CANopen Amplifier CD1
Contents
1. CD1 k INFRANOR CINFRANOR SERVO DRIVES amp MOTION CONTROL CD1 k User Guide gb CANopen Amplifier CD 1 k e User Guide u INF RANO R WARNING ZN This is a general manual describing a series of servo amplifiers having output capability suitable for driving AC brushless sinusoidal servo motors Please see CD1 k Installation Guide for the hardware installation of the amplifier dimensions wiring For the CANopen communication see manual CD1 k CANopen Communication Profile Instructions for storage use after storage commissioning as well as all technical details require the MANDATORY reading of the manual before getting the amplifiers operational Maintenance procedures should be attempted only by highly skilled technicians having good knowledge of electronics and servo systems with variable speed EN 60204 1 standard and using proper test equipment The compliance with the standards and the CE approval is only valid if the items are installed according to the recommendations of the amplifier manuals Connections are the user s responsibility if recommendations and drawings requirements are not met Any contact with electrical parts even after power down may involve severe physical damage Wait for at least 5 minutes after power down before handling the amplifiers a residual voltage of several hundreds of volts may remain during a few minutes ESD INFORMATION ElectroStatic Discharge INFRANOR a2. Motor encoder resolution parameter value and the Maximum speed parameter value In this case encoder pulse noise at a frequency lower than 1 5 times the maximum encoder frequency may involve uncontrolled motor movements that may be dangerous for operator and machine Note In the TTL incermental encoder configuration without HES the motor Phasing procedure must be executed again after a Counting fault release For the Sin Cos encoder configuration Check for the correct encoder supply voltage value Check for the correct encoder amplifier motor ground and shield connections with regard to the recommendations of chapter 4 of the CD1 k Installation Guide Check for the correct encoder A channel B channel and R reference signal waveforms AT ZAN T Tu Nou N A l ko a ae a ZIN TS TS Za aaa Q e NY NY gt B NOY Sy Kad TT ON R D SA Forward direction Reverse direction Check that the Motor encoder resolution and the Zero mark pitch parameter values are correct Check that the number of encoder pulses between two successive R reference signals is equal to the Motor encoder resolution value multiplied by the Zero mark pitch parameter value If this condition is not fulfilled the encoder counting protection must be disabled in order to cancel the Counting fault The encoder counting protection can be disabled by means of the parameter Zero mark pitch set at 0 For a linear motor with only one R reference
3. a control in speed mode otherwise close the position loop with a stable gain Select the PI speed mode and move the axis by means of the speed input command until a stall position where one motor revolution is not dangerous for operator and machine far enough from the mechanical stops Execute then the Autotuning procedure with the motor at standstill If the axis is moving the Autotuning procedure is not accepted by the amplifier Select the Position mode and set the Feedforward speed 1 gain value at 1 in order to avoid a high following error value 4 4 ROTATION COUNTING DIRECTION The counting direction can be reversed by selecting the Reverse movement in the Visual Drive Setup parameter setting software 5 PARAMETER SAVING When all adjustments have been made the parameters may have to be stored in a non volatile EEPROM the amplifier must be disabled 6 MOTOR PHASING PHASING AT POWER ON In the Incremental encoder without HES configuration the motor phasing procedure Phasing must be performed at each power on of the amplifier according to the diagram below AOK Power On INHIBIT Phasing command Phasing SS Power up Ready Phasing Ready for running End power up Start phasing End phasing phasing procedure is not possible The motor must be equipped with an incremental f On an unbalanced axis constant torque du to gravity effects on a vertical axis the motor encoder HES or wit
4. loop parameters Check that the values of the parameters Max current and Rated current are compliant with motor and amplifier lf necessary modify them according to the motor and amplifier specifications The parameter Max current defines the maximum output current value of the amplifier It may vary between 20 and 100 of the amplifier current rating The parameter Rated current defines the limitation threshold of the amplifier output RMS current If t It can vary between 20 and 50 of the amplifier current rating lf the Incremental encoder without HES sensor configuration is selected start a motor phasing Phasing procedure The motor phasing can be launched either in the control window of the VISUAL DRIVE SETUP software or via the CANopen bus THE MOTOR USED IN THE APPLICATION IS NOT CONTAINED IN THE MOTOR LIST OF THE PARAMETER SETTING SOFTWARE Select the New Motor function and follow the instructions 4 1 3 ENCODER COUNTING PROTECTION When servo motors are equipped with an encoder any error in the encoder pulse counting generates an error in the position measurement of the rotor and may involve uncontrolled motor movements that can be dangerous for both operator and machine The encoder counting protection of the CD1 k amplifier range allows the detection of pulse counting errors and immediately disables the amplifier for reasons of security The encoder counting protection checks that the number of encoder pulses bet
5. position The value 32767 corresponds to one revolution of the motor shaft The marker pulse width is equal to 4 of the A and B channels period 8 COGGING TORQUE COMPENSATION The cogging torque in brushless permanent magnet rotating motors or the cogging force in brushless permanent magnet linear motors results from the interaction between the rotor magnets and the stator slots This disturbance is due to the difference of reluctance between the copper of the windings and the iron of the stator teeth For a given motor the cogging can be easily evaluated by simply moving the motor manually when the amplifier is disabled The Cogging compensation option available in the CD1 amplifier range allows to cancel the motor cogging effects for specific applications where torque accuracy or force accuracy higher than 1 is required CD1 amplifiers must be factory set for getting the cogging compensation option reference CD1k U I CT Check for the presence of the cogging compensation option CT CD1 in the VDSetup Hardware option menu In this case the Cogging torque compensation menu can be selected in the Servo loop module For a brushless motor equipped with an incremental encoder the Cogging torque A compensation is only available if the encoder is providing one marker pulse per motor revolution Chapter 2 Commissioning 13 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL The cogging torque acquisition procedure is sta
