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1. 20 v 4 voneuuojur senbiuuoe 39 ees 9 aq pinoys eum sezis pue Beg S uonejado ejqeyorpadun aonpaid suid siempejnueui uo suid pasnun jou oq 4 11 40 2 2 woy eunsopue uesseoeu eq pue y Jo Bungi qj au ue pejejsur eq SHUN apis y uo Ajqeiejaud egeo jo pue auo uo 9ujj2euuoo Aug urod 2215 0 aq jou pue ejqeo y uo y si Buipuno6 aagoay 10 se au Jo epis eAup Y 0 esop se pue jaued pepuoq pedo d pinous 5 30N 20 suoneoybeds ees V 18 SERVOSTAR PD Danaher Motion Kollmorgen Wiring Instructions ELECTRICAL INTERFACE The following schematic diagrams show the I O electrical interface Digital Inputs and En
2. 2 OverTemperature trip Protection Functions UnderVoltage Trip nominal VDC OverVoltage Trip VDC Continuous Power KVA at 24 V Input 45 Ambient Continuous Power KVA at 80 V Input 0 433 45 C Ambient Continuous Current Arms 10 Main Output 20 Ma Mb Me Environment Derate 5 per 1000 ft 300 m above 3300 ft 1000 m 0 13 B o 10 SERVOSTAR PD Danaher Motion Kollmorgen Mounting MOUNTING The SERVOSTAR PD is designed for brick mounting This panel assembly is then mounted in a metallic enclosure Enclosures are supplied by the manufacturers of the final product and meet the environmental IP rating of the end product To ensure proper grounding and to optimize the enclosure should have continuous ground continuity maintained between all metal panels This ground continuity is intended to be both a safety ground and a high frequency ground The units are mounted on a backplane installed into the enclosure Ideally the backplane should be an unpainted metallic surface to optimize electrical bonding of the frame and provide the lowest possible impedance path to earth ground These enclosures also provide added safety Particular care should be used when layout of an enclosure is designed Separate power wires from small signal wires The following guidelines highlight some important wiring practices to implement e Control and signa
3. 3 Upon power up commutation signals are used to communicate coarse position information The first three signal types give approximate position information so the drive can commutate the motor forward until the Index pulse is found There are situations where the index signal is not available Course position information is used to commutate the motor indefinitely The fourth gives absolute information bypassing the need for the Index signal They are No Hall signals exist if no power up commutation signals are available The SERVOSTAR can excite two phases and lock the shaft in place It then approximates position of the locked shaft and uses only the incremental signals to commutate forward until the index is found Hall signals provide information representing the approximate location of the motor shaft 6 transitions per electrical cycle of the motor From this information the motor can six step commutate forward until the index signal is detected at which time true position is known and sinusoidal commutation begins These signals are isolated by an opto coupler and can be differential or open collector type signals e C D lines are an alternative to Hall signals These lines provide a SIN COS sinusoidal signal where one electrical cycle equals one mechanical revolution identical to single speed resolver feedback Interpolation is performed on these signals thus absolute position is known within 256 parts of a mechanical revolutio
4. Configurable under volt protection UVMODE UVTIME UVRECOVER Configurable motor thermal protection that accepts various thermostat types THERM THERMODE THERMTYPE THERMTIME Configurable drive thermal protection through the fold back feature FOLD FOLDMODE It sets the maximum time limit the drive can provide peak current to the motor Configurable motor thermal protection through the motor fold back feature MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT It sets the maximum time limit the drive can provide continuous current to the motor Speed and current protection VOSPD VLIM ACC DEC ILIM ILIM2 Hardware position limit switch detection CCWLIM CWLIM LIMDIS IN2 IN3 IN2MODE IN3MODE Configurable software position limits PLIM PMAX PMIN Configurable fault relay output RELAY RELAYMODE DISTIME INIMODE IN2MODE IN3MODE Active disable feature ACKFAULT that allows you to determine how the system should react at the occurrence of a fault The system can immediately disable where the motor will coast to a stop or it can be programmed to a controlled decelerated stop DECSTOP DISSPEED DISTIME STOPMODE ISTOP Active enable indicator through the Status Display decimal ACTIVE DRIVEOK SWEN READY REMOTE DIPEN Watchdog faults FEEDBACK DEVICES Encoders Maximum frequencies to 3 MHz before quad Up to 10 million lines per motor mechanical cycle MENCRES Enc
5. De eee er ee ____ Resolution and Accuracy eee 251 DIGITAL ENCODER 226 RS 232 Daisy Chae en en A E R EEA EE E 34 SS bending Retrieving System Data emm 381 Terminal Mode REA cM 4 SERVOSTAR PD Danaher Motion Kollmorgen Table of Contents Configurable Digital 481 TM E M as Vault Output Rela UPDATE DRIVE FIRMWARE 561 SERVOSTAR PD Danaher Motion Kollmorgen Table of Contents SERVOSTAR PD Danaher Motion Kollmorgen System Description SYSTEM DESCRIPTION The SERVOSTAR PD is a high performance servo drive that can operate in Torque Velocity and Position modes It comes in a miniature package measuring only 140 mm 4 1 in x 108 mm 4 25 in x 51 mm 2 in Numerous position control options are offered ranging from the classical 10 VDC command through encoder following and pulse direction all the way to SERCOS interface control The SERVOSTAR PD comes in standard packages of 5 and 10 amps continuous current and supports nominal bus voltages from 24 VDC through 80 VDC It has its own tailored software environment in Danaher Motion Kollmorgen s MOTIONLINK for Windows The SERVOSTAR PD includes a vast array of features Its various control
6. Increased accuracy due to the ability to calibrate and match the Sine and Cosine signals Increased reliability due to the use of fewer components The Process The SW resolver implements a 2nd order tracking filter which uses feed forward to zero ideally the tracking error for constant speed RESBW is the filter bandwidth and the tradeoff is the higher the bandwidth the faster the response but the more the system will be prone to noise The Sine and Cosine signals of the resolver should be calibrated in order to increase the accuracy of the measurement automatically at each power up old parameters are used until the calibration process can generate new parameters Thus there is no need to explicitly enter the SININIT instruction CORE PROCESSORS A 40 MHz embedded controller and a 40 MHz DSP controller are the heart of the SERVOSTAR PD They use its internal operating system to monitor inputs adjust outputs communicate serially maintain servo control and monitor faults The flash memory firmware that controls the core processor and gives the SERVOSTAR PD its operating characteristics is saved in EPROM The version number of the firmware can be read using the VER command When calling Danaher Motion Customer Support for technical support be sure to have the firmware version number The most recent version of firmware is available for purchase and is easily field upgradable through a PC It can be obtained by contacting a Danaher Motion
7. 641 Fax 201 379 1151 Corcom World Headquarters East Coast Sales Office 844 E Rockland Road Livertyville 60048 Phone 708 680 7400 Fax 708 680 8169 Filter Concepts Inc 2624 South Rouselle Street Santa Ana CA 92707 USA Phone 714 545 7003 Fax 714 545 4607 17 Sarah s Way Fairhaven MA 02719 Phone 508 992 4495 Fax 508 992 3798 FerriShield Interference Control Components Empire State Building 350 Fifth Ave Suite 7505 New York NY 10118 7591 Phone 212 268 4020 Fax 212 268 4023 Fair Rite Products Corp P O Box J One Commercial Row Wallkill NY 12589 Phone 914 895 2055 Fax 914 8985 2629 E Mail ferrites fair rite com Micrometals Iron Powder Cores 5615 E La Palma Anaheim CA 92807 Phone 800 356 5977 Fax 714970 0400 Worldwide 2 SERVOSTAR PD West Coast Sales Office 6700 Fallbrook Ave Suite 160 West Hills CA 91307 Phone 818 226 4306 Fax 818 704 1757 Phoenix Contact Inc P O Box 4100 Harrisburg PA 17111 0100 Phone 800 888 7388 Fax 717 948 3475 Magnetics P O Box 391 Butler PA 16003 0391 Phone 412 282 8282 800 245 3984 Fax 412 282 6955 714 970 9400 Danaher Motion Kollmorgen CONNECTOR PINOUTS Logic Power Connector Function 24 VDC Supply Input 2 24 V RTN Supply Input P2 Motor Power Connector Pin Function 1 Motor Output Phase A 2 Mb Motor Output Phase B 3 Motor Output Phase 4 Ch
8. Devices Resolution and Accuracy A SERVOSTAR encoder based system typically exhibits minimal inaccuracies outside of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used SINE ENCODER The SERVOSTAR can receive an analog or sine encoder feedback device to monitor the motor shaft position As opposed to a digital encoder which generates incremental square wave signals a sine encoder outputs analog differential sinusoidal signals These sine signals are quadrature decoded and passed to an interpolation circuit that breaks each 360 cycle into 256 parts before passing it to the drive s control board Thus the resolution seen by the drive is 256 times the fundamental sinusoidal track on the motor s encoder The advantage of this approach is the ability to obtain much high encoder resolution while maintaining a relatively low input frequency through the cable and into the SERVOSTAR The encoder interface includes three groups of wires 1 and complements lines make up the encoder quadrature signals The signals are received differentially at 1 V peak to peak amplitudes before being processed by the interpolation circuitry 2 The narrow Index pulse normally appears once per mechanical revolution and indicates known physical position of the shaft This pulse is received differentially through an op amp before being squared up and sent to the control board
9. Kollmorgen sales representative or by contacting Danaher Motion Customer Support SERVOSTAR PD 51 Danaher Motion Kollmorgen System Operation CONTROL LOOPS This section describes the servo control loops their characteristics and how to configure them Servo Loop Description The SERVOSTAR PD provides high performance motor control by controlling up to four distinct closed loop systems within the DSP the current commutation velocity and position loops The next figure depicts the control loops graphically __ _______ POSITION LOOP sesssseasesseassassseccchiccosnusi tes VELOGITY LOOP COMMUTATION LOOP CURRENT LOOP 330 VDC i 4 KA c EN 1 ais e S Power 0 H gt qt m id 5 Transistors 2 2 ul ho i i i i i i i i i i i i i i i i i i i i O E E E Current Loop Since current and torque are proportional in a Permanent Magnet PM motor the current loop is often referred to as the torque loop The function of the current loop is to regulate motor current as directed by a current command signal The current command
10. Setting Motor Variable Parameters Click the Motor button This screen allows you to access the MOTIONLINK motor database Select a motor family and then a model within that family Information will appear in the blank parameter fields on the right Click on the To Drive button beneath the fields to send the variable parameters to the drive Click Exit to return to the MOTIONLINK Start Up Wizard If you have a configured drive a From Drive button is provided to retrieve the motor data already the drive Retrieving this data does not erase it from the drive A If the motor cannot be found in the database contact the Danaher Motion Customer Support for detailed instructions 36 SERVOSTAR PD Danaher Motion Kollmorgen System Communication 3 Customizing to Application Click the Opmode button in the Startup screen to select the mode of loop control desired position velocity or torque Click Exit to return to the MOTIONLINK Start Up Wizard 4 Tune the drive Click on the Tune button in the MOTIONLINK Start Up Wizard to set the system bandwidth the type of loop control and the filtering necessary for the application handling the vibration caused as the shaft senses its load If this is in question manually tune the drive Also when the load inertia is very large and the selected bandwidth is high this feature may fail to perform 5 Setup Completion Click EXIT to go to the Main MOTIONLINK screen Caution shoul
11. The use of armored screened motor and power cables bonded as close to the drive as possible are essential for CE compliance and strongly recommended to better the overall performance and reliability of the system Motor cables and feedback cables exiting the cabinet going to the motor should be separated as much as possible Ideally the use of separate conduits provides good isolation which can limit coupling of noise from motor to feedback cables Feedback cable bonding is required for CE compliance As with the motor cables the feedback cables should be bonded to the back panel This bonding does two things it cuts down radiation from the drive that may be in the form of high frequency energy resulting from internal processor clocks and it provides immunity for the drive Since the feedback device is located internal to the motor it is going to pick up some noise currents and transmit them along the feedback cable The bonding directs the currents from the shield of the feedback cable to back panel ground This reduces the amount of noise entering the drive SERVOSTAR PD Routed to Motors 21 Danaher Motion Kollmorgen Wiring Instructions RECOMMENDED MANUFACTURERS LIST North America Schaffner EMC Inc 9 B Fadem Road Schaffner Electronik AG Nordstrasse 11 CH 4708 Luterbach Switzerland Springfield NJ 07081 Phone 065 802 626 Phone 201 379 7778 Fax 065 802
12. damaging either the PC or the SERVOSTAR PD The diagram below shows the connection from the PC to the first drive and from the first drive to subsequent drives To PC First Drive Connection Second Drive Connection To connect the PC to the first drive only pins 2 3 and 5 on the PC are required Pins 6 and 7 are optional and do not effect operation To connect between the drives only pins 5 8 and 9 are required The rest are optional and do not effect operation 34 SERVOSTAR PD Danaher Motion Kollmorgen System Communication Sending Retrieving System Data The following chart describes the flow of data between the PC and the SERVOSTAR When logic power is applied to the drive it loads the variable parameters stored in EEPROM into the dynamic RAM for fast and easy access You can read and write these variable parameters to and from the PC by one of several methods described in the INITIAL STARTUP section USER SETTING VARIABLE FILE SSV zx OR TERM NAL DUMP command LOAD command or Power up EEPROM variables SAVE command operating parameters MICRO PROCESSOR The PC transmits serial data to the drive and stores it in dynamic RAM However any variable data changed from the PC is lost when logic power is lost if it is not saved into non volatile EEPROM Each variable listed in VarCom Reference Guide indicates whether it can be saved to the EEPROM If
