with the control X X character Control X or X means that you hold down the control key Ctrl on your terminal or IBM PC and press the X key This has the same effect as typing B then S from your terminal 79 CHAPTER 8 GENERAL PROGRAMMING 8 8 2 Limiting Motion The VECTORSTAR allows you to limit motion of the motor with both Software and Hardware Travel Limits 8 8 2 1 Hardware Travel Limits If you have an application with boundaries which should never be crossed you are encouraged to use the Hard ware Travel Limits with limit switches Exceeding Hardware Travel Limits is a more severe error than exceeding Software Travel Limits The VECTORSTAR assumes that Software Travel Limits should catch normal overtravel conditions and that a Hardware Travel Limit indicates a serious problem Hardware Travel Limits disable the VECTORSTAR rather than just stopping motion as the software limits do This means that the motor must be backed away from the limit by hand Chapter 2 discusses how to wire LIMIT Usually two limit switches are wired in series and connected to LIMIT the contacts of these switches must be closed for the VECTORSTAR to be enabled If the contacts open the VECTORSTAR will be disabled the motor will coast to a stop and an error will be generated This limit is a safety device and not part of no
260. ervoltage detection level is set well under 100 VDC 70 VAC so that low line from brown out almost never causes an undervoltage fault Your system may include protective circuits that remove power from the VECTORSTAR when a problem is detected elsewhere in the system This can cause the VECTORSTAR to generate ERROR 14 and lead you to suspect the VECTORSTAR of causing the original problem If the problem occurs only rarely you may have to purchase or rent a device to monitor the DC BUS voltage to deter mine the cause 4 2 3 If Your VECTORSTAR System is Unstable If the motor was oscillating you need to retune your system First try to stabilize the system with the TUNE command Type TUNE 10 2 Enable the drive If your system is stable you can skip ahead to the next section If you want to improve the response see Section 4 5 for details on the TUNE command If your system is not stable disable the VECTORSTAR You need to detune the system First disable the position loop Type PL OFF Disable the integrating velocity loop in other words enable the proportional velocity loop Type PROP ON On power up the integrating velocity loop will be enabled that is PROP 15 turned off and the position loop will be turned on Be careful to turn PROP on and PL off every time you power up until you stabilize the system for an integrating loop VECTORSTAR PROP is turned off a
261. es rapidly the profile is not limited to ACC or DEC For example if the external frequency stopped suddenly the VECTORSTAR would command motion to stop just as suddenly Note also that large feed forward gt 4000 is normally undesirable during regulation because it causes overshoot 8 8 14 1 REG and REGKHZ REG enables the Profile Regulate mode If REG is on then profile regulation is enabled REG and GEAR cannot be on at the same time To use profile regulation you must determine 1 maximum frequency of the external input Set REGKHZ to this value 2 The desired speed of the move when the external input frequency is REGKHZ Use this value as the commanded velocity of the profile The maximum frequency of the external input is stored in the variable REGKHZ in kHz The profile will execute normally that is at the specified velocity and acceleration when the external input frequency is equal to REGKHZ Ifthe input frequency 15 less than REGKHZ then the profile will move the specified distance but the acceleration and velocity will be less than and in proportion to the input frequency The move will never go faster than specified in the original move command even if the input frequency goes above REGKHZ However the input frequency should always be less than REGKHZ REGKHZ is only resolved to 1 kHz for example 499 5 kHz is converted to 500 kHz REGKHZ is somewhat arbitrary it must be greater than the
262. essed Solid state controls of the VECTORSTAR may be affected by transient voltages These voltages are in excess of the specified voltage for any given circuit When these peak voltages occur even for less than a second permanent damage to the VECTORSTAR can occur 49 CHAPTER 5 MAINTENANCE In order to help avoid transient voltages that may interfere with electronic circuit functions within the PA and VECTORSTAR all switched inductive devices or their wiring solenoids relay coils starter coils etc must be suppressed A 220 ohm 1 2 watt resistor in series with a 0 5 micro farad 600 volt capacitor or equivalent is suggested 5 2 2 Surge Current Excessive current greater than that of the specified limits of the PA and VECTORSTAR can cause permanent damage to the system Current limiting means are recommended to protect from these currents If the short circuit inrush current generated by the power source is in excess of 5000 amps RMS symmetrical current an isolation transformer or line inductor must be utilized in the incoming power circuit Failure to observe this precaution could result in damage to or destruction of the PA and VECTORSTAR CAUTION Input transformers step up or step down input voltage and can be either autotransformers or isolation trans formers Isolation transformers help eliminate the following Damaging AC line voltage transients reaching the PA and VECTORSTAR Damaging current
263. ete er tee Su as 39 4 25 Low Speed Adjustment sine RS ES S q Endep 39 4 3 SYSTEM COMPENSATION LLL UU uuu aan aan entsteht 40 43 1 Cntcal ee eh ee ma Dh d Were Sa ge si 40 4 32 Underdampine opt e ette ne E h e eO 40 4 3 3 Oyerdamping ka ase a eden ente 40 AB A 41 4 TUNN EE 41 4 4 1 If Your System Is Completely Unstable 41 AA D gt Reducing iE REIS 42 45 TUNE COMMAND e t 42 4 6 TUNING THE VECTORSTAR YOURSELF IS aaa kasaqku ayasa eu 42 4 6 1 Tuning the Velocity Loop s a na selasa asa da asa 43 4 62 Tuning the Position Eo0p i be Nee n n ERE 43 IANADOGINPUT ote ctt ON e bte Niel bere ee eee 44 4 8 RECORD AND PLAY 44 49 PROBE MS sits ad Rete a UR E da 44 49 7 Overloading the MOtor n RC PE REI ERE ARI ERR 44 4 9 2 Compliance tabes eade ole i mtb bu iei t 45 4 9 3 Nori Diriear M charnlcs Rc 45 49 4 e ehe teer rene ha cues 0 EE 45 49 S Eilferg uu 46 CHAPTER 5 MAINTENANCE D
264. eters to get exactly the response you need THE MOTOR MAY OSCILLATE Unloaded motors tuned for a large inertia load may become unstable when the system is activated If the system be comes unstable remove the power immediately WARNING 4 4 1 If Your System Is Completely Unstable If your system is completely unstable when you enable it remove power immediately After restoring power but before enabling the VECTORSTAR turn off the switch PL reduce KV to 100 and reduce KVI to 0 This should make the system stable TYPE THESE LINES ONLY IF YOUR VECTORSTAR IS UNSTABLE WHEN YOU ENABLE IT DON T FORGET TO RESTORE PL WHEN YOU HAVE FINISHED TUNING PL OFF 0 KV 100 If the VECTORSTAR is still unstable remove power and contact the factory If it is stable continue on with tuning Do not forget to turn PL back on when you have finished tuning Also PL is always turned on during the VECTORSTAR power up 41 CHAPTER 4 OPERATION 4 4 2 Reducing ILIM You may need to reduce ILIM before executing the TUNE command since the TUNE command causes the motor to shake at about 15 Hz and at full torque This may damage some machines Also lightly loaded motors can overspeed if ILIM is too high You should raise ILIM to the highest level that does not cause problems because the tuning may not be acceptable if ILIM 15 too low The effect can be that the torque the VECTORSTAR produces is swamped
265. f VSA variables 3VS1 12 0012 V4 0 BAUD 9600 ISSUE 1 DEC 4500 MOTOR 2031 DEP 0 DIR 1 5 40 DTIMER 15000 VOLTS 230 ECHO 1 5 840 UNITS GEARIC 140 GEARIO 840 PNUM 1 16384 1 16384 44739 16384 VDEN 10 10 ANUM 4474 ILIM 100 ADEN 1000 10 4095 200 100 0 2000 2000 VXNUM 87250 KV 7705 VXDEN 1 KVI 1000 LOAD 0 5 LPF l UNPROTECTED VARIABLES LPFHZ 100 MORNT 3 A2D 0 MSG 1 ABAUD 0 MTIMER 120000 100000 100000 ADDR 0 116 100 32767 PDF 0 VECTORSTAR PL 0 0 2000000000 2000000000 2144 2 0 409600000 REGKHZ 1000 1 1 SLIPLIM 45000000 TRIP 0 VDEFAULT 200 VOFF 0 VORNT 250 VOSPD 13200 VUP 15 VUPH 5 VXDENC 1 VXDENO 1 VXNUMC 523500 VXNUMO 87250 VZR 5 WTIME 1000 41 20 42 2 43 30 45 3 X46 5000 47 2000 X48 1000 X49 100 X50 4000 X5 1000 X52 100 270 1 71 0 710 gt Zl 37 CHAPTER 9 SPINDLE PROGRAMMING STL VS1 12 0012 V4 0 ISSUE 1 MOTOR V 2031EN AMPS 40 VOLTS 230 UNITS INUM 4095 IDEN 100 44739 10 TUNING VARIABLES KF 0 KP 1000 KP
266. f all errors is given in Appendix C 6 4 5 Firmware Errors Firmware errors are an indication of a serious problem with the VECTORSTAR These errors stop communications disable the drive and flash the CPU LED The CPU LED flashes several times then turns off and pauses The number of flashes represents the error number These error numbers range from 2 to 9 See Appendix C for information on these errors Contact the factory should one of these errors occur For a detailed discussion of firmware errors see Chapter 8 Section 8 6 6 5 FACTORY SUPPORT AND REPAIR POLICIES Kollmorgen is committed to helping you install operate maintain and troubleshoot your VECTORSTAR servo system If your system did not pass the Initial Check Out tests or is not operating properly then contact the Kollmorgen Field Service Department Please see Chapters 7 10 before calling about software or program ming questions Be prepared to provide the full VECTORSTAR and PA model numbers listed on the front of your equipment Contact us at Kollmorgen Motion Technologies Group ATTN Field Service Dept 201 ROCK ROAD RADFORD VA 24141 TELEPHONE 540 639 2495 540 731 0847 FAX 710 875 3743 TWX VECTORSTAR C unn 7 SOFTWARE INSTALLATION CHAPTER 7 SOFTWARE INSTALLATION 7 1 INTRODUCTION The VECTORSTAR comes with its own PC software interface called MotionLink Plus which we will refer to by its generic name MotionLink MotionLink is
267. fied position at the specified speed If the speed 15 not specified it 1s assumed to be VDEFAULT Allowed from the interactive mode and the user program Format MA lt Position gt Velocity 227 APPENDIX SOFTWARE COMMANDS VECTORSTAR MCA MCD MCGO MCI 228 Example MA 10000 1000 MOVE AT 1000 MA 0 TO 0 VDEFAULT Define an absolute macro move section to the specified position at the specified traverse and ending speeds See Chapter 8 General Programming for descriptions of defaults Allowed from the interactive mode and the user program Format MCA Position Traverse End Example MCA 1000 100 500 MCA 2000 10 MCA 5000 7000 0 Define macro move dwell section for the specified time This is only valid when the previous macro move section ended at zero speed When used with the profile regulation mode time 15 inversely proportional to external input frequency Allowed from the interactive mode and the user program Format MCD Time Example MCD 500 DWELL 0 5 SECONDS Execute a macro move This is only valid when the last macro move section ended at zero speed Allowed from the interactive mode and the user program Format MCGO Define an incremental macro move section for the specified distance at the specified traverse and ending speed See Chapter 8 for descriptions of defaults Allowed from the interactive mode and the user pro
268. fthe VECTORSTAR front panel connectors C1 C2 C3 C4 C5 C6 and C10 Mating connectors for C1 C8 and C10 are supplied with the VECTORSTAR 16 VECTORSTAR 2 6 4 1 Wiring C1 Encoder Equivalent The Encoder Equivalent Connector connects encoder inputs and encoder equivalent outputs The VECTORSTAR uses standard encoder format A B quadrature This format has excellent noise immunity because only one channel changes at a time As an option pulse inputs in different formats are also sup ported The Encoder Equivalent Connector is used for master slave systems If your VECTORSTAR is the slave axis then connect the output from the master to INA and INB If your VECTORSTAR is the master axis connect OUTA OUTB and OUTZ to the inputs on the slave axis See Figure 2 2 and or Figures B 1 B 8 for connection dia grams All encoder signals are differential as opposed to single ended to increase noise immunity This means that each signal is transmitted with its logical inverse for example OUTA and OUTA Logical inverse means that if OUTA is 5 volts then OUTA 15 0 volts and that if is 0 volts then OUTA is 5 volts Note that Figure B 1 9 shows the inverse of OUTA as OUTA with a bar drawn directly above it here the inverse of OUTA will be designated OUTA The encoder equivalent inputs and outputs conform to RS 485 One standard RS 485 output can drive up to 32 standard RS 485 inputs provided that the c
269. g the AC Line Connect the three phase AC Line to La Lb and Lc on the Power Terminal Block located on the front of the PA unit The PA will work with a single phase AC Line 220 VAC single phase input lines may be connected to any two terminals La Lb or Lc Note that the PA must be derated for single phase AC Line operation A 12 Amp PA with a single phase AC Line can only provide 10 Amps a 20 Amp PA with a single phase AC line can only provide 16 Amps The PA must be derated when operated from a single phase AC Line CAUTION 2 6 2 6 Wiring the Regen Resistor If an external regen resistor is used wire it to the External Regen Resistor Connector on the PA Note that you must specify that you need an external regen resistor when ordering your PA as this is an option Refer to Notes 3 and 11 in Appendix B 2 6 3 Wiring the PA Front Panel Connectors This section will discuss wiring of the PA front panel connectors The mating connectors are supplied with the PA 2 6 3 1 Wiring the Control Power to PA The Control Power for the PA is 190 260 VAC Connect the Control Power to Connector Control Input of the PA Connect one AC line to Pin 1 and the other to Pin 3 2 6 3 2 Wiring to the PA Fault Output on Bus OK The PA Fault Output Contact closes approximately 250 milliseconds after power is applied to the PA This contact opens if a fault occurs in the PA This is a relay contact from Pin 1 to Pin 2 of Connector
270. gearbox Phase adjustment means that the slave will be locked to the master through the electronic gearbox but occasionally the slave VECTORSTAR adds a short profile on top of the gearbox command For example you may want to increase the slave position phase by 90 while remain ing in gear In this case enter the following commands VECTORSTAR GEARBOX NORMALLY SOME TIME WOULD PASS BETWEEN THESE COMMANDS MI 1028 10 PHASE ADJUST 90 DEGREES AT 10 RPM SYSTEM REMAINS GEARBOX THROUGH THE PHASE ADJUSTMENT You cannot use MA or MCA commands when GEAR 15 on Also you cannot use position dependent jogs JT or JF when GEAR is on 8 8 13 5 Velocity Offset VOFF VOFF velocity offset is added to the Velocity command when the gearbox is enabled VOFF is in velocity units It is normally used with the analog input to correct voltage offset in the optional analog velocity input VOFF can be changed at any time Note that VOFF is set to zero when GEAR 15 enabled This is done because if VOFF is large say 2000 RPM enabling the gearbox would immediately command motion N NOTE 8 8 13 6 Gearbox ACC DEC and Jogs When the VECTORSTAR is run as a velocity loop PL off acceleration and deceleration rates can be limited by the variables ACC and DEC This allows you to limit the acceleration from external velocity commands that are otherwise unlimited If you want the acceleration and deceleration to
271. generated This error can also be caused by the ratio of GEARO to GEARI being too large Note that large feed forward KF gt 4000 is normally undesirable in electronic gearbox systems because it causes overshoot 8 8 13 2 Gearbox Example 1 Two VECTORSTARs are connected in a master slave system Both have 12 bit R D converters so that one revolution is equivalent to 4096 counts Suppose we want the slave motor to rotate at one third the speed of the master motor What are the values of GEARI and GEARO 92 VECTORSTAR GEARI _ REVgA RESOLUTION Ave GEARO GEARI 1 Lk GEARO 3 1 3 You select any integer values for GEARI and GEARO that have the ratio 1 3 RESOLUTION Aster 8 8 13 3 Gearbox Example 2 Suppose the master signal in Example 1 came from a 500 encoder With quadrature encoding a 500 encoder will generate 2000 counts per revolution If you GEARI _ REV wr X RESOLUTION GEARO COUNTS MASTER still wanted 1 3 gearing then GEARI _ REVg4 RESOLUTION GEARO REV 44 RESOLUTION rg GEARI Bs _ 4096 GEARO 3 2000 6000 So GEARI would be 4096 and GEARO would be 6000 8 8 13 4 Profiles and Gearbox Gearboxing can be done in conjunction with incremental moves and jogs MI and Macro moves based on MCI are summed with the gearbox command to form the profile This can be used for phase adjustment common function used with electronic
272. gh the serial port to the terminal or computer The transmission can be stopped by sending an escape character You should not rely on the VECTORSTAR to store all your programs Keep back up copies elsewhere The lt BDS command will cause the VECTORSTAR to transmit the entire user program to your computer It cannot be issued in the Program 154 VECTORSTAR mode For example if you type the following command from the terminal the VECTORSTAR will respond by printing out the entire user program BDS 10 10 4 2 The gt 5 Command Transmitting to the VECTORSTAR The gt BDS command is used to send a new user program through the serial port to the VECTORSTAR The transmission is ended by sending an escape character Note that this command writes over the contents of the user program stored in the VECTORSTAR This command allows the program to be directly entered presumably by a computer to the VECTORSTAR It cannot be issued in the Program mode The BDS command writes over the entire user program NOTE The VECTORSTAR issues the 1 gt prompt to indicate that it is ready to load a new program line If you are loading from a computer you must wait for this prompt before beginning to transmit a new line The gt BDS command is password protected password was set in the VECTORSTAR Editor then it must be given in the gt BDS command Typing in these examples will erase the user program in
273. gram Format MCI lt Position gt Traverse End VECTORSTAR MI MOTOR MRD NORM APPENDIX G SOFTWARE COMMANDS Example MCI 100000 500 5000 MCI 3000 10 MCI 56000 MCI 8000 0 LAST SECTION Incrementally move the specified distance at the specified speed If the speed is not specified it is assumed to be VDEFAULT Allowed from the interactive mode and the user program Format MI Position Velocity Example MI 10000 1000 MOVE AT 1000 MI 1000 MOVE BACK 1000 Display the present motor drive combination This command is used to determine the motor for which your VECTORSTAR was configured when it was shipped This command is not normally used by the customer Format MOTOR Make an absolute move so that the output of the Resolver to Digital converter output PRD will equal the specified value A direction option indicates whether the motion should be clockwise CW counterclockwise CCW or whichever way is shortest no option specified Allowed from the interactive mode and the user program Format lt R D Position gt Velocity Option Where R D Position is greater than 0 and less than the resolution of the Resolver to Digital R D converter For the standard 12 bit resolution of R D converter the upper limit is 4095 Option is either CCW or CW Example MRD 3200 100 MOVE CCW 100 RPM MRD 0 50 GO BEST WAY AT 50 RPM Normalize the Pos
274. h PS that you did with P These results are identical except that the VECTORSTAR status is appended onto the line 136 VECTORSTAR Table 10 3 Printing VECTORSTAR Status OFF VECTORSTAR IS OFF READY VECTORSTAR is ready but REMOTE if OFF ACTIVE VECTORSTAR is active but no motion FAULT VECTORSTAR has a fault condition JOG VECTORSTAR is jogging PROFILE VECTORSTAR is executing profile GEAR VECTORSTAR is in gear mode 10 6 2 REFRESH R amp RS Commands The REFRESH commands R and RS are identical to P and PS except that R and RS send only a carriage return The P and PS commands print lines that end with linefeed and carriage return pairs R and RS commands display lines that can be overwritten The following example demonstrates how the REFRESH commands work Type in this example from the Editor 7 RS VELOCITY FEEDBACK VFB GOTO 7 Now exit the Editor and type RUN 7 Rotate the motor shaft by hand so that the velocity feedback changes Press the escape key and enter the Break command to break program execution Notice that the velocity is continuously updated but the line appears to be stationary A similar program with the P or PS commands would cause the lines to scroll to the top of the screen 10 6 3 INPUT So far printing information to the operator has been discussed This section will discuss how to prompt the operator for information using the INPUT comm
275. h are in position units You can program either at any time If the position feedback PFB is greater than or equal to PTRIPI then the TRIPI switch will be on If PFB is less than PTRIPI then TRIP1 will be off Similarly if PFB is greater than or equal to PTRIP2 then TRIP2 will be on otherwise TRIP2 will be off Trip points are not limits in the sense that they do not inhibit motion Trip points convert position feedback to an on or off signal Trip points are particularly useful with alarms and the HOLD command both of which are presented in Chapter 9 User Programs Position trip points require a lot of calculations Asa result they slow the execution of the user program by about 4 If you are not using trip points you can disable them by typing TRIP OFF When the VECTORSTAR is powered up TRIP and trip points are remembered 8 8 3 Profiles When a positioner commands the motor to move from one point to another it must control acceleration deceleration and traverse speed The velocity of the motion versus time is called the profile Simple profiles begin and end at zero speed and have three segments acceleration traverse and deceleration You must specify ACC the acceleration rate and DEC the deceleration rate before commanding the move The traverse speed and the distance to move are specified in the move command itself The graph in Figure 8 2 shows a simple profile The move begins at position 0
276. he PA The PA Power Supply module may be mounted on either side ofthe VECTORSTAR However a 20 millimeter 0 8 inch space is required between units Some units have resistors that dissipate the energy returned to the PA during regenerative braking These are referred to as regen resistors Some applications require externally mounted regen resistors while others may require none at all To determine if your PA has internal regen resistors check its model number REGEN RESISTORS GET HOT If your PA has internal regen resistors allow sufficient clear CAUTION ance above the PA Refer to Figures B 1 B 8 in Appendix B for more informa NOTE tion concerning mounting VECTORSTAR Refer to appropriate outline and dimension drawings in Appendix B for more information Figure B 10 Figure B 9 VECTORSTAR 24 and 28 Amp Unit PA 50 75 and 85 Amp Unit 2 5 3 Mounting the External Regen Resistor External mounting of regen resistors is an option on PA units To determine if your unit uses external regen resistors check its model number Also the model number indicates the standard resistor value These resistors should be enclosed to reduce shock hazard Regen resistors get hot They are a burn hazard and they are a fire hazard They can produce enough heat to melt insulation Enclose these resistors The enclosure must provide ventilation and withstand high tempera tures Do not mount the resistors underneath the VE
277. he PWM control dead time circuits and six 1solated power drivers that control the IGBT gates The isolated gate drives each have their own power supplies and isolated inputs to insulate the power section from the control section This card provides overcurrent overvolts undervolts and over temperature protec tion circuitry for the drive Remote enable and motor brake sensing is provided as a means of interface to customer processes that require these functions The Gate Drive card has been designed to accept drive signals from an external control systems and provides the correct gating signals to the power devices Current sensing 1s done by externally mounted LEM modules drives regardless of rating use the same Motion Link variables scheme and TL functions so it is easy for the user to interface the drives to specific processes and machine tools Since cards are common under standing of these systems 15 easier and parts inventory is reduced Internal wiring for the Integral Power Supply units 1s identical Since this 15 a fully programmable system no additional or option cards are needed to provide other functions 170 VECTORSTAR 12 4 INSTRUCTION FOR THE LINE REGENERATION UNIT 12 4 1 General Description The Line Regeneration Unit is a regulated three phase AC DC power supply Its functions are line regeneration and power factor correction The main application is for servo drives The unit is actually a