6. system error transistor short circuit or cycle too high O O O O 0 OOOO The VISUAL DRIVE SETUP software allows to identify the Power stage fault lf the fault occurs when starting the amplifier Check the AC voltage on the L1 L2 L3 inputs of the X9 connector CD1 k 230 l amplifier 196 VAC lt VAC lt 253 VAC CD1 k 400 l amplifier 340 VAC lt VAC lt 528 VAC Chapter 5 Troubleshooting amp maintenance 19 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL lf the fault occurs during the operation Check the braking system during the motor deceleration phases Check the sizing of the braking resistor with regard to the motor deceleration phases Check that the current cycle corresponds to the current table see table of the current ratings Check for no short circuit in the motor wiring and at the motor terminals Check for no short circuit between a motor phase and the ground 1 3 5 RESOLVER ERROR e Check the resolver connection on the amplifier X1 connector according to the connector description e Check for the correct resolver type with regard to the amplifier specifications e Check the connections between the resolver and the amplifier 1 3 6 RDC ERROR lf the failure occurs when starting the amplifier e Check for the correct resolver type with regard to the amplifier specifications lf the failure occurs during the operation e Check that the connections betwee
7. EEEE bk W H WE WW ki 10 4 3 SERVO LOOP ADJUSTMENT x sayeya A 11 4 4 ROTATION COUNTING DIRECTION j 9 5 PARAMETER SAVING oocceccccceccscscssccsecsscecesecesecesssessscerevesssesssessssstessstissverstessstiastesssesssesstesstesssesistesssestesseess 12 6 MOTOR PHASING PHASING AT POWER ON ccccseseseecescscececcecececceveceucesaceucevaceccavacucrvaveecevacenestarereavaceneass 12 7 INCREMENTAL ENCODER OUTPUTS r leke A AE E E E E ann 13 8 COGGING TORQUE COMPENSATION a sakal a a eee eleke ann 13 CHAPTER 3 FUNCTIONAL FEATURES e erene nenea nean akele ee kake kK nna nanan AKA AA ALAA A KA KAKA NAK AA KK AA NA nnana ane 15 4 LOGIC INPUTS o ENIE E TEE E E EEA TE EEE AT AE AE 15 E UIT 2 T TA T A E EE EN NE A Ye 15 1 2 LIMIT SWITCH IT E TE ANN A A ANE EN 15 1 3 LOW SPEED INPUT NE nan ka a kn ke ka sil n a A n a k pk E A E hk biik kadina 15 1 4 INDEX INPUT j saya az 15 2 BRAKE CONTROL e cecesececesessesescssscesevessesseisevesstesssissvesstessevisstesssessstirsvesssesssvrsvesssessevessvesssesstuitesstesesereses 15 3 ADDRESSING SWITCH SPEED SELECTION a eee eee eee ekse ke 16 CHAPTER 4 CANOPEN COMMUNICATION ccccccccccccsscccccccsseesccssccccsscuseussseesseeususeseesseesseusesuueseeusuvsneuseesseens 17 CHAPTER 5 TROUBLESHOOTING amp MAINTENANCE cccccccccecccccccssccscccscscesscsseuscstesseeuseeucseessceuseuseseeuseensaes 18 Ter OR ces N eee se ed i ee en renee 18 1 41 VTR ERROR N delal eni k
8. FRANOR SERVO DRIVES amp MOTION CONTROL Check that the following conditions are answered for taking into account the maximum value of the encoder pulse frequency at the maximum motor speed value Max motor speed rpm lt 60 x 10 Number of encoder pulses per revolution Max motor speed rpm lt 60 x Encoder pulse frequency limit Hz Number of encoder pulses per revolution Check that the Motor encoder resolution and the Zero mark pitch parameter values are correct Check that the number of encoder pulses between two successive Z marker pulses is equal to the Motor encoder resolution value multiplied by the Zero mark pitch parameter value If this condition is not fulfilled the encoder counting protection must be disabled in order to cancel the Counting fault The encoder counting protection can be disabled by means of the parameter Zero mark pitch set at 0 For a linear motor with only one marker pulse over the entire motor travelling range the parameter Zero mark pitch must be set at 15 In this case the encoder counting protection is checking that the measured encoder position has always got the same value when the marker pulse is activated no position measurement drift When the encoder counting protection has been disabled the amplifier is only checking that the encoder pulses frequency is lower than 1 5 times the maximum encoder frequency The maximum encoder frequency is calculated into the amplifier according to the
9. IER HARDWARE CONFIGURATION The standard amplifier configuration is adjusted to MAVILOR motors resolver sensor with transformation ratio 0 5 For the adjustment to other motor types please see CD1 k Installation Guide 3 POWERING OF THE AMPLIFIER Please see manual CD1 k Installation Guide before switching on the amplifier for the first time For switching on the amplifier please proceed as follows e Switch on the 24V auxiliary supply The green front panel LED OK must blink quickly Undervolt error displayed The AOK relay contact pins 9 and 10 of X2 is closed It is then possible to control the power ON relay e Switch on the power supply The green LED OK must be continuously lit the amplifier is ready to be enabled CAUTION The 24 V auxiliary supply must always be switched on before the power supply It is mandatory to wait for at least 30 seconds between switching off and on again the amplifier Windows is a registered trade mark of MICROSOFT CORPORATION 6 Chapter 2 Commissioning CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 4 STARTING AND ADJUSTING THE AMPLIFIER This chapter describes the commissioning procedure of the amplifier by means of the Visual Amplifier Setup software e Connect the serial link RS232 between PC and amplifier e Switch on the amplifier and start the Visual Drive Setup software on the PC under WINDOWS If the message No serial commun
10. a Vek VWe r kavl su VERA LSa kU NN NE EEE 18 1 2 NON STORED ERRORS A E EAA A A a e 18 1 3 STORED ERRORS cevveccccccccscscssecsssesscevscsesscessevssterstesssesstesstessesseusstestevsstesstessevssevsstesssestesssesssseesenes 18 2 ERROR RESET cece ceccssesesesssesssctssetseiseisstsssesssvsstssssitsisstesssvissvessssssvirstesstessstrstesssessevevstesssessurevesstensesesenes 23 3 OPERA TOA P O EA r t ki d kk nan a bik b yarali hev a ik ak e ka a l inet a ka d wa Ge aaa r 23 3 1 MOTOR DOES NOT MOVE jjA La 23 3 2 MOTOR ENABLED BUT LITTLE TORQUE J j LaA 23 3 3 SHAFT LOCKED ERRATIC OSCILLATIONS rotation AT MAXIMUM SPEED use 23 3 4 DISCONTINUOUS MOTOR ROTATIONS WITH ZERO TORQUE POSITIONS W sala 23 3 5 LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL LAL 23 4 SERVICE AND MAINTENANCE ccccccccescccesecececccsccesecesssessceesecesssessscerevesstesseeresessetesstesseeieterstesstenseseesease 23 CHAPTER 6 APPEDIX cc ccccscecccsccesecscecscesccsecsseusscusssucssceuseussseusseeusisusuuessueuseuusutesereusiuusnessseusseuseuseseesseeuseuseneesseens 24 SERVO CONTROLLER STRUCTURE ceceecccccccsscccescscsscesscsvccsesscensssesecesssersssssusesscersesesscetscsesusersssvsusesssarseseasenss 24 CD1 k 3 CD 1 k EA User Guide l INE RANO R Chapter 1 General description 1 INTRODUCTION CD1 k all digital amplifiers with sinusoidal PWM control are servo amplifiers that provide the control of brus