13. difficulty The safety alert symbols are Warning Alerts users to potential physical danger or harm Failure to follow warning notices could result in personal injury or death AS Caution Directs attention to general precautions which if not followed could result in personal injury and or equipment damage A Note Highlights information critical to your understanding or use of the product Directives and Standards The SERVOSTAR PD product series have been successfully tested and evaluated to meet UL cUL 508C for both U S and Canadian markets This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment such as frequency converters and servo amplifiers which is intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipment CE Mark Conformance Servo drives are components that are intended to be incorporated into electrical plant and machines for industrial use When the servo drives are built into machines or plants drives cannot be operated until the machine or plant fulfills the requirements of the EC Directive on Machines 89 392 EEC and the EC Directive on EMC 89 336 EEC EN 60204 and EN 292 must also be observed In connection with the Low Voltage Directive 73 23 EEC the harmonized standards of the EN 50178 series are applied to the amplifiers together with EN 60439 1 EN 60146 and EN 60204 The manufacturer of the
14. for I O lines Fair Rite Products Corporation also has a varied selection which suits most applications I O Filter Recommendations Manufacturer s Part Danaher Motion Kollmorgen Part FairRite 126431672581 This core must be used with the drives for CE compliance It should be applied to the 24 V or 80 V input power lines and the Remote Enable lines 7 amp 8 on C3 connector with approximately 3 turns through the core The following figure illustrates the use of multiple turns through a clamp on core The more turns created the more impedance is added to the line Avoid putting the shield in a clamp on core It is undesirable to place an impedance in line with the shield The use of ribbon cable may be common in many cabinets Some ferrite clamps are designed just for ribbon cable use as shown below SERVOSTAR PD 17 0 5 Instruct iring Danaher Motion Kollmorgen WIRING DIAGRAM LINN SIHL ONIHIM 30338 SALON TIV M3IA3 OL 9405 38 iA INO T3NNOSH3d GAlsITVND OL 9NILOOHS3 T8nOH L ANY NOILVTIVLSNI 43334 ANY NOILNVO ASN 5 S31V3dO SAIC JHL LNdLNO ONINYVM SNINSHVM p X STAGOW 502435 NO v2 S32 V 1934 LINSNVYL IVNNVW NI 1X31 33S NOWAOO Y 1 B LN3TIVAInO3 Y 9 II
15. machine or plant is responsible for ensuring that they meet the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding arrangement of filters treatment of connectors and the laying out of cabling can be found within this documentation Conformance with the EC Directive on EMC 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo drives within the European Community An authorized testing laboratory in a defined configuration with the system components has tested the servo drives Any divergence from the configuration and installation described in this documentation means that you are responsible for the performance of new measurements to ensure that the regulatory requirements are met Danaher Motion Kollmorgen s PD Series systems have been successfully tested and evaluated to the limits and requirements of the EC Directive on EMC 89 336 EEC and the EC Directive on Low Voltage 72 73 EEC The product lines have been evaluated to EN50178 and EN60204 as a component of a machine and other relevant standards The EMC of a system can be identified by emissions and immunity Emissions refer to the generation of EMI electromagnetic interference and immunity refers to the susceptibility levels of the equipment Limits were derived from generic standards EN55081 2 and EN55082 2 for heavy industrial environments The SERVOSTAR PD series drives have been tested for
16. movement Homing types are available that home to a particular analog input level and position count triggering either through the Configurable Inputs or the Remote Enable In this mode of operation the drive can also accept an external load feedback signal through the C8 connector DUALFB 1 This helps eliminate the positional inaccuracies due to gear backlash and poor coupling by positioning according to the load s position not the motor shaft s position The SERVOSTAR PD also operates in the position mode when the drive is in the hold position state HOLD 1 Torque Loop Operation The design of the control loops was discussed in the previous section Now the operation as a system is presented The SERVOSTAR PD has many internal variables that are used to examine and dictate system operation Many of these variables and their locations in MOTIONLINK are presented graphically in the following discussions to help disclose meanings and relationships Serial Torque The SERVOSTAR PD can be operated as a serial torque controlled amplifier OPMODE 2 It receives a serial command T via a host to a command generator which in turn creates a current command ICMD The current or torque command is checked against peak ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calcu
17. of this section describes the process of setting up a non configured drive Caution must be taken when applying power to the drive It is factory configured to enable upon application of power Verify that the hardware Remote Enable REMOTE enable switch is disabled RS 232 A Connection When communicating with the drive over RS 232 the each drive s address must be unique and set to a non zero value using the first 5 DIP switches The drive s communication protocol requires that the drive be addressed by software before it will respond MOTIONLINK automatically detects the drive s address When working through a terminal enter the instruction in order to address the drive x where x is the drive s address When one drive is addressed all other drives are unaddressed and ignore the instructions being transmitted over the bus RS 232 Daisy Chain The SERVOSTAR PD has RS 232 Daisy Chain support built into the communications port The Daisy Chain mechanism implements a communications bus that allows multiple drives to be connected together from a single PC Since the RS 232 communications between the drive and the host PC uses only three wires Transmit Receive Ground and the connector has 9 pins the spare pins are utilized for the Daisy Chain communication A ribbon cable can be used to connect the PC and the drive but care must be taken to cut some of the wires in the cable As The indicated cable wires MUST be cut to avoid
18. panel for the Analog command PD C4 Equivalent Encoder Output C8 Secondary encoder input 2 SERVOSTAR PD Danaher Motion Kollmorgen System Description Fiber optics connectors are mounted in the C4 location for the SERCOS interface option as shown below C4 Equivalent Encoder Output C8 Secondary encoder input The feedback connector C2 1s located on the left hand side panel as shown in the picture below GENERAL FEATURES enabling and disabling features S STOP REMOTE DIS e Flash firmware memory for easy field upgrade installation Danaher Motion Kollmorgen s patented Torque Angle Control for buried magnet motor designs MTANGLC MTANGLP MTANGLF MTANGLH defined as speed and torque optimization through commutation angle advancing of the drive s output current waveform with respect to the motor s back EMF waveform e Firmware and serial number information VER SERIALNO via terminal e Encoder Equivalent Output signal C4 connector eliminates the need for an additional position feedback device The maximum frequency of this output is 3 MHz for standard encoders SERVOSTAR PD 3 Danaher Motion Kollmorgen System Description FAULT AND SAFETY DETECTION Fatal and non fatal error coding with text explanation to the host ERR FLTHIST FLTCLR A run time counter TRUN that records the time the error occurred is also provided Faults status word STAT STATUS
19. protection SERVOSTAR PD 29 Danaher Motion Kollmorgen Feedback Devices EEO Phasing The EEO signals are not phased the same for resolver and encoder systems The following demonstrates these phasing relationships Resolver Systems A Leads B convention for clockwise rotation Channel A Lo Channel B SEE Index AB high rS e Encoder and Sine Encoder Systems B Leads A convention for clockwise rotation Channel A Channel Ti Index determined by encoder 30 SERVOSTAR PD Danaher Motion Kollmorgen DIP Switch Configuration DIP SWITCH CONFIGURATION DIP SWITCH DESCRIPTION The 10 position DIP switch is for setting the drive address and for certain drive configuration This switch provides the following functions Addressing Bit 0 of Address LSB Bit 1 of Address Bit 2 of Address Bit 3 of Address Bit 4 of Address Bit 4 of Address MSB Baud Rate 0 9600 1 19200 SERCOS interface Mode 0 2 1 4 HOLD Mode Switch 0 Hold Mode Inactive Drive Enable Disable 0 Drive Enable SERCOS Transmit Power 0 Low Power Factory Reserved Must Be set to 0 Address Select Switches through 5 set the drive s address A drive having address 0 powers up in the non addressed state If these five switches are set to anything but 0 the drive assumes an address code indicated by the switch settings The address switches are
20. read only at power up Baud Rate Switch 6 sets the baud rate to either 9600 bps switch off or 19200 bps switch on in the serial mode In the SERCOS interface mode the baud rate can be set to either 2 M bps switch off or 4 M bps switch on Position Hold Activating switch 7 causes the drive to enter a position hold mode The condition is signaled by a flashing status display The display maintains its current OPMODE code If the drive is running during a HOLD command detection the motor ramps to a stop at the DECSTOP rate Enable Switch 8 is an input to the drive enable circuitry and is used to force the drive to a disabled state SERCOS interface Power Level Functions only on SERCOS interface products If switch 9 is set to 0 the SERCOS transmitter uses a low power setting so it does not overdrive the receiver when using short cables Long cables require more power Factory Reserved Must be set to 0 SERVOSTAR PD 31 Danaher Motion Kollmorgen DIP Switch Configuration DRIVE ADDRESS DIP SWITCH SETTINGS The following table shows the DIP switch address settings Drive Address Switch 5 Switch 4 Switch3 Switch2 Switch 1 0 of or of of Of p 6 i om Om On 2 of of Oo __ p 03 J ow o _ ono O 04 0 of _ of _ F E m conc _ OH 5 4 94 00 ff 32 SERVOSTAR P
21. signal from the microprocessor can either come from a direct user input OPMODE 2 amp 3 or from the output of the velocity loop There are actually three current loops one for each motor phase Each current loop receives its own command input from the commutation loop The SERVOSTAR PD uses a fully digital pole placement current loop with high bandwidth and a current loop sampling rate of 16 kHz 62 5 us All coefficients of the current loop are digitally calculated inside the drive for a given set of motor and drive characteristics The current loop also includes adaptive gain terms to compensate for some non linear effects The current loop incorporates electrical isolation for protection from the high voltage BUS These current loops also convert the output voltage to a Pulse Width Modulated PWM signal providing the highest efficiency possible The PWM center frequency can be 8 or 16 kHz according to the drive size Commutation Loop This loop converts a single phase current command signal into a three phase position modulated sine wave input to the current loops The SERVOSTAR PD has a patented sinusoidal wave form generator that uses Torque Angle Advance to get top performance out of its motors The waveform generator is part of the microprocessor and is updated at a 16 kHz rate This provides hi fidelity sinewave commutation at both low and high velocities The sinewave output must be aligned to the back EMF MOTORBEMF characteristics of
22. techniques interfaces and user tools give you a compatible drive to meet most motion control applications Bulleted words that begin in capital letters indicate formal feature names Words that are capitalized indicate the software variables and commands associated with the feature This section is designed to direct you to the VarCom Reference Manual for details on these features PART NUMBER Px y 22 56w Feedback E Encoder B Sine Encoder R Resolver Cont Current 01 1 Amp 05 5 Amp 10 10 Amp Control Interface 0 Analog 1 SERCOS FO Bus voltage 2 24V 8 80 v Examples Note PE205560 Encoder Feedback 24 Bus 5A Analog interface 80510 available only by special request PBS 05 561 Sine encoder Feedback 0 Bus 5A SERCOS interface SERVOSTAR PD 1 Danaher Motion Kollmorgen System Description FRONT PANEL CONNECTOR LOCATIONS KOLLMORGEN PI 24 VDC Logic Power P2 Motor power output P3 Bus voltage input Serial Communications SIDE PANEL CONNECTOR LOCATIONS The right hand side panel of the PD has two versions one for the PD with that works with an Analog command signal 10 VDC and one for the PD with SERCOS interface The difference is that the Analog command version has an Equivalent Encoder Output connector while the SERCOS interface version has SERCOS interface connectors The picture below shows the side
23. will cause a latched disable sometimes controllable through software switches To clear fault toggle remote enable except for OverCurrent If the encoder initialization function ENCSTART is active the OPMODE number will flash at a 3 Hz rate Displays a character momentarily for 500 ms before returning to the steady state The timer is resetable Communications Error F Drive is in FoldBack mode Flashing Decimal Point State Steady OFF Steady ON Status Display Decimal Point Drive Status No power to the motor Drive enabled power to the motor Drive enabled power to the motor but a motor safety feature has been disabled for example LIMDIS 1 OPERATIONAL MODES The SERVOSTAR PD has the ability to assume different modes of operation It is factory configured in OPMODE 1 Analog Veloc ity Controller but may be reconfigurd Not all commands and variables are active or meaningful in every OPMODE l Serial Velocity Controller OPMODE 0 the SERVOSTAR PD is configured as a velocity loop controller and is controlled by issuing a velocity command J jog command or STEP step command to the drive via the serial port 2 Analog Velocity Controller OPMODE 1 the SERVOSTAR PD is configured as a velocity loop controller and is controlled through either a 10 V analog input signal or jog J commands stored the Configurable I O The commanded velocity is proportio
24. you are configuring the same system on similar applications the variables can be saved on disk in an SSV file for convenient downloading into other drives INSTALLING MOTIONLINK 1 Download MOTIONLINK from either the Product Support Package CD ROM or from the website www motionvillage com products software downloads MOTIONLINK 2 Select the version of MOTIONLINK for the SERVOSTAR PD and follow the instructions on the screen RUNNING THE PROGRAM Go to your Start Programs listing and select SERVOSTAR MOTIONLINK from the menu or click on the SERVOSTAR MOTIONLINK icon if loaded on the desktop USING MOTIONLINK MOTIONLINK gives you three methods to configure the drive The first uses the Startup screen and is the easiest and most highly recommended approach Its main purpose is for initial startups The second approach allows you to more indirectly perform the same configuration as the first using the Main MOTIONLINK screen This method is most convenient when corrections to an existing configuration is needed SERVOSTAR PD 35 Danaher Motion Kollmorgen System Communication The third method uses the Terminal Mode screen to directly set or monitor values for the same variables and commands that the other two methods configure through a more friendly user interface You can gain a more thorough understanding of the SERVOSTAR PD MOTIONLINK and its variable and command set by using the context sensitive Help F1 provided in MOTIO
