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Stepnet Panel Manual

1. Stepnet Panel Amplifier User Guide Specifications 3 20 2 Stepnet Panel AC STX Dimensions La 5 73 145 5 oe 35 135 9 gt 19 48 ei Fe 2 i 6 4 i d 4 40 111 7 i E A U 4 70 119 5 aa 5 35 135 9 4 48 113 7 19 4 8 m at II U 1 CH d 1 00 25 4 i l 2 17 55 H 73 18 5 S Ea Te 1 66 42 2 Optional heatsink shown j ge H 4 50 114 2 Copley Controls Corp 55 Specifications Stepnet Panel Amplifier User Guide 56 Copley Controls CHAPTER 4 WIRING This chapter describes the wiring of amplifier and motor connections Contents include Title Page 4 1 1 Stepnet Panel STP General Wiring Instructions 58 4 1 2 Stepnet Panel STP Connector Locations A 59 4 1 3 Stepnet Panel STP Power J1 vor 4 1 4 Stepnet Panel STP Motor J2 4 1 5 Stepnet Panel STP Signal J3 e 4 1 6 Stepnet Panel STP CAN Bus J5 and J6 iii 65 4 1 7 Stepnet Panel STP RS 232 Serial Communications LA 66 4 2 1 Stepnet Panel AC STX General Wiring Instructions 67 4 2 2 Stepnet Panel AC STX Connector Locations
2. Model Number Description STX 115 07 Stepnet Panel AC stepper amplifier 5 7 Adc 120 Vac single phase STX 230 07 Stepnet Panel AC stepper amplifier 5 7 Adc 240 Vac single phase Stepnet Panel AC STX Heatsink Kit Model Qty Description 1 Heatsink standard STX HK 1 Heatsink thermal material 1 Heatsink hardware mounting kit Stepnet Panel AC STX Connector Kit Model Qty Ref Description Mfr Model No 1 J1 Plug 3 position 7 5 mm female Wago 721 203 026 045 RN01 0000 1 J2 Plug 5 position 5 0 mm female Wago 721 605 000 043 RN01 0000 1 J3 3 position 5 0 mm female Wago 721 103 026 047 RN01 0000 1 High density D Sub male 15 position Norcomp 180 015 103L001 J6 solder cup STX CK 4 Backshell for J6 plug Norcomp 979 009 020R121 1 High density D Sub male 26 position Norcomp 180 026 103L001 J7 solder cup 1 Backshell for J7 plug Norcomp 979 015 020R121 2 J1 J2 Wire insertion extraction tool Wago 231 131 J3 Stepnet Panel AC STX CANopen Network Kit Model Qty Ref Description Copley Controls Model No 1 Sub D 9 position female to RJ 45 adapter STX CV STX NK 1 J4 J5 CANopen cable assembly 10 ft 3 m STX NC 10 1 CANopen network terminator STX NT Stepnet Panel AC STX Individual Cable Assemblies and Related Accessories Model Ref Description Mfr Model No SER CK J8 RS 232 Serial Cable
3. Pin Signal Function Speed Pull Up Pull Down Group 1 IN1 Enable Standard Group 1 2 IN2 Programmable Standard Group 1 3 IN3 Programmable Standard Group 1 4 IN4 Programmable Standard Group 2 5 Encoder A Motor incremental encoder input 6 Encoder A 7 Signal Ground Signal ground reference for input outputs and Encoder 5V 8 OUT1 General purpose programmable output 9 Frame Ground Frame Ground 10 IN5 Programmable Standard Group 2 11 IN6 Mode Dependent High Group 3 12 IN7 Mode Dependent High Group 3 13 IN8 Mode Dependent High Group 3 14 Encoder B Motor incremental encoder input 15 Encoder B 16 5V OUT Encoder 5 Vdc power supply output Total load current not to exceed 250 mA 17 OUT2 General purpose programmable output 18 OUT4 19 IN9 Mode Dependent High Group 4 20 IN10 Mode Dependent High Group 4 21 IN11 Mode Dependent High Group 4 22 IN12 Mode Dependent High Group 4 23 Encoder X Motor incremental encoder input 24 Encoder X 25 Signal Ground Signal ground reference for input outputs and encoder 5V 26 OUT3 General purpose programmable output 62 Copley Controls Stepnet Panel Amplifier User Guide Wiring Stepnet Panel STP J3 Mode Dependant Dedicated Inputs These inputs are dedicated to specific functions depending on operating mode Mode Input Function All IN Enable Current amp Velocity IN9 PWM Input
4. Specification Meee STP 075 07 STP 075 10 Boost peak current 7 Adc 5 Arms sinusoidal 5 10 Adc 7 Arms sinusoidal 5 Boost peak time 1 Sec n a Run continuous current 5 Adc 3 54 Arms sinusoidal 5 10 Adc 7 Arms sinusoidal 5 Efficiency 97 Full rated voltage and continuous output current 3 3 2 Stepnet Panel AC STX Power Output Specification Monel STX 115 07 STX 230 07 Boost peak current 7 Adc 5 Arms sinusoidal 5 7 Adc 5 Arms sinusoidal 5 Boost peak time 1 Sec 1 Sec Run continuous current 5 Adc 3 54 Arms sinusoidal 5 5 Adc 3 54 Arms sinusoidal 5 Note 2 Efficiency 97 Full rated voltage and continuous output current NOTES 1 Current ratings are for current vector produced by currents flowing in A and B phases 90 phase difference between phases 2 Mounting to heat sink required for operation at continuous current 3 3 3 Power Output Configuration STP and STX Type Dual MOSFET H bridges 15 kHz center weighted PWM space vector modulation PWM ripple frequency 30 kHz Minimum load inductance STX gt 200 uH per phase STP gt 400 uH per phase Note Contact factory if lower inductance is required Copley Controls Corp 45 Specifications 3 4 Control Loops Stepnet Panel Amplifier User Guide Type Servo mode current Servo mode velocity Stepper or servo mode position 100
5. Time S A T Accumulator 120 a 100 3 80 5 60 CT Setpoint g PT 5 40 E 20 0 0 1 2 3 4 5 6 7 Time S B At time 0 plot diagram A shows that the actual output current follows the commanded current Note that the current is higher than the continuous current limit setting of 6 A Under this condition the T Accumulator Variable begins increasing from its initial value of zero Initially the output current linearly increases from 6 A up to 12 A over the course of 1 2 seconds During this same period the IT Accumulator Variable increases in a non linear fashion because of its dependence on the square of the current At about 1 6 seconds the IT Accumulator Variable reaches a value equal to the I T setpoint At this time the amplifier limits the output current to the continuous current limit even though the commanded current remains at 12 A The TT Accumulator Variable value remains constant during 170 Copley Controls Stepnet Panel Amplifier User Guide CT Time Limit Algorithm the next 2 seconds since the difference between the actual output current and the continuous current limit is zero At approximately 3 5 seconds the commanded current falls below the continuous current limit and once again the output current follows the commanded current Because the actual current is less than the continuous current the IT Accumulator Variable value begins to fall incrementally
6. 128 6 6 Completion Steps we 129 6 6 1 Objective we 129 EE 129 Copley Controls Corp 115 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 1 Auto Phase Stepper Mode 6 1 1 Auto Phase Warnings and Notes Warnings Motor Motion Applying high voltage power to the amplifier before auto phasing may result in motor motion Be sure that motor motion will not cause injury Failure to heed this warning can result in equipment damage injury or death DANGER High Voltage Applying AC power to the STX amplifier applies high voltage to the amplifier motor connections and cabling Protect personnel against electrical shock Failure to heed this warning can result in equipment damage injury or death Danger Notes e Do not connect a load to the motor before performing Auto Phase procedure e Always connect the motor using the same configuration e Wire properly and consistently e Connections are actually changed within the DSP not at the motor terminals and the results are saved to flash memory The actual wire configuration should NEVER change Phasing a stepper motor establishes positive direction for the motor and if present encoder 116 Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 1 2 Auto Phase Preliminary Steps 6 1 2 1 Verify that the Enable Input is not activated 6 1 2 2 Apply power 6 1 2 3 Choose the appropriate auto phase proc
7. When the message window closes the firmware download is complete Copley Controls Stepnet Panel Amplifier User Guide Using CME 2 8 4 Control Panel 8 4 1 Control Panel Overview To access the control panel click the Control Panel icon on the Main screen Each of the features labeled below is described in the following sections Red if fault is active Yellow if warning gt is active Display error log gt gt Error Log Message box p Control Control functions gt and operational mode control Panel a Status Monitor gt Status indicators Monitor real time amplifier values 2 5 x Motor Output Active Limited Position v Bee o s Hardware Enabled Enabled amp Software Enabled Enabled ep Positive Limit Not Active actual Motor Position HEZ counts Negative Limit Not Active Software Limits Not Active actual Motor velocity S aa rpm Motor Phase OK Motion Abort Input Not Active s C M Control Program Not Running gt Home Not Referenced Mode Position Digital Input CAN Status poe Gain Scheduling Velocity Acceleration 212 rps Deceleration 212 rps Set Zero Position Disable Clear Faults Reset J Enable Jog Jog mode controls 8 4 2 Status Indicators and Messages The Status area includes status indicator lights described below and a message box
8. 5 7 3 3 Click Close 5 7 3 4 E On the Main screen click Save to Flash 5 7 3 5 Proceed to Servo Mode Phase and Tune p 131 Copley Controls Corp 113 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 7 4 Analog Command Input STX Servo Mode Only For more information see Analog Command Input STX Servo Mode Only p 25 5 7 4 1 5 7 4 2 5 7 4 3 5 7 4 4 5 7 4 5 114 Analog Command S zappen LA Analog Command to open the Analog Command screen ls Scaling o 4 10v Dead Band 0 my J Invert Command Analog Input Filter Offset Measure Set the input options described below Option Description Scaling Current mode output current produced by 10 Vdc of input Range 0 to 10 000 000 A Default Peak Current value Velocity mode output velocity produced by 10 Vdc of input Range 0 to 100 000 rpm mm sec Default Maximum Velocity value Position mode position change counts or mm produced by 10 Vdc of input Range 0 to 1 000 000 000 counts Default 1 Revolution of a rotary motor or 1 pole pair distance for a linear motor For more information see Scaling p 25 Dead Band Sets dead band Range 10 000 to 10 000 mV Default 0 For more information see Dead Band p 25 Invert Inverts polarity of amplifier output with respect to input signal Command Offset Current and Velocity modes only Used to offset input voltage
9. Copley GC Controls otepnet Panel Amplifier User Guide Revision A Stepnet Panel Amplifier User Guide TABLE OF CONTENTS ADOUt This a E A E E E E E E A E 5 1 Introduction 1 1 Amplifier zeg de Get Sp o ot 1 2 Amplifier Commissioning with CME 2 sci ses caudate dence aaaeeeaa nde ieda da edian eais edd andn ER ENER slide tente Copley Controls Corp 1 3 CANopen for Distributed Contr EE Operational Theory z 2 1 Amplifier Power Stepnet Panel STP 2 2 Amplifier Power Stepnet Panel AC STX 2 3 Stepper Mode Operation 2 4 Servo Mode Operation Se ge SH SE ae de 2 91 lege tu rel 2 6 COMMUNICATION wscesevecetiessecossatescavanccecstessoonncacsasensisst NEESS sa sais star EE AE EEEE ENEE EE EEN AER EES ti ont ares e san Sas 2 7 Limit Switches 2 8 Brake Operation 2 9 Status Indicators GR 2 10 Protectio ess vegerEkSRSEEEEdEKEK eech 2 11 Position and Servo Velocity Errors as ges So de vu Si 2 42 WA EE EEN Specifications seenen e 3 1 Agency Approvals 3 2 Power Input 3 3 Power Output Se e 3 4 Control LOOPS sirosis scenes cecasacesatssoneacdnaecsecinad catees 3 5 Stepnet Panel AC STX Internal Regen Circuit 3 6 Digital Command Wim Out saasina ae sx scence aae a Aa a aa a baei cans cheeks actus A E LEE de apse ete nd tas SRE Or 3 7 Stepnet Panel AC STX Analog Command Input 3 8 Digit
10. Profile Velocity Instantaneous velocity command output of the trajectory generator Profile Acceleration Instantaneous commanded acceleration deceleration rate Commanded Velocity Servo mode only Command input to the internal velocity loop Actual Motor Velocity With encoder only Actual motor velocity derived from the motor encoder Velocity Error With encoder only Difference between Profile Velocity and Actual Motor Velocity Commanded Position Position input to the trajectory generator Limited Position Instantaneous position command output of the trajectory generator Actual Position With encoder only Actual motor position measured by the motor encoder Following Error With encoder only Difference between the Limited Position and the Actual Position Bus Voltage Applied HV voltage Amplifier Temperature Internal power stage temperature Mode Displays the amplifier s present operating mode In camming it also displays the active cam table number Copley Controls Corp 161 Using CME 2 Stepnet Panel Amplifier User Guide 8 4 4 Control Functions The Control area of the screen provides functions related to overall amplifier control The screen options vary with model and configuration Control Enable Set Zero Position Disable Clear Faults Reset Control the operational state of the amplifier using the controls d
11. Run To Hold Time Position Loop Following Error Position Tracking Window Position Tracking Time Trajectory Maximum Velocity Jerk Brake Stop Delay Time Position Loop Following Warning Trajectory Max Accel Decel Abort Decel 616 81 1 1 2000 1000 2000 1000 500 10 1000 333 13320 ms ms uSteps uSteps uSteps ms rpm rps rps ms Cancel Note that in servo mode Peak Current and Continuous Current replace the stepper mode Boost Current and Run Current settings Verify the boost peak current limit and Run Continuous Current limit If one or more of these values seems inappropriate click Cancel and check Rated Torque or Force and Rated Current Correct them if needed See Rotary Motor Setup Parameters p 97 or Linear Motor Setup Parameters p 97 If the Motor Feedback values were correct but the peak current limit continuous current limit or velocity loop velocity limit values are not optimal for the application change these limits during the tuning process Load the values into amplifier RAM by clicking OK NOTE If the motor wiring configuration in the motor file does not match the configuration currently stored in the amplifier CME prompts for verification on which configuration to use Select the file configuration by clicking Yes The configuration will be tested during auto phasing ol On the Main screen click Save to Flash to avoid losing the