11. ameter when the limitation threshold is reached 4 2 1 OPERATION OF THE CURRENT LIMITATION IN FUSING MODE When the amplifier output RMS current l t reaches 85 of the rated current the OK LED is blinking on the amplifier front panel If the RMS current It has not dropped below 85 of the rated current within 1 second the lat error is released and the amplifier disabled otherwise the blinking is inhibited When the amplifier output RMS current I t reaches the rated current value the I t limits the amplifier output current at this value Diagram of the amplifier output current limitation in an extreme case motor overload or shaft locked Amplifier output current t1 Blinking Max current t2 Current limitation t3 l t error Rated current 1 second The maximum current duration before release of the blinking display is depending on the value of the parameters Rated current and Max current This value is calculated as follows T ayn second ty tp 3 3 x rated current A max current A The maximum current duration before limitation at the rated current is also depending on the value of the Rated current and Maximum current parameters This value is calculated as follows T max Second to tp 4 x rated current A max current A NOTE 1 When the Max current Rated current ratio is close to 1 the Tdyn and Tmax values given by the formula above are quite below the real values But t
12. any information contained in this manual without notice INFRANOR June 2006 All rights reserved Issue 2 11 2 CD1 k CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Content PAGE e YE PO Erne ki ii kk n ta ee a D ND DAYN YD DD Dr n l tk 3 CHAPTER 1 GENERAL DESCRIPTION ccccccssccsccssccsecccccccsseesccsscsecscssessecsseussesessceuseeusneusseesseuuseussseessussuseseesseesens 4 i INTRODUCTIOKN it in kai ar tas e ab ak l ke a an kk e ke ka k n kire nea sore ek e M ka e kk li Fk kk kaban 4 2 ARCHITECTURE OF THE AMPLIFIER cccccccccccccecececscesccsececesscessscecscesscsssscecscessesicescssesssuuesenssersesveseseseasesees 4 CHAPTER 2 COMMISSIONING c ccccccccssecscccsccccccescesccsccssecuceccususeseecsecsseusestesseeusesusueusseeusuuseusssesseeuseuseseuueneeess 6 1 INSTALLATION OF THE PARAMETER SETTING SOFTWARE cscscscecececccsecesecececesssesetesecesssessseesevesstenseees 6 2 CHECKING THE AMPLIFIER HARDWARE CONFIGURATION ccccccccscesecececcesecececeseseseesecesesesseetsseesesetseees 6 3 POWERING OF THE AMPLIFIER cccccccccccccccccceccsecececccecccsecececscesuseseececscesssesuecesscesssueesesssssuseeesesssenseeeeesenevenees 6 4 STARTING AND ADJUSTING THE AMPLIFIER cc cccccceccceccccecececececscessscesecesssesseceretesstesetesesesssesettaseesetenseeees 7 4 1 AMPLIFIER ADJUSTMENT TO THE MOTOR SPECIFICATIONS LALE 7 BP AI PROTECTION l 6 tt at tite dot ai a ad dad ka tap a evi aa
13. edure the feedforward speed 2 gain is set equal to the damping gain value if minimum following error is required The viscous friction compensation term can be calculated by measuring the current speed ratio at various motor speed values Feedforward acceleration gain KA defines the feedforward acceleration amplitude corresponding to the acceleration input command This term allows to reduce the following error during the motor acceleration and deceleration phases Its value is calculated by the amplifier during the auto tuning procedure if minimum following error is required It can then be modified by the user if required The auto tuning procedure identifies the characteristics of motor and load and calculates the controller gains During the procedure various choices are available to the user 24 Chapter 6 Appendix CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL The choice of the time interval for speed measurement speed measurement filter allows to select the speed measurement resolution value according to the position sensor resolution value speed resolution rom 60000 position sensor resolution time interval ms The higher the time interval value the better the resolution but also the lower the servo loop gains because of the increased speed measurement delay The choice of the anti resonance filter is necessary in case of loud noise in the motor due to the motor load coupling elasticity The c
14. enewed after the release of a Counting error because the current rotor position reference for the motor commutation is not correct 8 Chapter 2 Commissioning CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 4 1 4 PARAMETER ADJUSTMENT FOR A LINEAR MOTOR The Motor encoder resolution parameter is calculated as follows Kai Ka Gi Ka Ki ee rees AAA Pole pitch Motor pole pitch mm Motor encoder resolution 1000 x iso Bere pen am Encoder signal pitch um A 1 encoder signal pitch 4 counting increments The value of the motor Maximum speed parameter in rpm is calculated as follows Max speed rpm 60 x nelmr x max motor speed m s Motor pole pitch mm The linear speed value in m s is calculated as follows Motor speed rpm Motor pole pitch mm eee xX aS Linear speed m s 60 1000 4 1 5 MAXIMUM APPLICATION SPEED The parameter Max speed defines the maximum speed at which the amplifier can control the motor This parameter can be e lower than or equal to the maximum motor speed e slightly higher than the maximum motor speed in the application This margin allows a speed overshoot that avoids the position loop saturation position following This margin can be as small as possible when using a high bandwidth or at low acceleration 4 1 6 CONFIGURATION OF THE THERMAL SENSOR The thermal sensor is entering both X1 resolver and X3 encoder connectors according to the motor
15. h an absolute Sin Cos encoder 12 Chapter 2 Commissioning CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Note In the Incremental encoder without HES configuration the motor phasing procedure Phasing must be renewed after the release of a Feedback or Counting error The motor phasing procedure must also be renewed after modification of the motor or encoder parameter value 7 INCREMENTAL ENCODER OUTPUTS The incremental encoder outputs are two pulse channels A and B in quadrature and one Z marker pulse per ha lon revolution lan bo CW rotation CCW rotation motor shaft front view motor shaft front view The Output encoder resolution is selected according to the table below Maximum motor speed rpm up to 1600 up to 3200 up to 6400 up to 12800 up to 25000 Encoder output resolution ppr 512 to 16384 512 to 8192 512 to 4096 512 to 2048 512 to 1024 The resolution value defined in the Output encoder resolution parameter can be devided by 2 4 or 8 by selecting the Resolution division ratio parameter The Output encoder deadband parameter introduces a deadband at standstill around the current resolver position in order to avoid oscillations of 1 encoder edge on channels A and B The value of 4095 corresponds to 1 16 revolution of the motor shaft The Zero pulse origin shift parameter allows the shifting of the marker pulse position on channel Z with regard to the resolver zero