25. 8 dBm m Cable Length Specifications Low Power High Power 103m 1 Fiber optic cable attenuation is 0 18 dBm m 2 Cable length calculations assume that the fiber is not attenuated by intermediate connections SERVOSTAR PD 4l Danaher Motion Kollmorgen SERCOS Interface Setup For most applications the low power setting is sufficient Longer cable runs or the use of intermediate connectors may require the high power setting Communication problems may occur if the power level at the receiver is too large or too small Receiver power problems may cause erroneous data transfer resulting in the drive returning to or failure to advance out of For more information on SERCOS interface signal attenuation refer to the following sections of the IEC 61491 SERCOS interface specification 1 5 3 Optical Signals on the Transmission Line 2 Annex G Attenuation on the Transmission Line STATUS DISPLAY After the CP run up sequence has completed the drive is in OPMODE 5 when communicating on a SERCOS ring This is indicated by the number 5 on the Status Display The SERCOS version of the SERVOSTAR differs from the standard unit in that errors and faults are not communicated through this display only through the SERCOS ring to the controller Therefore if an error occurs the 5 remains on the display The Status Display decimal point turns ON and OFF when the drive is enabled or disabled The SE
26. APOS MASPEED MIDISTO MIDISTI MIDIST2 MIDIST3 MISPEEDO MISPEEDI MISPEED2 MISPEED3 through either the serial port or the hardware configurable inputs IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Position homing with I O triggering capability MH HOMESPD HOMESTATE HOMETYPE through either the serial port or the configurable inputs IN2 IN3 INIMODE IN2MODE IN3MODE Electronic Gearing Position Mode OPMODE 4 featuring pulse following or master encoder capability with resolution up to 3 MHz through C8 connector 2 5 kHz through opto isolators in C3 GEAR GEARMODE GEARI GEARO PEXT PEXTOFF VEXT XENCRES XENCDIR Homing capability is provided Dual loop mode DUALFB capable of positioning from a load feedback C8 input PEXTOFF PEXT VEXT XENDIR device while controlling velocity and torque from the motor feedback C2 input PID position loop tuning GP GPD GPI with feed forward acceleration gain input to both the velocity and current loops GPAFR GPAFR2 and feed forward velocity gain input to the velocity loop GPVFR Software position limits PLIM PMAX PMIN PEMAX Configurable integrator dynamics through travel range GPISATOUT GPISATIN Cumulative revolution and error position counters PFB HWPOS PRD PE Position indicators INPOS PEINPOS PE PEMAX PFB PFBOFF PROFILE RAMPING CONTROL Electronic Braking STOPMODE ISTOP Separate ACCEL and DECEL linear ramping control in v
27. D Danaher Motion Kollmorgen System Communication SYSTEM COMMUNICATION You communicate with the SERVOSTAR PD through either the serial port RS 232 or on a SERCOS interface fiber optic ring SERCOS interface versions only The serial port can communicate at baud rates of 9600 or 19200 bits per second DIP switch 6 in RS 232 configuration The SERVOSTAR PD comes with its own software interface called MOTIONLINK MOTIONLINK is a Windows based program designed to effectively assist you in setting up and controlling the drive s operation It is highly intuitive in nature and contains an extensive context sensitive on line Help F1 tool 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 You can download MOTIONLINK from the website www danahermotion com Also available is the VarCom Reference Guide detailing the complete variable and command set This guide is a great added resource to MOTIONLINK when using the package in the Terminal mode of operation Since the software is designed to guide you through the operation process of the drive the MOTIONLINK discussion in this section covers only general steps of use A dumb terminal can also be used to communicate to the drive You will find this method of communication very awkward until a certain level of familiarity with the drive s operation is achieved MOTIONLI
28. DE 4 This mode of operation sets the SERVOSTAR PD up to run as a pulse or master encoder follower by using the Electronic Gearing feature The pulse input can either be applied through the Configurable Inputs on the C3 connector up to 2 5 KHz max opto isolated or through the Remote Encoder Input on the C8 connector up to 3 MHz on top of the drive OPMODE 8 This mode of operation configures the SERVOSTAR PD as a simple positioning controller Once in this mode position commands can be given through the serial port through the Configurable I O or through the analog input determined by the PCMDMODE variable The position loop has been enhanced to a full PID controller with acceleration and velocity feed forward gains Two integral gain variables have been added to limit the action of the integral term during selected parts of the profile This helps to minimize overshoot and settling problems Using a serial command PCMDMODE 90 the SERVOSTAR PD executes simple absolute incremental or indexing and homing motion profiles This is done either by direct commands through the serial port MI MA MH or by pre configuring a profile in memory to be used in conjunction with the Configurable I O MASPEED MISPEEDO 3 MAPOS O1 OIMODE INx INXMODE Using an analog command PCMDMODE 1 the SERVOSTAR PD scales the analog input GEARI GEARO to establish a wide range of relationships between an analog input adjustment and a corresponding shaft
29. Danaher Motion SERVOSTAR PD Installation Manual KOLLMORGEN giving our customers freedom of design 55 011 0104 Record of Manual Revisions ISSUE NO DATE REVISIONS 1 05 31 01 Initial Release 2 09 30 02 Updated information for new firmware 3 11 30 02 Updated contact and connection information 4 02 20 03 Updated content information Copyright Information Copyright 2001 2003 Danaher Motion Kollmorgen rights reserved NOTICE This document is proprietary information of Danaher Motion Kollmorgen furnished for customer use ONLY No other uses are authorized without written permission of Danaher Motion Kollmorgen Information in this document is subject to change without notice and does not represent a commitment on the part of Danaher Motion Kollmorgen 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 Not for use or disclosure outside of Danaher Motion Kollmorgen except under written agreement All rights are reserved No part of this document shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the document the publisher assumes no responsibility for errors or omissions Neither is any liability assumed fo
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31. IMAX ICONT DICONT DIPEAK Speed V VCMD VE Position PCMD PFB PE HALLS HWPOS INPOS PRD PEXT PEINPOS Dual state digital output 01 OIRST O1TRIG that toggles according to various absolute current speed and position parameter settings Also can be used to communicate occurrences of fold back motor braking and the status of the Remote Enable hardware switch Status Display TESTLED indicator that communicates operational and fault characteristics Realtime reading of the 10 position DIP switch DIP DIPEN Software status switch indicator provided for configurable inputs IN2 IN3 INIMODE IN2MODE IN3MODE Danaher Motion Kollmorgen System Description SYSTEM COMMUNICATIONS Serial communications port address setting through DIP switch on top of drive RS 232 Data transmission DUMP GET LIST MLIST GETMODE baud rates of 9600 or 19200 Configurable protocol ECHO PROMPT ACKMODE GETMODE MSG Interface through Danaher Motion Kollmorgen s MOTIONLINK or a dumb terminal Differential analog input command ANIN 10 at 14 bit resolution X10 V at 15 bit resolution below 4 V of input for slow speed operation using the Dual Gain feature ANDG SE units only Input signal filtering ANLPFHZ Flexible analog input scaling VSCALE ISCALE ANOFF ANZERO ANDB SERCOS interface communications port SERCOS versions only 2 ms update rate Complete
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33. NIMODE IN2MODE IN3MODE INI IN2 or IN3 Motor Thermostat Input THERM THERMODE The SERVOSTAR PD provides a motor thermostat input on the C2 connector that is configured for different types of thermal protections THERMTYPE as well as manipulating of how the drive responds to a motor thermal condition THERM THERMODE THERMTIME Kollmorgen GOLDLINE motors and cables connect the thermostat through the feedback cable The input to the SERVOSTAR PD is electrically closed through the thermostat for proper operation The drive normally flashes an H in the Status Display when this input is electrically opened If a motor thermal device is not used set THERMODE to 3 to disable the feature turns the status display indicator off 48 SERVOSTAR PD Danaher Motion Kollmorgen System Operation SINE COSINE CALIBRATION Overview The software Sine Encoder and software Resolver algorithms are based on sampling the incoming sine and cosine signals Although the process is transparent to the user and therefore does not require additional commands the accuracy of the process depends on the sampling accuracy of the sine and cosine values In order to prevent accuracy degradation due to electronic component tolerances the sine and cosine values must be gain and offset compensated The process of finding the gain and offset compensation parameters is called Sine Zero The process matches an amplifier to an encoder or resolver a
34. NK also provides a terminal emulation feature that contains many useful editing tools for this type of communication COMPUTER REQUIREMENTS MOTIONLINK requires an IBM PC or compatible computer with the following features IBM PC XT AT 386 486 PS 2 or compatible computer 16 MB RAM Windows Windows98 or Windows NT 4 0 with Service Pack 3 CD ROM player Standard Video Adapter CGA MDA EGA MCGA and VGA Serial Port for communication link with SERVOSTAR The serial communications port may be COMI COM2 COM3 COM4 COMI is the normal configuration GV Ve coa pars COMI Address 3F8h Interrupt Request 4 2 Address 2F8h Interrupt Request 3 Address 3E8h Interrupt Request 4 Address 2E8h Interrupt Request 3 SERVOSTAR PD 33 Danaher Motion Kollmorgen System Communication DRIVE COMMUNICATION Review and be familiar with this section completely before applying power to the system Some drives are shipped from the factory already configured for a particular motor You can verify this by applying logic power and monitoring the Status Display A factory configured drive goes through a power up sequence flashing all segments of the display before settling out to a number indicating the mode of operation If the drive is not configured with a particular motor the display flashes a minus sign indicating that you must enter drive motor and application variable parameters The remainder
35. NLINK MOTIONLINK Startup Wizard SERVOSTAR MOTIONLINK New Amplifier Startup Demo mode D x Backup Welcome to the SERVOSTAR New Amplifier Startup You will be guided through the steps required to configure the SERVOSTAR to the motor and your machine Click Start to begin Click Exit to qo to the Main MOTIONLINK screen Start DontShow Nest Time Help Exit The MOTIONLINK Startup Wizard screen appears the first time and any time after should you leave it selected MOTIONLINK is run on a PC It is designed to guide you through a step by step approach to configure a drive Click the START button on the first user screen and walk through the complete sequence of buttons provided to set the drive motor and application Opmode Tune Backup Go variable parameters Should you de activate this screen it can be reactivated by going to the Main MOTIONLINK screen pulling down the Configuration menu and selecting the New Drive 123 option 1 Setting Drive Variable Parameters Click the Drive button This screen allows you to select a BUS value that corresponds to the incoming line voltage This selection actually determines the setting of the variable VBUS Also included is a realtime monitoring of the DIP switch on top ofthe drive so you can verify the proper setting for the drive address baud rate and various other parameters Click Exit to return to the Startup screen 2
36. ONLINK guides you through the setup stages of the configuration process It provides interactive setup screens for easy manipulation of the drive s parameters while giving you realtime monitoring and recording tools to optimize axis performance The parameters can be stored in the drive s EEPROM memory before establishing communication through the SERCOS interface Drive Configuration Before you can begin the CPx where x 0 1 2 3 4 run up process the drive should be configured and tuned for the axis of operation using the steps below Power down the drive Set the drive address to zero for single axis operation Select a serial baud rate Connect a serial cable from the drive to a host Power up the drive Install MOTIONLINK and communicate with the drive Follow the user screens to configure the drive and motor combination Enable the drive Tune the system as desired Save the drive parameters to EEPROM Power down and reset that actual DIP address Any non zero address will set the drive up for communication on the SERCOS ring Each drive on the ring must have a unique non zero address 12 Set the SERCOS baud rate DIP switch 6 off on for 2 4Mbits s QUO 13 Depending on the ring configuration link the fiber optic cables from drive to drive or drive to master as follows Tx1 to Rx2 Tx2 to Rx3 etc 14 Power up the drive It is now prepared to ascend through the SERCOS communication phases u
37. OSTAR PD 49 Danaher Motion Kollmorgen System Operation ENCODER INITIALIZATION WITHOUT MOTION Overview In brushless 3 phase motors the torque generated by the motor depends on the three phase currents and on the motor position In order to properly control the motor and extract maximum torque out of the available motor and power stage the controller must be provided with the current motor position In encoder based systems the initial position for commutation initialization may be found using hall sensors switching index finding or an appropriate commutation lock algorithm or a combination of the three methods In system that do not have hall sensors Encoder Initialization without motion uses a commutation lock algorithm Since on power up the absolute motor position is unknown two methods may be implemented e Applying a forced commutation to move the motor to a predetermined position where the torque generated is zero and updating controller variables accordingly e Using a motion control algorithm that will bring the commutation angle of the motor from the initial unknown position to the current motor position instead of moving the motor The first method described is currently implemented on the SERVOSTAR CD The disadvantage of this method is that it requires the motor to be moved which produces a jumpy motion that may not be tolerable in some cases for example linear motors applications The second meth