278. he profile must either continue along the original profile or the endpoint must be extended For example the program section begin ning at label 25 could be re written so that it watched a position trip point X1 2000 25 GT X1 2000 RET DONOT REDUCE SPEED IF gt SETPOINT REST OF 25 PROGRAM THE SAME 2 VECTORSTAR What value to use for the setpoint varies from one application to another These values must be set by experience On many applications the input will not request a speed reduction near an endpoint so that this may not be a problem 8 8 12 External Inputs External inputs are normally from a master motor or analog input As a standard these inputs are in digital encoder format Examples of master motors include the encoder like output from another VECTORSTAR output from an actual encoder or a customer synthesized encoder signal The external input can control motion in the two VECTORSTAR Master Slave modes electronic gearbox and profile regulation The VECTORSTAR acting as the slave accepts commands from these external sources The external input can also come from a feedback encoder which is mounted to the motor this encoder is occasionally used to improve the accuracy of the VECTORSTAR External inputs are connected to Channel A and B inputs of the Encoder Equivalent Connector Your program has direct access to the external input through the variables VEXT an
279. he switch is in the specified state when execu tion is enabled the alarm will be fired Otherwise the alarm 1s edge sensitive Specifying ON 18 actually specifying the positive edge Format lt Label gt Alarm Label gt Switch lt On Off gt Example 55 BACKGROUND A4 I1 VECTORSTAR CONTINUE DUMP APPENDIX G SOFTWARE COMMANDS Quick If Conditionally executes one instruction if the condition 1s true and another instruc tion if the condition is false Allowed from the interactive and monitor modes and the user program Format lt Condition gt Instruction Instruction Example PFB GT 100 P PFB X1 EQ 1 P X12 1 P X1 lt gt 1 2X1 X2 NE 4 5 5 B LIMIT EQ ON P LIMIT IS OFF Condition is the same as lt gt Logical lt gt Instruction is any instruction except TIL Break program execution Allowed from the user program or the monitor mode Format B Continue motion at the present speed Turn REG and GEAR off Optionally you can specify the number of milliseconds up to 1 second that you want the present speed averaged over If this time is not specified the speed is averaged over 1 millisecond Format CONTINUE CONTINUE lt time gt Example CONTINUE 100 AVERAGE SPEED FOR 1 SEC Display all the variables and the user program on the terminal or display the version lowed from interactive
280. hen the I1 input is on the Spindle Axis mode is selected and when the I1 input is off the Open Loop mode is selected When the Spindle Axis mode is selected the VECTORSTAR turns on the I 7 output named the Spindle Axis Active output The Spindle Axis mode is used by the controller to control the angular position of the motor as well as the speed of the motor Positional feedback 15 provided to the controller The command voltage 15 scaled to a given speed by the programmable variables GEARI and GEARO The RPMmax for the Open Loop mode is 10000 RPM The Spindle Axis mode can have a RPMmax of 2000 or less The controller and VECTORSTAR must be matched such that the maximum command voltage from controller to VECTORSTAR represents the same maximum RPM The designed input channel for C Axis is I1 Variables used GEARIO GEARI For Open Loop Mode The spindle command speed is scaled by GEARIO and GEAROO GEAROO For Open Loop Mode GEARO GEARIC For Spindle Axis Mode The Axis speed GEARI 15 scaled by GEARIC and GEAROC GEAROC For Open Loop Mode GEARO The ranges of the above four variables are the same as GEARI 32768 to 32767 and GEARO 0 to 32767 VXDENC VXDEN for Spindle Axis Mode VXNUMC VXNUM for Spindle Axis Mode VXDENO VXDEN for Open Loop Mode VXDENC and VXNUMC are used to convert the internal value to RPM for the specific gear ratio so Zero Speed and At Speed work in both modes CHA
281. iables Where Number is the number of intervals over which the variables will be recorded and Time is the time in milliseconds of each interval Note Number lt 1000 for 1 Variable Number lt 500 for 2 Variables Number lt 333 for 3 Variables Number lt 250 for 4 Variables Examples RECORD 1000 1 VFB RECORD VFB ONCEIMSEC FOR 31 SECOND RECORD 500 10 VCMD VFB RECORD VCMD AND VFB 10 MSEC FOR 5 0 SECOND RECORD 100 1000 VCMD VFB PCMD RECORD VCMD VFB AND PCMD ONCEISECOND FOR 100 SECONDS Return from a subroutine Allowed only from the user program Format RET Refresh screen with status This command is identical to the R command except status of the drive is displayed at the end of the printed line See P for format and examples Allowed from the interactive and monitor modes and the user program Run a program starting at the specified label Allowed from the interactive mode If no label 18 specified run multi tasking 231 APPENDIX SOFTWARE COMMANDS VECTORSTAR TIL TUNE 232 Format RUN lt Label gt RUN RUN MULTI TASKING Example RUN 4 RUN X1 RUN Stop motion using a deceleration of AMAX Allowed from the interactive and monitor modes and the user program Format S Continuously execute an optional instruction until condition is true If no instruction is specified then delay program execution until the condition is true I
282. ies to switches 8 3 5 Printing Variables variables can be displayed To display a variable on the terminal you should use P the PRINT command or if only one variable is to be printed can be omitted For example type P ILIM or ILIM Since the standard setting of ILIM on most systems is 100 the terminal should display 100 Suppose you want to display PFB the position feedback Type P PFB The position feedback should now be displayed Assum ing the motor and resolver are connected to the VECTORSTAR VECTORSTAR rotate the motor shaft about half a revolution Now print PFB as above and notice that it has changed to reflect the new position 8 3 6 Changing a Variable Variables are changed with assignment instructions An assignment instruction begins with the name of the particular variable followed by and ending with the new value One or more spaces can be substituted for the The following examples assign or at least attempt to assign ILIM a new value ILIM 10 CORRECT ASSIGN A NEW VALUE TO ILIM ILIM 10 CORRECT THE IS OPTIONAL ILIM10 INCORRECT THERE MUST BE A SPACE OR A few systems are set up with ILIM less than 100 If your terminal displays a number less than 100 write it down for reference later in this chapter NOTE The following examples will change ILIM and it must be reset t
283. ifferent prompt in the Trace and Single Step modes as the following table shows Table 11 1 Multi Tasking Debug Prompts TASK LEVEL SINGLE STEP TRACE PROMPT PROMPT PROMPT Alarm A Alarm B Alarm C Variable Input Main Program Background 11 4 REMOVING CODE If you cannot find the bug in your program with single step or trace then you must begin removing sections of your code that you do not think are causing the problem The procedure is to remove sections of your program a CHAPTER 11 DEBUGGING few lines at a time Of course save the original program on your computer for later use Remove lines that you do not think are involved in the problem Removing lines that you suspect are causing the problem can provide false leads for example the problem may be interaction between a section you removed which was operating properly and another unsuspected section of your program that was the actual source of the prob lem Your false suspicions can be incorrectly con firmed The best situation is when you can make a short 20 line program demonstrate the problem After this it is usually easy to determine the problem If you get to the point where you cannot figure out your problem call Kollmorgen we will be happy to help you However in order to make efficient use of your time and ours you must trim down your program to a few lines that are not working It is very difficult for even a skilled person to
284. ified state You can use any switch except and 511 550 XS1 XS10 are allowed is an idling command if you are using multi tasking suspends the task but lets other tasks proceed Allowed only from the user program Format Switch lt ON OFF gt Example H XS1 ON OFF Conditionally execute a block of instructions Allowed from the user program Format IF lt gt Logical lt Expr gt Example IF PFB GT 100 FOLLOW WITH ELSE ETC IF X1 X2 NE X4l X5 5 zas FOLLOW WITH ELSE ETC Prompt the operator for an input variable If limits are specified then make sure operator stays within them If they are not specified then use the limits of the variable being prompted for W 18 an idling command that is if you are using multi tasking INPUT suspends the task until the operator presses the enter key but lets other tasks proceed Allowed only from the user program Format INPUT lt Text gt Variable decimal Min Where Variable is any valid programmable variable You can optionally specify maximum and minimum limits if you include one you must include the other Min is the minimum input allowed and Max is the maximum input allowed If you specify decimal the input received from the operator will be multiplied by 10 decimalj The VECTORSTAR does not use floating point math internally The input command allows you to receive f
285. ill generate a USER PROGRAM CORRUPT error and the program cannot be modified or run If this happens use the NEW command to clear the user program and reset the corrupt error DO NOT TYPE IN THIS EXAMPLE NEW The NEW command also clears the editor password The gt BDS command discussed in Section 10 10 will also reset the program so that it is no longer corrupt although it will not clear the password 10 4 BUILDING A PROGRAM Programs are sequences of commands most of which can also be executed directly from the keyboard A program stores the sequences of these normal com mands Examples of these commands are MI MA and P Print However in order for a program to run properly other commands called program control commands are required Examples of these commands are GOTO and GOSUB 10 4 1 Basic Commands 10 4 1 1 Labels Labels are used to mark places in the program where execution begins or continues There are two kinds of labels general purpose labels and dedicated labels General purpose labels are numbers from 0 to 500 followed by a dollar sign You can execute a program that begins at a general purpose label with the RUN command You can jump to a label from within your program with the GOTO and GOSUB commands CHAPTER 10 USER PROGRAMS RUN GOTO and GOSUB are described later in this chapter Dedicated labels each have specific functions Dedi cated labels include alarms auto
286. in Chapter 1 Wiring the VECTORSTAR to a motor for which it is not config ured can cause the system to become unstable Verify that you are connecting the correct motor WARNING Verify that motor wiring is correct Itis very important that you wire the motor properly Brushless motors are not like induction motors You cannot simply inter change two phases to reverse the direction of rotation You MUST connect Pin A of the motor connector to Ma ofthe VECTORSTAR power connector Pin B ofthe motor connector to Mb and Pin C of the motor connec tor to Mc Follow this procedure to check motor wiring 1 Turn offthe main AC Line Leave Control Power on 2 Remove all loads from the motor The motor must be able to rotate freely for this test VECTORSTAR 3 Rotate the motor by hand until PRD is in the zero position as shown in Table 2 10 Note that the position must be less than the small number OR greater than the large number To display PRD type P PRD Table 2 10 PRD Range for Zero Position PRD R D Resolution Greater Than 4 Turnon close contacts of LIMIT MOTION and REMOTE 5 on Control Power only 6 Putthe VECTORSTAR into the zeroing mode Note that zero mode is not used in induction V Series motors Type ZERO ON Zero mode is not used in induction V Series motors NOTE 7 Turnon AC Line 8 Enablethe VECTORSTAR Type EN The
287. in Figure 4 5 shows how to manually tune an integrating velocity loop This procedure sets KV and KVI First you should use the TUNE command to set KV and KVI close to optimum values Apply DC bus voltage to the VECTORSTAR Follow the instructions shown the flow chart The motor should start and stop every second Press the escape key to enter the Monitor mode where you can change tuning constants The tach should be on the oscilloscope showing the motor performance As the drawing notes you should increase KV for increased stability and increase KVI to make the system more responsive You need to make several decisions Is the unit underdamped Is the system response too fast Is the system ringing Is there a resonance present Then take the action listed in Figure 4 5 There is a close relationship between the response of the system and the variable KVI Response is often mea sured by the system bandwidth Bandwidth is the frequency with which the system response falls to 70 of the nominal response For example 1f your velocity command was a sine wave with peaks of 100 RPM the bandwidth would be the frequency that the response fell to a sine wave with peaks of 70 RPM The relationship between velocity loop bandwidth and KVI is shown in Table 4 1 Table 4 1 Velocity Loop Bandwidth vs VELOCITY LOOP KVI BANDWIDTH CHAPTER 4 OPERATION If you are using a proportional velocity loop PROP is on then adjust KPRO
288. ing fan 230 volts for an AC fan and 24 28 volt DC source for a DC fan 2 6 4 9 Connect Logic of PA28 50 70 85 to C4 of the drive control logic power 4 wires 2 6 3 3 Connect an RS232 cable to a PC serial port see Figure B 4 2 6 4 8 Place two jumpers between pins 11 and 12 15 and 16 of C7 which is on the top of the drive to close MOTION and LIMIT For temporary setup only Close REMOTE by connecting pin 9 to 5 and pin 6 to 15 of C2 on the drive For temporary setup only Apply control logic and main power to the system The BUS CPU and SYSOK lights should be on Run Motion Link from the PC Gif you have a Windows version use Terminal mode press ENTER or Esc to establish communication 33 CHAPTER 3 QUICK START 15 Turn motor by hand read rotor position by issuing P PRD repeatedly which shows the resolver feedback If you have a 12 bit resolution setting for R D you should see the count change from 0 to 4095 when the rotor turns one revolution 16 the drive should be energized and you should hear a slight 10kHz sound from the motor 17 J 10 the motor will run at 10 RPM You can check it by typing P VFB to read the speed 18 J 1000 to make the motor run at 1000 RPM 19 J 0 and the motor will stop 20 K to disable the drive after motor stand still If you receive an error code check Appen
289. ion from the power section and the six independent gate drive circuits Overcurrent protec tion 15 also part of this card 3 TheIGBT Power Stage which boosts the control inputs to the necessary levels to drive an induction or PM motor IGBT power ratings are determined by the KW rating of the VSA drive Hall effect current sensors provide a continuous monitor of motor phase currents 169 CHAPTER 12 POWER 12 2 1 Logic and main DC bus voltages are provided by the external series power supply on all VSA drives 12 3 VSL P SERIES DRIVES The VSL series drives are composed of six distinct sections 1 The Power supply and LEM A 95125 contains the LEM motor current sensors and the logic power supply This card can be configured for 230 VAC or 460 VAC operation and provides transformer isolation from the AC line The outputs are 15 VDC 5 VDC and 14 VDC 2 The Interface card A 95140 provides connection from the MC3 control card described above and the Gate Drive card A 95117 This card also receives the inputs from the resolver and sends these signals to the MC3 card for conversion to a digital word A customer output section provides relay isolation for process interface Protection circuitry and monitor functions interface to the digital section on the MC3 card through the Interface card 3 Gate Drive Card A 95117 contains the current loops triangle wave generator for t
290. ions and unacceptable when the motor 18 in other positions Reducing the bandwidth eliminates the problem If the system performance is poor because of changing inertia you can make the following corrections Correct the system mechanics so that inertia 15 constant Detune reduce the bandwidth of the system If the times when your system will have excessively changing inertia are predictable you can write your program to detune your system in these regions 4 9 4 Resonance Resonance is a high frequency 500 Hz where the system mechanics oscillate Normally systems with resonance will be very stable when you tune with lower target bandwidths As you increase the target bandwidth you will begin to hear a fairly pure high pitch If you want to decrease resonance use shorter larger diameter driving shafts Often the low pass filter can help you raise the bandwidth 20 or 30 but this can bea difficult trial and error process you slowly lower the low pass filter frequency LPFHZ and attempt to raise the target bandwidth for tuning When your system has a resonance it will have the following characteristics The system will make a clear high pitch 7500 Hz Do not confuse this problem with compliance which has a low pitch 45 CHAPTER 4 OPERATION If the system performance is poor because of changing inertia you can make the following corrections Enable the low pass filter LPF and reduce LPFHZ if ne
291. is applied the brake 15 active If you set STATMODE to 0 you can use STATUS to control the brake Then when 73 CHAPTER 8 GENERAL PROGRAMMING HARDWARE FAULTS OVER TEMPERATURE BUS VOLTAGE 12 VOLT SUPPLY OVER CURRENT FEEDBACK LOSS HARDWARE WATCHDOG COMPENSATION BOARD SOFTWARE FAULTS FOLLOWING ERROR OVERTRAVEL GEARBOX OVERFLOW INTERNAL ERRORS MOTOR PARAMETERS OUT OF RANGE FIRMWARE FAULTS UP FAIL ROM CHECKSUM SOFTWARE WDOG 5 VOLT SUPPLY FAULT SOFTWARE SWITCH FAULT LED ACTIVE SOFTWARE READY SWITCH DRIVE SOFTWARE SWITCH VECTORSTAR VECTORSTAR ENABLE FAULT LOGIC DIAGRAM 74 COMMAND E COMMAND HARDWARE 9 HALT MICROPROCESSOR WATCHDOG t C2 PIN 47 L C2 PIN 16 REMOTE INPUT STATUS TRAN SOFTWARE LED C2 PIN9 OPTICAL SWITCH C2 PIN 6 ISOLATION STATUS OUTPUT OPTIONAL 6 C8 PIN 35 STATMODE SOFTWARE SWITCH loce val Figure 8 1 VECTORSTAR EnablelFault Logic Diagram VECTORSTAR the VECTORSTAR is disabled or powered down the brake will be active 8 6 8 Output Relay The relay Connector C2 Pins 16 and 17 represents the state of the hardware watchdog The hardware watchdog makes a system more reliable because the watchdog is independent of the microprocessor If the processor 15 not working the watchdog will usually detect it tho
292. is the opposite of RUN it stops program execution and normally returns to the interac tive state The Break command does not stop motion Profile commands are allowed to continue until they are complete If you want to break the program and stop motion precede the Break command with the Stop S command 10 4 1 4 GOTO The GOTO command is used within the program to jump to a label Before the following example of GOTO be done another function of the Print P command should be explained From the terminal type 127 CHAPTER 10 USER PROGRAMS P THIS PRINTS TEXT JUST LIKE I TYPED IT IN and the result will be THIS PRINTS TEXT JUST LIKE I TYPED IT IN When using the Print command characters between double quotes are printed back without modification Returning to the GOTO command use the Editor Insert command to enter the following short program 2 P AT LABEL 2 GOTO 3 P NEVER GOT HERE 3 P AT LABEL 3 B Exit the Editor and type RUN 2 The result should be AT LABEL 2 AT LABEL 3 Avoid the use of GOTO commands in favor of Block IF Quick IF and GOSUB commands This practice makes programs more readable and easier to modify 10 4 1 5 GOSUB and RET The third command that uses labels is GOSUB The GOSUB command goes to a subroutine at the specified label For example GOSUB 66 begins a subroutine at label 66 The RET command returns
293. it is remembered through powering down Enable disable loading of user application code from PROM 9 4 DEDICATED VARIABLES The following 16 user variables are for the application software use only These variables are similar to X variables except that they have dedicated names VZR Zero speed in RPM VUP Up to speed in RPM VUPH Up to speed hysteresis in percentage GEARIC GEARI Value for C axis range of 32768 to 32767 GEAROC Value for ratio for C axis range of 0 to 32767 Delay timer for motor over temperature long integer DTIMER Delay timer for drive over tempera ture long integer GEARIO GEARI value for open mode range of 32768 to 32767 GEARO value for open mode range of 0 to 32767 2 Orient positions in Unit range of 0 to 4095 VORNT Orient velocity in RPM long integer MORNT Orient mode range of 1 5 VXNUMO VXNUM value for open mode long integer VXDENO VXDEN value for open mode long integer VXNUMC VXNUM value for C axis mode long integer VXDEN value for C axis mode long integer VXDENC 9 5 SPINDLE FUNCTIONS 9 5 1 Power Meter Output VECTORSTAR generates the output which is propor tional to the torque This signal can be used to drive a power meter with 6 67 volts representing 10096 power VECTORSTAR 9 5 2 General Purpose Input Output Pin Assignments The VECTORSTAR has 16 inputs and 8 outputs of General Purpose
294. ith the MOTION input Emergency Stop should be connected to a contactor that removes power from the system This CHAPTER 8 GENERAL PROGRAMMING is because an emergency stop which is for safety should not depend on VECTORSTAR functions to operate properly Do not use MOTION or any other VECTORSTAR input for Emer gency Stop When Emergency Stop is activated it should directly remove power from the system WARNING 8 8 1 4 STOP S Command Any motion can be stopped using S the STOP com mand S has no parameters S decelerates the motor at AMAX and terminates all motion commands The S command does not disable the VECTORSTAR Normally the STOP command should only be given from the terminal or from the program in response to an error condition A better method for stopping motion from the program under normal circumstances is 70 JOG TO 0 SPEED STOP MOTION DEC NOT AMAX The J 0 command also stops motion from any mode much like the STOP command Unlike S 7 0 decelerates at the rate specified by DEC The S command should not be used as a part of normal pro gram operation Use J 0 At any time when motion is commanded if the MO TION input turns off an error is generated and all motion is stopped as if the STOP command were given Also any errors with a severity of 2 or 3 will stop motion in a straight line deceleration at a rate of AMAX Appendix C lists all
295. itial value is listed on the Test and Limits TL sheet which should be enclosed with your system Normally to IMAX How ever you may want to reduce it for protection The motor can normally run under no load with 15 25 current so you can set ILIM as low as 15 or 25 during preliminary operation Current units numerator Initially set to 4095 for percent Low speed graininess compensation Almost always set to 200 See discus sion in Chapter 4 where a procedure for fine tuning this variable is given VECTORSTAR KF KP KPROP KV KVI LPF LPFHZ Tuning gain for velocity feed forward Set to 0 for preliminary operation Tuning gain for position loop Leave at initial setting for preliminary operation The initial value 1s listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Tuning gain for proportional velocity loop Leave at initial setting for prelimi nary operation The initial value is listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Tuning gain 1 for integrating velocity loop when PDF 1 Leave at initial setting for preliminary operation The initial value 1s listed on the Test and Limits TL sheet which should be enclosed with your system Use TUNE command to change if necessary Tuning gain 2 for integrating velocity loop Leave at
296. ition command and position feedback to the specified position Allowed from the interactive mode and the user program when there is no commanded motion Format NORM lt Position gt 229 APPENDIX SOFTWARE COMMANDS PS PLAY 230 Example VECTORSTAR NORM 1000 Print the variables specified with optional formats on a new line Allowed from the interactive and monitor modes and the user program Format lt gt format lt Text gt Where format is the print format specifying field width and Hex output The ellipsis indicates that the P can be followed by up to 15 different expressions and text strings Format can be Blank nn m nn m p Examples Binary Hex ON or OFF ASCII Character Decimal Integer Floating Point Output where nn 15 the total number of digits m 1s the number of digits after the decimal point Same as nn m except only print p digits after the decimal point p must be less than m P PFB VFB IMON P PFB 4 P IN H P IN 5H P 123456 4 123456 4 2 P VECTORSTAR P PRINT 3 FEEDBACK VARS PRINT PFB IN 4 CHARS PRINT INPUT IN HEX PRINT INPUT 5 HEX CHARS PRINT 12 3456 PRINT 12 34 PRINT VECTORSTAR ON THE SCREEN PRINT PFB WITH TEXT Print with status This is identical to the P command except status of the VECTORSTAR is displayed on the end of the printed line See