16. heck the rated current value required from the amplifier with regard to the current table in pulse cycle e Check the amplifier rated current value defined in the Rated current parameter with regard to the current required for the operation cycle 22 Chapter 5 Troubleshooting amp maintenance CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 2 ERROR RESET A stored error can be cancelled as follows e by means of the parameter setting software Visual Amplifier Setup via the serial link RS232 e by means of the RESET function issued from the CANopen bus e by switching off the amplifier supply 3 OPERATION PROBLEMS 3 1 MOTOR DOES NOT MOVE Check that the amplifier is on Check for no error on the amplifier Check the wiring of the logic command inputs Check that the amplifier is enabled 3 2 MOTOR ENABLED BUT LITTLE TORQUE e Check the Max current and Rated current parameters 3 3 SHAFT LOCKED ERRATIC OSCILLATIONS ROTATION AT MAXIMUM SPEED e Check the resolver or encoder wiring on the amplifier connector as well as the mechanical fastening of the position feedback sensor on the motor e Check for the correct motor selection in the MOTOR LIST module e Check the value of the Motor parameters in the Advanced Functions menu and renew the AUTO PHASING command with unloaded motor if required 3 4 DISCONTINUOUS MOTOR ROTATIONS WITH ZERO TORQUE POSITIONS e Check the wiring of the three phase
17. his formula remains very precise as long as the Max current Rated current ratio is higher than 3 2 NOTE 2 The amplifier lt signal can be displayed on the digital oscilloscope by selecting the l t signal in the Channel menu The threshold values of the l t signal for the protection mode described above are calculated as follows Triggering threshold of the Idyn signal 96 Rated current Y6 70 Current limitation threshold Rated current Yo 50 Rated current 100 x Rated current A amplifier current rating A The corresponding RMS current value of the amplifier can be calculated as follows Amplifier RMS current A l t signal value x 50 x amplifier current rating A 100 10 Chapter 2 Commissioning CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 4 2 2 CURRENT LIMITATION IN LIMITING MODE When the amplifier output RMS current t reaches 85 of the rated current the OK LED on the amplifier front panel is blinking When the RMS el lt drops below 85 of the rated current the blinking is inhibited When the amplifier output RMS current I t reaches the rated current value the I t protection limits the amplifier output current at this value Diagram of the amplifier output current limitation in an extreme case motor overload or shaft locked Amplifier output current t1 Blinking t2 Current limitation Max current Rated current The maxi
18. hless AC motors with position sensor The CD1 k amplifier is a stand alone single axis block including power supply unit and mains filters It is available in both 230 VAC and 400 480 VAC mains operated voltages CD1 k amplifiers are working via a bus with CANopen communication protocol The amplifier parameter setting can be made either by means of e the CANopen bus or e the specific parameter setting software Visual Drive Setup via the serial port RS 232 2 ARCHITECTURE OF THE AMPLIFIER CANopen Position Speed Current interface regulator regulator regulator Current n measurements Position measurement Resolver 4 Chapter 1 General description CD1 k User guide Electric motor Brushless or synchronous motor Resolver Encoder Amplifier Current loop Current regulator Speed loop Speed regulator Position loop Position regulator Fieldbus CANopen Enabled disabled Servo On Off Chapter 1 General description SINFRANOR SERVO DRIVES amp MOTION CONTROL Electric device that transforms electrical energy into a mechanical movement This transformation is often made by means of current commutation Generally the movement is a rotation but there are also linear motors Electric brushless motor The current commutation is electronically made and requires a position sensor resolver encoder Hall sensor Absolute position sensor over one revolution The resolver is often
19. hoice of the maximum stiffness filter allows to get the maximum stiffness on the motor shaft with regard to the torque disturbances However this choice is only possible without any resonance due to the motor load coupling elasticity The choice of the speed loop bandwidth defines the cut off frequency value of the closed loop frequency response Low 50 Hz Medium 75 Hz High 100 Hz The choice minimum following error allows to get an accurate following of the position reference value during the entire motor displacement In this case all feedforward gain values are calculated The choice minimum position overshoot allows to get a motor positioning without any overshoot of the target position In this case all the feedforward gain values are set at 0 and the motor position is lagging with regard to the position reference value during the entire motor displacement Chapter 6 Appendix 25
20. ication found is displayed on the screen click on OK and check the following points o The amplifier must be on o The correct RS232 connection between amplifier and PC o The correct software configuration Com port For a parameter setting of the amplifier via the Visual Drive Setup software e Switch the amplifier to Local mode that means switch address 0 see Chapter 3 section 3 or e Disable the CANopen communication by means of Visual Drive Setup 4 1 AMPLIFIER ADJUSTMENT TO THE MOTOR SPECIFICATIONS 4 1 1 CONFIGURATION OF THE SENSOR TYPE The configuration of the sensor type is software selectable and saved in the amplifier EEPROM The amplifier is configured as standard for a resolver sensor For motors equipped with a position encoder please proceed as follows Select the appropriate encoder type in the Feedback configuration menu Then select Encoder feedback and confirm this selection If the motor is equipped with Hall effect sensors check that the INHIBIT input is enabled and the amplifier is on before moving manually the motor over one revolution or one pole pitch on linear motors If the HES error is displayed switch off the amplifier and check the following points before switching it on again The Hall effect sensors HES must be correctly connected on the amplifier X3 connector if 60 Hall sensor types are used check the various wiring combination of the HES signals for finding the right wir