38. PD 25 Danaher Motion Kollmorgen Feedback Devices System accuracy using resolver feedback is effected by several components The following table gives information on the inaccuracy that each of these components contribute to the total accuracy of a standard SERVOSTAR system Resolver Accuracy Specifications Components ArcMinutes R D Converter 4 Resolver mechanics rotational 8 Resolver mounting on motor shaft 2 Inter LSB digital dither over the least significant bit 5 Total Worse case 19 DIGITAL ENCODER The SERVOSTAR can use encoder feedback to monitor the motor shaft position As opposed to a resolver which is an absolute position feedback device the encoder is an incremental device that indicates changes in position The encoder resolution of the SERVOSTAR and therefore the drive s encoder equivalent output is fixed because it is a hardware characteristic of the encoder device The encoder interface includes three groups of wires 1 and complements lines make up the encoder quadrature signals The signals are received differentially through line receivers before being passed through a wire break detection circuit 2 The narrow Index pulse normally appears once per revolution and indicates a known physical position of the shaft This pulse is received differentially through a line receiver before being passed through a wire break detection circuit This signal is hardware capturable 3 Hall signals provide information re
39. RCOM manual for a complete list and description of these instructions The parameters are stored in non volatile memory in the drive to be used on power up MOTIONLINK is used to configure the drive FIRMWARE VERSION The firmware version is obtained by entering the VER instruction In response the drive returns a string that is similar to Kollmorgen Motion Technologies ServoStar PD ENCODER 5 0 Amp continuous 10 0 Amp peak rating Firmware version 6 3 3 Runtime 0 27 30 This response indicates the current rating in Ampere RMS Always know the firmware version when calling for technical support DRIVE ENABLE The drive is enabled by a combination of 3 signals and states The Remote Enable is a hardware signal generated by the motion controller 24Vdc applied between pins 6 and 7 of connector C3 The Software Enable is generated by one of the serial port instructions drive can be enabled only when no faults exist If a fault exists a code describing that fault is displayed on the 7 segment LED When the drive is enabled the decimal point in the display is lit If the decimal point is flashing this indicates that the user has disabled some safety related feature A typical example is when the drive is programmed to ignore limit switches LIMDIS 1 46 SERVOSTAR PD Danaher Motion Kollmorgen System Operation SYSTEM I O The SERVOSTAR PD has three digital inputs and one digital output that ca
40. RCOS interface version of the SERVOSTAR is not automatically enabled on power up no matter what the address CONNECTION The mating connector selected for the Tx and Rx ports follow the IEC 874 2 specification which recommends an 5 type connector hand tight connection is adequate Danaher Motion Kollmorgen offers 30 60 and 100cm plastic fiber optic cables with SERCOS interface compatible F SMA connectors The following specifications provide general cable information Cable Characteristics Specifications Cable Type lt 0 18dBmim Fiber NA Also refer to IEC 61491 specifications 5 2 2 Structure of the Transmission Lines 5 3 3 Fiber Optic Cable and 5 3 4 Connectors for more connector and cabling information COMMUNICATIONS The SERVOSTAR PD offers two communication approaches for drive configuration The first approach is to communicate via a multi axis SERCOS controller all the drive parameters through the fiber optic ring during the CP2 and CP3 run up stages This requires a broad understanding of the controller functionally and knowledge of the SERCOS interface standard and manufacturer s IDN set The standard and manufacturer IDNs supported by Danaher Motion Kollmorgen are functionally categorized to make this configuration method easier 42 SERVOSTAR PD Danaher Motion Kollmorgen SERCOS Interface Setup The second approach allows you to configure each axis separately through the serial port using MOTIONLINK MOTI
41. TAR drives can be configured on the SERCOS ring The first five switches of the DIP set the drive address When the address is zero 00000 the drive operates as a SERCOS repeater and as a single axis unit with serial communication You can monitor and configure the drive through the serial port Any other address setting 1 31 00001 1111 establishes the drive as an active SERCOS ring participant with communications through the Tx Rx ports When the drive has a non zero address you can communicate through the serial port only for monitoring purposes Setting Transmission Power Levels The SERCOS transmitter power level DIP switch 9 should be set according to the expected signal attenuation between a SERCOS transmitter and the next receiver Signal attenuation 1s based upon cable length cable type and intermediate connection losses e g bulk head connectors The following table may be used to calculate the maximum allowable and minimum required signal attenuation for a given power level and cable attenuation Power Level Attenuation Specifications Low Power High Power 9 5 dBm 2 m 12 5 dBm 2 m Minimum ___ L5dBm 2m Ac Note Ac Fiber optic cable attenuation in dBm m The maximum and minimum cable lengths may be calculated by dividing the maximum and minimum signal attenuations by the cable attenuation The following table shows the cable lengths for 1 mm plastic fiber with an attenuation of 0 1
42. TROUBLESHOOTING The 7 segment display on the front of the drive indicates the status of the drive When the drive is disabled and there are no faults the display is blank When the drive is enabled the decimal point is lit ERROR LEVELS The SERVOSTAR PD responds to an error according to the error s severity The three levels of severity are 1 Errors that cause warnings These are called Errors 2 Errors that disable the system and indicate fault status These are called Faults 3 Errors that disable almost all the SERVOSTAR PD functions including communications These are called Fatal Errors LED DISPLAY The SERVOSTAR PD has a LED Display that provides a quick visual indication of the status of the amplifier When a fault condition occurs the drive is disabled and the LED displays the cause of the fault so you can readily determine the source of the problem Faults are cleared by removing the cause of the fault and then toggling the drive enable signal The drive over current fault P can only be cleared by cycling the drive power Refer to the table of fault display codes in the following pages Display States The display has three types of states Steady State Flashing State and Momentary State Steady State A number is displayed to indicate the mode of operation set by the OPMODE command The steady state display indicates no errors are detected The number displayed indicates the following OPMODES 0 Serial Veloci
43. TVAR Transmit to the drive the custom variable SSV file The contents of this file should have the CONFIG command as its last statement The drive executes this command and configures itself to the parameters that were transmitted POWER UP SEQUENCE Upon powering up the SERVOSTAR PD performs a series of self tests If the Status Display illuminates a solid number no errors were found and the EEPROM has loaded its variable parameters or loaded with default values in case of invalid EEPROM data into RAM The Remote Enable switch on the I O connector C3 may now be energized thus enabling the servo loops ENABLING THE SYSTEM The drive enable logic is based on the following variable switches and flags ACTIVE This is the overall readiness flag indicating the enable disable state of the drive If high 1 the drive is enabled and power is being applied to motor The following equation must hold true for ACTIVE to go high ACTIVE READY AND REMOTE AND DIPEN where READY DRIVEOK AND SWEN READY flag that indicates the drive is free of faults and ready to hardware enable DRIVEOK switch indicates the status of the drive faults SWEN switch indicates the status of the software enable EN or DIS REMOTE switch indicates the status of the hardware Remote Enable line on the C3 connector DIPEN switch indicates the state of the DIP enable disable switch 8 DRIVEOK SWEN READY doit arve rendy 0 fault exists O disa
44. This high frequency ground is accomplished with the use of a flat braid or copper bus bar It is important not to rely on a standard wire for the high frequency ground In general a wire has an inductance of 8nH per inch regardless of diameter At higher frequencies this unwanted inductance between grounds equates to limited filter performance When connecting high frequency grounds use the shortest braid possible BONDING The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels of the drive system Its effect is to reduce the impedance between the cable shield and the back panel Danaher Motion Kollmorgen recommends that all shielded cables be bonded to the back panel Power input wiring does not require shielding screening if the power is fed to the cabinet enclosure via metallized conduit If the metallized conduit is used with proper high frequency grounds bonding technology and recommended wire routing then power input wire shielding has no affect In the event that metallized conduit is not implemented into the system shielded cable is required on the power input wires and proper bonding technologies should be implemented The motor and feedback cables should have the shield exposed as close to the drive as possible This exposed shield is bonded to the back panel using one of the two suggested methods described in this manual Non insulated Cable Clamp The following figures
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46. able The digital inputs include the enable signal and three general purpose inputs IN1 IN2 and IN3 These inputs are bi polar meaning the input common can be wired to either 24 V or ground The minimum requirement to enable the drive 15 to connect 24 VDC between the Input Common and the Enable amp Input Common CLA4C331KBNE RN705D 6 Samsung Qan 4 V33 BCN 4 7K Eva DGND as d Enable 6 2K 7 PS2805 4 RN705C O40 gt V33 2 1 R403 6 2K css 52805 4 RN705B 04028 ips V33 T BCN 4 7K i gn 1 DGND lt 2 R402 6 2K _ 39 PS2805 4 RN705A 402 8 V33 1 amp B WE 41 DGND C3 10 c IN 62K 1 PIGET Digital Output The PD has one general purpose uni polar digital output 150401 28 52802 1 525255 1 SERVOSTAR PD 19 IONS Instruct iring FEEDBACK DIAGRAM Danaher Motion Kollmorgen 02 SLIOA 21 338 HOLIMS LV LSOWY3HL LSNW YOLON VNH31X3 S THNNVHO OSAVH NOLLO3LOMd IVIAHGHL 3AVH LSNW SHO LOIN INIS HOI SLNANI HLON31318v2 NOILOALOYd LYOHS ONISN SH3009N3 LNIYYNO NI GSN 38 13S 318 0 NI 4 SOVIIOA 3ZINININ QVO TH3AO SNOLLO3NNOO A Idd 1S OML 1 SALO
47. assis P3 Bus Power Connector Function DC BUS 3 Chassis C1 Serial Communications This connector provides the RS 232 signals for serial communication between a PC and the PD Additional signals are provided for daisy chain connection from one PD to additional PDs Pin Function Shield RECV RXD RS232 XMIT TXD RS232 Reserved 5V Output Common N A N A Daisy Chain RxD Daisy Chain TxD 52 e SERVOSTAR PD Wiring Instructions C2 Feedback Connector Pin Resolver 1 Sine High A A 2 3 Comme 5 7 ESV Reta ESV Return e mow Hm ew Shield 13 Thermostat High i Shield i index i 7 Shield ESV Supply ESV Supply p ESV Supply ESV Supply m SV Supply ESV Supply Shield a m mow m RAD Ce x ma 25 Thermostat Low Thermostat Low Thermostat Low C3 User I O Connector Pin Function 1 Analog Differential Input High 2 Analog Differential Input Low 3 DC Common 4 Fault Output Relay Contact 5 Fault Output Relay Contact 6 24V Input Common Rail for Enable CW and CCW Inputs 7 Remote Enable Input 8 CW End Travel Limit Input IN1 9 CCW End Travel Limit Input IN2 10 IN3 Digital Input 3 11 OUTI Digital Output 1 12 REF Di
48. ationship to each other Vel Loop Design Failed Velocity loop could not be configured with the given parameters 43 Recording Active Requested command cannot be executed because it conflicts with a recording in process Rec Data not Available No data available for the GET Command EEPROM 15 Empty Data cannot be loaded because the EEPROM 5 empty Argument Must be Binary Requested value is not the set of acceptable parameters BURNIN is Active Requested function cannot be executed during BURNIN a factory function 51 Not Available Requested variable value or command is not available refer to its detailed ton te Yaron 60 Tune failed no rotation TUNE command failed because motor could not rotate 62 66 Tune failed current sat TUNE command failed because the current loop saturated 70 74 63 67 Tune failed no vel design UNE command failed because the vel loop could not be designed D TUN ae der dive onde oi ing 62 SERVOSTAR PD
49. bl 0 0 fault exists ____ 1 enabl 0 p s 1 no faults 0 disable no faults 1 enable Active Flag drive ready hardware enable DIP switch enable power to the motor 0 no 0 no 0 0 E e Ge SERVOSTAR PD 39 Danaher Motion Kollmorgen System Communication If the drive will not enable check the state of the switches and flags by clicking the Status button in the upper right hand corner of the Main MOTIONLINK screen If using a terminal you can query the drive for the value stored in the STATUS variable refer to VarCom Reference Guide for an explanation on STATUS parameters The Status Display indicates an enabled drive when the decimal point is illuminated solid 40 SERVOSTAR PD Danaher Motion Kollmorgen SERCOS Interface Setup SERCOS INTERFACE SETUP The SERVOSTAR PD comes with SERCOS interface communication capability It must be ordered from the factory with this option The Encoder Equivalent Output D9 connector C4 is replaced with two fiber optic ports transmitter Tx and receiver Rx This section provides the SERCOS specific information needed to complete the installation and setup of a SERCOS interface SERVOSTAR drive to the fiber optic ring DIP SWITCH CONFIGURATION DIP switch configuration 1s similar to that of the standard SERVOSTAR drive Through these switches the drive s address and communication power levels are set Setting Drive Address Up to 31 SERVOS
50. d be used when executing the AutoTune feature Some applications are not capable of Main MOTIONLINK Screen E SERVOSTAR MOTIONLINK Off Line lol x Ele Edit View Configure Tune Options Help Off Line Off Line SE03 160 volts 202 Operation Mode Serial Velocity Analo is 18109 iono Input Command Generator Geating Input Velocity Current RI LT V Encoder Feedback Output 52 Device oo System r Set oee 0 Motor KOLLMORGEN Device M gt OMS axis 0 7 se Disable Enable Exit This screen appears the when you exit out of the Startup screen All the screens mentioned in the method above can be accessed from this screen and should be used to make corrections in the current system configuration 1 Setting Drive Variable Parameters From the Configure menu click the Drive option The same screen appears as described in the Startup screen section Click Exit to return to Main MOTIONLINK Screen 2 Setting Motor Variable Parameters selecting the Motor option under the Configure menu you can obtain the same parameter screen found in the Startup screen Click Exit to return to Main MOTIONLINK Screen 3 Customizing to Application By dropping down the Operational Mode listing you can select the mode of loop control desired position velocity torque Clicking the Tune but