297. itor is a Common referenced signal scaled for full peak current 5 volts This output has a 3 01k Ohm resistor in series I Monitor is always positive Common Pins 12 14 15 Logic Power Supply Common is provided on several pins since it is used in several places Do not connect shields to Common Shield Pins3 13 The shield pins are connected directly to the VECTORSTAR frame You should connect shields from cables to the shield pins CHAPTER 2 INSTALLATION Relay Pins 16 17 These two pins are connected to a set of normally open relay contacts The contacts are open on power up and closed following the power up self tests and autobauding The relay 15 controlled by the watchdog timer Ifthe contacts open once the VECTORSTAR is running then there is a serious fault and you cannot depend on the microprocessor to operate properly Always wire all VECTORSTAR relays to disconnect all power in the event of the relay contacts opening These contacts are rated for a maximum current of 1 Amp anda maximum voltage of 115 volts AC or DC The maximum switched power is 30 Watts DC or 60 volt amps AC CYCLE CYCLERETURN Pins 8 7 CYCLE is on Pin 8 CYCLE RETURN is on Pin 7 CYCLE is normally used to STARt a cycle of a user program it can also be used as a general purpose input CYCLE is optically isolated CYCLE should be pulled up to between 12 and 30 volts with reference to CYCLE RETURN not Common to turn on or activate the CYCLE input
298. k 2 You cannot execute a label 3 The variable input must be self contained it cannot mix with other tasks It must be terminated with an END KILL K or BREAK B command Again most other commands are allowed for the variable input task including motion commands and Block IFs If the variable input task is present the execution time of your program increases by about 1 10 8 8 Main Program Level Task Level 5 Most of the time your program will run at task level 5 the program examples given earlier in this chapter executed at task level 5 Notice the discussion on multi tasking that all general purpose labels 0 500 and many dedicated labels POWER UP AUTOS MANUALS and ERRORS share task level 5 The routines that follow these labels share one task level and cannot run concurrently For example you cannot run AUTOS and MANUALS concurrently In other words only one task level 5 routine can run at a time Alarms and the variable input task are higher priority than task level 5 For example if an alarm fires while your program is running a task that begins at a general purpose label task level 5 task level 5 will be sus pended until the alarm is complete The background program BACKGROUNDS runs at the lowest level Generally alarms respond to conditions that are more urgent than most other sections of the program Simi larly background is for tasks that are not critical such as printing Multi ta
299. kground task 15 the lowest priority Normally the background task is used for non critical tasks such as refreshing the display and checking low priority inputs The background task runs continuously as long as no other task 1s active The background task begins with BACKGROUNDS You can then follow that label with various statements usually printing commands For example enter the following program BACKGROUND P EXECUTING BACKGROUND D 500 DWELL END Now you can enable multitasking by typing RUN Notice that you did not need to specify a label If you type RUN without a label you will enable multi tasking without executing a specific label When you are done with this example press X control X to break the program and return to the Interactive mode 10 8 9 1 Restrictions of Background Like alarms background has many restrictions 1 You cannot execute GOTO GOSUB or RET commands from background 2 Youcannot execute a label 3 The background task must be self contained it cannot mix with other tasks It must be terminated with an END Kill K or Break B command Again most other commands are allowed for the background task including Block IFs If the background task 1s present the execution time of your program increases by about 196 146 VECTORSTAR 10 9 UNITS The VECTORSTAR provides user units so that both you and the machine operator can work in units that
300. l distaste for writing flowcharts Many view flowcharts as something between a crutch and unnecessary work Most experienced program mers have a different view The most important point about flowcharts 15 that they are virtually required 1f you need help over the telephone Always write flowcharts for programs that are longer than 20 to 30 lines 5 COMMENT YOUR PROGRAM Always comment your programs Comments help explain your program to other people Keep in mind that others may need to modify your program in the future Comments also help you remember why you chose certain ways to do things 6 AVOID SPAGHETTI CODE A program with too much branching is often called spaghetti code because of the look of the flowcharts Avoid a lot of branching especially branching up towards the top of your program logic in programs that branch down is more intuitive and thus less prone to errors If you do branch up branch to the top of a major section In most programs there should only be one or two places that you branch up to Feel free to use small loops 2 or 3 lines which of course repeatedly branch to the top of the loop Avoid branching between sections he AVOID USER SWITCHES THAT MODIFY BLOCKS OF CODE Switches that modify functions can be difficult to understand This is commonly done when programmers attempt to use one block of code for two similar functions If possible write two different blocks of code rather than tr
301. l be controlling The MOTOR command changes these variables as necessary for the motor F 2 STANDARD VARIABLES Table F 1 Standard Variables VARIABLE DESCRIPTION PROGRAM UNITS PROGRAM LIMITS CONDITION Choose gear input ABAUD Autobaud On None C ACTIVE ADDR Multidrop Address Ame 0 48 57 65 90 amps DheAms 1 C None ADEN ACC Units Denominator None BAUD A2 HAMAX CAP 300 19200 ANUM ___ ACC Units Numerator __ Always None dmg AMAX Acc Dec Maximum Disabled CAP Enable C e e e e e e A N N N N N N CYCLE start yet Dec ____ Deveteion ate Aways ACC O AMAX CC on on on CAPDIR on ACC Table F 2 for description of long and short 215 APPENDIX VARIABLE QUICK REFERENCE VARIABLE DESCRIPTION UNITS PROGRAM LIMITS CONDITION dE On if CW is Positive EXTLOOP On for Encoder feedback Disabled PROGRAM VECTORSTAR FAULT Always FAULT OnforBDSS Fault Amas FOLD Monitor Foldback Mode GATE Monitor GATE Input noe ______ GATEMODE Enable Gate Mode 0 1 IDEN IFOLD Monitor Foldback ILIM Set Current Limit LPF V 216 Always Always Always Never Never Factory Always Never Always Factory Never Never Never Always Always Always Always Always Always Always Never As Needed Always r Short gt
302. l cable For RS 485 you should install jumpers across Pins 3 4 and 7 8 on J1 on the front of the VECTORSTAR at the end of the communication cable If the device you are using to commu NOTE nicate with the VECTORSTAR is at one end of the line you should terminate the line at that end with a 120 ohm resistor DISTANCE RS 232 generally works well up to 50 feet using standard cable Special low capacitance cable can extend this range up to 500 feet although the baud rate may need to be reduced These cables are available from many companies including Black Box Pittsburgh PA RS 485 can be used up to 4000 feet Be forewarned however that using very long cables may be more difficult than just making the connections Special attention must be paid to AC loading transmission line effects noise pickup and common mode voltages It would be wise to have a person who is knowledgeable in these matters to review the cable design beforehand Again baud rates may need to be reduced as the length increases and low capacitance cables may be required You can obtain a copy of the specification for RS 232 or RS 485 by contacting Electronic Industries Association Engineering Department 2001 Eye Street N W Washington D C 20006 CONNECTING TO A TERMINAL Connect the pins on the DE 9S connector that came with your VECTORSTAR as listed in Table 2 4 which assumes that your terminal has an RS 232 serial port which is configured
303. l inputs and a built in power meter driver circuit This circuit drives an external analog meter that is calibrated in percentage of power at the motor shaft Full scale is 10 VDC which corre sponds to 15096 power All 16 inputs and 8 outputs from this EXTI I O card can be used to receive and send logical signals to the higher level controllers such as CNCs These I O lines can be defined by the user to implement all spindle or other functions with a higher controller As an option a set of user programs can be embedded in the VECTORSTAR software which can perform spindle and customized functions through the I O lines after power up A software switch is used to disable the embedded programs so that user programs can be executed All VECTORSTAR drives accept the standard Motion Link communications package which can be accessed via an IBM type PC or the Kollmorgen Data Entry Panel The VECTORSTAR drive can also be used as a brushless motor control if the VECTORSTAR firmware is installed and the correct compensation is entered into the drive An externally mounted Regen Resistor is part of this system The power meter connects to the 50 pin connector on EXT1 card A calibration proce dure for the load meter is available from Kollmorgen the drives are calibrated prior to shipping CHAPTER 1 SYSTEM DESCRIPTION VECTORSTAR 24 VOLT DC CUSTOMER SUPPLIED C2 PIN 5 ALTERNATE POWER SOURCE SSS FOR REMOTE HOME
304. larm B are fired at the same time Alarm will run until it is complete then Alarm B will run until it is complete 10 8 1 Multi Tasking and Autobauding If you set the VECTORSTAR to autobaud multi tasking will not be enabled until communications have been established This means that the VECTORSTAR will not operate if a terminal or computer 15 not present Therefore you normally will want to disable autobauding by turning ABAUD off Turn ABAUD off if you plan to use multi tasking The VECTORSTAR will remember that ABAUD is off through power up NOTE 10 8 2 MULTI If you want to disable Alarm C the variable input routine and background type MULTI OFF For example if you have a time critical section of code you may turn MULTI off at the beginning of the section and then back on at the end of the section CHAPTER 10 USER PROGRAMS 10 8 3 END Command Tasks are normally terminated with the END command END signifies the end of the task whereas Break B implies that all tasks stop executing For example if you end an alarm with the Break command the entire program stops running and the VECTORSTAR returns to the Interactive mode However if you end an alarm with the END command the alarm stops but the other tasks continue running 10 8 4 Enabling and Disabling Multi tasking Multi tasking is always enabled when a program 18 running For example if you have a program that starts at 55
305. lddns SIHL 40 5 aaridans i3WO1SnO N s Adans po san 67 TWNOIS SLIOA S YALAW 167 SALON AlddNs 21901 Figure B 7 C8 Optional I O 192 VECTORSTAR APPENDIX B DRAWINGS NOTES TO ACCOMPANY FIGURES B 1 B 7 ALL WIRES TO BE COPPER WITH MIN TEMP RATING OF 60 C 1 WARNING The motor thermostat automatically resets when the motor cools The customer is responsible for latching this signal to inhibit operation after a motor thermostat fault connect thermostat using twisted pair wire 2 CAUTION The fault contacts rated 115 1 AMP must be wired in series with the overload relay as shown on Figure B 1 On the 50 75 and 85 AMP PA this contact closes on application of control power and after DC bus is active 3 CAUTION Resistor is connected to high voltage ensure sufficient electrical clearance mounting Resistor may become very hot during operation Do not mount near materials that are flammable or damaged by heat Ventilation may be required See wiring drawing for specific regen resistor kit Each kit has different series parallel resistor connection to obtain specific resistance and power rating 4 Wire sizes breakers and fuses for PA PA 50 has a maximum main power input current of 50 AMPS RMS PA 75 has a maximum main power input current of 75 AMPS RMS PA 85 h
306. le Axis Active 1 following the I O name indicates positive logic For example when 1 is 1 Zero Speed is indicated A 0 following the I O name indicates negative logic For example O5 being 0 indicates over temperature 103 CHAPTER 9 SPINDLE PROGRAMMING input The Pulse Enable input be the dedicated input located on connector C2 pin 9 9 6 3 Software Function Description Zero Speed The feature Zero Speed controls an output signal that indicates the motor is stopped The output is energized when the absolute value of the measured motor speed is ator below the parameter value named VZR in RPM units The measured motor speed is stored in the non programmable variable VAVG This feature is active in all modes of VECTORSTAR operation The Zero Speed output is the General Purpose O1 output Variables used VAVG Non programmable variable updated by VECTORSTAR VZR Defined zero speed upper range by the user in RPM The software reads the speed as zero if VAVG is less than VZR At Speed The feature At Speed controls the GP4 output signal that indicates the motor is rotating within a speedband around the commanded speed The absolute value of the differential between measured speed and command speed is compared to the At Speed parameter named VUP When the absolute value of the differential value is less than VUP the At Speed output energizes After the A
307. loating point input from the operator Example INPUT ENTER NEW SPEED X1 3 5000 5000 INPUT ENTER NEW CURRENT LIMIT ILIM VECTORSTAR JF JT MA APPENDIX G SOFTWARE COMMANDS In the first example if the operator entered 1 234 the VECTORSTAR would store 1234 0 in X1 that is 1 234 is multiplied by 1073 1000 Note that if you specify decimal Max and Min limit the value after the multiplication In the above example Max 5000 limits the operator to 5 000 Jog at a continuous speed Allowed from the interactive mode and the user program Format J Velocity Example J 1000 J X1 Jog but wait until the Position command PCMD crosses the specified position before beginning accel decel Speed must not be zero when executing this instruction Allowed from the interactive mode and the user program Format JF Position lt Velocity gt Example JF 10000 10 JF 100 X1 4000 Jog at a continuous speed but delay beginning accel decel so that the Position command will equal the specified position when the accel decel is complete Allowed from the interactive mode and the user program Format JT Position lt Velocity gt Example JT 610000 100 JT 100 X45 800 Disable the drive and break the program Allowed from interactive and monitor modes and the user program See Drawing C 84732 for more information Format K Move to the speci
308. ly about 2096 to improve performance 4 7 ANALOG INPUT If the drive needs to be configured as an analog input device turn on the GEAR and A2D switches For scaling the input command use variable VSCALE The units are RPM at 10 volts input After VSCALE 15 assigned VXNUM and VXDEN will be changed accordingly to this scale The analog input signal should be within 10 to 10 volts and goes to J10 The top left of J10 is Diff high and second down of left is Diff low For instance if you want 9 75 volts input generating 10000 RPM velocity command you need VSCALE 100000 9 75 10256 The drive will calculate the GEARI GEARO VXNUM and VXDEN If you want 10 volts input generating 2000 RPM velocity command just make VSCALE 2000 The GEARI GEARO VXDEN and VXNUM can be assigned individually any time after VSCALE is as signed but VSCALE will assign all of them 4 8 RECORD AND PLAY The RECORD command allows you to record most VECTORSTAR variables in real time for later playback You can simultaneously record up to four variables You can record any variable except PE REMOTE TMRI TMR2 TMR3 TMR4 VAVG VXAVG or any user switches You can specify the time between points from one millisecond to one minute You can record up to 1000 instances of 1 variable 500 instances of 2 vari ables 333 instances of 3 and 250 instances of 4 vari ables The format of the RECORD command is RECORD lt Number gt Time 1
309. mal overload protection is not provided internal to amplifier and must be provided externally Refer to National Electric Code for proper sizing or overload protection It is recommended that motor wiring be shielded cable Use proper size wire Use copper wire and 60 C or 75 C table from NEC for wire size 193 VECTORSTAR APPENDIX B DRAWINGS S4 0S Vd YSA ONILNNOW H3QO NI SNINIVA33 Alddns Vd JHL OL LX3N YANAN YSA LS3H9IH 31VOO1 2 W31SAS 38 5 3OVdS 3323 WNWININ L 8c SZ 05 GZ 08 Vd Figure 8 VSA 50 75 Mounting Hole Pattern 891 SNIT009 5 TIY N334138 194 VECTORSTAR APPENDIX B DRAWINGS mus 6 53 9 8 35 4X MOUNTING SLOTS 178 MAX 5 80 228 WIDE 7 01 D 101 60 4 000 10 24 302 11 89 264 282 10 39 11 10 CL OUTLINE 50 75 Based 96890 Figure B 9 50 75 Outline and Dimensions 195 VECTORSTAR APPENDIX B DRAWINGS 82 92 6 NOISNAWIG WIZ 3ALLISN3S SNIVLNOO LINN SIHL 0 0 S3OV ld Z 81 11 o
310. maximum frequency of the external input and less than 2 MHz Beyond those limits you can set it to any frequency that is convenient and adjust the commanded motion by changing the speed of the profile 93 CHAPTER 8 GENERAL PROGRAMMING AN NOTE The frequency of the external input should always be less than REGKHZ 8 8 14 2 Profile Regulation and Counting Backwards In general if you use profile regulation the external input should count forward that is VEXT should be positive when VXNUM and VXDEN are positive The profile regulation firmware allows the input to count backwards for up to 30000 counts This is useful for applications such as conveyor belts that generally go forward but can go backward for short distances If the external input counts backwards the Profile Regulation mode works as follows The profile stops no motion 15 commanded during backward counting The backward counting must be limited to 30000 counts Otherwise ERROR 64 15 generated The profile does not continue as soon as forward counting begins The forward counts must com pletely offset the backward counts before the profile will continue At the point where forward counts offset backward counts the profile continues as if the input had never gone backwards Profile Regulation works with standard moves MA MI and MRD Macro moves and all jogs 7 JT and JF 8 8 14 3 Regulation Example A machine has an axis that operates
311. mmand should be received from a computer on a regular basis If a complete command is not received from the serial port in the specified time an error will be generated that will disable the VECTORSTAR and break the user program The serial watchdog is a safety feature that disables the VECTORSTAR if the communications line breaks The serial watchdog waits for a carriage return to signify a completed command It does not test the validity of the command For example if your computer fails and begins sending random carriage returns the serial watchdog will not generate an error The VECTORSTAR serial watch dog is intended to detect a broken serial communications line It does not test the validity of data received from your computer WARNING Set WTIME in milliseconds to the time that you want the serial watchdog to timeout To enable the serial watch dog type WATCH ON 10 10 4 Transmit Receive Programs The VECTORSTAR provides commands that allow programs to be transmitted and received without using the Editor These commands are intended for applica tions which require that a computer directly transmit and receive programs This does not include Motion Link the software communications package that is run from an IBM PC or compatible Refer to Chapter 8 for commu nications format 10 10 4 1 BDS Command Receiving from the VECTORSTAR The BDS command is used to send the VECTORSTAR user program throu
312. motion is begun GATEMODE is turned off You must re enable GATEMODE for each move that you want gated Also you cannot turn GATEMODE on when motion is commanded from Jogs MA MI or 165 CHAPTER 11 DEBUGGING commands If you turn GATEMODE on and command motion but turn GATEMODE off before the GATE input turns on thus allowing motion to begin the commanded motion will be forgotten by the VECTORSTAR In the following example two MI commands are entered and precalculated with GATEMODE on GATEMODE ON ENABLE GATING MI 1000 100 PRECALC MOVES MOTION DELAYED MI 1000 MOTION DELAYED TIL GATE IS HIGH W 0 WAIT FOR MOTION TO START This means no motion will take place until the hardware input is high If the above lines were part of a program the W command would delay program execu tion until the GATE switch was on 11 6 HINTS The following section lists some hints addressing the most common problems Most result from a minor misuse or misunderstanding ofa VECTORSTAR function If you change your program in the Motion Link Editor and the program function does not change you may have forgotten to transmit your updated program to the VECTORSTAR If you command motion with MI MA MCGO J JT or JF and the motor does not move make sure GATEMODE is not preventing motion turn GATEMODE off if you are not certain make sure CLAMP is not preventing motion turn CL
313. n both the system rating and on the motor IMAX is in current units VECTORSTAR ILIM limits the peak of ICMD the commanded current You can set ILIM to any level below IMAX This allows you to limit the current below the maximum level that the VECTORSTAR can output You can set ILIM at any time even during profile moves ILIM is in current units 8 7 5 Enabling the Position Loop with PL PL 15 a switch that controls the position loop If PL is on then the position loop is enabled If PL is off then it 1s disabled and the VECTORSTAR is running as a velocity loop only Most positioning applications run with PL on See Section 8 9 1 for more information about the position loops PL is remembered through power down You can change PL at any time 8 7 6 Controlling the Velocity Loop with PROP PROP is a switch that controls the integration section of the velocity loop If PROP is on then the velocity loop 18 proportional and the integral is disabled If PROP is off then the velocity loop is fully integrating PROP is turned off at power up You can change PROP at any time Most applications run with PROP off Sometimes proportional velocity loops are used during set up See Section 8 9 2 1 for more information 8 7 7 Enabling the VECTORSTAR THE VECTORSTAR WILL BE ENABLED AND THE MOTOR WILL TURN SECURE THE WARNING MOTOR At this point you should turn REMOTE on as described in the Chapter 2 Type the following command to
314. n teneret tentent nennen 132 10 6 INTERFACING WITH THE OPERATOR 133 10 6 1 PRINT P 133 10 6 1 1 Printing Decimal Numbers 2 enne pne p eH toe n ere 133 10 6 1 2 Printing Decimal Points ence Er OR RATHER HER GRE 133 19621 3 Printing Hex Nuinbets erroe e DR ERR TNT qe cn y ete ee e et 134 10 6 1 4 Printing Binary Numbers nennen nnne nne 134 10 6 1 5 Printing Switches rite er ette a aet v e mI 134 10 6 1 6 Printing Expressions 4 seen Re e e e RR 135 10 61 22 Printing ASCIT Characters a e Re e edu ege Re 135 10 6 1 8 Printing Control Characters enne nenne nnne ens 135 10 6 1 9 Cursor Addressing eret eue eei e reta cu tede t ens 136 vi VECTORSTAR TABLE OF CONTENTS 10 6 1 10 Printing VECTORSTAR Status PS u nennen nennen enne 136 10 6 2 REFRESH amp RS Commands uu uuu a k 136 10 63 INPUT 136 106 T INPUTET 137 10 06 32 INPUT and Decimal Point ee ere recette 137 10 6 4 SERAL S WIE pente ertet dou HER CAR See Ei WERE 137 10 7 IDEING COMMANUDS terere ee reete rere pedet tpe ER Erbe ente eee creto it 137 10 722 o eS DRE lato E 138 WALT CW ete e
315. n this manual will assume that the VECTORSTAR is config ured with standard units 8 3 2 Three Types of Variables The VECTORSTAR has many variables all of which are listed in Appendix F The variables can be divided into three groups monitor control and user MONITOR VARIABLES Monitor variables watch the system You may display their values or use them in calculations However as a rule you may not change them The VECTORSTAR automatically changes these variables to reflect its status Position feedback PFB is an example of a monitor variable 64 VECTORSTAR CONTROL VARIABLES Control variables allow you to change or limit some process in the VECTORSTAR An example of a control variable is current limit ILIM ILIM limits the maxi mum current the VECTORSTAR can deliver It can be changed at any time USER VARIABLES User variables allow you to store information for later use or hold intermediate results of calculations They are discussed later in this chapter 8 3 3 Variable Limits variables have limits It is important to be aware of these limits since attempting to set a variable to a value outside its limits generates an error For example ILIM must be between 0 and 100 The limits of each variable are listed in Appendix F 8 3 4 Switches Switches are variables that can be set to 0 or 1 only In other words they have limits 0 and 1 Aside from this restriction this discussion about variables also appl