21. ifier address as well as of the of the CANopen bus communication speed e Addressing 6 selection bits 6 5 4 3 2 1 pen OFF OFF ore Ore or oF OFF OFF o 3 e Communication speed 2 selection bits 8 7 1Mbits 500Kbits 250Kbits 125kbits Note Address 00 must only be used in Local mode An address 00 is used in Remote mode use of the CANopen bus 16 Chapter 3 Functional features CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Chapter 4 CANopen communication For the commissioning of the CANopen communication protocole please see manual CD1k CANopen Communication Profile Chapter 4 CANopen communication a CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Chapter 5 Troubleshooting amp Maintenance 1 ERRORS 1 1 SYSTEM ERROR If the red SYS LED is lit at power on the logic board is defective e Check that the BUS and OK leds are synchronously blinking In this case load the amplifier firmware via the serial link by means of the CD1 updater software e Check for no conducting dust that may involve short circuits on the amplifier logic board 1 2 NON STORED ERRORS 1 2 1 BUS ERROR This fault is displayed by the BUS led This error is only displayed when there is a synchronization loss by the SYNC message The error is cancelled as soon as the communication is restored 1 2 2 UNDERVOLT ERROR This fa
22. ing order Check for the correct supply voltage of the Hall sensors Check for the correct value of the Motor encoder resolution parameter lf the motor Hall sensors do not work correctly select the appropriate incremental encoder type Incremental Encoder without HES in the Feedback configuration menu and start the amplifier commissioning with this configuration lf the motor used is equipped with an absolute Sin Cos encoder over one revolution Heidenhain ERN 1085 or compliant check that the INHIBIT input is enabled and the amplifier on Then move manually the motor over one revolution If the HES error is displayed switch off the amplifier and check the following points before switching it on again The commutation channels of the Sin Cos encoder must be correctly wired on the amplifier X3 connector Check for the correct supply voltage of the Sin Cos encoder Check for the correct value of the Motor encoder resolution parameter Perform the Save parameters to EEPROM procedure before switching off the amplifier in order to save the sensor configuration Chapter 2 Commissioning 7 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 4 1 2 SELECTION OF THE MOTOR TYPE THE MOTOR USED IN THE APPLICATION IS CONTAINED IN THE MOTOR LIST OF THE PARAMETER SETTING SOFTWARE Select in the motor list the motor used in the application The motor selection will start the automatic calculation of the current
23. iring of the limit switch inputs move the motor in one direction activate the limit switch placed in the rotation direction artificially if necessary check then the motor stopping if the motor goes on moving reverse the wiring of the limit switch inputs Notes When activating a limit switch input the motor is stopped with maximum deceleration The limit switch inputs are activated if disconnected from the 24V potential 1 3 LOW SPEED INPUT When this input is activated the amplifier switches to protected mode if the motor speed is exceeding the critical Low speed threshold Note The Low speed parameter cannot be higher than 33 of the Max speed parameter The Low speed input is activated if disconnected from the 24V potential The Low speed threshold can be parameter set via the CANopen bus 1 4 INDEX INPUT In Homing mode the Index input is used for a homing on the axis 2 BRAKE CONTROL The CD1 k amplifier has got a control for the operation of a powerless brake The brake control is enabled relay open or disabled relay closed according to the amplifier status enabled or disabled Chapter 3 Functional features 15 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 3 ADDRESSING SWITCH SPEED SELECTION Each amplifier of the network must be configured with one single address A DIP8 switch accessible to the operator allows the configuration of the ampl
24. lity can also be tested in Speed mode In this case after the execution of the Autotuning procedure in PI mode e check that the motor is correctly running in both directions e check the response at a small displacement without Idc saturation oscilloscope function In case of loud noise in the motor at standstill or when running check the rigidity of the mechanical transmission between motor and load backlashes and elasticities in motor and couplings If required start a new Autotuning procedure by selecting a lower bandwidth If the instability remains start a new Autotuning procedure by activating the Antiresonance filter If necessary adjust more accurately the loop response stability by adjusting the stability gain Chapter 2 Commissioning 11 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL lf the Autotuning procedure was executed in PI mode when the Position mode is selected the Feedforward gains of the position regulator must be adjusted manually Set the Feedforward speed 1 gain value at 1 in order to avoid a high following error value 4 3 2 LOOP ADJUSTMENT WITH A VERTICAL LOAD In the case of an axis with vertical load proceed as follows Select the Limiting current limitation mode Initialize the speed loop gains corresponding to the unloaded motor execute therefore the Autotuning procedure with the motor uncoupled from its mechanical load Couple the motor with its load If possible make
25. mplifier motor ground connections and shield answer the requirements of chapter 4 of the CD1 k Installation Guide For the Absolute single turn Sin Cos encoder configuration Check that the Sin Cos encoder commutation channels are correctly wired on the amplifier X3 connector Check for the correct Sin Cos encoder supply voltage value Check for the correct Sin Cos encoder C channel and D channel signal amplitude value Check that the Motor encoder resolution parameter value is correct Check that the encoder amplifier motor ground connections and shield answer the requirements of chapter 4 of the CD1 k Installation Guide 1 3 10 POSITION FOLLOWING ERROR lf the error occurs during the axis motion e Check the position loop adjustment e Check the coherence of the Static threshold parameter with regard to the motion cycle 1 3 11 LOW SPEED ERROR e Check that the Low speed parameter is coherent with regard to the axis motion speed e Check the wiring of the Low speed input 1 3 12 CURRENT OFFSET ERROR If the Current offset error occurs at power on this means that the offset compensation procedure has failed and the amplifier is not ready for operation This error cannot be cancelled 1 3 13 INIT 400V ERROR If the INIT 400V error occurs on a CD1 k 400 1 amplifier at power on e Check that the amplifier powering has been correctly made This error cannot be cancelled 1 3 14 PT ERROR e C