51. default settings of these inputs are for the hardware position limits The Status Display may flash an L upon power up indicating that a travel limit has been tripped If these position limits are not in use set LIMDIS 1 Configurable Digital Output The digital output O1 OTMODE can be toggled in an On Off state to indicate various drive motor and variable conditions These include absolute speed and current levels FoldBack conditions motor braking motion complete and Zero speed conditions position overshoot flagging programmable limit switch detection and an enable ACTIVE flag Condition reset and triggering levels are established through OTMODE OIRST O1TRIG Fault Output Relay RELAY RELAYMODE The SERVOSTAR PD provides a drive ready drive up output in the form of a relay RELAY output The relay RELAY output is controlled by the SERVOSTAR PD s microprocessor There is a software switch RELAYMODE that configures the relay RELAY output to act as a Drive Ready or Drive Up indicator 1 If RELAYMODE 0 the relay is closed when the drive is error free and ready to run This is a Drive Ready configuration 2 If RELAYMODE 1 the relay is closed only when the drive is enabled This is a Drive Up configuration 3 If RELAYMODE 2 the relay opens during a fault when the drive is disabled You can program this fault output to open on any system fault by triggering the Configurable Inputs I
52. e input voltage which extends the resolution to a 15 bit equivalent Above 4 V the system uses the straight 14 bit conversion Special software algorithms are used to minimize cross over distortion and add 0 25 V of hysterisis Analog systems often require scaling and offset bias The SERVOSTAR PD adds an analog offset ANOFF variable to this reading performs an analog deadband ANDB adjustment and scales it through the either the position loop input scaling GEARI GEARO velocity loop input scaling VSCALE or torque loop input scaling ISCALE before passing the data to the selected control loop The analog input ANIN variable indicates the analog reading after the offset ANOFF and the deadband ANDB adjustments but before the loop scaling The ANIN variable range is 22500 counts or mV The SERVOSTAR PD also offers an automatic analog input zeroing function Invoking the ANZERO command while the drive is enabled or disabled samples motor velocity over a 32 ms period and updates ANOFF accordingly to the analog input offset This command also incorporates an internal offset mechanism that has finer resolution than ANOFF is capable of providing Remote Enable Input REMOTE The opto isolated Remote Enable input REMOTE provides a hardware drive enable switch This 12 VDC to 24 VDC input disables or enables the power stage output to the motor The signal must be customer supplied in order to get the drive to enable in combinatio
53. eceive button to get the parameters from the drive Then click on the Save button to save the file to disk SERYOSTAR MOTIONLINK Editor lt none gt Off Line mj x File Edit Help SAVE 1 E m m Iz lt m d Axis HE C Disable Enable SAVE Clear the Drive Parameters Clear the drive parameter memory Go to the Terminal and enter the instruction CLREEPROM Exit from MOTIONLINK SERVOSTAR PD 55 Danaher Motion Kollmorgen Firmware Upgrade Procedure UPDATE DRIVE FIRMWARE Download the Firmware Use the WINIGNITE program to download the new firmware This is a Windows program Run the program the following screen appears Ignite UCB v2 0 2 Port This program will update your ServoStar firmware To do this take the following steps Come 1 Select the correct Com port C rouen 2 Select the correct baud rate Com3 3 Click the Start button Mu Hw Revision Ember version _ File name Address ego 19200 Start Advanced Exit 1 Selectthe correct Com 2 Select the correct baud rate try use 19 200 so that the process will be faster Make sure that the DIP switch 6 15 set to match the baud rate you select here 3 Click on the Advanced button Click on the Add button to select the file to be downloaded For e
54. ecific filters recommendations contained in the Installation Manual that adequately attenuate the conducted noise to levels well below the CE limits SERVOSTAR PD 15 Danaher Motion Kollmorgen Wiring Instructions The implementation of the EMI filter should be done in accordance with the following guidelines M Filter should be mounted on the same panel as the drive and Power Supply Filter should be mounted as close as possible to incoming cabinet power Filter should be mounted as close as possible to Power Supply If separation exceeds 30cm 1 ft flat cable braid 15 used for the high frequency connection between filter and Power Supply When mounting the filter to the panel remove any paint or material covering Use an unpainted metallic back panel 1f possible Filters are provided with an earth connection All ground connections are tied to ground Filters can produce high leakage currents Filters must be earthed before connecting the supply Filters should not be touched for a period of 10 seconds after removing the supply MOTOR LINE FILTERING Motor filtering may not be necessary for CE compliance of SERVOSTAR systems However this additional filtering increases the reliability of the system Poor non metallic enclosure surfaces and lengthy unbonded or unshielded motor cables that couple noise line to line differential are just some of the factors that lead to the necessity of motor lead filtering Moto
55. elocity and position mode ACC DEC PROFMODE S curve ACCEL and DECEL ramping control PROFSCRV PROFMODE in the position mode OPMODE 8 Controlled decelerating DECSTOP DISSPEED DISTIME with acceleration feed forward when the drive is left enabled STOP HOLD CWLIM CCWLIM LIMDIS or becomes disabled K S ACKFAULT DIS This feature can be used in conjunction with the Electronic Braking feature Torque compensator for coulomb friction and weight counter balancing IFRIC IGRAV SERVOSTAR PD Danaher Motion Kollmorgen Installation Quick Steps INSTALLATION QUICK STEPS High voltage can present dangerous and hazardous conditions if not performed by a qualified electrician Be certain to follow all national and local codes during installation Follow all safety precautions outlined in the front of this documentation Open the box es and remove all the contents Check to ensure there is no visible damage to any of the equipment Electronic components in this amplifier are design hardened to reduce static sensitivity However proper procedures should be used when handling to avoid damage to equipment Remove all packing material and equipment from the shipping container Be aware that some connector kits and other equipment pieces may be quite small and can be accidentally discarded if care is not observed when unpacking the equipment Do not dispose of shipping materials until the packing list has been checked Upon receipt
56. erly mount the filters the enclosure should have an unpainted metallic surface This allows for more surface area to be in contact with the filter housing and provides a lower impedance path between this housing and the back plane The back panel in turn has a high frequency ground strap connection to the enclosure frame or earth ground INPUT POWER FILTERING The SERVOSTAR PD electronic system components require EMI filtering in the input power leads to meet the conducted emission requirements for the industrial environment This filtering blocks conducted type emissions from exiting onto the power lines and provides a barrier for EMI on the power lines Care must be taken to adequately size the system The type of filter is based on the voltage and current rating of the system and whether the incoming line is single or three phase One input line filter is used for multi axis control applications These filters are mounted as close to the incoming power as possible so noise is not capacitively coupled into other signal leads and cables Similarly care should be taken when routing wires from the load side of the filter to the Power Supply These lines may be noisy and should be separated from other sensitive cabling to avoid unwanted coupling of noise Several manufacturers of these filters are listed below They should be able to recommend the best filter design for most typical motor control applications Danaher Motion Kollmorgen has also provided sp
57. feedback connection Under Voltage Bus voltage is too low The bus voltage may not be connected or powered up Motor Overheat Motor overload caused overheating or a bad connection 7 Analog 12V Supply Internal 12 volts power supply fault Software detected motor overspeed The application overspeed limit 15 set by the VOSPD parameter E EEPROM Failure Faulty EEPROM EEPROM Checksum Drive parameters have not been saved Execute the SAVE command Watchdog Fault Drive failure Can be caused by an unexpected drive condition Consult the factory 4 OverSpeed No Compensation The CONFIG instruction has not been executed Do so after entering all the motor data Foldback Load requiring too much RMS current RAM test failure display will not flash 15 EPROM Checksum Faulty code EPROM display will not flash i Bad Power Stage Code Internal hardware failure 17 Limit Switch Open A limit switch input to the system CWLIM or CCWLIM has been activated These faults can only be cleared by cycling power These faults usually indicate an internal failure necessitating repair or replacement of the unit Consult with the factory 14 SERVOSTAR PD 61 Danaher Motion Kollmorgen Troubleshooting Non Fatal Error Codes Fault Message Possible Cause 0 NoEmr Noemorwasrcorded 40 EXT Velocity Parameter D H R parameters for COMPMODE 3 do not have the proper Warning rel
58. gital output return 23 Danaher Motion Kollmorgen Wiring Instructions C4 Equivalent Encoder Output C8 Handwheel Secondary Encoder Pin Function Pin Function 1 Encoder Channel A Output High 1 Encoder Channel A Input High 2 Encoder Channel A Output Low 2 Encoder Channel A Input Low 3 DC Common 3 DC Common 4 Encoder Channel B Output High 4 Encoder Channel B Input High 5 Encoder Channel B Output Low 5 Encoder Channel B Input Low 6 Shield Connection 6 Shield Connection 7 Encoder Marker or Index Channel Output High 7 Encoder 5 V Supply 8 Encoder Marker or Index Channel Output Low 8 Encoder Channel I Input 9 Shield Connection 9 Encoder Channel I Input 24 SERVOSTAR PD Danaher Motion Kollmorgen Feedback Devices FEEDBACK DEVICES RESOLVER The SERVOSTAR uses either single two poles or multi speed multiple poles resolver feedback to monitor the motor shaft position A resolver can be thought of as a transformer whose output is unique for any given shaft position an absolute position feedback The transformer is driven with a sinewave reference signal Two AC signals are returned from the resolver into the Sine and Cosine inputs All three of these sinewave signals are low level and susceptible to noise Specifications Resolver Requirements Modulation Frequency 7 8 kHz Cable Lengths It is important to u
59. h automatic unit conversion Configurable back EMF characteristics for effective current loop controller design and command MBEMF MBEMFCOMP Danaher Motion Kollmorgen s patented Torque Angle control to maximize motor output power MTANGLC MTANGLP MVANGLF MVANGLH Motor speed and current limits MSPEED MICONT MIPEAK Thermal protection control MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT adaptable to any motor Auto configuration feature ACONFIG ACONFIGST MFBDIR automatically configures the motor s power and feedback cables It checks warns and corrects for incorrect wiring of these cables Configurable positive motion direction DIR CURRENT TORQUE CONTROL Digital current loop control Torque Mode OPMODE 2 or 3 receiving serial T or analog commands Pulse Width Modulated PWM sine wave commutation PWMFRQ providing smooth and precise low speed control and high speed performance Current loop adaptive gain MLGAINC MLGAINP MLGAINZ System current limiting capability ILIM ILIM2 IMAX MICONT Exponential current vs Time limiter FOLD FOLDMODE Back EMF compensator VELOCITY CONTROL SERVOSTAR PD Digital velocity loop control Velocity Mode OPMODE 0 or 1 receiving serial J analog ANIN or I O triggered commands MISPEED1 MISPEED2 MISPEED3 IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Velocity stepping and jogging capability STEP J Serial control th
60. iew of the SK device that clamps down on the shield of the cable The use of the Phoenix SK device is an excellent method for providing a low impedance path between the cable shield and the back panel Thumb screw to tighten down shield to bus bar cable shield compressed on copper bus bar 2 copper bus bar SK 8 14 20 Shielded terminal block Phoenix Contact Side View SERVOSTAR PD Danaher Motion Kollmorgen Wiring Instructions SEX for connecting shield to bus bar Support for bus bar Copper bus bar High frequency ground connection to back panel from bus bar Phoenix Contact Top View CE FILTERING TECHNIQUES The SERVOSTAR drive system power supply drive motor meets the CE Mark standards stated in the front of this manual It is imperative for you to apply proper bonding and grounding techniques described earlier in this section when incorporating EMC noise filtering components for the purpose of meeting this standard Noise currents often occur in two types The first is conducted emissions that are passed through ground loops The quality of the system grounding scheme inversely determines the noise amplitudes in the lines These conducted emissions are of a common mode nature from line to neutral or ground The second is radiated high frequency emissions usually capacitively coupled from line to line and are differential in nature To prop
61. ikes created by the PWM switching frequency of the drive The use of a ferrite or iron powder core toroid as shown in the figure above places common mode impedance in the line between the motor and the drive The use of a common mode choke on the motor leads may increase signal integrity of encoder outputs and associated I O signals The following is a list of toroidal and ferrite cores that can be used to make common mode chokes Toroidal Core Recommendations Manufacturer Manufacturer s Part Micrometals OD 4in 102mm ID 2 25in 57 2mm HT 1 3in 33mm OD 1 025 in 26mm ID 6 in 15 2mm HT 475 in 12 1mm OD 1 52 in 38 6mm ID 835 in 21 2mm HT 825 in 21mm 2 01 in 51 1mm ID 1 24 in 31 5mm HT 1 025 in 26mm OD 1 09 in 27 7mm ID 555in 14 1mm HT 472in 11 99mm Fair Rite OD 2 4in 61mm ID 1 4in 35 55mm HT 5in 12 7mm Pre wound Common Mode Chokes Manufacturer Manufacturer s Part Number Danaher Motion e choke 36 amps continuous choke 64 amps continuous FILTERING I O filtering may be desired depending on system installation application and integration with other equipment It may be necessary to place ferrite cores on I O lines to avoid unwanted signals entering and disturbing the drive system or other associated equipment The following chart lists some ferrite parts that may be used for I O filtering and noise attenuation These parts are ideal for providing in line common mode impedance
62. in these groups by typing the name of the variable space and the numerical value You are strongly encouraged to develop a full understanding of these variables before finalizing the configuration 5 Saving Variable Parameters to EEPROM Atthe prompt type SAVE This will save the variable parameters stored in the RAM to the EEPROM AII of the variables listed in the VarCom Reference Guide indicate whether its contents can be saved to EEPROM 6 Saving Variable Parameters to SSV file At the prompt type DUMP The DUMP command causes the drive to output variables and their contents to the serial port in the format of a variable file this includes the trailing CONFIG command This variable file format is an ASCII file consisting of a series of variable assignment statements The resulting transmission of data from the drive can then be saved with a SSV extension 38 SERVOSTAR PD Danaher Motion Kollmorgen System Communication 7 Restoring Factory Variable Parameters If you have not saved any changes stored in RAM to EEPROM type LOAD at the prompt and the original parameters will be loaded from the EEPROM into RAM If changes have already been previously saved contact the factory to obtain a set of motor variable parameters for the motor specified in the model number At the prompt re enter all the motor variable parameters Type the CONFIG command followed by the RSTVAR command 8 Restoring Custom Variable Parameters At the prompt type RS