316. n warrants that equipment delivered by it to the Purchaser will be of the kind and quality described in the sales agreement and or catalog and that the equipment will be free of defects in design workmanship and material APPENDIX WARRANTY INFORMATION The terms and conditions of this Warranty are provided with the product at the time of shipping or in advance upon request The items described in this manual are offered for sale at prices to be established by Kollmorgen and its autho rized dealers 183 APPENDIX WARRANTY INFORMATION VECTORSTAR 184 VECTORSTAR Areeni B DRAWINGS APPENDIX B DRAWINGS 185 VECTORSTAR APPENDIX B DRAWINGS 66 2 ABH SNOLLO3NNOO YOLOW 9 OV Wvsovia 9SNIHIM YSA 39Vd 15 1 S3 ON 33S vl ALON 33S ASVHd aa SALON 33s ze aariaans 3SVHd 319NIS HO 3SVHd lt Sasn4 LINDUID YOLOVLNOO F 30 SLOVLNOO YAWOLSND HO H3HLI3 ANNOYS HISV3 HO ANIHOVW OL GAIL NOWAWOO 21901 ILON 889 301991409 SERO NIV 3SvHd STONIS 9 o SILON 33 3ZISH3N3 OL ZH 09 05 LNANI OV AYVLNAWOW GLF OEZ H3MOd LOVLNOO ANVI
317. nal sese eene nennen nnne S enne 28 25 8 Checking Analog RR REPRE ERR SERE Ee 28 21 9 the Resolver ate eie eI toe han 28 2 110 Checking the Resolver Cable u e ste ld ive gals Genet 29 2 7 11 Checking the AC Line Voltages sess 29 2749 Checking the DG Bus Voltage u u teen ete 30 2113 Checking lesen 30 CHAPTER 3 QUICK STAR 33 3d INTRODUTGTION EEE 33 3 2 QUICK INSTALLATION FOR LOW POWER UNIT 33 3 3 ANALOG INPUT CONTROL ctt erede pesti 34 3 4 QUICK TEST FOR SPINDLE FUNCTIONS 34 CHAPTER 4 37 4 1 INERODUNGTION 33 37 4 2 START UP AND 37 42 T ERROR 17 FEEDBAGQGCK LOSS A ore ER aska 38 4 2 2 ERROR 14 POWER BUS pert OU I A D 38 4 2 3 If Your VECTORSTAR System is Unstable 38 4 2 4 TJogging the MOtOE etd etae qu
318. nd PL is turned on at power up If you are following this procedure to stop oscillations be certain to turn PROP on and PL off every time you power up the drive WARNING Now enable the drive by typing EN Reduce the proportional gain KPROP until oscillations stop Type KPROP 2 You may need to repeat this command a few times After oscillations stop enable the position loop by typing PL ON Next reduce the position loop gain KP until oscilla tions stop Type KP 2 You may need to repeat this command a few times If you need to tune your system for better performance see Section 4 3 4 2 4 Jogging the Motor If you can enable the VECTORSTAR without motor oscillations then you can jog the motor First you should temporarily disable the VECTORSTAR software position limits Type PLIM OFF Now type J 10 The motor should rotate at 10 RPM If PROP is on the motion will be very unsteady You need an integrating CHAPTER 4 OPERATION velocity loop for good low speed performance Disable the VECTORSTAR and enable the software position limits Type DIS PLIM ON 4 2 5 Low Speed Adjustment SKIP THIS SECTION IF YOU HAD TO TURN PROP ON TO STABILIZE YOUR SYSTEM The VECTORSTAR has a low speed adjustment This adjustment helps smooth very low speed motion This adjustment is made with th
319. nding at zero speed use the Macro Go MCGO command to begin the motion MCGO is only allowed when the speed at the end of the last Macro move is 0 MCGO also ends calculations for Macro moves Subsequent MCI MCA or MCD commands reset the Macro move sequence Subsequent executions of MCGO will execute the move again The effect of multiple MCGO s on Incremental Macro moves is that the Incremental move is executed again The effect of multiple MCGO s on Absolute Macro moves is more difficult to understand This is because all Macro moves are converted to Incremental before being executed whether they are MCI or MCA based This can cause undesirable effects if the position does not return to the starting point at the end of the Macro move Absolute Macro moves that are to be executed more than once should return to the starting position Enabling the VECTORSTAR resets the Macro move memory If you are typing in a Macro move and you make an error you should disable then enable the VECTORSTAR and retype the entire move Jog MA and MI commands do not reset the Macro move memory This means you can execute jogs or simple moves after the Macro move is calculated the MCGO command will still execute the move properly 8 8 7 2 Macro Move Example 1 As an example of Macro moves consider the following profile VECTORSTAR 1000 RPM 200 RPM 0 10000 11000 COUNTS COUNTS COUNTS Figure 8 4 Macro Move Example 1 There is
320. nector to your terminal or computer VECTORSTAR 2 6 5 3 Checking the Control Power SHOCK HAZARD 230 VAC is present on the Control Power Be very careful WARRING when measuring these voltages Control Power is the 230 VAC connection at PA Connector Control Input pins 1 and 3 NOTE Table 2 6 PA Logic Output Voltages 15 Volts 20 15 Volts 20 Pins 1 and 5 Pins 2 and 6 Pins 3 and 7 Pins 4 and 8 Common 8 Volts 20 Turn off Control Power Remove PA Connector Control Input Turn on Control Power Use an AC voltmeter to confirm that the voltage on PA Connector Control Input Pins 1 and 3 is 230 VAC 15 Turn off Control Power Re install PA Connector Control Input Remove PA Connector Logic Output Turn on Control Power Use a DC voltmeter to confirm the logic supply measure the pins in the PA Connector Logic Output If none of these voltages are present check control power 230 VAC on PA Connector Control Ouput Pins 1 and 3 If one or more ofthe voltages are missing one or more fuse in the PA may be open Refer to the spare parts lists in Chapter 5 for descriptions of the fuses Turn off Control Power Re install PA Connector Control Input Turn on Control Power The green CPU LED on the front ofthe VECTORSTAR should begin flashing about 10 times per second This indicates that the VECTORSTAR 18 autobauding to establish communicati
321. neral purpose outputs by turning them on and then off Be careful The procedure in this section will activate all of the general purpose outputs Be sure that activating an output will not cause a hazard to personnel or damage to equipment CHAPTER 2 INSTALLATION Commands in this section will turn on all general purpose outputs Be certain that this is not a safety hazard Make sure this will not damage equipment WARNING 1 Turn on O1 by typing O1 ON 2 Verify that the output is on If you are using a Kollmorgen Input Module or an industry standard OPTO 22 compatible input module there will be an LED on each output to indicate its state The LED will be on if the output is on 3 Turn off O1 by typing O1 OFF 4 Verify that the output is off Repeat this process for each discrete output that you are using Ol 02 4 5 O6 07 08 2 7 3 CYCLE READY cannot be checked without a program This topic is discussed in Chapter 10 User Programs Later when you are familiar with programming you can write a program that turns CYCLE READY on Check this output at that time 2 7 4 Checking STATUS Check STATUS later in this chapter when the VECTORSTAR is active The STATUS output will turn on when you enable the VECTORSTAR 2 7 5 Checking Encoder Output Check the encoder output with a two channel oscillo scope Place Channel 1 on OUTA and Channel
322. nments There are four special constants that make the VECTORSTAR easier to use ON OFF Y and ON is the same as 1 and OFF is the same as 0 Similarly Y is 1 and N is 0 These constants are normally used for switches Compare the two state ments 69 CHAPTER 8 GENERAL PROGRAMMING 01 1 Although both statements have the same effect the second is easier to read more intuitive When you write programs the use of ON and OFF and Y and N can make the program easier to understand Note however that the P command normally prints numbers not ON OFF Y or N For example O1 ON P OUT will result in 1 being printed not Another point to recognize 15 that the equal sign 1s optional The two statements O1 ON O1 ON produce identical results The program can be more readable if the equal sign is not used with Y N ON and OFF 8 4 MATH 8 4 1 Hexadecimal The VECTORSTAR allows constants to be entered in hexadecimal or hex Hex is base 16 representation which is often used when programming computers VECTORSTAR hex constants begin with a number and are followed by h For example 16h 0Fh OFFh are all hex numbers Appendix G shows the hex conversion of 0 through 255 From the appendix you can see that hex 25 15 equal to decimal 37 The follow ing two instructions have identical effects because 25 hex equals 37 decimal 9 37
323. nning friction at low speed ILIM is lowered to reduce the torque exerted by the motor when the machine stop is encountered Set PECLAMP to a level well above the normal following error usually the position unit equivalent of several hundred counts is sufficient Then turn CLAMP on and jog at low speed toward the stop The VECTORSTAR will run the machine into a stop and limit current to ILIM When SEG is equal to 0 the VECTORSTAR has clamped and thus recognizes that the machine has been run into the stop Often the repeatability of this operation 15 unacceptable because the stop may be soft or it may wear over time Here you can use the MRD command to force the VECTORSTAR to move to a fixed R D converter position This means that you will get a repeatable home as long as the clamp position does not vary more than one half of one revolution between different clamping operations This 15 not normally a problem To set the proper R D converter position for the MRD command first do the clamping operation by hand a few times Reduce ILIM and jog at low speed into the stop After the unit has clamped as indicated by SEG 0 print the R D converter position using P PRD Do this several times and record the average of PRD Now use the MRD command to back away from the stop about one half of one revolution For example suppose you jog clockwise into the stop several times and record 87 CHAPTER 8 GENERAL PROGRAM
324. not turn TQ off before turning PL on the VECTORSTAR will force TQ off When PL is turned on TQ is turned off automatically NOTE 8 9 2 Velocity Loop The velocity loop takes its input from the position loop if PL is on If PL is off motion commands directly control the velocity command VCMD The feedback is VFB velocity feedback and the difference of these two signals 18 VE velocity error Velocity error can be used in two control loops proportional and integrating 8 9 2 1 Proportional Velocity Loop If a proportional velocity loop is selected then the velocity error is multiplied by KPROP the proportional constant to generate ICMD the current command Proportional velocity loop is selected when the PROP switch is on PROP is turned off at power up Proportional velocity loops are much easier to stabilize than integrating loops so they are often used during machine setup However they also allow steady state velocity error and therefore they are generally replaced with integrating loops when the machine is fully opera tional CHAPTER 8 GENERAL PROGRAMMING 8 9 2 2 Integrating Velocity Loop If an integrating velocity loop is selected then the velocity error is integrated and multiplied by KVI the velocity integration constant Velocity feedback 1s subtracted from this signal then the signal is multiplied by KV the velocity loop gain to form ICMD This velocity loop is selected when PROP is off 8 9
325. ns based on the final position of the motor after a move For our example assume that the PFB should be between 50 and 50 If VECTORSTAR is within range the program should turn output O1 on and print an appropriate message If it is out of range should be turned off and a message should be printed The table below shows the desired operation Table 10 2 Desired Operation of Program Example PFB RANGE MESSAGE TO PRINT gt 50 lt 50 TOO SMALL 50 PFB 50 PFB WITHIN RANGE The IF ELIF ELSE and ENDIF commands implement the desired functions IF PFB GT 50 BEGIN BLOCK IF O1 OFF O1 MEANS WITHIN RANGE P PFB EXCEEDED MAXIMUM PRINT ERROR MESSAGE ELIF PCMD LT 50 CHECK THE NEGATIVE LIMIT P PFB EXCEEDED MINIMUM PRINT ERROR MESSAGE O1 OFF O1 MEANS WITHIN RANGE ELSE HERE THEN WITHIN RANGE O1 ON TURN ON O1 P PFB WITHIN RANGE PRINT MESSAGE ENDIF END OF BLOCK IF This example could have been written with commands as the following program shows Notice that the program requires more lines uses 3 labels and is harder to read that 15 less intuitive PFB LE 50 GOTO 10 START OF BLOCK O1 OFF EXECUTE BLOCK gt 50 EXCEEDED MAXIMUM 20 DONE GO TO END 10 PFB GE 50 GOTO 11 EXECUTE BLOCK PFB 50 CHAPTER 10 USER PROGRAMS P PFB EXC
326. nstruction cannot be another TIL Allowed only from the user program Format TIL lt gt Logical lt Expr gt Instruction Example TIL PFB GT 100 P PFB TIL X1 X2 NE X4l X5 5 GOSUB 100 TIL VFB LT 100 DELAY EXECUTION Tune the motor to a new load This command is used if the motor needs to be re tuned The tuning parameters KP KV KVI and KPROP determine the motor stability and response time Often when the motor load is changed tuning parameters need to be reset The Tune command specifies Bandwidth and Stability Higher bandwidth will produce faster response time Higher stability will produce less overshoot but noisier performance Allowed from the interactive mode and the user program Only available when PDF 1 Format TUNE Bandwidth lt Stability gt Where Bandwidth 1 5 10 15 50 Hz and stability is 1 2 or 3 Example TUNE 252 Wait for a specified motion profile segment to start before continuing program execution W is an idling command that is if you are using multi tasking W suspends the etask but lets other tasks proceed Allowed only from the user program VECTORSTAR ZPE lt BDS gt BDS APPENDIX G SOFTWARE COMMANDS Format W lt Segment gt Examples W3 FOR SEGMENT 3 TO START wo FOR MOTION TO STOP Clear the position error This command is useful when enabling the position loop when position error has been allowed to
327. nt Disabled 81 850 1 250 User Indirect Vars None Special Constan None 1 1 250 User Variables None ZERO ____ Enable ZEROing Mode None Long Limit Long gt 0 Limit Short Limit Short gt 0 Limit Table F 2 Description of Program Limits 2147483648 2147483647 2147483647 32767 32767 219 APPENDIX VARIABLE QUICK REFERENCE VECTORSTAR F 3 INTERNAL VARIABLES The following variables are internal variables and are not normally used by customers They are set at the factory and program theVECTORSTAR for the particular motor it will be controlling The Motor command changes these variables as necessary for the motor Table F 3 Internal Variables VARIABLE DESCRIPTION PROGRAM CONDITION 1 16 Internal ADVSLIP Internal ADVSPD Internal ADVLD Internal ANGLD Internal Factory none BSLIP Inductn Base Slip Factory mHz FOLDD Foldback Delay Factory sec 100 FOLDR Foldback Reset Factory sec 100 FOLDT Foldback Const Factory sec 100 IBASE Inductn Base Amps Factory IMAG Induc Mag Current Factory IND Select Induction Factory IZERO Zeroing Current Factory MADV Enable Manual Adv Factory MANG Internal MSLIP Manual Slip Factory None POLES Motor Poles Factory Poles 128 SGOOSE Induction Angle Factory None SLIP Induction Slip Never None SLOPE Inductn Slip Slope Factory 1 1095 VADVTBL Angle Table Max Factory VEL VBASE Inductn Base Speed Factory VEL 220 VECTOR
328. nto four categories l Overloading the Motor 2 Compliance 3 Resonance 4 Changing Load Inertia or Reflected Inertia 4 9 1 Overloading the Motor Overloading the motor is the most common problem for positioning systems that is systems with PL on If you overload the system the position error can grow to very large values When the command stops the motor reels the following error and can overshoot excessively It looks like a tuning problem but it is actually caused by the motor being undersized ACC or DEC being set too high or ILIM being set too low VECTORSTAR When a motor is overloaded it has the following characteristics The system overshoots sometimes excessively but does not ring or oscillate Reducing ACC and DEC eliminates the problem Turning off PL eliminates the problem The motor current is near or at saturation during a large part ofthe move Use the RECORD function to record ICMD If ICMD is equal to ILIM for more than a few milliseconds then your system is saturated Overloading the motor can be corrected by the following actions Reducing ACC and DEC Reducing the load on the motor Increasing if it is less than IMAX Using a VECTORSTAR with a higher current rating Using a motor with more peak stall torque 4 9 2 Compliance In compliant systems the load is not tightly coupled to the motor shaft If you move the load by hand you can feel springiness Compliant sy
329. o its original value Type the following line on the terminal ILIM 10 Next print the new value of ILIM with the P instruction P ILIM ILIM should now be 10 Return ILIM to its original value normally 100 by typing ILIM 100 Print ILIM to make sure the change was carried out properly 8 3 7 Programming Conditions Most variables can be changed but some can be changed only under certain conditions For example the maxi mum acceleration level AMAX can be changed only CHAPTER 8 GENERAL PROGRAMMING when the VECTORSTAR is disabled Attempting to change AMAX with the VECTORSTAR enabled will generate an error The conditions under which a variable can be changed are called programming conditions Some variables should never need to be changed after the VECTORSTAR has left the factory these variables are called factory settable Attempting to change a factory settable variable will generate an error The programming conditions of all variables are listed in Appendix Limits and programming condi tions for all variables are shown in Appendix F 8 3 8 Power up and Control Variables Table 8 2 Power Up State of Programmable Switches REMEMBER FROM LAST POWER UP CAPDIR ABAUD CLAMP DIR LPF DEP MULTI XS1 XS50 EXTLOOP PROMPT PL FAULT PLIM GATEMODE ROTARY GEAR TRIP O1 O8 PROP RAMP REG SS STATMODE TRC TQ 65 CHAPTER 8 G
330. o more than 250 times since 4 250 1000 4 4 Math Errors ERROR 92 ZERO DIVIDE SEVERITY 2 You attempted to divide a number by 0 This error breaks program execution if the instruction is issued from the user program ERROR 93 MATH OVERFLOW SEVERITY 2 The final result of a calculation or an intermediate result during the calculation of an expression was greater than 231 or less than 231 This error breaks program execution ERROR 94 gt 2 PARENTHESES SEVERITY 2 The VECTORSTAR evaluated an expression with more levels of parentheses than the VECTORSTAR supports Up to two levels of parentheses are allowed This error breaks program execution ERROR 95 UNEVEN PARENTHESES SEVERITY 2 The VECTORSTAR encountered an expression in which the number of closing parentheses was not equal to the number of opening parentheses This error breaks program execution 204 VECTORSTAR APPENDIX C ERROR CODES ERROR 96 SCALING OVERFLOW SEVERITY 2 During a conversion to or from user units the result was greater than 231 or less than 231 This error breaks program execution if the instruction is issued from the user program ERROR 97 GEAR OVERFLOW SEVERITY 3 The VECTORSTAR encountered an overflow when calculating the velocity from the external pulse input This can be caused when the variable GEARI is too small or GEARO is too large That is the input times the ratio of GEARO GEARI was greater than the highest allowable inp
331. of operation can be selected in the 1 1 application as to how the motor is moved to the orient position after stopping The modes of operation are selected by a parameter named MORNT and are as follows MORNT 0 The motor will orient in the direction it was rotating when the Orient Request input activated MORNT 1 The motor will orient in the CCW direc tion The direction of rotation is that direction as seen from the non shaft end of the motor MORNT 2 The motor will orient in the CW direc tion The direction of rotation is that direction as seen from the non shaft end of the motor MORNT 3 NOTE This mode selects the Orient cycle designed for the 2 1 application described in the next section MORNT 4 The motor will orient in the shortest direction Variables used MTIMER Motor OT 1 e Over Temperature timer The time from when the Motor OT I5 input thermo stat contact opens until the drive faults terminating application software execution and disabling the motor The time allows the controller to stop the motor before the VECTORSTAR stops the motor Care must be taken to select a value that is low enough to prevent damage to the motor The units are in milliseconds 106 VECTORSTAR P1 PORNT no longer used Orient position in R D units There are 4096 R D units per revolution ofthe motor so the programmed value can be in the range of 0 to 4095 VORNT Orient speed ofthe motor is in RPM units
332. ogram execution and disables the VECTORSTAR ERROR 201 SLIP TOO BIG SEVERITY 3 The induction motor variables that control slip are out of bounds Contact the factory This error breaks program execution and disables the VECTORSTAR ERROR 202 USER PROGRAM CORRUPT SEVERITY 3 The user program is corrupt Usually this problem is caused by installing a new battery back up RAM This can also occur if power to the is lost while editing the program This error will break program execution ERROR 203 AMPS BAD SEVERITY 3 VECTORSTAR variable AMPS is invalid Contact the factory This error breaks program execution ERROR 204 PROGRAM OVERRUN SEVERITY 3 This is an internal error Contact the factory This error breaks program execution and disables the VECTORSTAR ERROR 205 MBUF OVRRUN SEVERITY 3 This 1 an internal error Contact the factory This error breaks program execution and disables the VECTORSTAR ERROR 206 PROFILE OVERFLOW SEVERITY 3 This 1 an internal error Contact the factory This error breaks program execution and disables the VECTORSTAR ERROR 208 GENERAL INTERNAL SEVERITY 3 This is an internal error Carefully write down the entire line that 1 printed with the error and contact the factory This error breaks program execution and disables the VECTORSTAR ERROR 209 STACK OVERFLOW SEVERITY 3 This is an internal error Carefully write down the entire line that 15 prin
333. oi tte to ete tee o Leste Pee x ade UT 126 10 3 2 7 Delete DEL ient nee ettet qe nspa te et 126 ES S A 126 10320 NEW sa hy RERE 127 10 4 BUILDING A PROGRAM u e e eee eoe v verde ttes 127 19 41 Basic hich e RR RE epe PR Het acide 127 A T 127 1041 2 RUN M 127 IOA LI Break B uu mette ee E EA 127 104 4 E E E AEREE KAEA ISANE EAA 127 1041 5 GOSUB mE S em o eee re ede e rh RT 128 10 4 2 CONDITIONAL COMMANDS ne 128 10421 QUICK IE Command sasea ener eee 128 10 4 2 2 Nesting C mmands eee eei eee re edet ee d ee tendens 129 10 4 2 3 TIL Command g aaa nanum a m edt tefie e te oed fat etu 129 10 4 2 4 IF ELIF ELSE and ENDIF 65 00202000 0 00 0 00000 00 130 10 4 2 5 IE Vs iet efte tetti er e hb Ceu Gane re pee e SA 130 10 4 2 6 Nesting IF commands ede Seule tee e EI e RENE ates 131 10 4 2 7 IF s with and 131 10 5 USING THE GENERAL PURPOSE INPUTS eese nette
334. ommand 88 94 165 Jog To JT Command 88 94 165 Jogging the Motor 39 Jogs Position Dependent 88 165 K KC 39 KF 43 96 97 Kill K Command 73 KP 43 96 KPROP 43 97 102 KV 97 KVI 97 102 L Labels 127 202 AUTOS 145 Dedicated 127 ERRORS 145 MANUALS 145 POWER UP 145 LED ACTIVE 7 54 73 BLOWN FUS 54 CPU 7 25 54 72 D C BUS 54 FAULT 7 54 73 OVERLOAD 54 REGEN 54 RELAY 7 54 73 SYS OK 7 54 SYS OK 75 LED Status Indicators 54 LED s 7 LIMIT 23 Limit 23 Limiting Motion 80 Limiting Motor Current 78 Limits Travel 80 LOAD 102 Load inertia 45 Logical Math Functions 71 Logical NOT 132 Loop Control 96 Position 96 Position Gain 96 Position Tuning 43 Velocity Integral 97 Proportional 97 Low Speed Adjustment 39 VECTORSTAR Low Pass Filter 42 46 LPF 46 LPFHZ 46 M Machine Specific Units 148 Macro Absolute MCA 84 92 94 153 165 Macro Dwell MCD 84 92 94 164 165 Macro Go MCGO 84 92 94 165 Macro Incremental MCI 84 92 94 165 Macro Moves 84 164 MADV 102 Maintenance 49 MANUAL 145 Manual 24 MANUALS 145 Masking 132 masking 132 Master Slave 16 Master Slave 91 93 148 Matching Inertia 41 Math 70 Maximum Profile Time 83 Mode 59 Interactive 59 Monitor 59 201 Run 59 Single Step 59 Trace 60 Modes of Operation 58 Modified S Curve 81 Molex 53 Molex Assembly Tools 5 MONITOR 59 Monitor Mode 59 201 Monitor Variables 64 MORNT 102 106 MOTION 23 79
335. on PRD PRD is the output of the resolver to digital R D converter in counts PRD is not in position units If your system has the standard 12 bit R D converter then 4096 counts will equal one revolution The following table shows the R D ranges versus resolution The VECTORSTAR should be disabled at this point use the K or DIS command if it is enabled PRD can be printed on the screen From the terminal type P PRD and the R D output will be displayed on the screen Move the motor shaft by hand to several positions printing PRD each time Notice that PRD changes for each position The VECTORSTAR supports 10 bit resolver resolution for high speed applications 75 CHAPTER 8 GENERAL PROGRAMMING 8 7 2 4 Sampling PFB PCMD and PEXT When PFB and PCMD are used on the same line they are always sampled during the same sampling interval millisecond This allows you to use PCMD PFB and a third variable called PEXT which is discussed later in this chapter without concern that the variables might be sampled at different times For example P PCMD PFB This command would print the expected results because the VECTORSTAR stores PCMD and PFB at the beginning of every command then uses those stored values when the command is executed On the other hand if you type Table 8 6 PRD Ranges and RID Resolutions R D Resolution PRD Max P PRD