12. Verify that the CAN bus is properly wired and terminated according to the instructions in Stepnet Panel STP CAN Bus J5 and J6 p 65 1 J6 CAN CANopen cable 2 J6 CAN Termination plug aaen Click CAN Configuration to open the CAN Configuration screen If CAN is not the Position Loop Input choose Amplifier Network Configuration instead Here is a typical CAN Configuration screen Features may vary based on amplifier model and configuration CAN Configuration l x Network Type Input Mapping CAN C DeviceNet Number of Inputs 10 7 Bit Rate nek v Bit G none gt Switch Address Configuration Bit 1 none gt Switch JV Use Switch T Use Inputs Bit 2 None Y Switch I Use Programmed Value Bit 3 none Le Switch Switch value Bit 4 none v Input Lines values Bit S None E Programmed Values Riu none New Resulting Address Save amp Close Cancel Help Choose a Bit Rate and choose any combination of address sources Switch Inputs and Programmed Value The address is the sum of the values from these sources i For each source selected perform the additional steps described below Source Additional Steps Use Switch Verify the S1 switch setting Assigns values for Bit 0 Bit 3 of CAN address Use Inputs Enter the Number of inputs Choose the input that will represent each CAN address bit Use Programmed Enter the Programmed value Value Click Save amp Reset to sav
13. 69 4 2 3 Stepnet Panel AC STX Power Un 70 4 2 4 Stepnet Panel AC STX Motor J2 nsien eiia sa ie i aaraa tan aa aadi AAEN E aN ACATA Ee A ie ERECTIE a Ea ATEEN 71 4 2 5 Stepnet Panel AC STX Aux HV and Brake J3 ire 72 4 2 6 Stepnet Panel AC STX CAN Bus J4 and J5 13 4 2 7 Stepnet Panel AC STX Feedback J6 74 4 2 8 Stepnet Panel AC STX Control U N 78 4 2 9 Stepnet Panel AC STX J7 Digital Inputs Wiring Diagram eee 80 4 2 10 Stepnet Panel AC STX RS 232 Serial Communications J8 nenen 83 Copley Controls Corp 57 Wiring Stepnet Panel Amplifier User Guide 4 1 Stepnet Panel STP Wiring 4 1 1 Stepnet Panel STP General Wiring Instructions Stepnet Panel STP Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code NEC or its national equivalent and all prevailing local codes DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death DANGER Stepnet Panel STP Shielding and Grounding Considerations A
14. Hardware Amplifier enable input s is not active Amplifier Disabled by Software Amplifier is disabled by a software command Attempting to Stop Motor The amplifier while in velocity or position mode has been disabled In velocity mode amplifier is using the Fast Stop Ramp described in Servo Velocity Loop Limits p 21 In position mode the amplifier is using the Abort Deceleration rate described in Trajectory Limits p 23 The output remains active until the amplifier is re enabled Motor Brake Motor brake activated See Brake Operation p 34 for more information Activated PWM Outputs The amplifiers PWM outputs are disabled Disabled Home Switch is Axis has contacted the home limit switch Active Not Settled The motor is moving or it has not yet settled after a move The amplifier is settled when it comes within the position tracking window and stays there for the tracking time at the end of a move Once settled it remains settled until a new move is started Choose Output Active High to have the output go high when active or Output Active Low to have the output go low when active To optionally latch the selected events set Latch Output For more information on latching see Non Latched and Latched Custom Outputs p 108 Latching an output does not eliminate the risk of unexpected motion with non latched faults Associating a fault with a latched custom confi
15. The connecting or disconnecting of cables while the amplifier has 24Vdc and or mains power applied is not recommended Failure to heed this warning may cause equipment damage Copley Controls Corp 7 About this Manual Stepnet Panel Amplifier User Guide Revision History Revision Date ECO Comments 1 0 August 2004 Initial publication 2 0 June 2005 Detent compensation gain feature See Detent Compensation Gain p 181 3 June 2008 17137 Updated Web page references June 2009 32822 Updated to include Stepnet Panel AC STX amplifiers 8 Copley Controls CHAPTER 1 INTRODUCTION This chapter provides an overview of the Copley Controls Stepnet amplifier Contents include Title LAMPE a ates en nee sete eae te ee a eue Sapean 1 2 Amplifier Commissioning with CME 2 1 3 CANopen for Distributed Control Copley Controls Corp Introduction Stepnet Panel Amplifier User Guide 1 1 Amplifier Stepnet is a 100 digital stepping motor amplifier which can operate in two control modes stepper or servo In stepper mode conventional microstepping techniques are used In servo mode stepping motors fitted with encoders can be operated as DC brushless servo motors in closed loop current velocity or position modes Stepnet can operate as a stand alone amplifier or as a networked CANopen or DeviceNet node It can also be controlled using the Copley ASCII interface over a serial connection The mu
16. and Auto Phase p 132 Scope Opens Scope CME 2 User Guide Error Log Opens Error Log CME 2 User Guide Amplifier Properties Displays amplifier properties Network Opens the CAN or DeviceNet Configuration Configuration screen Rename Prompts for new amplifier name Renaming an Amplifier p 153 Auto Tune Auto Tune for Linear Servo Motors Gain Scheduling Opens Gain Scheduling screen CME 2 User Guide Tools Communications Starts sequence of prompts to set up Serial Port Setup p 89 Wizard communications Communications Log Opens Communications Log CME 2 User Guide Download Firmware Starts sequence of prompts to download Downloading Firmware p 157 new firmware image from disk to amplifier View Scope Files Opens Trace Viewer window CME 2 User Guide I O Line States Opens UO Line States window showing high low status of the amplifier s inputs and outputs CME 2 Lock Unlock Opens screen for locking and unlocking CME 2 User Guide CME 2 functionality ASCII Command Opens screen to accept ASCII format CME 2 User Guide Line commands Help CME 2 User Guide Opens the CME 2 User Guide All Documents Opens the Doc folder in the CME 2 installation folder typically c Program Files Copley Motion CME 2 Doc This folder contains all of the related documents that were installed with CME 2 Downloads Web Page Software Web Page Opens default web browser with relevant pages from Copley Controls website View
17. 3 Select one of the configurations described below and enter appropriate values for the parameters Configuration Description and Parameters In Position Activates the output while the axis is in the window between the programmed Upper Window and Lower positions Trigger at Activates the output for the programmed Time when the axis travels through the Position programmed Position Trigger Positive Motion Activates the output for the programmed Time when the axis travels in the positive direction through the programmed Position Trigger Activates the output for the programmed Time when the axis travels in the negative Negative Motion direction through the programmed Position 5 6 7 4 Choose Output Active High to have the output go high when active or Output Active Low to have the output go low when active 5 6 7 5 Choose Use Actual Position with encoder only or Use Limited Position 5 6 7 6 Click OK to save changes to volatile memory and close the Custom Output Configuration screen 5 6 8 Save Input Output Changes 5 6 8 1 On the Input Output screen click Close 5 6 8 2 E On the Main screen click Save to Flash Copley Controls Corp 107 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 6 9 Non Latched and Latched Custom Outputs Like an amplifier fault a custom configured output can be non latched or latched If a non latched custom configured digital output goes active it
18. Command Input 46 3 7 Stepnet Panel AC STX Analog Command Input 47 3 8 Digital INPUtS cccvei deecoccbetecvestetadnestenertesnesnerestaveres 47 3 8 1 Stepnet Panel STP Digital Inputs 47 3 8 2 Stepnet Panel AC STX Digital Inputs 48 3 9 Digital OUtpUtS sr r deteste termes 49 3 10 Encoder Power Supply Output 49 3 11 Incremental Quadrature Encoder Inputs 50 3 11 1 Incremental Differential Encoder Inputs 50 3 11 2 Stepnet Panel AC STX Single Ended Encoder Inputs 50 3 12 Stepnet Panel AC STX Multi Mode Port 51 3 13 Serial Interface a e 51 3 14 CAN Interface 51 3 15 Status Indicators 52 3 16 Fault Levels 52 3 17 Power Dissipation eee eeeeeteeneeeeenaeees 52 3 17 1 Stepnet Panel STP Power Dissipation 52 3 17 2 Stepnet Panel AC STX Power Dissipation 52 3 18 Thermal Impedance siit sirriissirsendar ineine rinan sniianiina 52 3 19 Mechanical and Environmental De 3 20 DIMENSIONS rune ed 54 3 20 1 Stepnet Panel STP Dimensions 54 3 20 2 Stepnet Panel AC STX Dimensions sienne 55 Copley Controls Corp 43 Specifications Stepnet Panel Amplifier User Guide 3 1 Agency Approvals Stepnet Panel STP and Stepnet Panel AC STX Agency Approvals CE Compliance EN 55011 2007 e CiSPR 11 2003 A2 2006 e Limit
19. Current Offset Commanded Current Peak Current Limit ET Time Limit Continuous Current Limit Current Loop Offset Correcting Torque Actual Current 0A Cp ol om ol o DA Drive Output Maximize Smoothness UR Maximize Speed 721 2 Set the following options as needed Current Limit Options Description Peak Current Used to limit the peak phase current to the motor Limit Max value depends upon the amplifier model Min value gt continuous limit T Time Limit Sets I T Time Limit in mSec For more information see I2T Time Limit Algorithm p 167 Continuous Used to limit the Phase Current Max Value is lt Peak Current and depends upon the amplifier model Min value 0 Current Loop Sets current loop offset Leave it set to zero until after tuning For more information see Offset Offset p 19 Cp Current loop proportional gain Range 0 32 767 Ci Current loop integral gain Range 0 32 767 Drive Output Maximize Smoothness Amplifier uses circular vector limiting to produce smooth operation even into the voltage limits Maximize Speed Allows for slightly more of the bus voltage to be used when in the voltage limit This may produce a small disturbance at top speed Auto Tune See the CME 2 User Guide Bandwidth Measure bandwidth using the Cp and Ci values now in the amplifier 136 Copley Controls Stepnet Pa
20. Current Limits 0 4 Fast Velocity In rpm Current Delay Time Po ms Slow Velocity a rpm Following Warning 0l pSteps Accel Decel a rps Actual Current A Actual Position uSteps Stop Save Exit 8 5 2 2 Select homing options described below Parameter Description Software limits Positive Position of user defined travel limits that take effect after homing operation Software limits Negative Deceleration Rate Deceleration rate used to stop a motor when approaching a software limit Software limits Disable Disables the use of software limits by setting both limits to zero Method Homing method See Homing Methods in the CME 2 User Guide Direction of Motion Initial direction of motion for the homing method Pos or Neg Fast Velocity The velocity used to find a limit or home switch Also used when moving to an offset position or a resolver or Servo Tube index position Slow Velocity The velocity used to find a switch edge incremental or analog encoder index pulse or hard stop Accel Decel The acceleration and deceleration rate used during homing Offset Execute a move of this distance after the reference is found Set actual position to 0 and call the new position home Current Limit Hard stop home is reached when the amplifier outputs the homing Current Current Delay Time Limit continuously for the time specified in the Delay Time Following Warning Shows the
21. FUNGUO EE 8 5 1 Overview 8 5 2 Homing Functions Settings Copley Controls Corp 149 Using CME 2 8 1 CME 2 Overview 8 1 1 Main Screen Overview Stepnet Panel Amplifier User Guide The CME 2 features called out in the diagram below are described in the following sections Copley E Copley Neighborhood Neighborhood Tree CT 2 5 1Beta13 STM 075 07 Step Net 1A o x File Amplifier Tools Help Main Menu fy GEE aiid al ARS EAN Network Address 1 State Pre operation CAN or DeviceNet WEES Virtual Amplifier RSS Information n CONG Step Net Input Output H CVM Control Program Functional Rotary Motor 8 1 2 Tool Bar Overview Click on any of the tools in the toolbar to access the tools described below CAN Configuration gt P Loop gt V Loop I Loop gt MotorFeedback i j i Amp Software Disabled Diagram Configure Faults F12 To Disable Icon Name Description For More Information Basic Setup Opens Basic Setup screen Basic Setup p 93 Control Panel Opens Control Panel Control Panel p 159 SE Auto Phase Opens Auto Phase tool Auto Phase p 116 and Auto Phase p 132 Scope Opens Scope CME 2 User Guide Error Log Opens Error Log CME 2 User Guide Amplifier Displays basic amplifier Properties properties Save amplifier data to disk Saves contents of amplifier R