26. mplifiers are conceived to be best protected against electrostatic discharges However some components are particularly sensitive and may be damaged if the amplifiers are not properly stored and handled STORAGE The amplifiers must be stored in their original package When taken out of their package they must be stored positioned on one of their flat metal surfaces and on a dissipating or electrostatically neutral support Avoid any contact between the amplifier connectors and material with electrostatic potential plastic film polyester carpet HANDLING If no protection equipment is available dissipating shoes or bracelets the amplifiers must be handled via their metal housing Never qet in contact with the connectors ELIMINATION In order to comply with the 2002 96 EC directive of the European Parliament and of the Council of 27 January 2003 on waste electrical and electronic equipment WEEE all INFRANOR devices have got a sticker symbolizing a crossed out wheel dustbin as shown in Appendix IV of the 2002 96 EC Directive This symbol indicates that INFRANOR devices must be eliminated by selective disposal and not with standard waste INFRANOR does not assume any responsibility for physical or material damage due to improper handling or wrong descriptions of the ordered items Any intervention on the items which is not specified in the manual will immediately cancel the warranty Infranor reserves the right to change
27. mum current duration before release of the blinking display t1 t0 and before limitation at the rated current t2 t0 is calculated the same way as in the Fusing mode 4 3 SERVO LOOP ADJUSTMENT 4 3 1 REGULATOR PARAMETERS The Autotuning procedure identifies the motor and load specifications and calculates the speed position loop parameters In P and PI speed mode only the speed loop gains are calculated In PI speed mode the proportional gain of the position loop is also calculated But the Feedforward gains of the position regulator are all initialized at O In Position mode all gains of both speed and position regulators are calculated Note The position loop stability can be tested in PI speed mode because the Feedback gains are identical to the Position mode The operator can select a bandwidth Low Medium or High as well as the filter type standard antiresonance or max stiffness The Autotuning procedure can be executed with the motor disabled or enabled i e vertical load Before executing the Autotuning procedure check that the motor shaft is free and that its rotation over one revolution is not dangerous for operator and machine Check that the brake is released the Autotuning command does not control the brake For a complete adjustment the Autotuning procedure must always be executed in Position mode at power on the amplifier is automatically in Position mode But the amplifier position loop stabi
28. n Check that the motor is unloaded and the shaft movement is free during the procedure Check that the motor current value corresponding to the cogging torque effect is lower than 5 of the amplifier current rating e This error may also occur during a homing procedure which time out is to low 1 3 2 EEPROM ERROR e Check for the presence of the EEPROM and check its correct orientation e If the error remains the EEPROM may not be correctly initialized CHECKSUM or is not compatible with the amplifier software e To cancel this error make a new parameter setting of the amplifier and save the new parameters 1 3 3 C MOTOR ERROR lf the error occurs when commissioning the amplifier e Check the CTN CTP parameter setting the Triggering threshold and the Warning threshold e Check the wiring of the thermal sensor on the amplifier If the error occurs during the operation e Check that the triggering threshold is compliant with the manufacturer s specifications of the sensor e Check the motor temperature and look for the reason of this overheating mechanical shaft overload duty cycle too high 1 3 4 POWER STAGE ERROR The POWER STAGE fault groups all faults issued from the power board Power supply overvoltage Phase ground short circuit Phase phase short circuit Fan Power stage short circuit Power stage overtemperature on CD1 k 400 I only PWM control error Power stage supply Braking
29. n the resolver and the amplifier are complying with the shield wiring recommendations 1 3 7 ENCODER ERROR Check the encoder supply connection on the amplifier connector X3 Check the encoder A channel and B channel connections on the amplifier connector X3 Note In the Incremental encoder without HES configuration the motor Phasing procedure must be carried out again after an Encoder fault release 1 3 8 COUNTING ERROR Check the marker pulse connection on the amplifier connector X3 If the motor encoder is not providing a marker pulse channel output the amplifier marker pulse channel must be disabled in order to cancel the Counting fault The amplifier marker pulse channel can be disabled by means of the parameter Zero mark pitch set at 0 more active In this case encoder pulse noise may involve uncontrolled motor movements that may be dangerous for operator and machine f When the amplifier marker pulse channel has been disabled the encoder counting protection is no For the TTL incremental encoder configuration Check for the correct encoder supply voltage value Check for the correct encoder amplifier motor ground and shield connections with regard to the recommendations in chapter 4 of the CD1 k Installation Guide Check for the correct encoder A channel B channel and Z marker signal waveforms Forward direction Reverse direction 20 Chapter 5 Troubleshooting amp maintenance CD1 k User Guide CIN