336. on card is installed A switch called A2D is used to switch the gear input If A2D 1 the signal is from the analog input if A2D 0 the signal comes from the encoder input If the analog input is a velocity command then use electronic gearbox Master Slave mode to make the VECTORSTAR a velocity drive If the analog input is going to be used for feedrate override use profile regulation The analog external input is connected to the customer T O 8 8 13 Electronic Gearbox Electronic gearbox is one of two VECTORSTAR Master Slave modes Refer to Figure 8 8 for a diagram of the two modes Electronic gearbox is used to link two motors together so that the velocity of one is propor tional to the velocity of the other The constant of proportionality can be negative allowing the velocities to be in opposite directions If the analog input is used a gear ratio calculation is not necessary Simply give a value to VSCALE which is the velocity input scale factor The value entered is the desired motor velocity of 10 volts applied to the analog input 8 8 13 1 Gear Ratio GEARI amp If input is in digital encoder format you must calculate the gear ratio In electronic gearbox the command signal comes from the external input The pulses are multiplied by a gear ratio to form the position or velocity command The ratio is defined by two variables input gear teeth GEARI and output gear teeth GEARO GEARI must
337. on parts passing by on a conveyor belt The profiles executed by the motor must be at a rate proportional to the conveyor belt speed The belt moves at about 200 inches minute An encoder has been placed on the conveyor and the maximum belt speed of 275 inches minute is equivalent to 780 kHz on the encoder If the belt 15 at maximum speed the profile of the motor is to rotate one revolution at a peak speed of 400 RPM Solution Connect the conveyor belt motor encoder to the input channel ofthe VECTORSTAR as shown in the Chapter 2 Wiring C1 The following program should be executed 94 VECTORSTAR REG ON ENABLE PROFILE REGULATION SET THE MAX EXTERNAL FREQUENCY TO 780 ONE REVOLUTION AT 400 RPM REGKHZ 780 MI 4096 400 In the case above the MI move will generate a one revolution move at a speed proportional to the external input frequency with 400 RPM the maximum rate when the external input frequency is 780 kHz Note that the belt speed virtually never reaches 275 inches minute However REGKHZ must be higher than the worst case maximum belt speed For example the above program can be modified to allow an even larger belt speed REG ON ENABLE PROFILE REGULATION SET THE MAX EXTERNAL FREQUENCY TO 1 56 MHZ ONE REVOLUTION AT 800 RPM REGKHZ 1560 MI 4096 800 Notice that REGKHZ was doubled However since the speed of the move was also doubled
338. ons Ifthe CPU LED is not blinking CHAPTER 2 INSTALLATION Check the logic voltages from Table 2 6 above If one or more of the voltages are missing a fuse in the PA opened because the logic supply was miswired You may have miswired either Connector Logic Output on the PA or Connector C4 on any VECTORSTAR Check your wiring carefully Make sure the MOTION input is off contacts are open when you power up the VECTORSTAR Ifthe contacts are closed open them and power down the VECTORSTAR and immediately power up again Ifthe CPU LED is still not blinking contact the factory 1 Ifyou are using Motion Link with an IBM PC type ML from DOS to start Motion Link Motion Link will establish communications Refer to Chapter 7 for more information on installing and running Motion Link 2 Whether you are using a terminal or a PC press the return key 5 to 10 times pressing the key about twice per second These steps cause carriage return characters to be sent to the VECTORSTAR When autobauding the VECTORSTAR looks for these characters and uses them to determine the baud rate or speed at which your terminal is transmitting Once the baud rate is deter mined the VECTORSTAR can establish communications with your terminal or computer Then the VECTORSTAR should print this message or one similar to it on your terminal MOTION LINK BDS5 VS1 V4 0 0 C 1996 KOLLMORGEN MOTION TECHNOLOGIES GROUP The green SY
339. orage Temperature 12 Support Policies 56 Surge Current 50 Switches 64 Synchronize Segments 164 Synchronizing 138 SYNCHRONIZING YOUR PROGRAM 163 SYS OK LED 7 54 SYS OK LED 75 System Compensation 40 System Description 1 System Dump 155 T Tach Monitor 19 Tasks 139 Terminal Connecting 21 Theory of Operation Microprocessor System 6 Theory of operation 6 Thermal overload relay 193 Thermostat 14 thermostat 193 Three phase AC line 15 TIL Command 129 205 Timers General Purpose 163 Timings 235 TL Sheet 110 TMRI 109 TMRI 4 163 TMR2 108 Torque 193 Torque Command 96 Torque Command Mode 97 Torsional Resonance 46 243 INDEX TQ 97 Trace 60 162 transformers 50 Transient Voltages 49 Travel Limits 80 Traverse 80 TRC 60 162 Triangular Moves 82 TRIP 80 Trip Points 80 TRIP1 TRIP2 80 TROTOR 102 Troubleshooting 53 TUNE Command 42 Tuning 40 41 42 96 Criterion 40 Default 41 Position Loop 43 Tuning Problems 44 Typical Application 156 U Underdamping 40 Units Application Specific 148 Basic 146 Current 146 External 148 151 Standard 148 npacking 11 nstable BDS5 System 38 nstable System 41 ploading 154 ser Error Handler 145 ser Programs 119 ser Switches 69 ser Trip Points 80 ser Units 146 ser Variables 64 ser Variables 69 Cee eevee eee CC lt VADVTBL 101 Variable Units 64 143 Variables 63 Changing 65 Control 64 Factory Settable 65 Indirect User 69 203 Limi
340. orgen for each new problem Occasionally an applications sales representative may refer you to the Engineering Department However if you call later with a new problem please ask for an applications sales representative 2 Be prepared to provide the following items a written spec of the system b Aflowchart and hard copy of the program 3 Be prepared to take the following actions should the applications sales representative determine that these actions are necessary a Strip out sections of your program to help locate a problem b Rewrite sections of your program that do not conform to the programming practices described in this chapter c Video tape your machine to help demonstrate the problem If you need help with your program Kollmorgen is committed to helping you VECTORSTAR software support is provided by l Helping you organize your program 2 Explaining proper programming practices 3 Discussing VECTORSTAR functions Contact the local Industrial Drives sales application representative All Regional Sales Offices are listed in Appendix D of this manual 123 CHAPTER 10 USER PROGRAMS 10 3 EDITING Wnting or modifying a program is called editing If you are using MotionLink Plus you can skip this section There are two ways you can edita VECTORSTAR program The VECTORSTAR has a simple resident editor As an alternative you can edit your program on a computer and transmit it to
341. otion has stopped idling command and thus allows lower level tasks to execute also it takes less space waits for the last motion program and it does not delay execution when motion has stopped Use the TIL command when you need a special function such as printing during the wait or if you specifically want to stop lower level tasks from executing Another example of the WAIT W command is seen when using multiple JOG TO JOG FROM commands Normally you should place a WAIT W command between these commands because the initial traverse of a JOG FROM JOG TO command begins as soon as the command is entered Usually you will want the traverse to begin at the end of the last specified acceleration segment For example consider Macro Move Example 1 in Chapter 8 It could have been done with one JOG and two JOG TO commands J 1000 START MOTION W 2 WAIT TIL JOG ACCEL IS DONE JT 10000 200 ENTER JT FOR FIRST DECEL W 3 WAIT TIL JT DECEL 8 DONE JT 11000 0 ENTER FINAL SEGMENT OF MOVE 11 5 5 Gating Motion with GATE The GATEMODE variable allows you to pre calculate a profile and begin motion within 1 5 milliseconds ofa switch closure To enable GATE turn on GATEMODE and follow it with either 1 Oneortwo MA or MI commands 2 One or two Macro Go MCGO commands or 3 One Jog or MRD command When the hardware input GATE transitions from low to high motion begins GATE is on Connector C7 Pin 17 After
342. our VECTORSTAR not the continuous rating For example the peak rating of a6 Amp VECTORSTAR is 12 Amps The conversion constants that determine user current units are INUM current units numerator and IDEN current units denominator VECTORSTAR TYPE RUN YES BREAK COMMAND OR ERROR ON CYCLE SWITCH NO POSITIVE TRANSITION SAMPLE AUTO ROUTINE AUTO MI 4096 100 END EXECUTE AUTO ROUTINE CHAPTER 10 USER PROGRAMS MANUAL SWITCH IS AN INPUT ON CONNECTOR C8 PIN 33 CYCLE SWITCH IS AN INPUT ON CONNECTOR C7 PIN 13 GO TO INTERACTIVE MODE gt SAMPLE MANUAL ROUTINE MANUAL IF 11 EQ 1 J 1000 ELIF 12 EQ 1 J 1000 ELSE J 0 EXECUTE ENDIF MANUAL END ROUTINE Figure 10 2 Auto Manual Mode Flowchart 147 CHAPTER 10 USER PROGRAMS INUM ILIM basic units ILIM user units XIDEN and IDEN have a range of 0 to 2 For standard current units percent INUM is 4095 and IDEN is 100 For example when setting ILIM to 100 in Chapter 8 you typed VECTORSTAR variables that have units associated with them should be set after you have specified the user units This is because the values actually stored in the variables are in VECTORSTAR basic units not user units Changing the user units will not affect the basic value stored in the variables For example if you want VOSPD to be 100 inches minute and you type ILIM 100 SET ILIM TO
343. out by friction If you are not sure how much ILIM is necessary reduce ILIM to a low value say 5 or 1096 and gradually raise it If the tuning is acceptable that 1s it does not ring or overshoot excessively and it does respond fast enough then you are done Do not forget to restore ILIM to its original value The TUNE command shakes the motor vigorously You may need to reduce ILIM before executing the TUNE command to protect your machine Do not forget to restore ILIM when tuning is complete CAUTION The TUNE command can cause the motor to overspeed You may need to reduce ILIM to prevent overspeed errors Do not forget to restore ILIM when tuning is complete 4 5 When you enter TUNE command you specify the response time and the stability level The response time 18 specified in the form of bandwidth The higher the bandwidth the faster the response The level of stability Is specified as follows 1 Slightly overdamped 2 Critically damped 3 Slightly underdamped 42 VECTORSTAR The drive will be enabled and the motor will turn Make sure the motor is secured Even if the VECTORSTAR is disabled it will enable long enough to execute the TUNE command WARNING Enable the VECTORSTAR and type this command TUNE 30 2 The VECTORSTAR will shake the motor and set the tuning so that the velocity loop has a bandwidth of approximately 30 H
344. owever if the drive is oversized that is it can provide continuous current that greatly exceeds the motor s continuous current rating you may want to add motor overload relays in series with the motor Also you can wire a contactor in series with the motor leads Always be careful to wire the motor properly 2 6 2 3 Motor Thermostat Kollmorgen V Series motors have a thermostat The thermostat contacts are closed during normal operation and open when the motor overheats The VECTORSTAR does not provide a direct input for the motor thermostat You should connect the thermostat contacts toa VECTORSTAR general purpose input and program your VECTORSTAR to bring about an orderly shutdown when the thermostat opens The thermostat ratings are Rated Voltage 277 VAC at 60 Hz 250 VAC at 50 Hz Rated Current 2 5 Amps at power factor of 1 0 1 6 Amps at power factor of 0 6 Resistance 50m Ohms The thermostat resets closes when the motor cools The customer is responsible for making sure that the VECTORSTAR motor does not begin moving unexpectedly when the thermostat closes Do not connect the thermostat directly in line with the VECTORSTAR REMOTE ENABLE or LIMIT inputs as this may allow the system to begin operation unexpectedly You must latch the thermostat switch either in hardware or software It can take several minutes for the motor to cool enough to allow the thermostat to close Unexpected operation several minutes after
345. peed is 1962 RPM 10 6 1 2 Printing Decimal Points You can also use the VECTORSTAR to print a decimal point The VECTORSTAR performs calculations with integers because it is much faster than floating point math However it is often desirable to convert integers 133 CHAPTER 10 USER PROGRAMS to floating point numbers especially when printing out information for the operator This allows you to make the integer math of the VECTORSTAR transparent to the operator For our example suppose you would prefer to print out the speed in KRPM thousands of RPM You can use print formatting to convert the program units RPM to KRPM with the following print command P SPEED VFB 5 3 KRPM Assuming VFB was 1962 this command would produce SPEED 1 962 KRPM The 3 which follows the 5 in the format causes the VECTORSTAR to insert a decimal point three places from the right of the number To the operator this is more convenient though the programmer still must work in integer units You also have the option of printing fewer digits than all those that follow the decimal point This also can be specified in the format For example suppose you only wanted to print one digit after the decimal point The print command from above would be changed to limit the number of printed digits VECTORSTAR X1 255 P X1 P X1 X1 H3 will cause the VECTORSTAR to print X1 FFH X1 F
346. pply essere 20 2 6 4 8 Wiring C5 Serial Communications sess nnne nnne nnns 20 2 6 4 9 Wiring C6 Fan a a a e a EEEE 22 26410 Wiri e CT Standard TO soie tette rte e RN er te peli 23 2 6 4 T1 Wiring C8 Optional aset e eter tette dope cols QR YET 23 2 64 12 Configuration Jumpers e e ee E teretes aR 24 2 6 5 Establishing Communications eene 24 2 6 5 1 Required Data Format 5 x SR tct e eR RI ER HER RAS 24 2 6 5 2 First S aa 24 2 6 5 3 Checking the Control Power OO 25 TABLE CONTENTS VECTORSTAR 2 6 5 4 If You Can t Communicate idee egest ete p rt prega 25 2 7 INITIAL CHECKOUT was 26 2 11 gt 26 2712 Checking General Purpose Outputs 42 aa eee street ed e e Terre ee etes eese OG 27 2 71 33Gyele Ready eee tte tee aee tt ehe uude ntt A 27 2 14 Checking STATUS cote tcrra e e rea rtu ne te p eer hn peur 27 2 7 5 Checking Encoder Output sss a 27 2 6 Checking Encoder eese WES ERE SH 28 2 7 7 Checking Pulse Input Optio
347. r Initially set to 44739 for RPM Offset velocity for electronic gearbox Reset to 0 whenever GEAR is turned on This variable should be left at 0 for preliminary operation Overspeed setting Initially set to 1 2 times the VMAX value This variable should be left at this value for prelimi nary operation but it can be reduced for protection External velocity units denominator Initially set to VDEN Value of this variable does not matter during prelimi nary operation External velocity units numerator Initially set to Value of this variable does not matter during prelimi nary operation Enable the serial watchdog timer This function disables the VECTORSTAR if a command is not received from the serial port every WTIME milliseconds Set to 0 on power up See WATCH above Initially set to 1000 User variables Initially set to 0 User switches Initially set to 0 Puts the VECTORSTAR in Resolver Zeroing mode This is set to 0 on power up Zeroing mode is used only during installation If 1 VECTORSTAR rotates the motor to the zero position If 0 the VECTORSTAR controls the motor normally Dead band for the analog input 1 unit will set dead band of 620 microvolts VECTORSTAR 8 3 10 User Variables User variables are like memory on a hand held calcula tor They can be used as application specific variables or for storing intermediate results of complex calcula tions There are 2000 user variables
348. r and type RUN 11 and the response should be ERR 83 LINE2 2 BAD OR OUT OF RANGE This message shows that the error occurred on line 2 You can enter the Editor and type P2 and the line PROP2 will be displayed 11 7 2 DEP If your VECTORSTAR prints to a Data Entry Panel DEP 01 or any other 40 character wide display the standard error messages will not print properly The problem 15 that error messages are based an 80 character wide display and the DEP 01 is only 40 characters wide To correct this problem the VECTORSTAR provides the DEP switch which when turned on cuts all error messages down to 40 characters If your VECTORSTAR prints to a DEP 01 type DEP ON 11 7 3 Error History The VECTORSTAR stores the twenty most recent errors in the Error History To display the entire Error History type ERR HIST 168 VECTORSTAR This causes the Error History to be sent to the terminal with the most recent error sent first When the VECTORSTAR is powered up a DRIVE POWERED UP message is inserted into Error History even though this 18 not an actual error To clear the Error History type ERR CLR Error History remains intact even through power down 11 7 4 Displaying Error Messages The ERR command can also be used to display an abbreviated description of the error For example type ERR 50 The VECTORSTAR responds
349. r phasing can cause erratic operation runaway or damage to the system Use of Kollmorgen resolver cable sets is highly recommended WARNING If you are making your own resolver cables you must obtain the procedure from Kollmorgen to make cables 2 6 4 7 Wiring C4 Logic Power Supply Wiring is discussed above with Wiring tor C2 since these two connectors are connected to each other 2 6 4 8 Wiring C5 Serial Communications Connector C5 the Serial Communications Connector is on the front ofthe VECTORSTAR It is a 9 pin D type sub miniature plug connector DE 9P The communica tions cable must have the mating DE 9S connector See the System Wiring Diagram Figure B 3 Note that wiring for RS 232 and RS 485 is completely different Refer to the model number to determine if your unit is RS 232 or RS 485 Be sure that the common ofthe VECTORSTAR and the power supply common of your computer or terminal are electrically connected to each other whether you are using RS 232 or RS 485 Use the COM pin on the serial connector Connector C5 for the VECTORSTAR common 5 232 vs RS 485 The VECTORSTAR can communicate with a terminal or a computer over a serial data line with RS 232 C the most common electrical interface for terminals and personal computers It can also communicate with EIA RS 485 a standard that supports multiple devices on one serial line RS 485 is an upgrade of RS 422 RS 42
350. r the VECTORSTAR or both can be damaged if the commons are not at the same potential CAUTION 22 VECTORSTAR Table 2 5 PC Wiring WIRING TO AN IBM PC COMPATIBLE COMPUTER VECTORSTAR VECTORSTAR IBM AT DE 9P DB 25S DE 9P DE 9S Female Female Female Female Usually you will only connect the shield at one end Sometimes the shield should be connected at both ends This is system dependent and generally found by trial and error The PC AT does not have a pin for shield If you want to hook the shield to the PC AT end of the cable you must connect it directly to the frame of the computer If you use a computer you will need communications software The recommended communications software for use with the VECTORSTAR 15 Motion Link a Kollmorgen software package specially designed for the VECTORSTAR Other communications software packages include XTALK PROCOM KERMIT and PC TALK See Chapter 7 for information about Motion Link 2 6 4 9 Wiring C6 Fan Power Connect the 230 VAC Control Power from the PA Connector C8 to the fan power connector Connector As the wiring diagram Figure B 1 shows 230 appears side by side on each connector similar to the logic power supply connector This allows you to daisy chain the Control Power to each unit that requires it Connector C6 is only used on VECTORSTAR amplifiers with continuous ratings of 20 Amps NOTE and abov
351. rating conditions with a dyno setup Note that the two variables below are for factory use only MADV Manual Slip Control Switch MADV 1 for Manual Slip Control Default 0 factory use only MSLIP When 1 amount of slip is solely controlled by MSLIP Factory use only In this representation 1 Hz slip corresponds to SLIP 524 9 3 COMMANDS FOR INDUCTION DRIVE The following variables are related to the vector control SLIPLIM User variable SLIPLIM limits the maximum amount of slip At all speeds slip fre quency cannot exceed SLIPLIM value If 1 Hz slip is maximum put SLIPLIM 4294967 which is 65 54 x 65536 Normally the maximum slip is 4 8 times greater than rated slip at base speed TROTOR This variable sets the rotor time constant 75 corresponds to 300 mSec GIMAGF Low pass filter gain for dynamic Imag control PDF System uses PDF velocity control by using KPROP and KVI only PDF 0 for most spindle applications KV is not used when PDF 0 KPROP Determines the proportional gain Range 1 32000 KVI Determines integral frequency Range 0 4095 PROP If integral control is undesirable you may set PROP to 1 to disable integral action proportional gain only VXANG Averaging of VEXT LOAD User s application code may be embedded in the firmware and loaded upon power up A switch variable LOAD enables 71 or 102 VECTORSTAR disables 0 this loading upon power up Note that
352. rmal program operation Hardware Travel Limits are always enabled 8 8 2 2 Software Travel Limits PMAX and PMIN There are two software limits maximum and minimum If position feedback PFB moves outside the software limits an error is generated and motion stops Software Travel Limits are intended as a guard against motion that is out of range due to improper operation or program ming errors PMAX is the maximum position allowed and PMIN is the minimum If PFB is greater than PMAX negative motion is allowed but positive motion 15 not If PFB is less than PMIN only positive motion is allowed PMAX and PMIN are in position units and can be changed at any time Software Travel Limits are enabled with PLIM which can also be changed at any time If PLIM is on software limits are active otherwise PMIN and PMAX are ignored PLIM is remembered If you have an application with boundaries which should not be crossed you are encouraged to use Software Travel Limits Note that you should set DIR before setting the Software Travel Limits This is because DIR relates PMAX and 80 VECTORSTAR PMIN to clockwise and counter clockwise motion limits If you change DIR you must reset PMAX and PMIN 8 8 2 3 User Position Trip Points PTRIP1 amp PTRIP2 The VECTORSTAR provides two user position trip points which control a switch You can use this switch to control your program The two trip points are and PTRIP2 Bot
353. rom 32767 1 to 1 32767 and can be negative to allow the slave to move in the opposite direction Also the index on gearing feature permits phase adjustments MASTER SLAVE PROFILE REGULATION With profile regulation you can control the slave s motion profile according to an external master motor or frequency Profile regulation modifies the velocity and acceleration of the slave axis without affecting the final position of the move You can use profile regulation to implement feed rate override MOTION GATING AND REGISTRATION VECTORSTAR can precalculate moves to begin motion within one millisecond after a transition on the GATE input This provides rapid and repeatable motion initiation VECTORSTAR has the ability to capture the current position within 25 microseconds after a transition of the HOME input This results in fast homing and accurate registration sequences MATHEMATICS Algebraic math is provided for commands such as X1 2x X2 X3 VECTORSTAR has 100 program labels 50 user definable variables and 50 user definable switches It also has 15 mathematical logical operations and over 150 system variables USER UNITS Quantities such as position velocity and acceleration are automatically scaled into user defined units This feature lets you program your VECTORSTAR in convenient units such as feet inches miles RPM and degrees VECTORSTAR SUPERIOR SERVO LOOP CONTROL VECTORSTAR offers smooth