22. If this is the last amplifier on the network JS 7 use Copley Terminator Plug PN STX NT to terminate the bus J5 8 Copley Controls Corp 73 Wiring Stepnet Panel Amplifier User Guide 4 2 7 Stepnet Panel AC STX Feedback J6 Stepnet Panel AC STX J6 Mating Connector Description 15 Position High Density D Sub Male Solder Style Connector and backshell Manufacturer Part numbers Norcomp 180 015 103L001 connector Norcomp 979 009 020R121 backshell Wire Size 24 30 AWG Connector and backshell are included in connector kit STX CK Pin connections are shown here 74 J6 pin connections Copley Controls Stepnet Panel Amplifier User Guide Stepnet Panel AC STX J6 Pin Description Wiring Pin Signal Function 1 Frame Ground Cable shield connection 2 5 Vdc Encoder 5 Vdc power supply output Total load current on J7 20 and J6 4 not to exceed 250 mA 3 Encoder B2 Single ended primary incremental encoder input 4 5 Vdc Encoder 5 Vdc power supply output Total load current on J7 20 and J6 4 not to exceed 250 mA 5 Signal Ground Signal and 5 Vdc ground 6 Encoder X2 Single ended primary incremental encoder input 7 Encoder X Input Differential primary incremental encoder inputs 8 Encoder X Input 9 Encoder A2 Single ended primary incremental encoder input 10 IN12 Motemp Motor over Standard speed Pull up pull down t
23. Kit for connecting PC to amplifier STX CV Sub D 9 position female to RJ 45 adapter PC to CANopen cable adapter STX NC 10 CANopen Network Cable 10 ft 3 m generic CatSE Cat6E patch cable STX NC 01 J4 J5 CANopen Network Cable 1 ft 0 3 m STX NT CANopen Network Terminator Software Model Description CME2 CME 2 Drive Configuration Software CD ROM CML Copley Motion Libraries CD ROM CMO Copley Motion Objects CD ROM Copley Controls Corp 187 Ordering Guide and Accessories Stepnet Panel Amplifier User Guide E 3 Stepnet Module STM Amplifier Stepnet Module Model Number Model Number Description STM 075 07 Stepnet Module amplifier 5 7 Adc 75 Vdc For more information see data sheet http www copleycontrols com Motion Downloads stepnetData html Stepnet Module Heatsink Kit Model Qty Description 1 Heatsink standard STM HS 1 Heatsink thermal material 1 Heatsink hardware mounting kit 1 Heatsink low profile STM HL 1 Heatsink thermal material 1 Heatsink hardware mounting kit Stepnet Module Development Kit Model Description TDK 075 01 Stepnet Module Development Kit TDK CK Stepnet Module Development Kit Connector Kit SER CK RS 232 Serial Cable Kit for connecting PC to development kit Software Model Description CME2 CME 2 Drive Configuration Software CD ROM CML Copley Motion Libraries CD ROM CMO Copley
24. LO A low input stops motion but amplifier remains enabled Hi Res Analog Divide Active HI A high input causes the firmware to divide the level of the analog input signal by 8 Hi Res Analog Divide Active LO A low input causes the firmware to divide the level of the analog input signal by 8 High Speed Position Capture on LO HI Transition Position will be captured on the low to high transition of the input High Speed Position Capture on HI LO Transition Position will be captured on the high to low transition of the input PWM Sync Input PWM synchronization input 5 6 3 Standard Input Function Assignments Enable Input On the Stepnet amplifier IN1 is dedicated to the enable function Other inputs can be programmed as additional enables If there is more than one input programmed as an enable then all the inputs must be in the enabled state before the amplifier PWM output stage will be enabled Motor Over Temperature On the STX amplifier IN12 is located on the motor feedback connector and is intended to be used for Motor Over Temperature Other Other inputs may have predefined functions depending on mode of operation 102 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 6 4 Standard Digital Outputs 5 6 4 1 Click the Digital Outputs tab of the Input Output screen A typical Digital Outputs screen is shown below Features may vary with amplif
25. PWM 50 Current amp Velocity IN9 PWM Input PWM 100 IN10 Direction Input Position IN9 Pulse Input Pulse amp Direction IN10 Direction Input Position IN9 Count Up Up Down IN10 Count Down Position IN9 Channel B Quadrature IN10 Channel A Stepnet Panel STP J3 Input Wiring Diagram Motion Typical Controller Circuit 5 Vdc R1 pull up pull down 74HC14 Standard inputs IN1 IN4 R1 10 KQ R2 10 KQ C 3300 pf High speed input IN6 IN12 R1 10 KQ R2 1 KQ C 100 pf INS R1 4 99 K9 R2 10 KQ C 2200 pf Copley Controls Corp 63 Wiring Stepnet Panel Amplifier User Guide Stepnet Panel STP J3 Digital Outputs Wiring Diagram Typical Output Loads Typical Circuit Motion Controller External Power Supply Signal Ground Flyback diode required for inductive loads Stepnet Panel STP J3 Incremental Encoder Wiring Diagram Amplifier Typical Circuit Incremental Encoder Encoder Power Case Ground 64 Copley Controls Stepnet Panel Amplifier User Guide 4 1 6 Stepnet Panel STP CAN Bus J5 and J6 Stepnet Panel STP J5 and J6 Mating Connector 8 position modular connector RJ 45 style Copley Controls provides the following assemblies e Prefabricated 10 foot cable PN STP NC 10 e Prefabricated 1 foot cable PN STP NC 01 e Terminator Plug PN STP NT A diagram of the female connector is shown below Stepnet Pane
26. Pulses 1 uStep I Invert Command 5 7 1 2 Set the options described below Option Description Control Input Pulse and Direction One input takes a series of pulses as motion step commands and another input takes a high or low signal as a direction command Pulse Up Pulse Down One input takes each pulse as a positive step command and another takes each pulse as a negative step command Quadrature A B quadrature commands from a master encoder via two inputs provide velocity and direction commands Increment position Rising Edge Increment position on the rising edge of the input pulse om Falling Edge Increment position on the falling edge of the input pulse Stepping Input Pulses Number of Input Pulses required to produce output counts Resolution Range 1 to 32 767 Default 1 Output Counts Number of Output Counts per given number of input pulses Range 1 to 32 767 Default 1 Invert Command When selected inverts commanded direction 5 7 1 3 Click Close 5 7 1 4 E On the Main screen click Save to Flash 5 7 1 5 Proceed to Stepper Mode Phase and Tune p 115 Copley Controls Corp 111 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 7 2 CAN Interface For more information on CAN see CAN Addressing p 32 For information on DeviceNet see the Copley DeviceNet Programmer s Guide 5 7 2 1 5 7 2 2 5 7 2 3 5 7 2 4 5 7 2 5 5 7 2 6 112
27. RS 232 serial connection to one amplifier as a gateway to other amplifiers linked together by CAN bus connections The CME 2 Auto Phasing routine eliminates the wire and try method of connecting the motor and optional encoder to the amplifier After wiring the motor and encoder to the amplifier the Auto Phasing routine determines the correct motor polarity and encoder phasing to match the user s positive direction The amplifier configuration data can be saved to the PC as a file that contains all the amplifier settings This file can then be copied to new amplifiers making it possible to quickly duplicate amplifier motor configurations 1 3 CANopen for Distributed Control CANopen compliance allows the amplifier to take instruction from a master application over a CAN network to perform homing operations point to point motion and interpolated motion Multiple drives can be tightly synchronized for high performance coordinated motion Copley Motion Libraries CML and Copley Motion Objects CMO make CANopen system commissioning fast and simple All network housekeeping is taken care of automatically by a few simple commands linked into your application program CML provides a suite of C libraries allowing a C application program to communicate with and control an amplifier over the CANopen network CMO provides a similar suite of COM objects that can be used by Visual Basic NET LabVIEW or any other program supporting the COM o
28. Release Notes Opens latest CME 2 release notes in a text viewer About Displays CME 2 version information Copley Controls Corp 151 Using CME 2 8 1 4 Functional Diagram Stepnet Panel Amplifier User Guide The functional diagram shown below provides button click access to most of the screens used to configure an amplifier It also indicates the flow of control from input across all active control loops to motor feedback Only those control loop buttons that are appropriate to the operational mode appear on the diagram Control Loops Input Output CVM Control Frogram pl Input Command fjm Digital Position Inputs gt Home V Loop gt Configure Faults The command input button reflects the selected command input Name Description For More Information Opens Input Output screen Theory Inputs p 42 and Outputs p 42 Input Output SE i i Programming instructions Amplifier Configuration p 100 CVM Control Opens Copley Virtual Machine Copley Indexer Program User Guide Program screen Input Command Configure the input command Button label varies depending on the selected control loop input Theory Input Command Types p 25 Programming instructions Basic Setup Screen p 93 Control Loops Each opens a control loop configuration screen Theory Servo Modes and Control Loops p 18 Programming instructions Stepper Mode Phase and
29. Rev 2000 Sas a 5 5 2 2 Click the Motor tab to view or change Rotary Motor Setup Parameters p 97 or Linear Motor Setup Parameters p 97 Feedback Click the Feedback tab For rotary motors enter the number of Encoder Lines For linear motors enter the Encoder Resolution value and select the units for that value mm nm or um 5 5 2 4 STX only Verify the Enable Encoder Loss Detection setting See STX Encoder Loss Detection p 38 5 5 2 3 5525 Erake Stop Click the Brake Stop tab to view or change Brake Stop Parameters p 98 Read the Brake Stop Notes p 98 for important related information Calculate 5 5 2 6 Use The Calculate Function p 99 to calculate initial gains and limits 5 5 2 7 E On the Main screen click Save to Flash to avoid losing the changes 96 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 5 3 Rotary Motor Setup Parameters View or change the settings described below Options vary with amplifier model Metric units are shown here Setting Description Manufacturer Motor manufacturer s name Saved for reference in the motor data file Model Number Motor model number Saved for reference in the motor data file Units Selects whether the parameters entered in this screen are in Metric or English units Motor Inertia The rotor inertia of the motor Used in servo mode for calculating initial velocity loo
30. Set the following Position Loop Values as needed Stepnet Panel Amplifier User Guide Option Description For More Information Gains Aff Acceleration feed forward Servo Position Loop Gains Range 0 to 32 767 p 24 Vif Velocity feed forward Range 0 to 32 767 100 Vff 16 384 Pp Position loop proportional gain Range 0 to 32 767 Gains The output of the position loop is multiplied by Multiplier this value before being passed to the velocity loop Following Error Fault The level in encoder counts at which the Following Error Fault Details following error produces a fault We p 40 recommend raising the fault level before tuning the loop Warning The level in encoder counts at which the following error produces a warning Disable Prevents following error from triggering a fault Fault Tracking Tracking Width of the tracking window in counts Tracking Window Details Window p 41 Tracking Position must remain in the tracking window for Time this amount of time to be considered tracking Position Wrap disabled Opens the configuration controls for the Position Wrap feature This feature causes the amplifier to wrap back the reported position value set it back to zero at a user defined position instead of continually increasing By default this feature is CME 2 User Guide Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Ph
31. Sets the input debounce time how long an input must remain stable at a new state Time before the amplifier recognizes the state Increase to prevent undesired multiple triggering caused by switch bounce Debounce time is ignored for digital command inputs such as PWM Range 0 to 10 000 mSec See Debounce Time p 42 Hold position when limit switch is active Available in position mode when one or more inputs are configured as a limit switch NEG Limit HI Inhibits NEG Limit LO Inhibits POS Limit HI Inhibits or POS Limit LO Inhibits The Hold position option prevents any motion while a limit switch is active WARNING WARNING Limit switches may be disabled If the amplifier is switched back to current or velocity mode with Hold position when limit switch is active set the limit switches will no longer function Failure to heed this warning can cause equipment damage The Restore Defaults button restores all inputs and outputs to factory defaults The Close button closes the screen Copley Controls Corp 101 Mode Selection and General Setup 5 6 2 Digital Input Functions Stepnet Panel Amplifier User Guide Input Function Description AMP Enable LO Enables with clear faults A low input will enable the amplifier Any transition will clear latched faults and outputs AMP Enable HI Enables with clear faults A high input will enable the amplifier Any transition will clea