63. ivalent Output EEO signals depends on the type of motor feedback device Resolver Systems The output signal is developed through the R D hardware circuitry for minimal phase lag and has a maximum frequency determined by the motor speed and limits It provides a configurable ENCOUT resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft The placement of the index pulse INDEXPOS can be varied on resolver systems within 360 electrical degrees of the feedback signal For single speed resolvers this means you can vary the position of this signal over one mechanical revolution For multi speed resolvers the mechanical position variation is determined by the pole pair count of the resolver e g three speed resolver gives mechanical variation of the pulse within 1 3 of a revolution Encoder Systems The output signal is the actual encoder feedback signal that is pre configured MENCRES in the drive s motor parameters It can be scaled down by multiples of two ENCOUTO 1 2 4 8 16 and has a maximum frequency limit of 3 MHz Sine Encoder Systems This output signal is developed for a resolution that is determined by a divisor SININTOUT 128 64 32 16 8 4 2 1 of the actual sine encoder line resolution MENCRES It is then encoded to a quadrature signal before being exported out of the drive The maximum frequency limit is 1 2 MHz A frequency limiter MSINFRQ is provided with burst frequency fault
64. l cables must be separated from power and motor cables Distance of 20 cm 8 in is sufficient in most cases e Control and signal cables must be shielded to reduce the effects of radiated interference When control cables must cross power or motor cables they should cross at an angle of 90 if possible This reduces the field coupling effect OUTLINE DIMENSIONS A Units are given in mm 139 5Z Type For Screw 04 15 MM Cup Round Fillister Head SERVOSTAR PD 11 Danaher Motion Kollmorgen Mounting HARDWARE SPECIFICATIONS Hardware Mating Connector Hardware Vendor Info WAGO 733 112 2 5mm pin spacing Combicon 12 pins female connector _ Cat No 733 112 Wire Size 16705 1 AWG wire gauge 28 20 AWG 0 08 0 5 mm Clearance Side to Side At least lin 2 54 mm Distance Top Bottom 2 5 in 63 5 mm 1 SERVOSTAR PD Danaher Motion Kollmorgen Wiring Instructions WIRING INSTRUCTIONS GROUNDING System grounding is essential for proper performance of the drive system A ground bus bar may be used as a single point ground for the system Safety grounding should be provided to all pieces of the system from a star point In addition to the safety grounding a high frequency ground must be provided that connects the back panel to the enclosure and ultimately to earth ground The objective is to provide an extremely low impedance path between the filters drives power supplies and earth ground
65. lates a current error This error is then fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC Power Supply typical 325 VDC bus to supply the required current to the motor windings The actual motor current is updated and the process begins again SERVOSTAR PD 53 Danaher Motion Kollmorgen System Operation Analog Torque The SERVOSTAR PD can be configured to operate as an analog torque loop controller OPMODE 3 In this case the current loop receives its input from the analog to digital A D conversion system After conversion the input command signal is processed through an algorithm which adjust the signal ANOFF ANDB ANZERO filters it ANLPFHZ and then scales it ISCALE before developing the current command ICMD The current or torque command is then checked against peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calculates a current error This error 5 then fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC Power Supply typical 325 VDC bus to supply the required current to the motor
66. n The motor can commutate forward until the Index signal is detected e Sine encoders with Endat capability add another approach to communicating commutation position Here absolute position information is stored in the encoder and is serially communicated to the drive upon power up The data is received synchronously by a clock signal provided by the drive Absolute position is known immediately therefore an index signal is not needed e Sine encoders with Hiperface capability are similar to EnDat but the data is transmitted asynchronously SERVOSTAR PD 27 Danaher Motion Kollmorgen Feedback Devices Specifications Sine Encoder Requirements Types A B with or without Index A B Index with discrete Hall Channels A B Index with C D once per revolution A B Endat Differential Differential Differential or Open Collector System Voltage 5 VDC Maximum Input Frequency From encoder 125 kHz line 500 kHz quad After Internal Drive Interpolation 31 25 MHz line 125 MHz quad Maximum Line Count per Motor 39 000 Line counts cuum ee cer the SERVOSTAR for encoders Protection Separate Regulator Broken wire detector for B Index and Hall channels Illegal Hall Code Detection A B signals out of range burst pulse overflow Maximum Drive Internal x256 before quad Interpolation input Cable Lengths The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft 15 m Lo
67. n be configured to a variety of functions This section discusses the I O features of the C3 connector except for the thermostat input on C2 Refer to the VarCom Reference Guide for details Analog Input ANIN The position velocity or torque loop can receive its command from an analog voltage source and is selectable through the OPMODE variable The analog input to the SERVOSTAR PD is differential This means the signals received at the two inputs are subtracted from each other to create a difference which is used to command the rest of the system This type of input has a high degree of noise immunity and in many cases allows for ground isolation between systems This analog input also has a low pass filter ANLPFHZ to prevent high frequency noise from entering the system The input voltage from the differential receiver is applied to a precise 14 bit Analog to Digital A D conversion system The A D conversion system is read by the microprocessor every 50015 for the position loop modes every 250 us for the velocity loop mode and every 62 5 us for the torque current loop mode of operation Encoder based units come with the additional benefit of a Dual Gain ANDG input When enabled the system uses two 14 bit A D inputs to read the user supplied analog signal One input is a direct reading of the 10V signal while the other incorporates a 2x gain term When the input voltage is less than 4 V the 2x channel is used to determine th
68. n with other parameters ACTIVE and operate Tapping the signal off the logic supply is possible but is not recommended The toggling of this switch will also initiate an attempt to recover from a fault condition It can also be used to trigger various position homing features HOMETYPE SERVOSTAR PD 47 Danaher Motion Kollmorgen System Operation Configurable Inputs IN1 IN2 IN3 These 12 VDC to 24 VDC inputs are defined by the INXMODE variable Placing the appropriate value in INXMODE See the VarCom Reference Guide for details sets up the inputs to be used for such features as CC CCW hardware position limits Electronic Gearing serial and analog position triggering for incremental moves and homing fault output relay configuration MOTIONLINK scope triggering and more When set for the CC CCW hardware position limits the inputs prevent any further motor travel in their respective direction but do not disable the drive or prevent motion in the opposite direction If acceleration control is in place PROFMODE 1 the motor ramps to a stop after the opening of the End Travel Limit These inputs are opto isolated and considered active enable meaning current must flow through these signals to allow the system to operate This provides a dead man safety feature Energizing both the CW and CCW hardware position limits causes the SERVOSTAR PD to enter the HOLD mode These inputs can also be inverted ININVx where 1 2 3 The
69. nal to the input voltage 3 Serial Torque Current Controller OPMODE 2 the SERVOSTAR PD is configured as a torque loop controller and is controlled by issuing a current command using the T command to the drive via the serial port 4 Analog Torque Current Controller OPMODE 3 the SERVOSTAR PD is configured as a torque loop controller and is controlled via a 4 voltage SERVOSTAR PD 10 V analog input signal The commanded current is proportional to the input 45 Danaher Motion Kollmorgen System Operation 5 Gearing Position Controller OPMODE 4 the SERVOSTAR PD is configured as a positioning controller that can operate in one of three settings Encoder Follower Pulse Direction Up Down Counter The setting used is determined by the GEARMODE variable 6 Position Controller OPMODE 8 the SERVOSTAR PD is configured as a serial or an analog positioning controller depending on the value of PCMDMODE that can receive simple absolute incremental indexing homing and analog commands T SERCOS interface Controller OPMODE 5 the SERVOSTAR PD must be ordered from the factory as a SERCOS interface unit to establish communications in this OPMODE The drive is shipped with Connector C4 as the Transmit Receive port no longer the Encoder Equivalent Output DRIVE CONFIGURATION The drive functionality is set using various drive parameters and instructions communicated over the RS232 serial port Refer to the VA
70. nd hence must be done after replacing a motor or an amplifier After the process terminates the gain and offset values are stored in the non volatile memory and are loaded each time the amplifier is powered on The process includes finding 128 maximum and minimum Sine and Cosine peaks and calculating the average gain and offset values Due to accuracy restrictions the motor must be rotated at a slow speed so that the Sine Cosine waves generated will be at a frequency low enough for a valid result The speed must be such that the frequency of the Sine Cosine signals does not exceed 250Hz For a rotary motor the maximum motor speed in RPM can be calculated from 60 x 250 MENCRES x MSININT For a linear motor the maximum motor speed in mm sec can be calculated form 250 x MPITCH MSININT x MENCRES The Process During calibration the motor can be moved manually or under servo control preferably under velocity control The following steps should be taken 1 Initialize the process by entering the instruction S7NINIT without parameters 2 Move the motor in either direction While moving the motor query the status using the SINJNIST instruction 3 The process is complete when S NINIST returns a value of 3 done 5 fault Use the SINPARAM instruction to query or set the sine calibration values There are four calibration parameters when working with a Sine Encoder and six calibration parameters when working with a Resolver SERV
71. nder the master s control CP Run up Upon power up the Status Display should alternately flash a P and a 0 to indicate SERCOS interface communication phase 0 As the drive ascends through each communication phase the display will alternately flash a P and a number indicating the next sequential communication phase phase 0 4 Upon reaching communication phase 4 CP4 the display will briefly flash P and 4 before displaying a steady state 5 This indicates that SERCOS interface has been initialized and the drive and motor system is ready for commanding motion CP2 Initialization IDN 18 contains a list of IDNs that must be written to the drive CP2 The transition procedure IDN 127 verifies the drive s readiness to transition from CP2 to CP3 and checks whether each IDN listed in IDN 18 has been written by the master If any IDN has been written with illegal values the drive will not transition to CP3 If the drive fails to transition IDN 21 contains a list of improperly configured IDNs The following IDNs should be configured during CP2 Communication cycle time tncyc Must be 2000 6 6 AT transmission starting time t1 0 9 Position of data record 22 10 MDT length i 1 8 MDT transmission starting time t2 Po SERVOSTAR PD 43 Danaher Motion Kollmorgen SERCOS Interface Setup during CP3 and CP4 In this case initialize the control unit synchronization bit monitori
72. ng IDN Some masters do not support togeling the control unit synchronization bit control word bit 10 P152 to 0 during CP2 Refer to the IDN descriptions for more information CP3 Initialization IDN 19 contains a list of IDNs that must be written to the drive during CP3 If the drive was properly configured using MOTIONLINK IDN 19 should be empty and the master requires no IDN initialization during this phase Operational Notes 1 Remember that the hardware enables DIP switch 8 and the Remote Enable line must be enabled before the drive be system enabled through the MDT control word during CP4 If system enabling fails refer to IDN P15 for a list of conditions that prevent this action 2 Ifa fault occurs the drive will not allow the master to clear faults while any of the MDT control bits 13 15 are set SERCOS Torque Units Standard SERCOS torque units are based on 0 196 of motor continuous current However when using MOTIONLINK the torque units are based on 0 1 of drive peak current 5 SERCOS Velocity Units counts CUCT 256 The following formulas may be used to convert to and from the SERCOS interface units and rpm Vel rpm Vel cnts CUCT 256 1875 8 cnts CUCT Vel cnts CUCT 256 Vel rpm 8 CUCT 1875 Equation Notes 1 Cnts the number of encoder or resolver equivalent counts per revolution Where Encoder counts Encoder lines 4 Resolver counts 2 16 MRe
73. ng encoder cables tend to have high DC resistance that may create significant loading affects in the supply lines to the encoder Consider this carefully when designing the system An option that would allow the use of longer lengths would be to put a separate supply at the motor to source the encoder Except for noise susceptibility signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths Resolution and Accuracy Internal resolution of the system can be derived through the following calculation Encoder line resolution x 256 x 4 quadrature System accuracy is largely dependent upon the accuracy of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used 28 SERVOSTAR PD Danaher Motion Kollmorgen Feedback Devices ENCODER EQUIVALENT OUTPUT The SERVOSTAR provides a motor position output to you in the form of quadrature encoder signals eliminating the need for an additional position feedback device The outputs are differential line drivers There is an associated DC common output C4 pin 3 which can connect to your port to keep common mode noise and voltage spikes minimized for device protection Because there are normally differences of potential between your controller and the drive connection 1s recommended if ground loops occur disconnect and retest The source of the Encoder Equ