354. rved by the program 9 6 1 Features This application software is able to implement the following features CHAPTER 9 SPINDLE PROGRAMMING 1 Zero Speed 2 At Speed 3 C Axis Spindle Axis Open Loop Modes 4 Drive Over Temperature 5 Motor Over Temperature 6 Orient 7 Spindle Reset 8 Drive Enable 9 Drive Ready 10 Remote Each function is described below 9 6 2 VECTORSTAR General Purpose Input Output Definition In this application software the VECTORSTAR GEN ERAL PURPOSE I O connectors are used as an interface to a higher level controller and from sensors Three inputs are commands from the controller two inputs are the sensor signals and seven outputs are for feedback signals for VECTORSTAR status to the controller Connect these I Os and program the higher controller properly based on the following definitions to implement the spindle functions A Inputto VECTORSTAR H Spindle Axis Open Loop 1 0 D Orient Request 1 B Dual Orient Position Select select P1 or P2 position H Drive Over Temperature 0 Negative Logic 1 is normal 15 Motor Over Temperature 0 Negative Logic 1 is normal 16 Spindle Reset 1 data reset I7 Drive Enable 1 B Output from VECTORSTAR OI Zero Speed 1 O2 At Speed 1 O3 Orient Complete 1 O4 Drive Ready 1 OS Drive Over Temperature 0 Negative Logic 1 is normal O6 Motor Over Temperature 0 Negative Logic 1 is normal O7 C Axis Spind
355. ry affordable even though it is full of advanced features Use all or only a portion of these features to accomplish your application EASY INSTALLATION VECTORSTAR is easy to install because the servo amplifier and the positioner are integrated into one package Many interconnects including the tachometer and encoder are eliminated SIMPLE PROGRAMMING LANGUAGE VECTORSTAR uses simple BASIC like commands such as RUN GOTO for branching and GOSUB RETURN for subroutines In addition to a simple comparison statement advanced IF ELIF ELSE END IF state ments result in more readable and less error prone programs You can comment every line in your program ADVANCED MOTION CONTROL MOVES The simple language does not prevent you from solving complex problems VECTORSTAR has separate accelera tion and deceleration rates as well as linear half S curve CHAPTER 1 SYSTEM DESCRIPTION and full S curve acceleration profiles VECTORSTAR has Macro Moves for applications where simple indexes cannot do the job A Macro Move is a combination of up to 30 accelerations traverses and decelerations which are fully precalculated for faster execution You can program teach modes where position end points can be changed by a factory operator MASTER SLAVE ELECTRONIC GEARBOX The electronic gearbox 1s used to link two motors together so that the velocity of the slave 1 proportional to the velocity ofthe master The ratio can be f
356. s 2 3 UNPACKING AND INSPECTION Electronic components in this amplifier are static sensitive Use proper procedures when handling CAUTION component boards Upon receipt of the equipment closely inspect compo nents to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately 11 CHAPTER 2 INSTALLATION Carefully remove packing material and remove the equipment from the shipping container Do not dispose of shipping materials until the packing list has been checked Parts that are contained within the shipment but not physically attached to the equipment should be verified against the packing list If any parts are missing notify Kollmorgen at once 2 4 INSTALLATION REQUIREMENTS Proper installation and field wiring are of prime impor tance when considering the application of servo amplifi ers Many problems may be avoided if installation of the equipment is done properly Users should familiarize themselves with and follow installation and wiring instruction in addition to all applicable codes laws and standards Pay special attention to the following topics when installing Kollmorgen equipment 2 4 1 Environmental Considerations The environment in which this equipment is placed can dramatically affect its operation Kollmorgen recom mends that the VECTORSTAR and PA unit be operated and stored under the following conditions Operating Temperature 0 C to 45 C Stor
357. s Like F pressing the escape key will abort the process and return to the Edit mode 10 3 2 7 Delete DEL The Delete DEL command can be used to delete one line or a whole range of lines DO NOT TYPE THESE EXAMPLES For example DEL 5 10 DELETE LINES 5 6 7 8 9 AND 10 DEL 12 DELETE LINE 12 DEL DELETE CURRENT LINE of these delete instructions are valid For an example that you can type in you entered line 1 TEST LINE FOR LEARNING ABOUT THE EDI TOR then type in the following command to delete that line P1 POINT AT THE FIRST LINE TEST LINE DEL 1 DELETE THAT LINE Line 1 should be deleted 10 3 2 8 Size The VECTORSTAR program memory has space for about 16000 characters If you want to see how much memory is left type SIZE The VECTORSTAR will respond with VECTORSTAR 65 LEFT which means the available space is about 65 If you try to enter a program larger than the VECTORSTAR can store an error will be generated 10 3 2 9 NEW The NEW command resets the password and clears the program The user program is stored in battery backed up RAM Normally the program is remembered indefinitely However if power to the VECTORSTAR 18 lost when it 15 executing an Editor command there 15 a small chance that the program will be corrupted This can happen for example if power is lost during the Change or Delete command In this case the VECTORSTAR w
358. s You can determine if your serial cable has open circuits by connecting your terminal on one end and disconnecting the cable on the VECTORSTAR end Again temporarily connect the transmit and receive pins this time on the far end of the cable then type on the keyboard The characters that you type should appear on the terminal screen If they do not then your cable is not functioning properly If your cable is functioning properly the serial cable may still be the problem You can determine if your cable is wired properly with an oscillo scope For RS 232 systems disconnect the cable from Connector C5 Connect ground on the scope probe to Pin 5 of the DE 9 connector on the cable Use the oscilloscope to monitor Pin 2 with the time base between 1 and 20 milliseconds division and the voltage sensitiv ity to 5 volts division While monitoring Pin 2 press several keys on the keyboard The oscilloscope display should show Pin 2 changing between 9 volts every time you press a key If not check Pin 3 If Pin 3 15 respond ing then Pins 2 and 3 are reversed Remove power and exchange Pins 2 and 3 If there is no response then the terminal may not be properly connected If you do not have an oscilloscope you may be able to use a digital voltmeter Many digital voltmeters are quite sensitive and can detect character transmissions You should see some activity change in voltage on the meter display every time you press a key
359. s about to be executed and the line is then executed This process 15 repeated for each command The Trace mode is enabled by turning TRC on When TRC is on the VECTORSTAR will enter the Trace mode when the user program is executed TRC can be turned on and off from the Interactive mode before executing the program or from the program itself It can be turned on from the Monitor mode Pressing the escape key from the Trace mode will cause the VECTORSTAR to exit the Monitor mode and turn TRC off If both TRC and SS are on then the VECTORSTAR will be in Single Step mode 7 6 2 6 Other Modes Other modes shown in Figure 7 1 include the communi cation modes Program Load Program Dump and System Dump These modes are covered in later chapters 60 VECTORSTAR VECTORSTAR CHAPTER 7 SOFTWARE INSTALLATION PROGRAMMING MODES PROGRAM DUMP Esc or lt CR gt lt CR gt RUNNING MODES POWER UP STEP POWER UP POWER UP NOT PRESENT PRESENT VECTORSTAR TASK LEVELS ALARM A Esc or ALARM B SS OFF 2 RUN 55 VARIABLE RUN label POWERUP RUN PROGRAM ERROR PRESENT TRC ON MAIN PROGRAM TRC OFF TRC ON BACKGROUND Esc OFF text Operator Entered italic Program Executed text Equivalent Command Figure 7 1 VECTORSTAR State Table 61 CHAPTER 7 SOFTWARE INSTALLATION VECTORSTAR 62 VECTORSTAR
360. s an option with the VSL P series Programmable control is identical in both the VSA and VSL P series The Motion Link communications language is used and configured to match the motor and application with the same TL and Variables parameters The power interface 1 different for these 2 product lines due to the difference in power levels However all VSA power levels use the same power interface and all VSL P power levels use a common power interface design Mechanical package power elements cooling and scaling set the power level for each model of the VSL P drive but all control cards are identical between units CHAPTER 12 POWER This modular approach simplifies inventory build testing and understanding of the Kollmorgen high power drives The customer can reduce the inventory needed for maintaining the drives and can transfer knowledge of programming and maintenance from one size drive to another because operational theory is identical 12 2 VSA DRIVES The VSA Drives are composed of three distinct control sections 1 The MC3 Control Card A 95078 contains the micro and its associated peripheral components the R D conversion circuitry the A D converter circuitry circuits and several housekeeping and monitor circuits This card can accept either analog command or RS232 485 serial inputs 2 The VECTORSTAR MIBD A 93285 card contains analog current loops opto isolation to isolate the control sect
361. s on I ODC Pin5 I O DC is provided for occasions when you do not need optical isolation for HOME CYCLE and REMOTE ENABLE Anunregulated low current power supply 15 provided on I O DC to power those three inputs Do NOT use I O DC as a power supply for anything except these three isolated inputs If you want to use I O DC then connect the return lines HOME RETURN CYCLE RETURN and or REMOTE RETURN to Common Then you can connect HOME CYCLE and or REMOTE ENABLE to I O DC usually through a relay contact to activate those inputs Using VECTORSTAR internal power supply DC for any purpose except power for HOME CYCLE and REMOTE CAUTION ENABI E can damage the PA Ol Pins 10 20 Ol is an optically isolated output It is a solid state relay rated for 0 25 Amps and 30 VDC maximum Only DC voltages with the more positive voltage on Pin 10 may be applied to this output You must observe polarity when connecting O1 You should install a 0 25 amp fuse in series with OI as it is not fused internally Note that O1 is also available on Connector C8 The O1 signal on Connector C8 is not optically isolated You can use both O1 signals at the same time 2 6 4 6 Wiring C3 Resolver Install the resolver cable between the motor and the VECTORSTAR Make the connection at the motor resolver connector and Connector C3 on the VECTORSTAR 20 VECTORSTAR Connect the resolver leads correctly Incorrect motor resolve
362. s which may develop if a point inside the PA or VECTORSTAR becomes grounded 5 2 3 Electrical Noise The low levels of energy in the VECTORSTAR control circuits may cause them to be vulnerable to electrical noise Sources of electrical noise are those pieces of equipment that have large fast changing voltages and currents when they switch on and off These devices have the capability of inducing critical current and voltage transients on their respective power lines These transients must be accommodated for with noise immu nity provisions 50 VECTORSTAR Electrical noise is prevented with the same methods as Surge Current and Transient Voltages However there are other methods of preventing electrical noise Such as Maintain physical separation between electrical noise sources and the VECTORSTAR amplifier Maintain physical separation between electrical noise sources and the VECTORSTAR control wiring This can be accomplished by using separate conduits or wiring trays for control wiring and power wiring Use twisted pair wiring for control circuits of the VECTORSTAR Follow good grounding practices when wiring the PA and VECTORSTAR Be careful not to create a grounding loop with multiple ground paths Follow the NEC s provisions on grounding 5 2 4 Radio Frequency Energy This equipment generates radio frequency energy NOTE This equipment uses and can radiate radio frequency energy and must be installed and
363. select the formats 2 6 4 4 Encoder Equivalent Output The Encoder Equivalent Output provides position information to another device in the system The output is in standard encoder format The Encoder Equivalent Output must be phased correctly If the VECTORSTAR is being used as a velocity drive and another controller is closing a position loop reversing the Encoder Equivalent Output can cause the VECTORSTAR to run away or oscillate Be careful to connect the encoder equivalent output so that the direction is correct Phase the Encoder Equivalent Output correctly Incorrect phasing of the Encoder Equiva lent Output can cause excur WARNING sions oscillations or runaways 2 6 4 5 Wiring C2 and C10 Customer and Analog Input The VECTORSTAR accepts an analog input If you use the analog input then the encoder input is not available If you use the analog input refer to Chapter 10 fora program that configures the VECTORSTAR as a velocity drive CIO Analog InputH Pin5 AnalogInputL Shield Pin8 The input is scaled for 10 volts full scale Input impedance is gt 20 Ohm The analog input is differen tial that 15 the input voltage 15 taken to be the voltage at Pin 5 minus the voltage at Pin 6 Differential two wire signals have higher noise immunity than single wire signals since noise picked up by the wires is eliminated when the two voltages are subtracted VECTORSTAR Typically one ofthe t
364. ser of ILIM and IFOLD IFOLD has no effect under this condition If IMON the output current stays below ICONT then IFOLD remains at its original high value If IMON is greater than ICONT IFOLD gradually decreases The greater IMON is the faster IFOLD decreases Since IFOLD starts out well above ILIM initially this has no effect However when IFOLD is less than ILIM IFOLD will limit the current This is called being in foldback If IMON remains on average above ICONT long enough IFOLD will decrease all the way to ICONT forcing IMON eventually to become less than or equal to ICONT Typically it takes at least 2 to 3 seconds for IFOLD to decrease from its original high value to IMAX Atthis point the VECTORSTAR is in foldback It takes an additional 10 seconds to reduce IFOLD from IMAX to ICONT 78 VECTORSTAR If IMON is reduced below ICONT then IFOLD will increase the smaller IMON is the faster IFOLD will increase If IMON remains below ICONT long enough IFOLD will return to its original high value 8 7 8 3 Monitoring Current Limits There are two switches that provide information on current limiting SAT 15 a switch that is on if the current 18 limited by either or IFOLD FOLD 1 a switch that is on if the current is limited by IFOLD only The operation of the foldback software is as follows If gt ICONT then IFOLD decreases If lt ICONT then IFOLD increases If IFOLD lt
365. sking controls which task runs by executing commands from the highest priority task that is not idle The rest of this section will discuss the dedicated labels in task level 5 POWER UP ERRORS AUTOS and MANUALS VECTORSTAR 10 8 8 1 Power Up Routine POWER UP On power up the VECTORSTAR checks your program to see if you entered POWER UP If you did the power up routine is executed For example enter the following program POWER UP 1 1 1 SAMPLE COMMAND B Now power down your VECTORSTAR for a few seconds and power up again After establishing commu nications the VECTORSTAR should display the sign on message followed by EXECUTING POWER UP LABEL indicating that the power up routine was executed The power up label is run after the autobaud NOTE If you want your program to start automatically on power up begin it with POWER UP If POWER UP is not found in the program the VECTORSTAR powers up in the Interactive mode If the VECTORSTAR is set to autobaud it will not execute the power up label until communications have been established If you want to leave multi tasking active after your power up routine is done end the power up routine with the END command instead of the Break command If your routine ends with the END command then multi tasking will be enabled and the Alarms Background and other multi tasking functions will be working If you want to return to the Intera
366. some low level After the clamp has occurred the motor is assumed to be at zero speed When the clamp has occurred you can raise or lower ILIM to set the holding torque as desired You can tell whether a clamp has occurred by looking at SEG the present motion segment If SEG is 0 then motion has stopped After the VECTORSTAR stops motion the position error stays at approximately PECLAMP Before commanding any new motion you should zero the position error with the ZPE command Clamping can be used with all move and jog commands If jogs are used the motion continues until the stop is found If move commands are used then motion does not continue past the specified endpoint regardless of whether a part is found An example of clamping follows PECLAMP 1000 CLAMP 1000 POS UNITS ENABLE CLAMPING MODE MOVE AT MOST 100000 POS UNITS THE MOTOR GETS ALL THE WAY TO 100000 CLAMP ON MA 100000 400 CHAPTER 8 GENERAL PROGRAMMING THEN THE STOP WAS NOT ENCOUNTERED ASSUMED THE PART IS NOT THERE Wo0 DELAY UNTIL MOTION STOPS IF PCMD EQ 100000 P PART NOT FOUND PCMD 100000 FINAL POSITION THEN THE PART WAS NOT FOUND 8 8 10 1 Clamping and Homing Clamping can be used to home your machine by gently running the machine into a stop this eliminates the need for a home limit switch In this case you should reduce ILIM to a level just high enough to overcome ru
367. stems often are very stable when you tune with lower target bandwidths However they oscillate vigorously at low frequencies when you try to tune them for higher bandwidths When a system is compliant it has the following characteristics There 15 springiness between the motor and the load or at the motor mounting plate The TUNE command calculates tuning variables that cause the system to oscillate The frequency of oscillation is less than 100 Hz Compliance can be corrected by the following actions Reduce the bandwidth of the system Stiffen the machine so the load is not springy CHAPTER 4 OPERATION 4 9 3 Non Linear Mechanics VECTORSTAR tuning is based on linear control theory The most important requirement of a linear motor controller is that the total reflected inertia should not change substantially during operation Load inertia includes all the inertia reflected to the motor such as inertia through gearboxes and leadscrews Inertia can change in ways that are easy to understand such as the inertia of a spool of cable decreasing when the cable is unrolled It can also change in less intuitive ways such as chain drives which have load in one direction but are unloaded in the other and systems with excessive backlash where there is no load when gear teeth are not touching When the inertia changes the system has the following characteristics System performance 15 excellent when the motor is in some posit
368. such as 1 the VECTORSTAR will print the carat and the 1 1 Only A to Z and allowed 10 6 1 9 Cursor Addressing Many displays allow you to address the cursor For example the DEP 01 from Kollmorgen 15 an 80 character display that allows you to address any location from 0 leftmost top line to 79 rightmost bottom line First send ASCII 27 followed by the address of ASCII 0 through ASCII 79 For example you can address the rightmost space of line one space 39 with the control character sequence The specifies cursor addressing and ASCII 39 specifies space 40 One problem with cursor addressing is that the VECTORSTAR cannot transmit ASCII 0 This is a common limitation for terminals If you want to address space 0 you must first address space 1 then transmit a backspace ASCII 8 or H For example if the following line is executed from the user program while the VECTORSTAR serial port is connected to the DEP 01 X will be printed on space 0 P MARKS THE FIRST SPACE 10 6 1 10 Printing VECTORSTAR Status PS The PRINT STATUS PS command is like the P command except that it appends the VECTORSTAR status to the end of the printed line There are five different status words that can be printed with the PS command Each is listed with its meaning in Table 10 3 You can use all formats and combinations wit
369. t P 127 133 Print Status PS 136 Quick If 7 128 RD 164 202 RECORD 44 Refresh R 136 Refresh Status RS 136 Return RET 128 131 206 RUN 59 127 Stop S 79 127 TIL 129 205 TUNE 42 Wait W 90 138 165 Zero PE ZPE 83 87 96 Commented Program 123 Comments 63 Common 19 Communication Establishing 25 Format 24 Multidrop 58 155 Communication problems 25 Complement 132 Compliance 45 Computer Requirements 57 Conditional Commands 128 Conditions 128 Connecting the Terminal 21 238 VECTORSTAR Connector 250 190 Connector C2 190 Connector C5 Serial Port 189 Connector C7 Standard UO 191 Connector C8 Optional I O 192 CONTINUE 96 Control Characters 135 Control Loops 96 Power Up 97 Control Variables 64 Control V 143 Control X 79 CPU LED 7 25 54 CPU LED 25 72 Critical Damping 40 Current Command 76 Limit 77 Maximum 76 Monitor 76 Current Loop Compensation 7 Cursor Addressing 136 Customer Service 123 CYCLE 19 59 145 Cycle 23 CYCLE READY 145 Cycle Ready 23 27 CYCLE RETURN 19 D D C BUS LED 54 daisy chain 22 DC Bus 30 DC Fan PA and Motor Connections 187 Debugging 161 Debugging and Multi Tasking 162 DEC 78 79 80 81 83 84 88 93 Deceleration 80 Limit 78 Decimal Point 133 Decisions 128 Dedicated Labels 127 Default Tuning 41 Delay 138 DEP 01 56 136 143 168 Detuning 40 Digital Input 16 DIR 75 80 86 152 Direction 75 Disable DIS Command 73 Discrete Inputs 6 Discrete Ou
370. t Speed output energizes a second hysteresis param eter named VUPH is added to VUP to provide a new band around the command speed The output will remain energized until the command speed or the measured speed is changed significantly enough so that their absolute differential is greater than the VUP VUPH band Once the output goes off the absolute differential between measured speed and command speed must be less than the VUP parameter for the output to reenergize The measured speed command speed VUP parameter and VUPH parameter are in percentages The measured speed is stored in the non programmable variable VAVG The VECTORSTAR will accept a analog DC voltage over the range of 10 to 10 VDC as a speed command input in the Spindle Axis i e Closed Loop mode or the Open Loop mode The VECTORSTAR converts the analog voltage input into a bi directional speed com 104 VECTORSTAR mand The value of the speed command is controlled by the parameters GEARI and GEARO Review the Spindle Axis Open Loop Modes below discussion on the GEAR and GEAR parameters The design output channel for At Speed is 2 Variables used VXAVG VAVG Non programmable variables from The feature Zero Speed controls an output signal that when on indicates the motor is stopped The output is energized when the absolute value of the measured motor speed is at or below the parameter value named VZR in RPM units VUP Defined band around
371. t have changed or should have changed very little Now raise the input voltage to a few volts Type P VEXT and VEXT should have changed much more than it did with the input zeroed 2 7 9 Checking the Resolver The VECTORSTAR provides a feedback loss circuit which is designed to detect broken wires in general it will not detect wiring errors You should use the following procedure to verify feedback circuit The feedback loss circuit is designed to detect broken wires In general it does not detect WARNING wiring errors Turn the motor shaft by hand until the R D converter output is within the ranges listed below You can display the R D output by repeatedly typing PPRD The standard R D resolution is 12 bits The resolution of your VECTORSTAR is listed as part of the model number which is shown on the front of the drive and described at the beginning of this chapter Rotate the motor shaft by hand until PRD is in the target range listed below Table 2 7 Target of PRD vs RID Resolution R D Resolution 12 Bit 14 Bit 16 Bit Target Minimum 0 0 0 Target Maximum 250 1000 4000 Now rotate the motor shaft approximately 1 4 revolution CLOCKWISE PRD should now fall in the range listed below VECTORSTAR Table 2 8 Target of PRD Versus RID Resolution After Clockwise 1 4 Revolution R D Resolution 12 Bit 14 Bit 16 Bit Target Minimum 800 3500 12500 Target Maximum 1300 5500 22500