32. The I T Accumulator Variable value continues to fall until at approximately 5 0 seconds when the commanded current goes above the continuous current limit again The actual output current follows the current command until the IT Accumulator Variable value reaches the TT setpoint and current limiting is invoked Copley Controls Corp 171 IT Time Limit Algorithm Stepnet Panel Amplifier User Guide 2 L A 2 FT Scope Trace Variables STX Only Two Scope Tool trace variables are available for monitoring whether the TT accumulator is accumulating or discharging The I T Amplifier Accumulator variable evaluates the accumulator against the factory set current limits of the amplifier The I T Motor Accumulator variable evaluates the accumulator against the user programmed current loop values The value shown in the scope has been normalized so that 100 equals the TT setpoint When either trace variable line reaches 100 current limiting will be invoked For instructions on using these variables in the Scope Tool see the CME 2 User Guide 172 Copley Controls APPENDIX C THERMAL CONSIDERATIONS This chapter describes Stepnet Panel STP and Stepnet Panel AC STX amplifier operating temperature characteristics heatsink options and heatsink mounting instructions Contents include C 1 Operating Temperature and Cooling Configurations sen men di non E E noie 174 GAMeStepmet Panel STP gece an ER A Anne el DE A en AA A Me hate 174 C
33. al On the Main screen click Save to Disk for backup or duplication 7 5 2 8 Click Control Panel and then click Reset OR Power cycle the amplifier 7 5 2 9 The servo setup procedure is complete 148 Copley Controls CHAPTER 8 USING CME 2 STEPPER OR SERVO MODE This chapter provides an overview of CME 2 software features Contents are relevant to operation in both stepper and servo modes and include Title Page 6 1 CME 2 e EE 150 8 1 1 Main Screen Overview 8 1 2 Tool Bar Overview 8 1 3 Main Menu Overview ee 8 1 4 Functional Diagram cece eee eeeeeeeees w 152 8 1 5 8 1 6 CAN or DeviceNet Information and Status Bar au 1 6 Choosing an Amplifier from a List of Amplters enn 153 8 1 7 Renaming an e le EE 8 2 Manage Amplifier and Motor Data 8 2 1 Memory 8 2 2 Disk Storage eeeee 8 2 3 Data Management TOOISiisisciccsseccescicctvsasceacesenticsaeccesaccesessncscousnecasccdccaaventpodsreaniiectsoevaeisvasstedousd ssepeeestousinnandedeasbeods 8 24 Quick Copy Setup Proc dure tins Muret tienne ratternre gaa EE lean aden age is 8 3 Downloading Firmware 8 3 1 Acquiring Firmware Updates from Web Site 8 3 2 Downloading Firmware to Amplifier bts 8 4 Control Panel WEE 8421 Control Panel Overview EE 8 4 2 Status Indicators and Messages 8 4 3 Monitor Functions 8 4 4 Control Functions dds Re NEE 85 HOME
34. amplifier can be operated in stepper mode or servo mode as described below Mode Features Stepper Amplifier operates as a traditional open position loop stepper drive With the addition of encoder feedback the amplifier can monitor and report actual motor position and provide encoder correction Also a position tracking window can be set up along with a programmable following error warning and fault Servo Amplifier operates as a true closed loop servo amplifier controlling a stepper motor In this mode the amplifier can be configured to accept current velocity or position commands Encoder feedback is required for all servo modes of operation This chapter contains procedures required for and information relevant to all modes of operation Start here to begin amplifier set up and then continue as instructed to the appropriate mode specific chapter To copy setup data from an existing Copley Controls axis file ccx skip to Quick Copy Setup Procedure p 156 NOTE In the procedures described in this chapter CME 2 uses a serial connection to a single amplifier to set up that amplifier As an alternative the multi drop feature allows CME 2 to use a single RS 232 serial connection to one amplifier as a gateway to other amplifiers linked together by CAN bus connections For more information see the CME 2 User Guide Step 5 1 5 2 5 3 5 4 5 5 5 6 5 7 Elle Creer sisueaeususuennsadedsdssue
35. an attempt to control current Commonly occurs when motor is running as fast as available bus voltage allows Positive Limit Switch Axis has contacted positive limit switch Negative Limit Axis has contacted negative limit switch Switch Positive Software Actual position has exceeded the positive software limit setting Limit See Home Function p 164 Negative Software Actual position has exceeded the negative software limit setting Limit See Home Function p 164 Following Warning Following error has reached programmed warning limit See Following Error Fault Details p 40 Velocity Limit Velocity command from analog input PWM input or position loop has exceeded Reached the velocity limit that was set as described in Servo Velocity Loop Limits p 21 Acceleration Limit In velocity mode motor has reached an acceleration or deceleration limit that was reached set as described in Servo Velocity Loop Limits p 21 Velocity Outside of Difference between target and actual velocity has exceeded the window Tracking Window See Tracking Window Details p 41 Position Outside of The following error has exceeded the programmed value Tracking Window See Tracking Window Details p 41 Continued Copley Controls Stepnet Panel Amplifier User Guide 5 6 5 3 5 6 5 4 5 6 5 5 Mode Selection and General Setup Continued Custom Events Status Status Description Amplifier Disabled by
36. and Modes In servo mode the Stepnet uses up to three nested control loops current velocity and position to control a motor in three associated operating modes Servo Mode Nested Loops Illustration In servo position mode the amplifier uses all three loops as shown below The loops are nested the current loop within the velocity loop within the position loop Stated another way the position loop drives the velocity loop which drives the current loop Limits Target Position Velocity Limited Current Limited PWM Position Demand Demand Velocity Demand Current Command Trajectory Position ee ty Eli i Motor Generator Loop oc d Sensors Actual Position Derived Velocity Actual Current Servo Control Loops per Operating Mode The loops are employed in the operating modes as described below Operating Servo Position Loop Servo Velocity Loop Servo Current Loop Mode Input Output Input Output Input Output Current Velocity and position loops not employed in current mode External command 7 PF Voltage Velocity een EE employed in e Current command command Current input to the Position External Velocity Velocity input to command from PWM power command command command current loop velocity loop stage input to the from position velocity loop loop Basic Attributes of All Servo Control Loops These loops and servo control loops in general share several commo
37. backup and distribution Amplifier RAM and Amplifier Flash Memory Amplifier RAM holds status data and certain user entered information data during operation whereas flash memory permanently stores the data for loading into amplifier RAM at power up or reset as described below Amplifier RAM Amplifier Flash Contents erased when amplifier is reset or powered off Permanent Contents retained when the amplifier is reset or powered off Initial contents read from flash on power up Contents then updated in real time to reflect certain operational conditions and changes entered with CME 2 software At any time the user can use CME 2 to restore data from Modified only by using a Save to Flash tool or by closing certain screens Motor Feedback Basic Setup or CAN Configuration whose contents are automatically saved to flash upon closing of the screen flash into amplifier RAM How the Amplifier Uses RAM and Flash Memory As described below some data resides in flash only some in RAM only and some in both Data Resides In Data Flash only This category includes all data represented on the Motor Feedback screen Basic Setup screen and CAN Configuration screen This data is automatically saved to flash as soon as its entry is confirmed when the user clicks the appropriate Save to Flash button or closes the screen Flash and RAM Includes all user entered data represented on other screens such as
38. click on CME 2 5 2 3 3 When prompted save the file to the folder chosen or created in Step 5 2 3 1 The folder should now contain a file named CME2 zip 5 2 3 4 Extract the contents of the zip file to the same location The folder should now contain the files CME2 zip and Setup exe Copley Controls Corp 87 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 2 3 5 If desired delete CME2 zip to save disk space 5 2 4 Installing CME 2 Software 5 2 4 1 5 2 4 2 5 2 4 3 88 If installing from a CD insert the CD Copley Controls part number CME2 Normally inserting the CD causes the installation script to launch and a CME 2 Installation screen appears If so skip to Step 5 2 4 3 If the software installation file was downloaded from the Copley Controls website navigate to the folder chosen or created in Step 5 2 3 1 and then double click on Setup exe OR if you inserted the CD and the CME 2 nstallation screen did not appear navigate to the root directory of the installation CD and then double click on Setup exe Respond to the prompts on the CME 2 Installation screens to complete the installation We recommend accepting all default installation values Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 2 5 Serial Port Setup One or more serial ports on a PC can be used to connect amplifiers Use the following instructions to add enable ports for
39. digital Sampling rate time Servo mode current Servo mode velocity Stepper or servo mode position 15 kHz 67 us 3 kHz 333 us 3 kHz 333 Us Current loop small signal bandwidth gt 2 kHz Tuning and load impedance dependent Servo mode velocity loop filters Type Frequency range Programmable Low Pass 1 Pole Low Pass Butterworth 2 Poles Bi Quadratic 2 Poles amp 2 Zeros Programmable 20 1500 Hz Voltage compensation Changes in HV or Mains voltage does not affect current loop bandwidth 3 5 Stepnet Panel AC STX Internal Regen Circuit Specification Model STX 115 07 STX 230 07 Type Internal MOSFET dissipater Continuous power 40 W Peak power 80 W Turn on voltage 2 Bus voltage gt 195 Vdc Bus voltage gt 390 Vdc Turn off voltage 2 Bus voltage lt 190 Vdc Bus voltage lt 380 Vdc 3 6 Digital Command Input Digital position command Stepper or servo mode Step and direction Count up count down maximum rate STP 1 MHz max pulse rate STX 1 5 MHz max pulse rate Quadrature A B encoder 5 M line sec 20 M count sec after maximum rate quadrature Digital current amp velocity command PWM frequency range 1 kHz 100 kHz Servo mode only PWM minimum pulse width 220 nSec 46 Copley Controls Stepnet Panel Amplifier User Guide Specifications 3 7 Stepnet Panel AC ST
40. error in an open loop system Not recommended for use when the amplifier is part of a closed loop system Range 10 000 to 10 000 mV Default 0 For more information see Offset p 26 Analog Input Programmable input filter Disabled by default See Low Pass and Bi Quad Filters in Filter the CME 2 User s Guide Click Close E On the Main screen click Save to Flash Proceed to Servo Mode Phase and Tune p 131 Copley Controls CHAPTER 6 STEPPER MODE PHASE AND TUNE This chapter describes the general procedure for auto phasing and tuning an amplifier with a motor to operate in stepper mode Step 6 1 Auto Phase Stepper Mod 2 14e srsmmmrmrrneneeentermnr a tire rA Patte dent AEEA TENA 6 1 1 Auto Phase Warnings and Notes wis 6 1 2 Auto Phase Preliminary Steps iii 6 1 3 Auto Phase Stepper Mode No Encoder ss 117 6 1 4 Auto Phase Procedure Stepper Mode with Encoder ais 118 6 1 5 Trouble Shoot Motor Direction Setup 119 6 1 6 Trouble Shoot Motor Wiring Setup 119 6 2 Position Limits Stepper Mode with Encoder 120 6 3 Current LOOP cirri eege ieow 122 6 3 1 Current Loop Settings 122 6 3 2 Manually Tune Current Loop 123 6 3 3 Optimize Hold and Run Current Ratings 124 6 4 Profile Move Tests 125 6 4 2 Test S Curve Profile 127 6 5 Encoder Correction
41. exception of the specifications and wiring diagrams For specifications and wiring information on the Stepnet Module and Stepnet Micro Module refer to the appropriate data sheets Related Documentation See the Stepnet data sheets at http www copleycontrols com Motion Downloads stepnetData html Choose the appropriate data sheet Related Copley Controls manuals include e CME 2 User Guide e CANopen Programmer s Manual e Copley Motion C Libraries CML Reference Manual license purchase required e Copley Motion Objects CMO Programmer s Guide e Copley Camming User Guide e Copley ASCII Interface Programmer s Guide e Copley DeviceNet Programmer s Guide e Copley Amplifier Parameter Dictionary Information on Copley Controls Software can be found at http www copleycontrols com Motion Products Software index html Comments Copley Controls welcomes your comments on this manual See http www copleycontrols com for contact information Copyrights No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Copley Controls Stepnet STP STX CML CMO and CME 2 are registered trademarks of Copley Controls Windows NT 2000 XP Vista Visual Basic and NET are trademarks or registered trademarks of the Microsoft Corporation LabVIEW is a registered trademark of National Instruments Corporation Document Validity We reser