30. nction is disabled Note 2 When exchanging an amplifier on an axis the file of the adjustment parameters PAR as well as the cogging torque file COG corresponding to the motor must be uploaded once again in the amplifier Note 3 When exchanging the motor or when disassembling the resolver sensor the acquisition procedure must be renewed 14 Chapter 2 Commissioning CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Chapter 3 Functional features 1 LOGIC INPUTS 1 1 INHIBIT INPUT Activating the Inhibt input during the operation makes the axis decelerate At the end of the deceleration the motor is automatically disabled The motor is enabled via the CANopen bus or via the Visual Drive Setup software as the Inhibit input is disabled Notes The amplifier inhibiting function is activated if the Inhibit input is disconnected from the 24V potential The Deceleration parameter can be parameter set via the CANopen bus 1 2 LIMIT SWITCH INPUTS The Limit switch inputs are inputs for a detection sensor that allows to stop the motor with maximum deceleration The purpose of both limit switches when they are mounted at the right place on the axis stroke is to protect the mechanics in case of uncontrolled movements The limit switches are only defined according to the motor hardware rotation They are independent from the rotation counting direction selection For checking the w
31. ng Check that the Motor encoder resolution parameter value is correct Check that the Motor parameters Pole pairs and Phase order values are correct Check that the INHIBIT input is disabled Check that the limit switches inputs are not activated Check that the motor is not locked and the shaft movement is free during the procedure e Ifthe BUSY error is displayed after execution of the Autophasing this procedure has failed because of an external cause and the calculated parameters are wrong Check at first the status of the amplifier logic inputs Check that the motor is unloaded and the shaft movement is free during the procedure 18 Chapter 5 Troubleshooting amp maintenance CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL e Ifthe BUSY error is displayed after execution of the Autotuning this procedure has failed because of an external cause and the calculated parameters are wrong Check at first the status of the INHIBIT input and of the limit switches Then check that the motor shaft is free during the execution of the procedure e Ifthe BUSY fault is continuously displayed after the execution of the COGGING TORQUE ACQUISITION procedure the procedure has failed because of an external cause and the cogging torque acquisition is not valid Check that the INHIBIT input is disabled Check that the limit switch inputs are not activated Check that the encoder is providing one marker pulse per motor revolutio
32. ng the auto tuning procedure It can then be modified by the user if required Integral speed gain KI defines the integral gain of the controller which acts on the speed error Its value is calculated by the amplifier during the auto tuning procedure It can then be modified by the user if required Damping gain KC defines the proportional gain of the controller which acts only on the speed feedback Its value is calculated by the amplifier during the auto tuning procedure It can then be modified by the user if required Proportional position gain KP1 defines the proportional gain of the controller which acts on the position error Its value is calculated by the amplifier during the auto tuning procedure It can then be modified by the user if required Feedforward speed 1 gain KF1 defines the feedforward speed amplitude corresponding to the speed input command This term allows to reduce the following error during the motor acceleration and deceleration phases Its value is set at 1 after the auto tuning procedure if minimum following error is required It can then be modified by the user if required Feedforward speed 2 gain KF2 defines the feedforward speed amplitude corresponding to the viscous frictions This term allows to reduce the viscous frictions effect during the motor acceleration and deceleration phases The gain value is equal to the damping gain value the viscous friction compensation term After the auto tuning proc
33. position feedback sensor 4 1 6 1 Selection of the sensor type The motor can be equipped either with a CTN sensor ohmic resistance decreasing temperature function or with a CTP sensor ohmic resistance increasing temperature function Check that the selected thermal sensor type actually corresponds to the sensor type mounted on the application motor 4 1 6 2 Triggering threshold adjustment Enter the sensor ohmic value KOhm corresponding to the required temperature value for the release of the Motor overtemperature protection according to the manufacturer s specifications 4 1 6 3 Warning threshold adjustment Enter the sensor ohmic value KOhm corresponding to a warning temperature value When the warning temperature is reached an information is sent via the CANopen bus Note When using a CTN sensor the warning ohmic value will be higher than or equal to the triggering ohmic value When using a CTP sensor the warning ohmic value will be lower than or equal to the triggering ohmic value Chapter 2 Commissioning 9 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL 4 2 PT PROTECTION 2 selection modes are available Fusing or Limiting It is advisable to use the Fusing mode during commissioning phases In Fusing mode the amplifier is disabled when the current limitation threshold is reached In Limiting mode the motor current is only limited at the value defined by the Rated current par
34. rted by means of the Start button The motor must be uncoupled from its load and the shaft must not be disturbed during the procedure Before starting the acquisition switch the drive on manual mode and then disable it Drive control Off Then start the Auto tuning procedure with following selections Regulator PI Filter Max stiffness and Bandwidth High At the end of the cogging torque acquisition procedure the amplifier parameter file PAR can be uploaded again in order to recover the initial adjustments The Enable cogging torque compensation function allows the commissioning of the motor cogging torque compensation This function is saved in the amplifier EEPROM The Save cogging torque data into a file function allows to store in a PC the cogging torque value corresponding to a motor after the acquisition procedure COG file The Write cogging torque data into the drive function allows to upload in the amplifier the cogging torque value corresponding to a motor if this value has previously been stored in the PC COG file For a brushless motor equipped with an incremental encoder the Cogging torque compensation is only available if the encoder is providing one marker pulse per motor revolution Note 1 The motor cogging torque value is checked at the amplifier power up If it contains some errors storage problems in the amplifier memory the EEPROM error is displayed and the Enable cogging torque compensation fu