372. t the VECTORSTAR does not recognize This error breaks program execution if the instruction 1s issued from the user program ERROR 81 NOT PROGRAMMABLE SEVERITY 2 You attempted to change a variable that is not programmable This error will break program execution if the instruction 18 issued from the user program ERROR 82 BAD NUMBER ENTRIES SEVERITY 2 The instruction that is executing has too many or too few parameters Look up the instruction in Appendix E to deter mine the correct number of entries This error breaks program execution 1f the instruction is issued from the user program ERROR 83 BAD OR OUT OF RANGE SEVERITY 2 You entered a parameter to an instruction that was too large or too small Check Appendix F for limits on variables This error can also occur when a parameter is in the wrong format such as a character string where a number is expected This error breaks program execution 1f the instruction is issued from the user program ERROR 84 OUT OF BOUNDS SEVERITY 2 The variable listed is out of bounds If the variable is protected that is set by the factory as defined in Appendix F contact the factory If the variable is not protected set it within its bounds This error breaks execution ERROR 85 BAD INDIRECTION SEVERITY 2 You attempted an indirect reference to a user variable that does not exist For example X1 10000 P X X1 X X1 refers to user variable X10000 which does not exist The P
373. tart the variable input routine However after you have entered a new value for X1 the variable input routine will be idled waiting for you to enter X2 In this case the next MI command will be executed with the new X1 and the old X2 You can correct this problem by temporarily storing the input values in user variables and loading them all together For example the above program can be modified as follows TASK LEVEL 4 VARIABLE INPUT INPUT NEW DISTANCE X11 INPUT INPUT NEW SPEED X12 1 11 LOAD X1 AND X2 WITH 2 12 VALUES END VARIABLE TASK LEVEL 5 20 MI X1 X2 GOTO 20 Temporarily storing the input values in X11 and X12 guarantees that the MI command will execute with either all new or all old values Since there are no idling commands between the commands that load X1 and X2 144 VECTORSTAR there is no possibility for task level 5 to run until X1 and X2 are both loaded or neither is loaded In addition if the variable input routine changes vari ables used in different lines of task level 5 you probably should turn MULTI off at the beginning of the block of lines and back on at the end This prevents the variable input routine from reloading the variables in the middle of a block of lines 10 8 7 2 Restrictions of Variable Input Like alarms variable input has many restrictions 1 You cannot execute GOTO GOSUB or RET commands from the variable input tas
374. tch to a general purpose input This input can be used as a general purpose input if these primary func tions are not required HOME is available on two connectors See the descrip tion of HOME on Connector C2 in section 2 6 4 5 LIMIT 11 PART OF QUICK START This input must be turned on for normal operation Connect the normally closed contacts of the overtravel limit switches in series with LIMIT Ground to enable If your application does not allow you to use hardware travel limit switches then you must hardwire LIMIT on If you are not using Connector C7 you can hardwire CHAPTER 2 INSTALLATION LIMIT on by installing a jumper directly on C7 between Pins 11 and 12 The VECTORSTAR is shipped from the factory with this jumper installed CYCLE Pin 13 CYCLE is an input that is normally used to start a cycle of a user program It can be used as a general purpose input if this primary function is not required See the description of CYCLE on Connector C2 above MOTION Pin15 PART OF QUICK START MOTION is used to enable motion of any kind If MOTION is off then no motion will be allowed MOTION is often connected to a stop button Ground pin is to enable motion If MOTION is off during power up the VECTORSTAR will autobaud If your application does not allow you to use MOTION then you must hardwire it If you are not using Connector C7 you can hardwire MOTION by installing a jumper directly on C7 between
375. te you should receive the interactive prompt gt Type RUN 10 Your program should print HELLO WORLD This should provide you with enough information to enter the examples from this chapter Read Chapter 8 for a complete description of Motion Link 10 3 2 VECTORSTAR Resident Editor If you are not using the VECTORSTAR Editor skip ahead to the next section Building a Program VECTORSTAR resident editor allows you to enter small programs and make changes without Motion Link Note that you can use this editor from Motion Link just as you would use it from a terminal To enter the VECTORSTAR Editor type ED When you are in the Editor the VECTORSTAR will respond with the editor prompt gt exit the Editor press the escape key 10 3 2 1 Editor Print P The Print P command prints a program line or lines then goes to that line Each line in the program memory has a number Many editor instructions such as Print expect you to specify the line number or numbers that applies to the instruction Type in the following example from the VECTORSTAR Editor P BEG END The VECTORSTAR will print the entire program and go to the end of the program When you specify a range the command works for all the lines in the range You can specify one line For example type P1 VECTORSTAR The VECTORSTAR will print and go to line 1 If you w
376. te th dte o tret ote eet de dee 138 LOPS MUPIPIASEI N T V lt C oI gt w HG IIIEI zum SS mam m u Q 139 10 8 1 Multi Tasking and Autobauding essere nnne nennen nennen nnn 139 TOS 2 IMD asics Bos os ees hives pana 139 10 53 END Commando sa n ep eg eedem ete m Ede e 139 10 8 4 Enabling and Disabling Multi tasking sse nnne 139 10 92 oe er e atu RN tet Meet rato i MD 141 10 8 531 PrezExecution Idle ERA a ATH AR ee 141 10 8 5 2 Post Execution Idle 1 u u S e ac d eden 142 10 8 5 3 Avoiding E IUD ER SII EN 142 10 8 6 Alarms Task Levels 1 3 sessi neret innen nennen enne nen 142 10 8 6 1 Restrictions Of Alarms uoce he re n a UTR 143 10 8 6 2 Printing with Alarms oce eee eee eren err cete 143 10 8 7 Vaniable Input Task ce ee S er PERRA URN ET 143 10 8 7 1 Using Variable Input with Profiles sese 143 10 8 7 2 Restrictions of Variable Ipp ut u u y a Ru nu Sus nennen enne nente nnne 144 10 8 8 Main Program Level Task Level 5 eene nnne nne 144 10 8 8 1 Power Up Routine POWER UPS u ul 1 tenente nenne 145 10 8 8 2 Error Handler ERRORS L S n u 145 10 8 8 3 Routine AUTOS 145 10
377. ted with the error and contact the factory This error breaks program execution and disables the VECTORSTAR 206 VECTORSTAR APPENDIX C ERROR CODES ERROR 211 219 INTERNAL 1 9 SEVERITY 3 These are internal errors Contact the factory These errors break program execution and disable the VECTORSTAR ERROR 255 UNKNOWN SEVERITY 3 This is an internal error If this error exists in the error history upon initial power up clear it with ERR CLR Contact the factory 1f this error occurs during operation This error breaks program execution and disables the VECTORSTAR 207 APPENDIX C ERROR CODES VECTORSTAR 208 VECTORSTAR APPENDIX D CUSTOMER SUPPORT CUSTOMER SUPPORT Kollmorgen is committed to quality customer service Note If you are unaware of your local sales representa Our goal is to provide the customer with information and tive please contact us at the number below Visit our resources as soon as they are needed This one number web site for MotionLink software upgrades technical provides order status and delivery information product articles and the most recent version of our product information and literature and application and field manuals techncial assistance Kollmorgen Customer Support Network 203 Rock Road Suite A Radford VA 24141 Phone 888 774 KCSN 5276 Fax 540 639 1640 Inside Sales Fax 540 639 1574 Technical Support Email servo Kollmorgen com Http www Kollmorgen
378. tep Trace Load 7 6 2 Mode Descriptions The following section describes each of the modes of operation Figure 7 1 is a diagram of each mode and how it interacts with the other modes 7 6 2 1 Interactive Mode The VECTORSTAR normally powers up in the Interac tive mode This mode allows you to start programs display and change variables and enter motion com mands for immediate execution The interactive prompt gt is written to the screen and the VECTORSTAR awaits a new command Refer to Figure 7 1 There are many ways to enter the Interactive mode First if the power up label POWER UP is not present the VECTORSTAR will power up in the Interactive mode The BREAK B command and errors that break program execution cause the VECTORSTAR to exit the Run mode and enter the Interactive mode 7 6 2 2 Run Mode The VECTORSTAR is normally in the Run mode when a program is executing There is no prompt because input is not accepted from the terminal The program is running it can display errors and print to the terminal Refer to Figure 7 1 After autobauding the Run mode is normally entered from either the Interactive mode the RUN command or from multi tasking If the power up label POWER UPS is present the VECTORSTAR will start running your program at that label on power up Errors can also cause the VECTORSTAR to change modes Some errors are serious enough to cause the VECTORSTAR to break program execution
379. the VECTORSTAR Do not type them in unless your program is NOTE backed up For example if a password was not set in the Editor gt BDS will begin transmitting the new program If you press the escape key before typing anything else the process will be aborted without changing the program in the VECTORSTAR If a password was set in the Editor then the password must follow the command For example if the password was set as SECRET type VECTORSTAR gt BDS SECRET and the VECTORSTAR will accept programs directly from the terminal The user program is stored in battery backed up memory If the program changes because of a hardware problem the VECTORSTAR issues a USER PROGRAM CORRUPT error The gt BDS command resets the user program memory which eliminates this condition 10 10 5 System Dump The VECTORSTAR can transmit all variables in addition to the user program This is called a system dump and you request it with the DUMP command For example type DUMP and the VECTORSTAR will provide pages of informa tion including the program all VECTORSTAR vari ables user variables and user switches This also includes all protected variables The system dump is provided so that the information from the dump can be directly re transmitted to any VECTORSTAR This changes all VON PROTECTED variables The DUMP command precedes protected variables with a semicolon This m
380. the VECTORSTAR will watch the HOME input When the HOME input changes to the state specified by CAPDIR the VECTORSTAR will store the position in the variable PCAP After the capture the VECTORSTAR turns CAP off This tells you that the capture is complete PCAP 1 in position units You can then use PCAP as you would any other monitoring variable 8 8 9 2 Capture Direction CAPDIR The capture is triggered when the HOME input changes from 0 to 1 or vice versa If CAPDIR is 1 the capture occurs when the HOME input changes from 0 to 1 If CAPDIR is 0 the capture occurs when HOME changes from 1 to 0 CAPDIR can be changed at any time Changing CAPDIR always turns CAP off 8 8 9 3 Speeding Up Homing Sequences One application of capture 1s to speed up homing sequences Homing sequences traverse very rapidly until the HOME switch is tripped Then the motor decelerates to zero and begins to traverse at a medium speed in the opposite direction until the HOME switch trips again Then the motor decelerates again to a slow speed until the HOME switch trips again Since the final speed was low the distance to decelerate is considered negligible and the motor is assumed to be at home Using capture the approximate home location can be determined when the motor is traversing at high speed eliminating the need for the medium speed traverse The following program illustrates this CAPDIR 1 CAP ON J 5000 AT 5000 RPM GET
381. the VECTORSTAR Motion Link is a software package designed specifically for this purpose Motion Link runs on IBM PC s and com patibles and it handles the communications between the VECTORSTAR and the computer Motion Link also features a full screen editor Editing with Motion Link is preferred because it has more features than the resident editor and it allows you to save your program on disk Having the program on disk 15 a significant advantage since it is a simple matter to transmit or download the program should the VECTORSTAR be replaced or multiple systems be programmed 10 3 1 Motion Link Editor Chapter 8 provides an in depth procedure for installing and using Motion Link This section provides you with enough information to get started in most cases Enter a simple program with the following procedure 1 Establish communications with the VECTORSTAR as discussed in Chapter 7 2 Pressthe right arrow key to display the menu bar Select PROGRAM 3 Select NEW 4 Enterthis program 10 P HELLO WORLD B 5 Press the escape key to exit the Motion Link Editor 6 Follow the instructions on your computer screen Motion Link will ask you if you want to save your program Enter and give the name TEST as the name of your program 7 Motion Link will now ask you if you want to transmit the program to the VECTORSTAR Enter 124 VECTORSTAR 8 After the transmission is comple
382. the VECTORSTAR The system may be unstable The motor may begin oscillating or run away Be prepared to disable the VECTORSTAR quickly by turning off opening the contacts of LIMIT or REMOTE This section discusses how to enable the VECTORSTAR Follow this procedure l Turn on close contacts of LIMIT MOTION and REMOTE 2 Turn on Control Power 3 Turn on the AC Line 4 Enable the VECTORSTAR Type EN The motor should be still If your motor is oscillating disable the VECTORSTAR by typing 37 CHAPTER 4 OPERATION DIS 4 2 1 ERROR 17 FEEDBACK LOSS If the VECTORSTAR generates ERROR 17 FEED BACK LOSS then a lead in the resolver cable is probably broken First verify that the cable is wired correctly using the procedure in Checking the Resolver Cable in section 2 7 10 If the cable appears to be wired correctly use an oscilloscope to verify that the sine Connector C3 Pin 7 and the cosine Connector C3 Pin 9 are present Note that the amplitudes of both these signals vary with motor position so you will need to rotate the motor by hand to force sine and cosine to their maximum values Expect a sine wave with a maximum peak to peak level of about 6 5 Volts at 8 KHz If both sine and cosine are present on the connector and your VECTORSTAR continues to generate ERROR 17 your unit may be malfunctioning contact the factory 4 2 2 ERROR 14 POWER BUS ERROR 14 POWER BU
383. those units Refer to Appendix F which lists all variables and the units associated with them 10 9 1 3 External Units External units are for the external inputs VEXT and PEXT The user units are set by VXNUM and VXDEN for external velocity VEXT and by PXNUM and PXDEN for external position PEXT Figure 10 3 shows how external position and velocity come into a slave VECTORSTAR and are displayed as PEXT and VEXT If the external input is a system with the same resolution as your VECTORSTAR set external units as follows VXNUM VXDEN VDEN PXNUM PXDEN PDEN If the command is something other than a motor of similar resolution see Machine Specific Units in the next section 10 9 2 Machine Specific Units The VECTORSTAR allows you to specify user units for your machine You must determine the conversion constants PNUM amp PDEN for position VNUM amp VDEN for velocity and ANUM amp ADEN for accelera tion Two tables have been provided to help you calculate those constants Tables 10 8 and 10 9 are for position velocity and acceleration units based VECTORSTAR Table 10 8 English Conversion 12 bit RID Only POSITION UNITS Motor Movement In Revolutions g Movement In Your Units VELOCITY UNITS Motor Velocity In Rev Min 1173922 amp _ s VDEN Velocity In Your Units ACCELERATION UNITS Motor Acceleration In RPM
384. ting a command This is called a pre execution idle because the task 15 idled before executing the command that causes the idle There are two conditions that can cause a pre execution idle A task about to execute a motion command MI MA or MCGO will be idled if the motion buffer is full Also a task about to execute a printing command P PS R RS or INPUT will be idled until the previous printing command is finished For example the VECTORSTAR can store up to two MI or MA commands This is called buffering Chapter 8 This means that if you wrote a task with three MI commands in a row then the third MI command could not be executed until the first move was complete So that task would be idled until the first move finished If there was another lower priority task it would execute until the first move finished When the first move finished the first task would no longer be idled and thus would proceed CHAPTER 10 USER PROGRAMS Consider the following program which has two tasks a routine starting at 1 task level 5 and a background task starting at BACKGROUNDS task level 6 The background task is the lowest priority task and will only execute when the general purpose task is idle In the following example the task is idle between the second and third motion command Use the VECTORSTAR Editor to enter this program TASK LEVEL 5 1 MAIN PROGRAM EN MI 10000 10 FIRST MOVE P FIRST MOVE PROCESSED
385. tions of these conven tions are as follows Safety warnings cautions and notes present material that is important to user safety Be sure to read any safety notices you see as they could prevent equipment damage personal injury or even death to you or a co worker Bold text highlights other important information that is critical to system operations 2 CAPITALIZED text stresses attention to the details of the procedure Underlined text emphasizes crucial words in sentences that could be misunderstood if the word 1 not recognized DOUBLE BLOCKED text defines words that are to be typed into the computer by the user to interface with the VECTORSTAR system SINGLE BLOCKED text defines words that are displayed by the VECTORSTAR on the computer terminal to inform the user of system operations or prob lems ABBREVIATIONS CCW Counter Clockwise CW Clockwise D L Direction Limit GC Goldline Cable GCS Goldline Cable Set LED Light Emitting Diode NEC National Electrical Code P N Part Number R D Resolver to Digital Regen Regeneration TL Test Limits UL Underwriters Laboratories VECTORSTAR TABLE OF CONTENTS TABLE CONTENTS CHAPTER 1 SYSTEM DESCRIPTO N itte u eene o gute donde Sene tienes eeu 1 IT INTRODUGTION tert Peintre Utere tree er AU to Io m OI i rU Gag RUNI 1 I 23PRODUCT DESCRIPTION 6 1 1 3 FEATURE
386. titasking by typing RUN 10 This program resets X1 then begins to count up Now enter V from your terminal or ATTN from your DEP 01 The VECTORSTAR should print the value of X1 which has been continuously incrementing since you typed RUN 10 Next enter a new value for X2 and notice that the program prints out a new value for X1 which is larger than the value it printed at the beginning of the variable input task This is because the variable input task was idle while you were entering the new value Since the higher priority task is idle the lower priority 11 will run and continuously increment X1 10 8 7 1 Using Variable Input with Profiles You can use the variable input routine while the VECTORSTAR is executing motion profiles However you must be careful if you are changing parameters of motion Specifically if you are changing two or more parameters which you want to take effect at the same time you must write your program to store those values away For example suppose you are using the variable input routine to prompt for speed and distance You might use a program like this 143 CHAPTER 10 USER PROGRAMS TASK LEVEL 4 VARIABLE INPUT INPUT NEW DISTANCE X1 INPUT INPUT NEW SPEED X2 END END VARIABLE TASK LEVEL 5 20 MI X1 X2 GOTO 20 If you type RUN 20 this program will continuously move the motor X1 distance at X2 speed even after you press V to s
387. to 4 Variables where number is the number of intervals over which the variables will be recorded and time is the time in 44 VECTORSTAR milliseconds of each interval Note Number lt 1000 for 1 Variable Number lt 500 for 2 Variables Number lt 333 for 3 Variables Number lt 250 for 4 Variables The following example records the velocity response of the VECTORSTAR to a JOG command 405 BEGINNING LABEL EN ENABLE VECTORSTAR RECORD 500 1 VFB RECORD VFB FOR J 1000 112 SECOND JOG B 71000 RPM After data 1s recorded you can use the PLAY command to print each point on the screen However Motion Link provides all the routines to retrieve plot print and store recorded data on your computer and line printer The RECORD command is useful when tuning a system because you can display the VECTORSTAR response to commands without an oscilloscope However it is not limited to tuning For example you can record VCMD to plot a motion profile or you can plot VEXT to watch the external encoder analog input You can also plot user variables to watch the performance of your program 4 9 PROBLEMS Sometimes there are problems tuning Usually the TUNE command will provide you with a tuning that is either acceptable or close to acceptable If not you can tune the system yourself Sometimes there are physical factors that prevent you from attaining the performance you need These problems fall i
388. to 800 RPM the commanded move is identical 8 8 15 Encoder Feedback Some special applications demand more accuracy than can be provided with a resolver based system For these cases you can mount an encoder to the motor and feed the encoder s output into the external input The requirements for such a system are 1 The resolution of the encoder must match the resolution of the resolver on your VECTORSTAR system Refer to the Chapter 1 and the model number to determine the resolution of your system Select the encoder as follows VECTORSTAR Master Encoder fo Motor VSA or VSA cm or Pulse Signal or Analog Signal Digital Input Analog Input CHAPTER 8 GENERAL PROGRAMMING Slave or w Resolver Feedback Electronic Gearbox Slave Velocity VXDEN VXNUM YEN X4 Decode Posi AID osition Option Card GEARI GEARO o PCMD Motion Profile Command Generation Profile Regulation Digital Input or Analog Input Digital Input or Analog Input Conn C2 Motion Command Slave Position PXDEN gt PXNUM X4 Decode Velocity 1 REGKHZ Profile Generation Figure 8 8 VECTORSTAR MasterlSlaving CHAPTER 8 GENERAL PROGRAMMING Table 8 9 Encoder Resolution R D Resolution Encoder Lines Revolution 2 The encoder must be mounted directly to the motor It cannot
389. tor would prefer to see 1t then in mils as the VECTORSTAR motion commands process it 10 6 4 SERIAL Switch You can use the SERIAL switch to make sure that the serial port is not busy before you execute a command If SERIAL 15 on the serial port is ready For example suppose you do not want to execute an INPUT command if the serial port is busy It might be busy from a print command or from a previously executed input com mand In that case use these commands SERIAL EQ ON INPUT ENTER SPEED X1 10 7 IDLING COMMANDS There are four idling commands HOLD H DWELL D WAIT W and INPUT This section discusses the first three The INPUT command was discussed above HOLD DWELL and WAIT cause the user program to wait for an event before executing the next command HOLD waits for switches DWELL waits for a timer and WAIT waits for a motion segment 137 CHAPTER 10 USER PROGRAMS 10 7 1 HOLD H The HOLD command waits for a switch to be either on or off You specify the HOLD command with the switch and the desired state For example 11 ON HOLD UNTIL INPUT I1 IS ON H O2 OFF HOLD UNTIL OUTPUT 0215 OFF H TRIP1 ON HOLD UNTIL gt PTRIP1 Use the VECTORSTAR to enter the following program 29 P TURN I1 ON H 11 ON P IS NOW B Exit the Editor turn input I1 off and observe the action of the HOLD command by typing RUN 29
390. tputs 6 Distance To Go 83 Disturbance 46 Downloading 154 VECTORSTAR Drive Control 75 DT 108 DTIMER 102 108 DUMP Command 155 Dwell D Command 138 164 E Editing 124 Editor Change C 126 Delete D 126 Enter Exit 124 Find F 125 Insert T 125 NEW 127 Next Line 125 Password PASS 125 Print Goto P 124 SIZE 126 Editor ED Command 124 Electrical Noise 50 Electronic Gearbox 16 Electronic Gearbox 91 205 ELIF Command 130 ELSE Command 130 Emergency Stop 79 Enable EN Command 73 79 Enabling the BDS5 77 Enclosures 12 Encoder Equivalent Output 18 Encoder Feedback 94 Encoder Input 6 16 END Command 139 ENDIF Command 130 Environmental Considerations 12 Error Display Message 56 168 Firmware 56 168 From Program 55 59 168 Handler 59 201 203 Hardware 55 167 History 56 168 Message 55 167 Program Corrupt 127 Severity 55 167 197 ERROR 14 POWER BUS 38 ERROR 17 FEEDBACK LOSS 38 Error Levels 55 167 Error Log 55 167 ERRORS 59 145 Example Application 120 External Inputs 91 External Units 148 151 EXTLOOP 96 INDEX F Factory Support and Repair Policies 56 FAULT 73 FAULT LED 7 54 FAULT LED 73 Fault Logic 72 Faults 55 167 Firmware 72 Hardware 73 Software 73 Features 1 Feed To Positive Stop 87 Feed forward 97 Feedback Position 75 Feedrate Override 91 Filter Low Pass 46 Final Position 83 Firmware Version 155 First Transmission 24 Floating Point 152 FOLD 78 Foldba