42. gains limits and I O and faults Initial values for this data are factory set in flash They are loaded from flash to RAM with each power up or amplifier reset This data is saved to flash only when a user clicks the appropriate Save to Flash button It is flushed from RAM with each power down or amplifier reset RAM only Includes operating status data such as actual position actual current and amplifier temperature Such data is never stored in flash It is flushed from RAM with each power down or amplifier reset 8 2 2 Disk Storage Amplifier Data Files and Motor Data Files At any time the user can save certain data from RAM and flash memory to a file on disk From the Main screen the user can save all user entered data represented on all screens the data described as Flash only and Flash and on p 154 This data is saved in a Copley Controls amplifier data file with a ccx filename extension From the Motor Feedback screen the user can save all data represented on the Motor Feedback screen This data is saved in a Copley Controls motor data file with a ccm filename extension A ccx file can be restored to return the amplifier to a previous state or to copy settings from one amplifier to another as described in Quick Copy Setup Procedure p 156 154 Copley Controls Stepnet Panel Amplifier User Guide Using CME 2 8 2 3 Data Management Tools Amplifier Data Management Tools Operations performe
43. goes inactive as soon as the last of the selected events is cleared If a latched output goes active it remains active until at least one of the following actions has been taken e power cycle the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel and press Clear Faults or Reset e clear faults over the CANopen network Latching an output does not eliminate the risk of unexpected motion with non latched faults Associating a fault with a latched custom configured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without operator intervention In this case motion may re start unexpectedly DANGER For more information see Clearing Non Latched Faults p 37 Failure to heed this warning can cause equipment damage injury or death Custom Event Output Faults An output configured for Custom Event can be programmed to go active in response to events including any of the amplifier faults described in Fault Descriptions p 38 Example Custom Output Fault Handling vs Overall Fault Handling A fault on an output configured for Custom Event is separate from a fault on the amplifier For instance suppose e OUT3 has a Custom Event configuration Only the Under Voltage fault condition is selected and the output is latched e Under Voltage is not latched
44. information see Communication p 30 and the Copley DeviceNet Programmer s Guide Trajectory Limits In servo position mode the trajectory generator applies the following user set limits to generate the motion profile Limiter Description Maximum Velocity Limits the maximum speed of the profile Maximum Acceleration Limits the maximum acceleration rate of the profile Maximum Deceleration Limits the maximum deceleration rate of the profile Abort Deceleration Specifies the deceleration rate used by the trajectory generator when motion is aborted When the amplifier is driven by pulse and direction commands Maximum Velocity Acceleration and Deceleration function as maximum values When the amplifier is driven by any other command input Maximum Velocity Acceleration and Deceleration function as commanded values Copley Controls Corp 23 Operational Theory Stepnet Panel Amplifier User Guide Servo Position Loop Inputs From the Trajectory Generator The servo position loop receives the following inputs from the trajectory generator Input Description Profile Velocity The instantaneous velocity value of the profile Used to calculate the velocity feed forward value Profile Acceleration The instantaneous acceleration deceleration value of the profile Used to calculate the acceleration feed forward value Limited Position The instantaneous commanded position of the profile Use
45. inputs IN1 IN12 IN1 is always used as an enable input IN2 IN12 are fully programmable See Digital Input Functions p 102 2 12 2 Input Filters Two types of input RC filters are used GP general purpose and HS high speed The digital command inputs such as Count Up Count Down and PWM are wired to inputs having the HS filters Inputs with the GP filters are used for general purpose logic functions limit switches and the motor temperature sensor 2 12 3 Debounce Time To prevent undesired multiple triggering caused by switch bounce upon switch closures each input can be programmed with a debounce time The programmed time specifies how long an input must remain stable at a new state before the amplifier recognizes the state The programmed debounce time is ignored if the input is programmed as a digital position command PWM input or encoder input 2 12 4 Configure for Pull Up Pull Down Resistors by Groups Pre defined groups of inputs can be programmed to have either an internal pull up or pull down resistor See Stepnet Panel STP J3 Pin Description p 62 or Stepnet Panel AC STX J7 Pin Description p 79 for groupings 2 13 Outputs 2 13 1 Digital Outputs The amplifier has four programmable digital outputs These outputs are open drain MOSFETs each with a pull up resistor in series with a diode connected to the amplifier s internal 5 Vdc supply This design allows the outputs to be directly connected to optic
46. limit Max Accel Maximum trajectory acceleration Max value may depend upon the load inertia and boost current stepper mode or peak current Servo mode Min 0 Max Decel Maximum trajectory deceleration Max value may depend upon the load inertia and boost current stepper mode or peak current Servo mode Min O disables limit Servo Position Mode and Position Loop p 23 Abort Decel Deceleration rate used by the trajectory generator when motion is aborted Min 0 disables limit Brake Operation p 34 Jerk The value of jerk set during the calculate procedure produces an S Curve whose maximum slope is equal to the trapezoidal profile slope This value will produce a maximum acceleration that is not more than the initial default value of acceleration Small values will produce less jerking but will take longer to complete move Large values will produce more jerking and a more trapezoidal profile but will complete the move faster Clear Limits Sets Max Velocity Max Accel and Max Decel to zero disabling the trajectory generator Set Default Limits Restores Max Velocity Max Accel and Max Decel to calculated defaults Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Phase and Tune 7 4 1 3 Open the Position Loop Values tab Position Loop ET RS 0 Copley Controls Corp 143 Servo Mode Phase and Tune 7 4 1 4 144
47. of the profile The deceleration is set to be the same as acceleration Maximum Jerk The value of jerk set during the calculate procedure produces an S Curve whose maximum slope is equal to the trapezoidal profile slope This value will produce a maximum acceleration that is not more than the initial default value of acceleration Small values will produce less jerking but will take longer to complete move Large values will produce more jerking and a more trapezoidal profile but will complete the move faster Profile Tab Distance Increase the move distance to produce a complete trajectory profile Use an acceptable value the does not exceed mechanical limits of the system Move Relative Type S Curve 7 4 3 3 Click Start 7 4 3 4 Adjust values for desired results 7 4 3 5 Try multiple sets of profiles representing typical moves that might be executed in the application Starting with Set up an S curve profile repeat the process as needed Copley Controls Corp 147 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 5 Completion Steps 7 5 1 Objective Save the work and perform additional testing with load and under normal control source 7 5 2 Steps 7 5 2 1 E On the Main screen click Save to Flash 7 5 2 2 Remove power 7 5 2 3 Attach load 7 5 2 4 Reconnect power 7 5 2 5 Re tune velocity and position loops if applicable 7 5 2 6 E On the Main screen click Save to Flash 7 5 2 7
48. on the Configure Faults screen An under voltage condition occurs and the amplifier goes into fault condition output stages are disabled and faults are reported At the same time OUT3 goes active The under voltage condition is corrected and e The amplifier fault is cleared Output stages are enabled e OUT3 remains active 108 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 6 10 Fault Latching 11 Click Configure Faults to open the Fault Configuration screen Fault Configuration x Latch Fault FM Short Circuit JV Amp Over Temperature M Motor Over Temp J Over Voltage J Under Voltage JV Feedback Error F Motor Phasing Error IV Following Error F Command Input Fault Optional Faults IT Over Current Latched OK Cancel Help Note that with no encoder the Following error fault is not displayed as a choice 5 6 10 2 To make a fault condition latching click to put a check mark next to the fault description Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against DANGER Unexpected motion Failure to heed this warning can caus
49. sections 24 Vdc logic signal and high voltage Each is isolated from the other 2 2 1 Logic Signal Power An internal DC DC converter operates from the 24 Vdc Logic Supply input and creates the required logic signal operating voltages the isolated voltages required for the high voltage control circuits and a 5 Vdc supply for powering the motor encoder circuits All the digital and analog inputs digital outputs and encoder inputs are referenced to the same signal common The CAN interface is optically isolated Deriving internal operating voltages from a separate source enables the amplifier to stay on line when the mains have been disconnected for emergency stop or operator intervention conditions This allows CAN bus and serial communications to remain active so that the amplifier can be monitored by the control system while the mains power is removed 2 2 2 High Voltage Mains power drives the high voltage section It is rectified and capacitor filtered to produce the DC bus the DC link power that drives the PWM inverter where it is converted into the voltages that drive the stepper motor An internal solid state switch and power resistor provides dissipation during regeneration when the mechanical energy of the motor is converted back into electrical energy This prevents charging the internal capacitors to an overvoltage condition Copley Controls Corp 15 Operational Theory Stepnet Panel Amplifier User Guide 2 3 Ste
50. tuning values Min 0001 Kg Max 100 000 Kg Default 0001 Kg Resistance Motor resistance line to line Used for calculating the initial current loop tuning values Min 0 01 Max 327 Q Default 0 01 Q Inductance Motor inductance line to line Used for calculating the initial current loop tuning values For inductance range see Power Output p 45 Rated Force Motor s rated operating force Min 001 N Max 1000 N Rated Current Motor s rated continuous current Min 0 01 A Max 1000 A Full Step Fundamental stepper motor step distance Min 0 0001mm Max 5000 mm UStep Full Step stepper mode only Number of microsteps per full step Min 1 Max 25 000 000 Copley Controls Corp 97 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 5 5 Brake Stop Parameters Enter the following parameters as appropriate Parameter Description Brake Stop Delay Time Range of accepted values 0 to 10 000 mSec Brake Activation Velocity Range of accepted values motor dependent PWM Delay Brake Stop Response Time Range of accepted values 0 to 10 000 mSec Brake Stop Notes Many control systems employ a brake to hold the axis when the amplifier is disabled On brake equipped systems disabling the amplifier by a hardware or software command starts the following sequence of events e The motor begins to decelerate at Abort Deceler
51. 051 Crimp Terminal Molex 39 00 0039 5 required Wire Size 18 24 AWG Connector housing and terminals are included in connector kit STP CK Stepnet Panel STP J2 Pin Description Pin Signal Function 1 Chassis Ground Motor frame ground and cable shield 2 Motor B Phase B output of amplifier 3 Motor B Phase B output of amplifier 4 Motor A Phase A output of amplifier 5 Motor A Phase A output of amplifier Stepnet Panel STP J2 Motor Wiring Diagram Typical wiring for a 4 lead motor Amplifier J2 I A a Ground 1 wi J2 1 Motor Er B ITT i J2 2 e Ba Se B B 2 lt J3 3 A B S X A J2 4 KC e au a J2 5 F A Typical wiring alternatives 8 lead motor coils in parallel 8 lead motor coils in series 6 lead motor B S 3 GN Ki Bol 3 e N Bot Ke Dy No pe _ Connection BOF D So 2 B x A Ce SC Copley Controls Corp 61 Wiring Stepnet Panel Amplifier User Guide 4 1 5 Stepnet Panel STP Signal J3 Stepnet Panel STP J3 Mating Connector Description Plug High Density D Sub 26 Position Manufacturer Part numbers Connector solder cup Norcomp 180 026 102 001 Backshell Norcomp 979 015 020R121 Wire Size 22 26 AWG shielded cable Connector and backshell are included in connector kit STP CK Amplifier pin locations are shown here Stepnet Panel STP J3 Pin Description