74. od is designed to solve this problem by implementing a closed loop commutation lock algorithm that adjusts the commutation angle to the motor position rather than moving the motor to a predetermined place The motor will move very slightly motion of at least 4 electrical degrees is expected The Process 1 Disable the drive 2 Select the encoder initialization process by entering the instruction V TMODE 2 3 Set the encoder initialization current using the JENCSTART instruction Set this to the maximum allowed application current 4 Set the gain for the process using the JN TGAIJN instruction This gain is typically set to 1000 5 Setthe correct value for the motor inertia using the MJ instruction 6 Initialize the process by entering the instruction ENCSTART 7 Begin the process by enabling the drive 8 Monitor the process by reading the status word STATUS2 and the status of ACTIVE If the process completes successfully the drive will be enabled and ACTIVE will be set to 1 If the process is not successful bit 2 in the first word of STATUS2 will be set 50 SERVOSTAR PD Danaher Motion Kollmorgen System Operation SOFTWARE RESOLVER INTERFACE Overview The resolver to digital RDC conversion is done in the Series 5 products using software techniques as opposed to using a dedicated integrated circuit The benefits of this mechanism include Enhanced system performance since the resolution is not a function of the velocity
75. oder based systems actual encoder signals are exported through this output MENCRES and can be scaled down by multiples of two ENCOUTO Configures automatically ENCINIT ENCINITST ENCSTART IENCSTART INITMODE Index pulse offsetting capability MENCOFF Variety of encoder types MENCTYPE l Encoder with or without index 2 Encoder hall effects with or without index MHINVA MHINVB MHINVC HALLS Wake No Shake Encoder initialization with very little motion when working without halls or commutation tracks SERVOSTAR PD Danaher Motion Kollmorgen System Description Resolvers Variety of motor and resolver pole combinations MPOLES MRESPOLES Resolver zero offsetting MPHASE System accuracy s better than 20 arc minutes reduced when resolver pole count is increased 18 bit velocity control and 16 bit positioning capability Sine Encoders Up to 4096x internal interpolation MSININT Up to 128x encoder equivalent output SININTOUT Most standard encoder features mentioned above Support for Heidenhain EnDat and for Stegmann Hiperface encoders The Hiperface encoders must work with a 5 V supply Halls Only The PD can drive a motor with Halls only feedback MENCTYPE 5 MONITORING AND TROUBLESHOOTING TOOLS SERVOSTAR PD Performance recording RECDONE RECING RECOFF RECORD RECRDY RECTRIG System status checking STAT STATUS STATUS2 Control loop monitoring Current torque IC ICMD
76. of the equipment inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Check all shipping material for connector kits documentation diskettes CD ROM or other small pieces of equipment gt gt gt Mount the SERVOSTAR PD to the back panel Metal to metal contact is important for electrical noise control o Connect solid earth ground to frames of all components Wire the motor to connector P2 P2 Motor Power Connector additional information o Verify that all wiring is correct Verify that earth grounds are connected Verify all electrical and safety codes are met o Connect the serial cable to connector C1 and to your PC o Install MOTIONLINK on the PC MOTIONLINK can be found either on the website www danahermotion com or on the Product Support Package CD ROM Startup processes can cause motor motion Be certain that all applicable safety precautions are taken to ensure that no harm to personal or machine can occur e Using the Startup Wizard in MOTIONLINK o Configure the PD for your particular motor if this was not done at the factory o Tune the PD for the load and desired performance 24 volts must be present at the C3 enable input to get power to the motor o Enable the system SERVOSTAR PD 9 Danaher Motion Kollmorgen Electrical Specifications ELECTRICAL SPECIFICATIONS The environment that any elec
77. or lines Should cross at a 90 angle This minimizes the coupling effect Additionally the power lines should be routed as close to the back panel as possible Any noise currents on the lines are capacitively coupled to the ground plane and not to other lines Cabinet Enclosure Input power enters enclosure from metal conduit Contactor Fuses Xfmr etc EMI filter Back Plane Control I O signals should be kept separate from all power and motor cables if possible Keep control wiring as short as possible and use screened wire Bonding is also recommended but not required for CE compliance A separation distance of 20 cm 8 in is sufficient in most cases Where control cables must cross power cables they should cross at a 90 angle EMI filter grounding Safety grounds must be provided on the filters Hazard potentials exist CNC PLC Controller Controller even when the power is off because of the capacitors internal to the filters High frequency ground between conductive back panel and enclosure Also a high frequency ground is required between the enclosure and earth ground Single point ground A bus bar ground bus is an excellent way to achieve this Bonding of motor and power cables
78. presenting the approximate absolute location of the motor shaft From this information the motor can sinusoidally commutate forward until the index signal is detected at which time true position is known These signals are isolated by an opto coupler and can be differential or open collector type signals Specifications Encoder Requirements Required Signals Types A B with or without Index pulse A B Index with or without Hall Channels Halls may be integral or discrete Differential do not connect single ended Halls Differential or Open Collector From encoder 3 before quad 12 MHz after quad System Dependent 50 ft 15m Recommended 0 000 000 250 mA Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels Illegal Hall Code Detection Cable Lengths The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft 15 m Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder Please consider this carefully when designing the system An option that would allow the use of longer lengths implements a separate supply located at the motor to source the encoder Quadrature signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths 26 SERVOSTAR PD Danaher Motion Kollmorgen Feedback
79. r damages resulting from the use of the information contained herein Kollmorgen GOLDLINE and SERVOSTAR registered trademarks of Danaher Motion Kollmorgen Safety Instructions Only qualified personnel are permitted to transport assemble commission and maintain this equipment Properly qualified personnel are persons who are familiar with the transport assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 Read all available documentation before assembly and commissioning Incorrect handling of products in this manual can result in injury and damage to persons and machinery Strictly adhere to the technical information on the installation requirements It is vital to ensure that all system components are connected to earth ground Electrical safety is impossible without low resistance earth connection The SERVOSTAR product contains electro statically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the product Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface During operation keep all covers and cabinet doors shu
80. r lead noise may be either common mode or differential The common mode conducted currents occur between each motor lead and ground line to neutral Differential radiated currents exist from one motor lead to another line to line The filtering of the lines feeding the motor provide additional attenuation of noise currents that enter surrounding cables and equipment I O ports in close proximity Differential mode currents commonly occur with lengthy motor cables As the cable length increases so does its capacitance and ability to couple noise from line to line While every final system is different and every application of the product causes a slightly different emission profile it may become necessary to use differential mode chokes to provide additional noise attenuation to minimize the radiated emissions The use of a ferrite core placed at the drive end on each motor lead shown in the diagram below attenuates differential mode noise and lowers frequency 30 to 60 MHz broadband emissions to within specifications Danaher Motion Kollmorgen recommends a Fair Rite P N 264354002 or equivalent ferrite core Wrap each motor lead through the core several times as shown in the figure below Never wrap a ground lead through a core Differential Mode Filtering Common Mode Filtering To motor To Motor From Drive From Drive Output 16 SERVOSTAR PD Danaher Motion Kollmorgen Wiring Instructions Common mode currents occur from noise sp
81. radiated emissions conducted emissions EFT ESD surge conducted immunity and radiated immunity These tests have been done in accordance with EN55011 EN61000 4 2 ENV50140 IEC 1000 4 4 EN61000 4 5 and 50141 Installation of the equipment is critical in designing for system and machine electromagnetic compatibility You must apply the installation recommendations the CE filtering Practices when mounting and installing the drive system for CE conformance Customer Support Danaher Motion Kollmorgen technical documentation is updated periodically and may be changed without notice The latest documentation can be found on our website For information on this product or where to purchase near you contact your local distributor To locate a distributor near you visit the website www danahermotion com Danaher Motion Customer Support Continental US Customers 1 800 777 3786 International Customers 815 226 2222 Fax 540 731 5641 Email customer service danahermotion com Website www danahermotion com Danaher Motion Kollmorgen Table of Contents Table of Contents VELOCITY CONTROL POSITION CONTROL SERVOSTAR PD Danaher Motion Kollmorgen Table of Contents eeN C4 Equivalent Encoder eren eren C8 Handwheel Secondary Encoder FEEDBACK DEVICES poc omm E Specifications Cable
82. rough stored commands triggered through the Configurable I O IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Automatic control loop tuning through the auto tune feature TUNE Configurable application and system speed limits VLIM VOSPD VMAX Advanced control algorithms COMPMODE Proportional Integral GV GVI Pseudo Derivative with feed forward KV KVI KVFR Standard Pole Placement BW MJ LMJR TF Extended Standard Pole Placement BW MJ LMJR TF First and second order low pass filtering capability FILTMODE LPFHZ1 LPFHZ2 COMPFILT Notch filtering capability FILTMODE NOTCHHZ NOTCHBW Danaher Motion Kollmorgen System Description Bandwidths up to 400 Hz On the fly homing capability HOMETYPE in analog velocity mode OPMODE 1 through either the Configurable Inputs or terminal On the fly switching between velocity and current torque control IN1 IN2 IN3 INIMODE IN2MODE IN3MODE POSITION CONTROL Serial positioning loop control Position Mode OPMODE 8 amp PCMDMODE receiving serial or controlled command IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Analog positioning loop control Position Mode OPMODE 8 amp PCMDMODB over a 10 V range with scaling capability PSCALE GEAR GEARI GEARO and triggering Incremental and absolute positioning with an position indicator MA INPOS PEINPOS Simple absolute and incremental indexing with I O triggering capability M
83. sPoles 2 2 CUCT The control unit cycle time IDN 1 in ms The units CUCT ms is the number of CUCT periods per mS For example a 2 ms has 1 2 a per 1 ms 4 Remember the following when monitoring a SERCOS drive through the serial port The SERCOS interface address is also the serial communications address SERCOS interface operation changes the UNITS variable to internal units SERCOS interface version of the SERVOSTAR is not automatically enabled on power up even with the drive address set to 0 44 SERVOSTAR PD Danaher Motion Kollmorgen System Operation SYSTEM OPERATION The SERVOSTAR PD has a seven segment indicator called a Status Display that indicates four types of states Power up Steady State Flashing State and Momentary State The decimal point directly relates to the global drive enable DRIVE STATE Power up Steady State No Faults Flashing State Momentary Fault Status Display DISPLAY APPEARANCE Momentarily illuminates all display segments forming an 8 and the decimal point Displays the operational mode OPMODE of the drive 0 8 Used to indicate an abnormal operating state If the position hold feature is active the OPMODE number will flash at a 1 Hz rate If a fault was detected a flashing code will be displayed to identify the fault Some codes consist of a sequence of two or more digits see Troubleshooting section In general these faults
84. se properly shielded cable and to keep it away from other noise radiating devices and cables It is not recommended to run the feedback and motor cables in the same conduit Danaher Motion Kollmorgen has tested cable lengths up to 75 ft 22 9 m without degradation of performance However performance may vary depending on motor and resolver type Tests were performed with standard Danaher Motion Kollmorgen cable and its low impedance and Danaher Motion Kollmorgen GOLDLINE motor resolver Please consult the factory for cable and resolver impedance specifications when long cable runs above 250 ft 76 m are desired Danaher Motion Kollmorgen recommends twisted shielded pair for feedback cables Resolution and Accuracy The SERVOSTAR calculates motor velocity as the derivative of position change in position over time With its patented technique all readings are extended to a resolution of 16 bit For velocity feedback calculations the drive converts the resolver input to 18 bits of resolution giving smooth motor velocity control The digital resolution RDRES of the Resolver to Digital Converter system is determined automatically according to the application velocity limit VLIM The following is a summary of the SERVOSTAR s resolution capabilities R D Converter Specifications VLIM RPM RDRES Encoder Eqv Output C4 gt 6100 4096 4096 quad counts 1500 to 6100 16384 16384 quad counts 1500 65536 65536 quad counts SERVOSTAR
85. seconds the drive enters FoldBack mode FOLD 1 and begins an exponentially FoldBack to the system s continuous current It takes approximately six seconds for the exponential decay to drop from the system s peak current to its continuous level For drive currents that exceed ICONT but are below IMAX the system period before FoldBack occurs is extended beyond two seconds Two seconds is the shortest time period that will elapse before the drive enters FoldBack and only occurs when maximum peak current is drawn This FoldBack feature is designed to protect the drive electronics not the motor The Configurable Output O1 pin 12 can be configured to indicate a drive FoldBack condition Motor FoldBack The FoldBack algorithm is designed to provide motor protection in cases where the drive s continuous current rating is above the motor s continuous rating This combination is often desired in applications where maximum peak motor torques are required However the possibility exists that the drive could source current on a continuous basis indefinitely to the motor and would force it beyond its thermal capability Unlike the drive FoldBack you have complete configurability over this feature MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT 54 SERVOSTAR PD Danaher Motion Kollmorgen Firmware Upgrade Procedure FIRMWARE UPGRADE PROCEDURE PREPARATIONS Retrieve Drive Parameters Using MOTIONLINK go the Drive Backup screen Click on the R