391. trt ee d RR aka a D EO ce ETUR ai Slee 70 842 Algebraic bore eed ceteri uie ep ee Mie teas tela dean eee eee 70 8 43 Logical Functions AND OR a Se ice au eee din 71 8 5 GENERAL PURPOSE INPUT OUTPUT 12 1 71 8 5 Whole Word scores e uq be RE 71 8 6 ENABLE AND FAULT LOGLIC unun 72 8 6 1 Firmware Area core tero 72 8 6 2 Fault Area e ES 73 8 6 3 Fault Latch Area ren tete 73 8 64 Ready Latch Area ua n E 73 8655 ACTIN EX Are aS sei uy wu tier tavi ete comet 73 8 6 6 Relay and STATUS Control Area 6 eene enne ennt innen enne 73 8 6 8 Output Relay see nO Reden etas eq 75 P DRIVEIGONTROL tette e t n E RERO REA GEO NR 75 8 7 1 ODir ctionxControL DIR esee Un ERN Db QUID S 75 8 2 erotic teen ct eS ett estie ciues s eect Sane 75 8 7 2 1 Position Command and Feedback PCMD amp PFB sese 75 8 7 2 2 Position Error PE amp a a E ea Raai oa ena Rea A nennen nennen nnns 75 8 7 2 3 RJD Position nete redeem eden e e eS 75 8 7 2 4 Sampling PCMD and
392. ts 64 Monitor 64 Printing 64 User 64 244 VECTORSTAR VAVG 76 104 VBASE 101 VCMD 76 96 VDEFAULT 81 VDEN 148 VE 76 96 Velocity Command 76 Error 76 Feedback 76 Maximum 76 Offset 93 Velocity Command 96 velocity drive 156 Velocity Loop 77 97 Ventilation 51 Version 155 VEXT 91 VEB 76 VMAX 76 VNUM 148 VOFF 93 VORNT 102 106 VOSPD 76 198 VSA OPTI 193 VUP 102 104 106 VUPH 102 104 VXAVG 91 104 110 VXAVGS 102 VXDEN 148 151 VXDENC 102 105 VXDENO 102 105 VXNUM 148 151 VXNUMC 102 105 VXNUMO 102 105 VZR 102 104 W Wait W Command 90 138 165 Warning 11 WATCH 154 Watchdog Serial 154 Watchdogs 72 Whole Word 71 Wire size 193 Wiring 13 Wiring C1 Encoder Equivalent 16 Wiring C2 Customer I O 18 Wiring C3 Resolver 20 Wiring C4 Logic Power Supply 20 Wiring C5 Serial Communications 20 Wiring C7 Standard 23 Wiring C8 Optional I O 23 VECTORSTAR Wiring the AC Line 15 Wiring the DC Bus 15 Wiring the Ground 13 Wiring the Motor 14 Wiring the Power Connections 14 Wiring the 5 4 5 Front Panel Connectors 15 Wiring the Regen Resistor 15 Wiring the VECTORSTAR Front Panel Connectors 16 WTIME 154 X X X1 X X250 69 X1 X250 69 X41 106 X42 106 X43 107 X45 107 X46 107 XSI XS50 69 Y Y 69 7 Zero PE ZPE 83 87 96 Zero Speed 104 INDEX 245
393. ts with the print command This process will be demonstrated with the hardware travel limit switch LIMIT If you are not using the LIMIT switch you can substitute another hardware switch such as CYCLE or HOME available on Connector C2 In this case substitute the words CYCLE or HOME for LIMIT in the following discussion 1 Open the switch contacts VECTORSTAR 2 Verify that the contacts are open If you are using a Kollmorgen Input Module or an industry standard OPTO 22 compatible input module there will be an LED on each input to indicate its state The LED will be off if the contacts are open 3 Use your terminal to enter PLIMIT 4 The VECTORSTAR should respond with 0 indicating that the contacts are open 5 Close the switch contacts 6 Verify that the contacts are closed LED should be on 7 Use your terminal to enter PLIMIT 8 VECTORSTAR should respond with 1 indicating that the contacts are closed Repeat this process for each discrete input that you are using D _13 __ 14 _ 15 __16 __18 19 __ 12 I13 15 I16 CYCLE __ __ _ LIMIT _ MANUAL __ __ Note that fault condition exists the state on or off of REMOTE may not be available In this case the value of REMOTE will print as 1 2 7 2 Checking General Purpose Outputs You can check all of the ge
394. u can enter 10000 Setting has the same effect NORM command Use whichever you think makes your program easier to understand Now type in P PFB Now normalize the position to 1000 with NORM 1000 Again print PFB P PFB 8 8 4 JOG J Command This section describes J the JOG command Jogging 15 useful when you want to command motion without position endpoints For example the following com mand causes the motor to rotate at 500 RPM indefinitely J 500 Jogs are useful for machine set up and testing ACC and DEC are in effect with Jogs as 15 SCRV Software and Hardware Travel Limits are also in effect Jog 15 the only move command that can cause motion to change direction without stopping first However since chang ing direction involves both acceleration and deceleration Jog commands that change direction of rotation use ACC or DEC whichever is lower Jog commands should be used with caution since motion continues indefinitely and see that it is now 1000 The NORMALIZE com mand cannot be used when either GEAR 15 on or when motion is commanded from MA MI or any other motion command 8 8 6 Zero Position Error ZPE Command The ZPE command zeros position error by setting PCMD to PFB without changing PFB There are occasions when this will be necessary For example if the VECTORSTAR is run for some time as a velocit
395. ugh this is not guaranteed On power up the contacts are open until the VECTORSTAR passes its power up self tests Then the contacts close and the VECTORSTAR begins normal operation Note that if the VECTORSTAR is set to autobaud on power up the contacts will not close until after autobauding and establishing communications One way to use the relay 15 to interconnect it with the main power contactor In this case a hardware watchdog fault will disconnect all power to the system The SYS OK LED indicates that there is not a hardware watchdog fault If this LED goes out you should remove the VECTORSTAR from operation and contact the factory 8 7 DRIVE CONTROL This section discusses several variables that you must be familiar with before you can control the VECTORSTAR 8 7 1 Direction Control DIR DIR 15 a switch that controls the algebraic sign of command and feedback variables When DIR 15 on clockwise position velocity and torque are all positive If DIR is off then clockwise position velocity and torque are negative DIR is turned on at power up 8 7 2 Position 8 7 2 1 Position Command and Feedback PCMD amp PFB PCMD is the commanded position It is generated internally from motion commands like the JOG com mand PCMD is in position units The standard position units are R D converter counts as specified in Table 8 6 PCMD is set to PFB when the VECTORSTAR is disabled CHAPTER 8 GENERAL PROGRAMMING
396. umed to be in velocity units End is used in macro moves as the end speed of two and three speed moves 221 APPENDIX SOFTWARE COMMANDS VECTORSTAR Text b Constants ON OFF and N G 2 COMMANDS lt Text gt 15 any text string of characters The control character symbol 7 converts the succeed ing character to a control character Indicates an optional parameter ON and Y are equivalent to 1 OFF and N are equivalent to 0 The constants can be used in any expression and in response to the Input command The following commands are the instructions used to program the VECTORSTAR 222 Comment Comments can follow any instruction Also entire lines can be comments The semicolon must be preceded by a space unless it 15 the first character in a line Allowed on any line including the VECTORSTAR Editor GOTO 5 THIS IS A COMMENT FOR A COMMAND THIS ENTIRE LINE IS A COMMENT Labels Labels can be 0 500 and cannot be repeated They must be decimal constants They are allowed only from the user program The following labels are special purpose labels 5 alarm label B B alarm label C C alarm label VARIABLES variable input label POWER UP power up label AUTO AUTO label MANUAL MANUAL label ERRORS error handler label BACKGROUNDS background label Alarm labels require that you specify the switch that starts the alarm and the state of the switch ON or OFF that should trigger the alarm If t
397. ut frequency 2 MHz This error breaks program execution and disables the VECTORSTAR C 4 5 Communication Errors ERROR 103 BAUD RATE SEVERITY 1 The variable BAUD contains a value that is not supported by the VECTORSTAR This error occurs during the autobaud sequence and so is never printed to the terminal You will only see it in the error history buffer This error has no action ERROR 104 ABAUD amp MULTIDROP SEVERITY 1 This error is caused by attempting to autobaud while in multidrop communications which is not allowed The variable ABAUD is on indicating request for autobaud and the variable ADDR is not zero indicating multidrop communica tions This error occurs during the autobaud sequence and so is never printed to the terminal You will only see it in the error history buffer This error has no action ERROR 105 SERIAL WDOG SEVERITY 3 The serial port did not receive a valid command for WTIME milliseconds when the serial watchdog was enabled that is WATCH 1 This error breaks program execution and disables the VECTORSTAR C 4 6 Password Errors ERROR 110 EDIT PASSWORD SEVERITY 1 You attempted to execute an instruction that requires the Editor password This occurs with the gt BDS command In this case you must follow the command with the password ERROR 111 FACTORY SETTABLE SEVERITY 2 You attempted to change a variable that is protected These variables are set at the factory This error breaks program e
398. velocity can vary considerably The CONTINUE command allows you to specify a time period up to 1 second over which velocity command is averaged For example if you entered CONTINUE 50 CONTINUE would change the velocity command to the average velocity command over the previous 50 millisec onds CONTINUE always sets SEG to 1 The VECTORSTAR provides several control loops These loops or control algorithms allow you to select the best control method for your applications 8 9 CONTROL LOOPS There are four sections of control loops that are of interest input output feedback and tuning variables The input is compared to the feedback to generate an error The error signal is modified using the tuning variables to generate the output The tuning variables can be modified to produce higher levels of perfor mance unfortunately higher performance brings with it greater noise susceptibility and reduced stability The system designer must optimize noise and performance for the application VECTORSTAR control loops have one or two tuning variables All VECTORSTAR loops follow the conven tion that larger constants provide higher gain Each loop 18 described below and shown in Figure 8 9 at the end of this chapter 8 9 1 Position Loop The Position Loop input 15 the variable PCMD the position command The feedback is PFB the position feedback The output is VCMD velocity command and its two tuning variables are KP
399. venience as either will work MCA 10000 1000 200 MCA 11000 0 MCD 500 ADD DWELL 0 1000 0 RETURN TO HOME NOTE THAT VELOCITY IS ALWAYS POSITIVE MCGO Note that Macro moves have one inherent weakness If you are using user units and you specify an incremental move that translates to a non integer number of counts the Macro move will move the closest number of integer counts If the move is repeated the small error in the position command will accumulate This problem does not happen if you use MI commands 8 8 8 R D BASED MOVE MRD Command This section describes MRD the command that gener ates moves based on the feedback from the R D con verter rather than the Position command PCMD These moves are less than one revolution and are always Absolute rather than Incremental With the MRD command you specify the desired R D output at the end of the move and the peak velocity For example the following command moves the motor so that the R D output is 1000 85 CHAPTER 8 GENERAL PROGRAMMING MRD 1000 100 100 RPM is the traverse speed ACC DEC and SCRV are all in effect with MRD As with MI and MA if 100 RPM is too large to be attained given ACC and DEC the move becomes triangular As an option directions of CW or CCW can be specified to force the motor to rotate the desired direction If direction 15 left out then the motor rotates whichever direction is shortest
400. vices which are isolated from the VECTORSTAR by the I O modules The common of this supply should not be connected to the VECTORSTAR Common You must provide an additional power supply for the modules NOTE O1 O6 Odd numbered Pins from 37 to 47 O1 O6 are general purpose outputs STATUS Pin 35 The STATUS output indicates the status of the VECTORSTAR You can configure STATUS to indicate active or ready to be activated with the software switch STATMODE See the Enable and Fault Logic Diagram in Chapter 8 Figure 8 10 The state of the STATUS output is undefined for up to 25 milliseconds on power up STATUS may turn on for up to 25 milliseconds after power up WARNING MANUAL Pin33 MANUAL is used to change the VECTORSTAR from AUTO mode to MANUAL mode For more information refer to User s Manual Chapter 10 MANUAL may be used as a general purpose input if its primary function is not required 6 Odd numbered Pins from 1 to 31 11 116 are general purpose inputs PowerMeter 9 24 VECTORSTAR 2 6 4 12 J1 Configuration Jumper Jumper J1 connects the RS 485 terminators Refer to Section 2 6 4 8 Line Termination for information 2 6 5 Establishing Communications Kollmorgen supplies a communications package called Motion Link that is designed especially for communicat ing with the VECTORSTAR Other terminal emulators can also be used as long as the required data format 1s followe
401. wer 10 2 2 Application Specification 1 Allow a variable cut length acceleration decelera tion and speed Use user variables X1 X4 as follows Acceleration X2 Deceleration X3 Speed X4 Cut Length added to registration mark 2 Turn output at the end of the move This output will be connected to start the saw Use output Ol CHAPTER 10 USER PROGRAMS 3 Allow contacts that stop the process after the present cycle is complete Use input I1 4 Wait for a start signal to begin each cycle Use input D 10 2 3 Application Flowchart When you write flowcharts use three symbols a circle a square and a diamond A circle indicates the start or end of a program It also indicates the start or end of a subroutine A square is an execution block That is the VECTORSTAR should do something turn on an output print a message or command motion A dia mond is a decision block There are two exits from a diamond one if the condition is true and the other if it is false Figure 10 1 presents a sample flowchart for this application 121 CHAPTER 10 USER PROGRAMS VECTORSTAR TURN OFF SAW OUTPUT ENABLE VECTORSTAR SET REGISTRATION DIRECTION TO POSITIVE NORMALIZE TO ZERO SET ACC AND DEC TURN ON REGISTRATION IS STOP INPUT ON WAIT FOR START INPUT TURN OFF SAW OUTPUT START MOVE WAIT FOR REGISTRATION MARK DISABLE VECTORSTAR PRINT STOP HAS BEEN ISSUED SET
402. with ERR 50 VECTORSTAR INHIBITED You may display messages for errors from 1 through 999 If you type in an error number that the VECTORSTAR does not recognize it will respond with ERROR NOT FOUND A description of all errors 18 given in Appendix 11 7 5 Firmware Errors Firmware errors are an indication of a serious problem with the VECTORSTAR These errors stop communica tions disable the drive and flash the FAULT LED The FAULT LED flashes several times then turns off and pauses The number of flashes represents the error number These error numbers range from 2 to 9 See Appendix C for information on these errors Contact the factory should one of these errors occur VECTORSTAR 12 POWER 12 1 INTRODUCTION VECTORSTAR Series of drives consists of two families the VSA modular units and the VSL Series The VSA series features 230 volt units that are available to 28 KW 85 Amps continuous The VSA units require an external PA series power supply of the appropriate current rating Axis drives are also powered from this same power supply All units use a resolver as a feedback device The PA series power supply can also be a stand alone line regenerative supply in an 110 Amp rating The 110 model adds line regenerative capability to the 110 unit The VSL P series features integral power supplies and is available to 90 KW The VSP can be applied on 460 VAC lines Line regeneration i
403. wo wires will be at a voltage nominally the same as Common Preferably this wire should be connected to Pin 6 It is important to note that swapping Pins 5 and 6 reverses the polarity of this input When using the analog input you must be careful to shield it properly You should use shielded twisted pair cable Connect the shield to Pin 8 on Connector C10 on the VECTORSTAR or to the frame at the source of the signal or at both ends Determining the best shield connection is often a matter of trial and error Begin by wiring the shield only at the VECTORSTAR Ifthe VECTORSTAR is being used as an analog velocity drive you must be careful to connect the analog input with the correct polarity since the polarity determines the direction of rotation Ifthe VECTORSTAR is being used as a velocity drive and a different controller is closing a position loop reversing the polarity of the analog input can cause the VECTORSTAR to run away or oscillate Be careful to connect the analog input so that its polarity is correct Phase the analog input cor rectly Incorrect polarity of the analog input can cause excur WARNING sions oscillations or runaways Connector C2 has a variety of signals Tach Monitor Pin2 Tach monitor indicates velocity It is referenced to Common and scaled for 1000 RPM clockwise 1 volt This output has a 1k Ohm resistor in series and a 4700 pF filter capacitor connected to Common I Monitor Pin4 I mon
404. xecution if the instruction is issued from the user program C 4 7 Errors From IF TIL and GOSUB Commands ERROR 115 IF ENDIF SEVERITY 2 The program executed an IF command to begin an IF BLOCK but could not find the corresponding ENDIF to end the IF block This error breaks program execution ERROR 116 IF NOT STARTED SEVERITY 2 An ELSE ELIF or ENDIF was encountered when there was no IF This will occur among other times if you use a GOTO to branch to the middle of an IF ELIF ELSE ENDIF block This error breaks program execution ERROR 117 TIL FOLLOWS 2111 SEVERITY 2 The or TIL instruction was used to execute a conditional TIL This error breaks program execution 205 APPENDIX C ERROR CODES VECTORSTAR ERROR 118 TOO MANY GOSUBS SEVERITY 2 The last GOSUB was one GOSUB too many The VECTORSTAR has 4 levels of subroutines This error breaks program execution ERROR 119 RETURN wlo GOSUB SEVERITY 2 The VECTORSTAR encountered a RET when it was not expecting one This occurs when there are more returns than GOSUBs This error breaks program execution C 4 8 Power Up Marker Not An Error ERROR 199 DRIVE POWERED UP NIA This 18 not a true error ERROR 199 is used to mark the error history buffer when the VECTORSTAR powers up C 4 9 Internal Errors ERROR 200 FOLDBACK OUT SEVERITY 3 The factory set variables that control foldback are out of bounds Contact the factory This error breaks pr
405. xes number of 193 INDEX B 142 Background 146 Restrictions 146 Bandwidth 43 Basic Units 146 BAUD 153 Binary 134 BLOCK IF 130 BLOWN FUSE LED 54 Brake 73 Break B Command 59 127 139 Breakers 193 Broadcast 156 BSLIP 101 142 15 104 Encoder Equivalent 188 CAP 86 CAPDIR 86 Capturing Position 86 Caution 11 Changing Profiles During Motion 90 Checking Analog Input Optional 28 Checking Discrete Inputs 26 Checking Encoder Output 27 Checking General Purpose Outputs 27 Checking Pulse Input Optional 28 Checking STATUS 27 Checking the Control Power 25 Checking the Motor 30 Checking the Resolver 28 CLAMP 87 Clamping 87 COMI 58 2 58 63 Command Timing 235 Commands BDS 154 gt BDS 127 154 205 128 Break B 59 127 139 Commenting 63 CONTINUE 96 Disable DIS 73 237 INDEX DUMP 155 Dwell D 138 164 Edit ED 124 ELIF 130 ELSE 130 Enable EN 73 79 END 139 ENDIF 130 GOSUB 128 131 206 GOTO 127 131 Hold H 138 IF 130 205 INPUT 136 Jog J 63 79 83 92 94 Jog From JF 88 94 165 Jog To JT 88 94 165 Kill K 73 Labels 127 Macro Absolute MCA 84 92 94 153 165 Macro Dwell MCD 84 92 94 164 165 Macro Go MCGO 84 92 94 165 Macro Incremental 84 92 94 165 Move Absolute MA 81 92 94 153 165 Move Incremental MI 82 92 94 165 MRD 85 87 94 200 Normalize NORM 83 96 44 Prin
406. y loop then position error can accumulate well beyond PEMAX Ifthe position loop is turned on with this condition a position error overflow error will occur To prevent the error you must first zero the position error then turn the position loop on by entering 83 CHAPTER 8 GENERAL PROGRAMMING ZPE PL ON The ZPE command is also frequently used with clamp ing See the explanation of clamping in Section 8 8 10 8 8 7 MACRO MOVES This section describes functions to implement Macro moves Macro moves are complex user defined moves that execute as one move Simple moves such as MI and MA always begin and end at zero speed and have one acceleration segment one deceleration segment and one traverse segment Macro moves allow up to 30 user definable segments for one move The moves are fully precalculated and therefore can execute very fast Like other moves ACC DEC and SCRV are in effect These parameters can be changed between Macro move segments allowing more flexibility Also PFNL indicates the ending position of the entire Macro move Like MI and MA the entire Macro move must begin and end at zero speed although beginning and ending speeds of individual sections are not constrained to 0 RPM Dwell segments can be embedded in Macro moves 8 8 7 1 MCA MCI MCD and MCGO There are two kinds of Macro moves Macro Absolute MCA and Macro Incremental MCI Dwells can be inserted using the Macro Dwell MCD
407. y 2000 RPM when the JF command is executed ASSUME PRESENT SPEED IS 2000 RPM JF 50000 1000 88 VECTORSTAR 2000 RPM COMMAND ENTERED HERE 1000 RPM Figure 8 6 Jog From JF Command The next graph shows the effect of the Jog To JT command This example also assumes that the speed is 2000 RPM when the command is executed ASSUME PRESENT SPEED IS 2000 RPM JT 50000 1000 2000 RPM COMMAND ENTERED HERE 1000 RPM 50000 COUNTS Figure 8 7 Jog To JT Command Position dependent commands must be used with care If you specify a position that has already passed the VECTORSTAR will generate ERROR 42 MOVE W O TIME Also if the Jog To command is given so that ACC or DEC prohibits the profile from reaching final speed before the specified position the VECTORSTAR will generate ERROR 42 ERROR 41 MOVE NEEDS MOTION is generated if Jog or Jog From are commanded when the velocity is 0 Finally a position dependent jog that attempts to change the direction of rotation will generate an error All of these errors stop motion VECTORSTAR 8 8 11 1 Registration The VECTORSTAR allows you to combine the position capture with the Jog To command to implement index to registration One example of index to registration 1s a conveyor belt on which items are placed in random positions An optical sensor detects the item upstream of the operation The VECTORSTAR
408. ying to use one block for two functions 10 2 1 Example Application Suppose you are working on a project that is defined by someone besides yourself It may be a co worker a supervisor a customer or an operator For this example we will use a customer Suppose you have this conversa tion VECTORSTAR Customer machine feeds plastic from a roll onto a conveyor then cuts it into sheets The length of the sheet varies There is a registration mark on each plastic sheet which is detected while the plastic 15 moving After this mark 15 detected the motor must move the plastic a variable distance and stop There is a stop input that should stop and disable the VECTORSTAR after it completes the cycle You there other parameters that should be variable such as speed acceleration and deceleration Customer Now that you mention it all those parameters should be variable I also need an output at the end of the move to start the saw blade rotating You How often do these variables change Customer About once or twice a year You Do you mind typing them in from a keyboard Customer No That would be fine You What controls the start of the move Customer PLC activates an input Can ESTOP be programmed so that it can be overridden when the cycle is almost complete You No Since ESTOP is a safety function it is always hardwired to remove po
409. z and is critically damped The allowed bandwidths are 5 10 15 20 25 30 40 and 50 Hz The TUNE command only works when PDF 1 When PDF 0 a PI controller is used For PI controller KPROP represents the proportional gain and KVI represents the integrating gain If PDF is on autotuning will change the values of KV and KVI The tune command does not always provide an accept able tuning If not you can tune the VECTORSTAR yourself 4 6 TUNING THE VECTORSTAR YOURSELF If you use the TUNE command and the resulting tuning variables cause the system to oscillate there are gener ally two reasons 1 The bandwidth the TUNE command is set too high for the system to function properly 2 The low pass filter is set too low this only applies if LPF is on In either case first raise the low pass filter frequency LPFHZ to as high a level as is acceptable You may even decide to remove it by setting LPF to off If the TUNE command does not provide a suitable set of tuning variables then you have the option of tuning the VECTORSTAR yourself You will need an oscillo scope Connect an oscilloscope channel to TACH MONITOR on Connector C2 Pin 2 attach the scope ground to COMMON on Connector C2 Pin 14 Use the TUNE command to get as close as possible VECTORSTAR 4 6 1 Tuning the Velocity Loop The drive will be enabled and the motor will turn Make sure the motor is secured WARNING The flow chart

VECTORSTAR (VSA/VSP/VSL) Installation and User`s Manual

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