52. 1 2 Stepn t Panel AC SUX WEE EE 176 C 2 Heatsink Mounting INStrUCtiONS isccicss 12e Raman op tueesssociecesdbceasina ss ceschenideasdeshancapeldin leat Gant E A EE a 179 Copley Controls Corp 173 Thermal Considerations Stepnet Panel Amplifier User Guide C 1 Operating Temperature and Cooling Configurations C 1 1 Stepnet Panel STP Power Dissipation Stepnet Panel STP The following chart shows the internal power dissipation for of the Stepnet Panel STP amplifier versus output current levels at different HV voltages The output current is calculated from the motion profile motor and load conditions The values on the chart represent the rms root mean square current that the amplifier would provide during operation The HV values are for the average DC voltage of the power supply Drive Dissipation vs Output Current Power Dissipation W Output Current Arms 174 Copley Controls Stepnet Panel Amplifier User Guide Thermal Considerations Max Ambient Temperature vs Current Output Stepnet Panel STP The following chart shows the maximum allowable ambient temperature of the Stepnet Panel STP amplifier versus output current levels at different HV voltages The values shown represent applications where the amplifier is installed without a heatsink and uses natural convection cooling The addition of forced air 100 Wm minimum or forced air and a heatsink will allow the Stepnet to operate at maximum vo
53. 2 Auto Phase Preliminary Steps AAA 7 1 3 Auto Phas Proc dure vivicsisccsccaisscenscicecesesseecesentacsecscvecseseaseiscousncsusacdaeaavaniposerogsiiestbeavsbisia ssticcssasdsaegecssiosetanauabisasteode 7 1 4 Trouble Shoot Motor Direction Setup s 135 7 1 5 Trouble Shoot Motor Wiring Setup aa 135 1 23 Gurr ntiLoOp arr aan nan des 136 7 2 1 Current Loop Settings 136 7 2 2 Manually Tune Current Loop 137 G3 Velocity LOOP smart 139 7 3 1 Velocity Loop Settings 139 7 3 2 Manually Tune the Velocity Loop 140 T4 Position LO6p 222 rennes ee 141 7 4 1 Position Loop Settings eeesaee 141 7 4 2 Manually Tune the Position Loop 145 7 4 3 Test S Curve Profile eeeeee 147 7 5 Completion Steps cee 148 7 5 1 Objective 148 EE eege 148 Copley Controls Corp 131 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 1 Auto Phase Servo Mode 7 1 1 Auto Phase Warnings and Notes Warnings Motor Motion Applying high voltage power to the amplifier before auto phasing may result in motor motion Be sure that motor motion will not cause injury Failure to heed this warning can result in equipment damage injury or death DANGER High Voltage Applying AC power to the STX amplifier applies high voltage to the amplifier motor connections and cabling Protect personnel against electric
54. 2 line receiver Non isolated RC filter Signals A A B B X X Common mode Vin range 7 Vdc Differential input threshold 0 2 Vdc Differential input impedance 121Q Maximum frequency 5 MHz Line 20 Mcount sec Function Incremental encoder required for servo mode of operation or for position monitoring and correction in stepper mode X is equivalent to Marker Index or Z channels depending on the encoder manufacturer This channel is only required in certain homing modes 3 11 2 Stepnet Panel AC STX Single Ended Encoder Inputs Channels 3 Type Single ended 5V CMOS Non isolated RC filter 2 KQ pull up to 5V Signals A B X Vin Low lt 1 35 V Vin High gt 3 65 V Vin Maximum 10 Vdc Vin Minimum 7 Vdc Maximum frequency 1 MHz Line 4 Mcount sec Function Incremental encoder required for servo mode of operation or for position monitoring and correction in stepper mode X is equivalent to Marker Index or Z channels depending on the encoder manufacturer This channel is only required in certain homing modes 50 Copley Controls Stepnet Panel Amplifier User Guide Specifications 3 12 Stepnet Panel AC STX Multi Mode Port Channels 3 Type Bi Directional differential RS 422 Non isolated Signals A A B B X X Common mode Vin range 7 Vdc Differential input threshold 0 2 Vdc Termination resist
55. 5 Vdc Input voltage range 0 V 12 Vdc Copley Controls Corp 47 Specifications Stepnet Panel Amplifier User Guide 3 8 2 Stepnet Panel AC STX Digital Inputs Channels 12 7 general purpose 5 high speed Function IN dedicated to enable input function IN2 11 programmable IN12 motor over temperature may be reprogrammed Scan time 333 LSec pulse and direction PWM input and secondary encoder are handled at DSP clock rate of 25 nSec Debounce Digital programmable from 0 10 000 mSec General purpose inputs 1 4 10 11 Type 74HC14 Schmitt trigger w RC filter RC time constant 330uSec 10 kQ resistor programmable as pull down or pull up to internal 5 Vdc Input voltage range 0 V 24 Vdc Logic low input voltage lt 1 35 Vdc Logic high input voltage gt 3 65 Vdc High speed Type 74HC14 Schmitt trigger w RC filter input 5 RC time constant 0 1uSec 10 KQ resistor programmable as pull down or pull up to internal 5 Vdc Input voltage range 0 V 12 Vdc Logic low input voltage lt 1 35 Vdc Logic high input voltage gt 3 65 Vdc High speed Type RS422 line receiver w RC Filter inputs 6 9 RC time constant 0 1 uSec 10 KQ resistor programmable as pull down or pull up to internal 5 Vdc May be programmed as 4 independent inputs or 2 differential inputs Input voltage range 0 V 12 Vdc Logic low input voltage lt 2 30 Vdc Logic
56. AM to a disk file Restore amplifier data from disk Restores contents of an amplifier file from disk to amplifier RAM Save amplifier data to flash Saves contents of amplifier RAM to amplifier flash Se eg mg Restore amplifier data from flash Restores contents of amplifier flash to amplifier RAM Manage Amplifier and Motor Data p 154 150 Copley Controls Stepnet Panel Amplifier User Guide 8 1 3 Main Menu Overview The CME 2 Main Menu choices are described below Using CME 2 Menu Selection Description For More Information File Save Amplifier Data Saves contents of amplifiers RAM to a Manage Amplifier and Motor Data p disk file 154 Restore Amplifier Restores contents of an amplifier file Data from disk to amplifier RAM Restore CVM Prompts for a Copley Virtual Machine Copley Indexer 2 Program User Control Program program file The program in this file will Guide replace the current program in flash Restore Cam Tables Prompts for a saved Cam Table file cct See Copley Camming Users Guide file All tables in amplifier flash will be replaced by the ones in this file Exit Closes CME 2 Prompts for data saving decision Amplifier Basic Setup Opens Basic Setup screen Basic Setup p 93 Control Panel Opens Control Panel Control Panel p 159 Auto Phase Opens Auto Phase tool Auto Phase p 116
57. All green lights indicate the amplifier is enabled and ready to accept motion commands Indicator States Description Motor Output State of the PWM output stage Red if the output stage is inactive disabled Hardware State of the hardware enable input s Red if one or more enable inputs are inactive Enabled Software State of the software enable Red if the amplifier is disabled by software Enabled Positive Limit State of the positive limit switch input Red indicates an activated positive limit switch Negative Limit State of the negative limit switch input Red indicates an activated negative limit switch Software Limits State of the software limits Red indicates an activated software limit Motor Phase Indicates a motor phasing error Red indicates a motor phasing error exists Motion Abort State of the programmed Motion Abort Input Red indicates the input is active Input CVM Control Status of the CVM Control Program Program Home Indicates whether the axis has successfully been referenced homed Continued Copley Controls Corp 159 Using CME 2 Stepnet Panel Amplifier User Guide continued Indicator States Description CAN Status The status of the CAN Bus Yellow indicates a CAN warning limit reached Red indicates a bus error detected If the CAN Status indicator is replaced by the DeviceNet Status indicator see the Copley DeviceNet Programmer s G
58. CAN PA Il ol rN i J1 P al D 4 ower S1 CAN gt Ucht Address Switch Copley Controls Corp 59 Wiring Stepnet Panel Amplifier User Guide 4 1 3 Stepnet Panel STP Power J1 Stepnet Panel STP J1 Mating Connector Description Receptacle Single Row 4 Position Manufacturer part numbers Housing Molex 39 01 4041 Crimp Terminal Molex 39 00 0039 4 required Wire size 18 24 AWG Connector housing and terminals are included in connector kit STP CK Stepnet Panel STP J1 Pin Description Pin Signal Function 1 Chassis Ground Earth ground connection 2 Aux HV Auxiliary power input 3 HV Power input 4 Ground Power common Stepnet Panel STP J1 Power Input Wiring Diagram Amplifier J1 t Auxiliary e Power Supply J1 1 optional S i Aux J1 2 Fees HV T DE J1 4 Power Supply Vv N A Logic J Supply V Ka Note 1 Diode and capacitor should be installed if using a switching power supply 60 Copley Controls Stepnet Panel Amplifier User Guide Wiring 4 1 4 Stepnet Panel STP Motor J2 Stepnet Panel STP J2 Mating Connector Description Receptacle Single Row 5 Position Manufacturer part numbers Housing Molex 39 01 4
59. CANopen Network Kit Model Qty Ref Description Copley Controls Model No 1 Sub D 9 position female to RJ 45 adapter STP CV STP NK 1 JET CANopen Network Cable 10 ft 3 m generic Cat5E Cat6E patch cable 1 CANopen Network Terminator STP NT Stepnet Panel STP Individual Cable Assemblies and Related Accessories Model Ref Description Mfr Model No SER CK J4 RS 232 Serial Cable Kit for connecting PC to amplifier STP CV Sub D 9 position female to RJ 45 adapter PC to CANopen cable adapter STP NC 10 CANopen Network Cable 10 ft 3 m generic Cat5E Cat6E patch cable STP NC 01 J5 J6 CANopen Network Cable 1 ft 0 3 m STP NT CANopen Network Terminator Software Model Description CME2 CME 2 Drive Configuration Software CD ROM CML Copley Motion Libraries CD ROM CMO Copley Motion Objects CD ROM Order Example Order 1 STP 075 07 amplifier with factory installed heatsink CME 2 CD and serial cable kit Qty Item Description 1 STP 075 07 H Stepnet Panel STP stepper amplifier with heatsink installed 1 STP CK Connector kit 1 STP NK CANopen network kit 1 CME 2 CME 2 CD 1 SER CK Serial Cable Kit for connecting the PC to the amplifier 186 Copley Controls Stepnet Panel Amplifier User Guide Ordering Guide and Accessories E 2 Stepnet Panel AC STX Amplifier Stepnet AC Panel Model Numbers
60. IES This chapter lists part numbers for all Stepnet amplifiers and accessories Contents include E 1 Stepnet Panel STP Amplifier Sue re tar E E eegene T ti dense ans 186 E 2 Stepnet Panel AC STX AMplif e crores EE entente nent serie EELER ENEE asian ty 187 E3 St pnet Module STM Amplifiers e 22e recense ina vice en sn naines en EE een errant etranger 188 EA Stepnet Micro Module STL Amplifier siennes 189 Copley Controls Corp 185 Ordering Guide and Accessories E 1 Stepnet Panel STP Amplifier Stepnet Panel Model Numbers Stepnet Panel Amplifier User Guide Model Number Description STP 075 07 Stepnet Panel amplifier 5 7 Adc 75 Vdc STP 075 10 Stepnet Panel amplifier 10 10 Adc 75 Vdc NOTE Add H to order Panel amplifier with factory mounted heatsink Heatsink kits may be ordered separately Stepnet Panel STP Heatsink Kit Model Qty Description 1 Heatsink STP HK 1 Heatsink thermal material 1 Heatsink hardware mounting kit Stepnet Panel STP Connector Kit with Solder Cup Feedback and Control Connectors Model Qty Ref Description Mfr Model No 1 J1 Housing Molex 39 01 4041 4 J1 Crimp terminal Molex 39 00 0039 STP CK 1 J2 Ronee Molex 39 01 4051 5 J2 Crimp terminal Molex 39 00 0039 1 J3 Connector solder cup Norcomp 180 026 103L001 1 Back shell Norcomp 979 015 020R121 Stepnet Panel STP
61. Motion Objects CD ROM 188 Copley Controls Stepnet Panel Amplifier User Guide Ordering Guide and Accessories E 4 Stepnet Micro Module STL Amplifier Stepnet Micro Module Model Numbers Model Number Description STL 055 04 Stepnet Micro Module amplifier 3 4 5 Adc 55 Vdc For more information see data sheet http www copleycontrols com Motion Downloads stepnetData html STL 075 03 Stepnet Micro Module amplifier 2 3 Adc 55 Vdc For more information see data sheet http www copleycontrols com Motion Downloads stepnetData html Stepnet Micro Development Kit for Stepnet Micro and Stepnet Micro Module Model Description LDK 075 01 Stepnet Micro Development Kit LDK CK Stepnet Micro Development Kit Connector Kit SER CK RS 232 Serial Cable Kit for connecting PC to development kit Software Model Description CME2 CME 2 Drive Configuration Software CD ROM CML Copley Motion Libraries CD ROM CMO Copley Motion Objects CD ROM Copley Controls Corp 189 Stepnet User Guide DIN CC95 00294 000 Revision A June 2009 2004 2005 2008 2009 Copley Controls 20 Dan Road Canton MA 02021 USA All rights reserved
62. NVERTER FRAME SAFETY L GROUND ISOLATION BARRIER 24 Vdc GROUND 7 CONTROL SYSTEM e D q O QO ENABLE IN1 CONTROL LOGIC J SIGNAL GND a SIGNAL GND Dee EE CONTROL SIGNAL GROUND Stepnet Panel AC STX Primary Grounding Functions A grounding system has three primary functions safety voltage reference and shielding Stepnet Panel AC STX J1 2 Primary Ground The primary ground at J1 2 is the safety ground and is intended to carry the fault currents from the mains in the case of an internal failure or short circuit of electronic components This ground is connected to the amplifier chassis Wiring to this ground should be done using the same gauge wire as that used for the mains This wire is a bonding conductor that should be connected to an earthed ground point and must not pass through any circuit interrupting devices The pin on the amplifier at J1 2 is longer than the other pins on J1 giving it a first make last break action so that the amplifier chassis is never ungrounded when the mains power is connected 68 Copley Controls Stepnet Panel Amplifier User Guide Wiring Stepnet Panel AC STX J2 Ground The ground terminal at J2 1 also connects to the amplifier chassis Motor cases can be safety grounded in one or optionally both of these ways e Direct grounding of the motor frame assuming the frame of the machine is gr