86. sed systems Power Supply Under voltage Hardware monitors the internal analog 12 VDC supply for out of tolerance voltages In addition to the Status Display and LEDs the PD also sends error codes with a text message to the serial port The same message is saved in non volatile memory in an error history log See FLTHIST Fault Logging In addition to the status display LEDs and the serial notification of errors the SERVOSTAR PD also records the error message in non volatile memory for later review Each entry into the error log has an associated error code number as defined in the tables below The SERVOSTAR PD stores the ten most recent faults in the Fault History Buffer To display the entire Fault History type FLTHIST This causes the fault history to be sent via the serial port to the terminal with the most recent fault sent first FLTCLR Used to clear the fault history The fault history Buffer remains even through power down ERR Displays the last error generated The PD responds with the last most recent fault in the fault history not previously transmitted and the S last error 60 SERVOSTAR PD Danaher Motion Kollmorgen Troubleshooting Fatal Error Codes Fatal Error Codes Error Code Status LED Associated Text Message and Possible Cause Meaning 1 Power Stage Over Temperature Overload fan malfunction or power stage failure 2 Over Voltage Excessive decel rate can cause voltage regeneration Feedback Loss Bad
87. set of manufacturer s IDNs MOTIONLINK communication through the serial port MOTIONLINK SOFTWARE ENVIRONMENT Easy setup commanding and monitoring techniques Contains an extensive database for many of Danaher Motion Kollmorgen s motor series A backup screen that provides automatic loading of system parameters Realtime metering of many system parameters PC scope feature for profile recording and realtime motion performance measuring Optional terminal mode feature for keystroke commanding and monitoring Status screen indicating system operation and fault error checking Extensive on line help file F1 designed to assist you in MOTIONLINK s intuitive nature A set of limits folders allowing you to manipulate the position velocity current and filtering limits from one screen An I O screen for easy manipulation of the drive s I O thermostat options encoder output and hardware position limits capabilities A feedback device screen that provides realtime pictorial positioning information It also includes an encoder initialization folder A tuning screen designed to allow you to adjust control loop gains quickly while visibly watching the affects on performance A control loops screen that provides direct manipulation of velocity and position loop gain parameters SERVOSTAR PD Danaher Motion Kollmorgen System Description MOTOR CONTROLLABILITY Provides linear and rotary motor control MOTORTYPE MPITCH MENCRES wit
88. shows how cable bonding is implemented using non insulated metallic cable clamps The first figure demonstrates clamping to the back panel in the vicinity of the drive The second shows a technique for bonding a terminal strip for best results it is recommended not to break the shielding of the cable From the drive D Terminal Strip ojo ojojojo Eu Plane D a To Motor Terminal Clamp and Power Block Clamp SERVOSTAR PD 13 Danaher Motion Kollmorgen Wiring Instructions Alternative Bonding Methods Another option is to use cable bonding clamps offered by Phoenix Contact and others When using the Phoenix Contact parts make sure that a low impedance high frequency ground is connected from the ground bus bar to the back panel using a flat braid or a copper bus bar The SK parts from Phoenix SK8 SK14 amp SK20 slide onto the bus bar The cable with exposed shield is inserted through the SK piece and the thumbscrew on top of the SK piece is used to tighten the connection between the cable shield and the bus bar Phoenix Part Descriptions Phoenix Contact Part Cable Diameter Range shield on bus bars shield on bus bars shield on bus bars ground bus varying lengths The next two figures represent a side and top v
89. t Otherwise there are deadly hazards that could possibility cause severe damage to health or the product In operation depending on the degree of enclosure protection the product can have bare components that are live or have hot surfaces Control and power cables can carry a high voltage even when the motor is not rotating Never pull out or plug in the product while the system is live There is a danger of electric arcing and danger to persons and contacts After powering down the product wait at least ten minutes before touching live sections of the equipment or undoing connections e g contacts screwed connections Capacitors can store dangerous voltages for long periods of time after power has been switched off To be safe measure the contact points with a meter before touching When these symbols are seen in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational
90. the current to the motor to protect the drive This condition is a self resetting error SERVOSTAR PD 59 Danaher Motion Kollmorgen Troubleshooting Decimal Point The decimal point directly relates to the global drive enable The states are Steady Off No power to the motor Steady On Drive is enabled and power on the motor Flashing Drive is enabled power is on the motor but some safety feature has been disabled the motor thermostat input has been disabled or limit switches have been disabled This is not considered a fault FAULTS The following provides a description of some of the more important faults detected by the PD Motor Over temperature The motor s thermostat input is monitored for an open circuit condition Drive Over temperature The internal heat sink temperature is monitored for an unsafe condition The fault is reset only after the drive cools Bus Over voltage This fault occurs during a regen operation where the BUS is raised to higher values than that produced by the power supply Bus Under voltage This fault occurs if the incoming line voltage drops or if a problem occurs in the power supply Power Stage Fault Over current Hardware circuitry monitors load short circuit transistor failure and instantaneous over current power stage fault cannot be reset by toggling the enable line only by cycling the power Feedback Loss Hardware detects a wire break condition in encoder ba
91. the motor making resolver or encoder alignment to the motor is critical Velocity Loop The purpose of the velocity loop is to regulate motor speed Like the current and commutation loops the velocity loop is fully digital and uses the resolver or the encoder feedback signals to calculate actual motor velocity The command for the velocity loop can come from either a direct user input OPMODE S 0 amp 1 or the output of the position loop The velocity loop is a digital sampling system operating at 4 kHz 532 SERVOSTAR PD Danaher Motion Kollmorgen System Operation The difference between actual and desired velocity is filtered through a compensator algorithm and fed to the commutation loop The SERVOSTAR PD offers four velocity compensators methods of regulating velocity selectable through the COMPMODE variable The four are Proportional Integral PI Pseudo Derivative Feedback with Feed Forward PDFF Standard Pole Placement and Extended Standard Pole Placement Position Loop The final control configuration is the position loop The purpose of this loop is to maintain motor shaft position Like the previous loops the position loop is fully digital and uses resolver encoder and sine encoder feedback signals to determine actual motor position The drive can also accept a position signal from an external feedback device e g load encoder It samples at a rate of 2 kHz and can be configured for three different modes of operation OPMO
92. ton you can select the system bandwidth the type of loop control and the filtering necessary for the application These are the same parameter screens found in the Startup screen Click Exit to return to Main MOTIONLINK Screen 4 Saving Variable Parameters to EEPROM At the top of this screen you can click the button labeled RAM E to save the modified variables from RAM to EEPROM SERVOSTAR PD 37 Danaher Motion Kollmorgen System Communication 5 Saving Variable Parameters to SSV file Occasionally you may wish to backup the variable parameters from one drive for use in another To do this pull down the Edit menu and select Backup Variables request the information from the drive Receive button into the editor and save Save button the contents in a SSV format to a specified disk location 6 Restoring Factory Variable Parameters To restore the original factory variable parameters pull down the Configure menu select Motor and select the motor family and motor model Click the To Drive button to send the variable parameters to RAM and the RAM E SAVE button to save to EEPROM 7 Restoring Custom Variable Parameters This process assumes that you saved the custom variable parameters to a SSV file as described above To restore the custom parameters pull down the Edit menu select Backup Variables and click on Open Highlight the custom SSV file to import variable parameters into editor Click Xmit to send
93. tronic control system lives in can effect its operation Danaher Motion Kollmorgen recommends that the SERVOSTAR PD be operated and stored under the environmental conditions stated in the product s electrical specification tables The system may be operated in higher temperature ambient conditions with a derating applied Check with the factory for derating information Attention to proper installation and field wiring are of prime importance to ensure long term and trouble free operation Users should familiarize themselves with and follow the installation and wiring instructions listed in this document In addition to these practices some localities and industries may require applicable electrical and safety codes laws and standards Product Model 20 805 210 5 5 Peak Curent amps for S00 mSee24V 125 f as Peak Curent amps 54 125 25 Main Input Power Si Continuous Peak Current amps for 500 ms at 80 V ee 2 Peak Current amps for 2 s at 80 V Line Fuses FRN R LPN or equivalent A 1 Logic Input Power 24 VDC Ext Logic Voltage volts NE o E 24 VDC Ext Logic Current amps sink SoftStart Max Surge Current amps Max Charge Time Fault Contact Rating A Fault Contact Closing Period ms N Un 22 27 75 0 25 1 3
94. ty Mode 1 Analog Velocity Mode 2 Serial Torque Mode 3 Analog Torque Mode 4 Gearing Mode 5 Reserved 6 Reserved 7 Reserved 8 Position Mode 9 Reserved Flashing State A letter is displayed to indicate an abnormal operating state If the position hold feature is active the display flashes its operational mode number For a fault a letter displays indicating a fatal error condition or state In general these faults cause a latched disable some latches are controlled by software switches You can attempt to reset the fault except OverCurrent by removing the remote enable and then re asserting it or by software disable K DIS or S and then re enabling it EN Momentary State A letter is displayed for at least 500 ms to indicate a momentary fault condition The display then returns to its appropriate state The timer 1s resettable The letter displayed indicates the appropriate fault in the following table Description Communication Error This fault indicates there is a problem with serial communications This is typically a framing error overrun error baud rate or parity error etc This is not a latched error Foldback This fault indicates the current to the motor is higher than what the drive can deliver for an extended period of time The drive 15 self protecting for its rated current level Peak current to the motor is allowed for two seconds After the two seconds the drive folds back limits
95. variable parameters to drive Terminal Mode Use the MOTIONLINK Terminal Mode or any other dumb host to directly monitor or modify the variable set and command the drive This approach should only be taken when a PC with a Windows operating system is not available or you are well versed with the SERVOSTAR PD variable and command set The VarCom Reference Guide contains the complete variable and command set Each variable or command must be referenced for its syntax and parameter definition The variables and commands are grouped by function for terminal users 1 Clear EEPROM Ifa does not appear and you wishe to enter a new set of variable parameters type CLREEPROM at the terminal prompt to clear the EEPROM memory 2 Setting Drive Variable Parameters At the prompt enter a value for VBUS Other drive parameters are determined automatically 3 Setting Motor Variable Parameters Locate the motor parameter group of variables in the VarCom Reference Guide At the prompt enter values for the variable parameters listed in this group by typing the name of the variable space and the numerical value 4 Customizing to Application Locate the following variable groups in the VarCom Reference Guide A Analog Input Related B Current Parameters C Velocity Parameters D Position Parameters E Loop Compensation and Gains Parameters Hd Motion Control Parameters At the prompt enter values for the variable parameters listed
96. windings The actual motor current is updated and the process begins again Current Sampling The current loop receives corrective feedback from the current sampling circuitry The current sensors use closed loop hall sampling techniques in all units The current sample is used by the current loops to regulate the current in each of the three motor phases Two phases A and C of the current signal are sampled by the microprocessor at a 16kHz rate The momentary A phase current and C phase current can be monitored by examining the IA and IC variables respectively The microprocessor calculates the equivalent absolute current which can be monitored as I This value can be averaged for 2 4 8 16 32 or 64 samples Foldback The SERVOSTAR PD offers two types of FoldBack protection for both the motor and the drive The drive s microprocessor monitors the current feedback signal and develops a RMS value of this signal for the purpose of providing a value that represents the current in the motor The system is similar to an I squared T accumulator Drive FoldBack This FoldBack algorithm monitors current feedback and if the feedback exceeds the continuous current rating of the drive motor combination ICONT will decrease the system s current to the ICONT level For example under a step command input condition the FoldBack algorithm will allow maximum peak current IMAX output from the drive for 2 seconds or second for Cx units After two
97. xample Browse For Ember File BU zi xl Look in C 06 47 e E3 LUCB647 EMB EMB File Size 509 KB File name UCB647 EMB Files of type Ember Files emb Cancel read only 2 4 Select the correct EMB file 56 SERVOSTAR PD Danaher Motion Kollmorgen Firmware Upgrade Procedure 5 Click on Open and return to the Advanced Options screen Advanced options Files to download FieNam Fi 47 I Neng UCB2 Firmwares Cancel Delete Use the specific 0 Skip drives seeking Execute reset after downloading 6 Select the EMB file and click on OK 7 Now click on the Start button to start the firmware download Ignite UCB v2 0 2 This program will update your ServoStar firmware do this take the following steps 1 Select the correct Com port 2 Select the correct baud rate 3 Click the Start button Hw Revision Ember version File _ Address Baud Rate 9600 19200 SERVOSTAR PD 57 Danaher Motion Kollmorgen Firmware Upgrade Procedure Cycle Power Once the download is finished cycle drive power Connect to the drive with MotionLink From the Terminal screen type in the VER instruction and verify that the drive firmware version is as expected 58 SERVOSTAR PD Danaher Motion Kollmorgen Troubleshooting

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