35. s between motor and amplifier 3 5 LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL e Check that the Motor Amplifier Host system ground connections comply with the wiring recommendations e Check the rigidity of the mechanical transmission chain between motor and load backlashes and elasticity in the gears and couplings e Start a new Autotuning procedure by selecting a lower bandwidth than the initial one 4 SERVICE AND MAINTENANCE When exchanging a amplifier on a machine proceed as follows e Check that the new amplifier has got the same voltage and current ratings as well as the same hardware configuration as the one to be replaced e Reload and save the parameters of the old amplifier via the serial link or the CANopen interface The new amplifier is now ready for operation Chapter 5 Troubleshooting amp maintenance 23 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL Chapter 6 Appendix SERVO CONTROLLER STRUCTURE KA s Position reference Position Speed error low pass filter Fev defines the cut off frequency at 3dB of the first order filter which acts on the current command Idc This value is calculated by the amplifier during the auto tuning procedure and depends on the selected bandwidth and the selected filter type Proportional speed gain KP2 defines the proportional gain of the controller which acts on the speed error Its value is calculated by the amplifier duri
36. signal over the entire motor travelling range the Zero mark pitch parameter must be set at 15 In this case the encoder counting protection is checking that the encoder measured position has always got the same value when the R reference signal is activated no position measurement drift Chapter 5 Troubleshooting amp maintenance 21 CD1 k User Guide CINFRANOR SERVO DRIVES amp MOTION CONTROL When the encoder counting protection has been disabled the amplifier is only checking that the encoder pulses frequency is lower than 1 5 times the maximum encoder frequency The maximum encoder frequency is calculated into the amplifier according to the Motor encoder resolution parameter value and the Maximum speed parameter value In this case encoder pulse noise at a frequency lower than 1 5 times the maximum encoder frequency may involve uncontrolled motor movements that may be dangerous for operator and machine Note In the Sin Cos encoder without HES configuration the motor Phasing procedure must be executed again after a Counting fault release 1 3 9 HES ERROR For the Incremental encoder amp HES configuration Check that the HES are correctly wired on the amplifier X3 connector with 60 type HES you must check the various wiring combinations to find the right wiring order Check for the correct HES supply voltage value Check for the correct Motor encoder resolution parameter value Check that the HES a
37. ult is displayed by a quick blinking of the OK led When switching on the auxiliary 24 VDC supply the CD1 k amplifier always displays the UNDERVOLT fault The UNDERVOLT Led will go out when switching on the power voltage after a few seconds time delay that corresponds to the power capacitors soft start If the fault display remains after switching on the power supply check that the power supply is actually on 1 3 STORED ERRORS If an error occurs on the amplifier it can generate the detection of several other errors which are only a consequence of the initial one In order to make diagnostic and maintenance easier the errors are displayed and processed with the precedence described below For safety reasons the power must be turned off for the cancelling of some errors that requires the handling of the amplifier in this case the amplifier is automatically reset when power is turned on again If power is not turned off do not forget to make a RESET immediately after the error is cancelled 1 3 1 BUSY ERROR e If the BUSY error is displayed after power on the AUTOTEST procedure has failed and the amplifier is not ready for operation Check that the power voltage is not on before the 24 V auxiliary supply e Ifthe BUSY fault is continuously displayed after the motor PHASING procedure at power up Incremental encoder without HES configuration the procedure has failed because of an external cause and the calculated phase value is wro
38. used together with brushless motors because of its robustness Incremental or absolute position sensor The encoder is used together with brushless motors for its accuracy Electric device for the control of electric motors It also includes a current regulator a speed regulator and often a position regulator Used for the motor current control The motor torque is generally proportional to the current amplitude Allows the motor speed control Allows the motor position control Digital link that allows real time data exchange between various electric devices The characteristic of fieldbusses is their high protection and error correction level as well as a predictable communication time Communication protocol on CANbus Standards CiA DS301 CiA DSP402 When a motor is enabled it is controlled by the amplifier and the servo loops are operating When it is disabled its rotation is free and there is no current in the motor CD 1 k EA User Guide l INF RANO R Chapter 2 Commissioning CAUTION Do not make the amplifier parameter setting by means of both Visual Amplifier Setup software and CANopen bus at the same time 1 INSTALLATION OF THE PARAMETER SETTING SOFTWARE The Visual Drive Setup software is PC compliant under Windows and allows an easy parameter setting of the CD1 k amplifier Please see our website www infranor fr for downloading the Visual Amplifier Setup software 2 CHECKING THE AMPLIF
39. ween to successive Z marker pulses or R reference signals is equal to the value of the Motor encoder resolution parameter multiplied by the one of the Zero mark pitch parameter The encoder counting protection also checks that the encoder pulse frequency is lower than 1 5 times the maximum encoder frequency The maximum encoder frequency is calculated in the amplifier according to the value of the Motor encoder resolution and Maximum speed parameters The value of the Motor encoder resolution parameter defines the number of encoder pulses or encoder signal periods per motor revolution for a rotary motor or per motor pole pairs for a linear motor The value of the Zero mark pitch parameter defines the number of motor revolutions for a rotary motor or of motor pole pairs for a linear motor between two successive Z marker pulses or R reference signals With a rotary motor the Zero mark pitch parameter is generally equal to 1 because the encoder has got one Z marker pulse or one R reference signal per motor revolution On a linear motor with only one marker pulse over the whole motor travel the Zero mark pitch parameter must be defined at 15 In this case the encoder counting protection checks that the measured encoder position has still got the same value when the marker pulse is activated no drift in the position measurement Note In the Incremental encoder without HES configuration the motor phasing procedure Phasing must be r
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