63. P J4 RS 232 Serial Communications Wiring Diagram To PC RS 232 Port 66 Copley Controls Stepnet Panel Amplifier User Guide Wiring 4 2 Stepnet Panel AC STX Wiring 4 2 1 Stepnet Panel AC STX General Wiring Instructions Stepnet Panel AC STX Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code NEC or its national equivalent and all prevailing local codes DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death DANGER Risk of electric shock High voltage circuits on J1 and J2 are connected to mains power Failure to heed this warning can cause equipment damage injury or death DANGER Do not ground mains connected circuits With the exception of the ground pins on J1 and J2 all of the other circuits on these connectors are mains connected and must never be grounded Failure to heed this warning can cause equipment damage WARNING Do not plug or unplug connectors with power applied The connecting or disconnecting of cables while the amplifier has 24Vdc and or mains power applied is not recommended gt Failure to heed this warning may cause equipment damage WARNING Copley Controls Corp 67 Wiring Stepnet Panel Amplifier User Guide Power and Grounding Diagram Stepnet Panel AC STX AMPLIFIER CHASSIS DC BUSS PWM MAINS 2 I
64. Phasing Error Motor fails to properly phase initialize Amplifier is reset and re enabled in servo mode only Feedback error STX only Under voltage condition detected on output Encoder power returns to specified of the internal 5 Vdc supply used to voltage range power the encoder Differential encoder signal fault Line errors are corrected Motor Over Temperature Motor over temperature input changes Input changes back to normal operating state to indicate an over temperature state condition Under Voltage HV voltage falls below specified voltage HV voltage returns to specified limit voltage range Over Voltage HV voltage exceeds specified voltage HV voltage returns to specified limit voltage range Following Error User set following error threshold See with encoder only exceeded Position and Servo Velocity Errors p 39 Short Circuit Detected Output to output output to ground internal Short circuit has been removed PWM bridge fault Over Current Latched Output current TT limit has been Amplifier is reset and re enabled exceeded Command Input Fault PWM command at 0 or 100 duty cycle Proper PWM input command is with the Allow 100 Output option restored disabled PWM frequency out of range Latched by default STX Encoder Loss Detection The Stepnet Panel AC STX amplifier incorporates Encoder Loss Detection circuitry that continuously monitors the integrity of the differential encoder feedbac
65. STP Stepnet Panel AC STX Size inches mm without heatsink 5 35 x 3 51 x 1 65 135 9 x 89 3 x 41 8 See Stepnet Panel STP Dimensions p 54 5 73 x 4 70 x 2 17 145 5 x 119 5 x 55 0 See Stepnet Panel AC STX Dimensions p 55 Weight Without heat sink With heat sink 0 94 Ib 0 43 kg 1 34 Ib 0 61 kg 1 73 Ib 0 79 kg 2 65 Ib 1 20 kg Ambient temperature Storage 40 to 85 C 40 to 85 C Operating 0 to 50 C 0 to 45 C Humidity 0 to 95 non condensing Contaminants Pollution degree 2 Environment IEC68 2 1990 Cover material Meets U L Spec 94 V 0 Flammability Rating Copley Controls Corp 53 Specifications Stepnet Panel Amplifier User Guide 3 20 Dimensions 3 20 1 Stepnet Panel STP Dimensions Le 5 35 135 9 19 4 8 4 97 126 2 t I 52 13 2 2 00 50 8 3 01 76 4 i 3 24 82 2 w ji Stapmet j 5 00 127 4 97 126 2 19 4 8 3 51 89 3 1 65 41 8 i Optional heatsink shown selte 5 38 136 5 rs 3 31 84 1 eg 54 Copley Controls
66. Tune p 115 Servo Mode Phase and Tune p 131 Motor Feedback Opens the Motor Feedback screen Motor Setup p 95 Home Configure and test homing Home Function p 164 Configure Faults Opens Fault Configuration screen Theory Faults p 37 Programming instructions Non Latched and Latched Custom Outputs p 108 152 Copley Controls Stepnet Panel Amplifier User Guide Using CME 2 8 1 5 CAN or DeviceNet Information and Status Bar The Main screen displays basic CAN or DeviceNet information as shown here CAN Network Address 1 State Pre operational Address shows the amplifiers CAN or DeviceNet address This value is updated on 24 Vdc power up or reset only see CAN Addressing p 32 or the Copley DeviceNet Programmer s Guide When the Command Source is set to CAN State shows the state of the amplifier s CANopen state machine see Copley Control s CANopen Programmer s Manual The status bar describes the present commutation mode motor type and amplifier control status as shown below It also includes a reminder that pressing the F12 function key while CME 2 is running disables the amplifier Sinusoidal Commutation Rotary Motor Amp Software Disabled F12To Disable 8 1 6 Choosing an Amplifier from a List of Amplifiers If as shown at left below there is only one serial port set up for communications with an amplifier CME 2 automatically attempts to connect to th
67. X Analog Command Input Channels 1 Type Differential non isolated Measurement range 10 Vdc Maximum voltage Differential 10 Vdc Input to Ground 10 Vdc Input impedance 5kQ Resolution 12 Bit Accuracy 2 of reading 0 5 of range Bandwidth 7 kHz Sample period 200 Sec Function Current velocity or position commands Analog input filter Type Frequency range Programmable Low Pass 1 Pole Low Pass Butterworth 2 Poles Bi Quadratic 2 Poles amp 2 Zeros Programmable 20 1500 Hz 3 8 Digital Inputs 3 8 1 Stepnet Panel STP Digital Inputs Channels 12 5 general purpose 7 high speed Function IN1 dedicated to enable input function IN2 IN12 programmable Logic low input voltage lt 1 35 Vdc Logic high input voltage gt 3 65 Vdc Scan time 333 uSec pulse and direction PWM input and secondary encoder are handled at DSP clock rate of 25 nSec Debounce Digital programmable from 0 10 000 mSec General purpose Type 74HC14 Schmitt trigger w RC filter inputs 1 5 Inputs 1 4 RC time constant 33uSec Input 5 RC time constant 22uSec 10 kQ resistor programmable as pull down or pull up to internal 5 Vdc Input voltage range 0 V 30 Vdc High speed Type 74HC14 Schmitt trigger w RC filter inputs 6 12 RC time constant 0 1uSec 10 kQ resistor programmable as pull down or pull up to internal
68. a 0 Vdc input command would be interpreted as 5 Vdc which would produce 1000 rpm CCW rotation A 10 Vdc command would be interpreted as 5 Vdc and produce 1000 rpm CW rotation Monitoring the Analog Command Voltage The analog input voltage can be monitored in the CME 2 control panel and oscilloscope The voltage displayed in both cases is after both offset and deadband have been applied Analog Command in Position Mode The amplifiers Analog Position command operates as a relative motion command When the amplifier is enabled the voltage on the analog input is read Then any change in the command voltage will move the axis a relative distance equal to the change in voltage from its position when enabled To use the analog position command as an absolute position command the amplifier should be homed every time it is enabled The Homing sequence may be initiated by CAN ASCII serial or CVM Indexer program commands 26 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 5 2 Digital Position Inputs Three Formats In position mode the amplifier can accept position commands via two digital inputs using one of these signal formats pulse and direction count up count down or quadrature In all three formats the amplifier can be configured to invert the command Pulse Smoothing In position mode the amplifier s trajectory generator ensures smooth motion even when the command source cannot control accelerati
69. al Function 1 Return 24 Vdc return or common Brake Output Return or low side of motor brake 3 24 Vdc 24 Vdc Logic power supply Stepnet Panel AC STX J3 Logic Supply and Brake Wiring Diagram Amplifier Isolated Logic Power Supply 24 Vdc Power Supply Required 72 Copley Controls Stepnet Panel Amplifier User Guide Wiring 4 2 6 Stepnet Panel AC STX CAN Bus J4 and J5 Stepnet Panel AC STX J4 5 Mating Connector 8 position modular connector RJ 45 style Copley Controls provides the following assemblies e Prefabricated 10 foot cable PN STX NC 10 e Prefabricated 1 foot cable PN STX NC 01 e Terminator Plug PN STX NT A diagram of the female connector is shown below Stepnet Panel AC STX J4 5 Pin Description Pin Signal Function 1 CAN_H CAN_H bus line dominant high 2 CAN L CAN_L bus line dominant low 3 CAN_Gnd Ground 0 V V 4 Pass though to second connector no internal connection 5 Pass though to second connector no internal connection 6 CAN_SHLD Pass though to second connector no internal connection 7 CAN_Gnd Ground 0 V V 8 CAN V Pass through to second connector no internal connection Table applies to both J4 and J5 CAN connectors Stepnet Panel AC STX J4 5 CAN Bus Wiring Diagram Amplifier CAN CAN Network Opto isolation Eu J5 2 CAN Gnd CAN Network J5 3 J5 4 J5 5 J5 6 Note 1
70. al le CN 3 9 Digital Outputs 3 10 Encoder Power Supply Output 3 11 Incremental Quadrature Encoder Inputs S vi E D A 3 12 Stepnet Panel AC STX Multi Mode Port 3 13 Serial un EE 3 14 CAN Intertace 3 15 Status Indicators 3 16 Fault Levels 3 17 Power Dissipation 3 18 Thermal Impedance Li wed ws Di dx D 319 Mechanical and Environmental sisses ssion ennan aaee ENEE EA E FE aaner ETA se ete rnennen donnee en fad upusviendshacnaesaseene 3 20 D ie 4 1 Stepnet Panel STP Wiring 4 2 Stepnet Panel AC STX Wiring Mode Selection and General Setup 5 1 WARNINGS acre ccecatecsveceeuneee nent ne SS adh o e ger 5 2 CME 2 Installation and Serial Port Setup rete ene ee eee ee ee caae sees eee ceaaaaeeeeeeeeeeaaeeeeeeegeccaaeeeeeseeseeeeeeeeeeseeneaeeee OLS BALE LS 0 EE 5 4 Basic Setup vis ge D ved Sr is li a SS Mol S Te GE unten UE NEE 5 7 Command Input du Stepper Mode Phase and Tune 6 1 Auto Phase Stepper Mode 6 2 Position Limits Stepper Mode with Encoder 6 3 Current Loop de Ee Ges we ae a 6 4 Profile MOVE T6StSisicciscasiscccsdscessvcnccocepestsscaccuseneneceeeessactecdscesvesninedsveses sivas covacecwoweatede annee attente Rien ane es astesvsiabasdeancvedencsd once 6 5 Encoder Corrector cvacsiincetecssncsciccecsrescseccneveanncaduvesdeechecearsctsdousacocausbncnasuacesdstaccadaeceibast ctuasddseavesgenesdbedesuddeacsud
71. al shock Failure to heed this warning can result in equipment damage injury or death Danger Notes e Do not connect a load to the motor before performing Auto Phase procedure e Always connect the motor using the same configuration e Wire properly and consistently e Connections are actually changed within the DSP not at the motor terminals and the results are saved to flash memory The actual wire configuration should NEVER change Phasing a stepper motor establishes positive direction for the motor and encoder 7 1 2 Auto Phase Preliminary Steps 7 1 2 1 Verify that the Enable Input is not activated 7 1 2 2 Apply power 132 Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Phase and Tune 7 1 3 Auto Phase Procedure 7 1 3 1 7 1 3 2 7 1 3 3 7 1 3 4 7 1 3 5 El Click Auto Phase to open the Auto Phase Motor Direction Setup screen auto Phase x Motor Direction Setup Move the motor in the direction that you want to be positive Press Next when done Motor Actual Position 0 counts Release Brake Skip gt Cancel Activate the Enable Input Move the motor in the direction to be considered positive OR if you cannot move the motor click Skip you will confirm motor direction later NOTE If an output is configured as a brake you can temporarily release the brake by holding down the Release Brake button The brake will be reactivated when you release the button The Ac
72. ally isolated PLC inputs that reference a voltage higher than 5 Vdc typically 24 Vdc The diode prevents current flow between the 24 Vdc supply and the internal 5 Vdc supply though the pull up resistor This current if allowed to flow could turn on the PLC input giving a false indication of the amplifier s true output state The outputs require an external fly back diode to be installed across any inductive loads such as relays that are connected to them NOTE Outputs will remain off high after powering up the amplifier for a maximum delay of 2 seconds They will then assume their programmed states The outputs will also turn off during an amplifier reset and return to their programmed state after a maximum delay of 0 5 seconds 42 Copley Controls CHAPTER 3 SPECIFICATIONS This chapter describes the amplifier specifications for the Stepnet Panel STP and Stepnet Panel AC STX amplifiers Contents include Title Page 3 1 Agency ete EE 44 3 2 Power Input vs 3 2 1 Stepnet Panel STP Power Input 44 3 2 2 St pnet Panel AC STX Power Input te nes nine See EENS cesse era ane EEEE 44 3 3 POWER 8 ue EE 45 3 3 1 Stepnet Panel STP Power Output 45 3 3 2 Stepnet Panel AC STX Power Output 45 3 3 3 Power Output Configuration STP and STX 45 3 4 Control LOOPS noiire a aa 46 3 5 Stepnet Panel AC STX Internal Regen Circuit 46 3 6 Digital
73. ambient temperature of the Stepnet STX 120 07 amplifier versus output current levels with different cooling feature configurations Maximum Ambient Temperature vs Output Current Heat Sink Fan Cooled No Heatsink Fan Cooled A Heatsink No Fan No Heatsink No Fan Ambient Temperature CO 0 1 2 3 4 5 Output Current Arms Copley Controls Corp 177 Thermal Considerations Stepnet Panel Amplifier User Guide Max Ambient Temperature vs Current Output Stepnet Panel AC STX 230 07 The following chart shows the maximum allowable ambient temperature of the Stepnet STX 230 07 amplifier versus output current levels with different cooling feature configurations Maximum Ambient Temperature vs Output Current Heat Sink Fan Cooled f No Heatsink Fan Cooled A Heatsink No Fan No Heatsink No Fan Ambient Temperature C 0 1 2 3 4 5 Output Current Arms Thermal Resistance Stepnet Panel STX Configuration Thermal Resistance No Heat Sink Convection Cooled 2 2 C W No Heat Sink Fan Cooled 200 LFM minimum 1 1 C W With Heat Sink Convection Cooled 1 2 C W With Heat Sink Fan Cooled 200 LFM minimum 0 6 C W Air flow 200 LFM minimum 178 Copley Controls Stepnet Panel Amplifier User Guide Thermal Considerations C 2 Heatsink Mounting Instructions Use the following procedure to mount a heatsink on a Stepnet Panel amplifier O
74. amplifiers to choose baud rates for those ports and to remove disable ports for amplifiers eS 5 2 5 1 SES Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop If a serial or CAN port has not been selected the Communications Wizard Select device screen appears Kl Communications Wizard x Select device Serial Ports CAN Network 5 2 5 2 If the CME 2 Main screen appears instead of Select Devices choose Tools gt Communications Wizard 5 2 5 3 Choose Serial Ports and click Next to open the Communications Wizard Select Ports screen i communications Wizard x Select Ports To add serial ports select them from the Available Ports list then press Add To remove serial ports select them from the Selected Ports list then press Remove Available Ports Selected Ports COM4 coms lt Remove Back Nei Cancel 5 2 5 4 From the Available Devices list on the Select Devices screen choose the serial ports that will be used to connect to amplifiers 1 Toallow connection of an amplifier through a port highlight the port name and click Add or click Add All to enable all available ports 2 To remove a port from the Selected Devices list highlight the port name and click Remove Copley Controls Corp 89 90 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 2 5 5 Click Next to save the choices and open the Communications Wizard Configure Ser
75. ance None Function Programmable Output Mode Buffered primary incremental encoder Input Mode Current velocity mode PWM input Position mode digital command input Maximum frequency Output mode Buffered encoder Input Mode PWM input Digital command 5 MHz Line 20 Mcount sec 100Khz 5 MHz 50 Duty Cycle 3 13 Serial Interface Channels 1 Type RS 232 Signals Rxd Txd Gnd Baud rate 9 600 to 115 200 defaults to 9600 on power up or reset Data format N 8 1 Protocol Binary or ASCII format Function Amplifier set up control and diagnostics 3 14 CAN Interface Channels 1 optically isolated from amplifier circuits Connectors 2 eight position modular RJ 45 style wired as per CAN Cia DR 303 1 V1 1 One connector for signal input Second connector for daisy chaining to next node Signals CAN H CAN L CAN Gnd CAN Power Pass though only Format CAN V2 0b physical layer for high speed connections compliant Protocol Motion Control Device Under DSP 402 of the CANopen DS 301 V4 01 EN 50325 4 Application Layer Supported modes Profile Torque Profile Velocity Profile Position Interpolated Position and Homing Node address selection 16 position rotary switch on front panel OR programmable digital inputs OR stored in flash memory OR combination of above Bus termination External 121 Q resistor across CAN H and CAN L when
76. and distance See table Trajectory Limits Tab Maximum Velocity Maximum Acceleration Set values typical of those expected to be used in the application Maximum Deceleration Profile Tab Distance Set the move distance to produce a complete trajectory profile Be sure that this distance does not exceed mechanical limits of the system Move Relative Type Trap NOTES 1 The profile may not reach constant velocity during a short move 2 At higher speeds motor back EMF may limit Boost and Run currents 6 4 1 5 Click Start The Profile Generator executes the move 6 4 1 6 Verify that the boost run and hold currents are appropriate for the move 6 4 1 7 Try multiple sets of profiles representing typical moves that might be executed in the application Starting with Set up a trapezoidal profile repeat the process as needed 126 Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 4 2 Test S Curve Profile NOTE Skip this step unless the amplifier will perform CANopen S Curve profile moves Jerk is the rate of change of acceleration S Curve moves reduce jerk to provide a smooth profile To tune the level of jerk run an S Curve profile and adjust velocity acceleration deceleration and jerk levels until the desired profile is obtained Oscilloscope Bisi Trace Status Ready x Profile Type C Trap SCurve 6 4 2 1 On the Profile tab click the S Curve b
77. ase and Tune 7 4 2 Manually Tune the Position Loop Minimize following error and oscillation by running profiles and adjusting position proportional gain Pp velocity feed forward Vff acceleration feed forward Aff and other settings Trace Status Ready NOTE During position loop tuning observe any warnings that appear to the left of the trace 7 4 2 1 Perform an auto setup test 1 Click the Scope Tool to open the Oscilloscope window rator Profile 2 Select the Profile tab 3 F Auto seiu On the Settings tab make sure that Auto Setup is checked Auto Setup automatically sets the following options Profile Tab Move Relative Type Trap Distance 2 revolution rotary or 2 cm linear Reverse and Not selected repeat Settings Tab Channel 1 Profile velocity green Channel 2 Following error white Distance 2000 counts 4 If the auto setup default profile distance is not appropriate enter an appropriate short distance 5 Set up a trapezoidal profile by setting the trajectory limits and distance on the Trajectory Limits tab See table Trajectory Limits Tab Maximum Velocity Maximum Acceleration Set values typical of those expected to be used in the application Maximum Deceleration Profile Tab Distance Set the move distance to produce a complete trajectory profile Be sure that this distance does not exceed mechanical limits of the system Move R
78. ation rate in position mode or Fast Stop Ramp rate in velocity mode At the same time the Brake Stop Delay Time count begins This allows the amplifier to slow the motor before applying the brake e When the motor slows to Brake Stop Activation Velocity OR the Brake Stop Delay Time expires the brake output activates and PWM Delay Brake Stop Response Time count begins e When response time has passed the amplifier s output stages are disabled This delay ensures the brake has time to lock in before disabling the power section Enable Input ni Brake Stop delay time Speed Nr Brake Stop activation velocity Brake Ouptput Enable Power Section i La PM delay Brake Stop response time This sequence is not available in the current mode of operation Instead in current mode the amplifier output turns off and the brake output activates immediately when the disable command is received 98 Copley Controls Stepnet Panel Amplifier User Guide 5 5 6 The Calculate Function The Calculate function uses the motor and encoder values entered to calculate initial loop gains and limits These can be modified later to fine tune the amplifier 5 5 6 1 5 5 6 2 5 5 6 3 5 5 6 4 Mode Selection and General Setup Click Calculate crue to calculate and display the settings Calculated Amplifier Settings x Current Loop Cp Gain Current Loop Ci Gain Boost Current Run Current Time at Boost Current Hold Current
79. bject interface Copley Controls Corp 11 Introduction Stepnet Panel Amplifier User Guide 12 Copley Controls CHAPTER 2 OPERATIONAL THEORY This chapter describes the basics of Stepnet operation Contents include Title Page 2 1 Amplifier Power Stepnet Panel STP 14 2 2 Amplifier Power Stepnet Panel AC STX Bet 2 3 Stepper Mode Operation 16 2 4 Servo Mode Operation 18 2 5 Input Command Types 25 2 6 Communication 30 2 7 Limit Switches 133 2 8 Brake Operation 34 2 9 Status Indicators 90 2 10 Prot cti M icis 37 2 11 Position and Servo Velocity Errors 39 2 12 INDUTS sorer nes sakes dem ancoesadet aaa 42 PRE TT 42 Copley Controls Corp 13 Operational Theory Stepnet Panel Amplifier User Guide 2 1 Amplifier Power Stepnet Panel STP 2 1 1 Stepnet Panel STP High Voltage HV Power A Stepnet Panel STP amplifier typically operates from a transformer isolated unregulated DC power supply The supply should be sized such that the maximum output voltage under high line and no load conditions does not exceed the amplifier s maximum voltage rating Power supply rating depends on the power delivered to the load by the amplifier In many cases the continuous power output rating of the amplifier is considerably higher than the actual power required the load By appropriately selecting the boost run and ho
80. changes Copley Controls Corp 99 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 6 Amplifier Configuration 5 6 1 Digital Inputs 5 6 1 1 RS Click Input Output on the Main screen to open the nput Output screen A typical Input Output screen is shown below Features vary with model and configuration Red inhibited motion or active input depending on input function Grey motion not inhibited None not configured Lo Hi Indicates state of input a Input Output Digital Inputs 1 5 Digital Inputs 6 12 Digital Outputs Debounce time CAN address IN1 amp Enable LO Enables With Clear Faults e O ms Lo Ze Pull up 5 C Pull down IN2 not Configured v o ms Lo BIT 0 IN3 Not Configured X Oo ms Lo BIT 1 e pulup sy N4 Not Configured O Af os H BIT 2 Le down UNS TT 0 ms Hi BIT 3 P Hold position when limit switch is active Restore Defaults Hold position setting Indicates input is used as a CAN address bit 100 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 6 1 2 Change or verif the following settings Setting Description Pull up 5 V Pulls up the group of inputs up to internal 5 V Pull down Pulls the group of inputs down to internal signal ground IN1 IN12 Select the function for the input See Digital Input Functions p 102 for input function descriptions Debounce
81. city portion of moves Hold Current Current used to hold motor at rest Run to Hold The period of time beginning when a move is completed during which the output stays Time at Run Current level before switching to Hold Current level Hold to The period of time beginning when a move is completed during which the output stays Voltage Time at Hold Current level before switching to the voltage mode in which the amplifier locks the duty cycle to prevent jitter Setting to zero disables Voltage Mode Cp Current loop proportional gain Range 0 32 767 Ci Current loop integral gain Range 0 32 767 Drive Output Maximize Smoothness Amplifier uses circular vector limiting to produce smooth operation even into the voltage limits Maximize Speed Allows for slightly more of the bus voltage to be used when in the voltage limit This may produce a small disturbance at top speed Auto Tune See the CME 2 User Guide Bandwidth Measure bandwidth using the Cp and Ci values now in the amplifier Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 3 2 Manually Tune Current Loop To tune the current loop apply square wave excitation to the current loop and adjust current loop proportional gain Cp and current loop integral gain Ci to obtain a desired waveform Trace Status Waiting for Trigger NOTE During tuning observe any warnings that appear to the le
82. cking Position must remain in the tracking window for Time this amount of time to be considered tracking 6 2 1 5 Click Close 6 2 1 6 E On the Main screen click Save to Flash to save the changes Copley Controls Corp 121 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 3 Current Loop Initial current loop proportional gain Cp and current loop integral gain Ci values were calculated during general amplifier setup For an introductory overview of the control loops see Stepper Mode Operation p 16 NOTE For Copley digital amplifiers current loop gain is independent of power supply voltage 6 3 1 Current Loop Settings For more information see Current Control in Stepper Mode p 17 6 3 1 1 6 3 1 2 122 Commanded Current Boost Current Time at Boost Current Run Current Hold Current Run to Hold Time Hold To Voltage Time 9 un Click Loop to open the Current Loop screen current Loop l x Correcting Torque Actual Current 14 Cp 479 2000 ms Ci 63 1 A Drive Output Maximize Smoothness 0 75 C Maximize Speed 250 ms Auto Tune Bandwidth 0 ms Close Set the following options as needed Options Description Boost Current Current used during acceleration and deceleration Time at Boost Current Maximum time at boost current Run Current Current used during continuous velo
83. ctio 3 On the CME 2 Main screen click Encoder Correction to open the Encoder Correction screen a Encoder Correction 6 5 1 2 Ecp 25 Max Step Rate 60 rpm Close 6 5 1 3 Set the following options Options Description ECp Gain used to correct following error Max Step Controls the maximum rate at which the axis is moved to provide encoder correction Rate 128 Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 6 Completion Steps 6 6 1 Objective Save the work and perform additional testing with load and under normal control source 6 6 2 Steps 6 6 2 1 E On the Main screen click Save to Flash 6 6 2 2 Remove power 6 6 2 3 Attach load 6 6 2 4 Reconnect power 6 6 2 5 Re test profiles 6 6 2 6 E On the Main screen click Save to Flash 6 6 2 7 al On the Main screen click Save to Disk for backup or duplication 6 6 2 8 E Click Control Panel and then click Reset OR Power cycle the amplifier 6 6 2 9 The amplifier stepper mode tuning procedure is complete Copley Controls Corp 129 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 130 Copley Controls CHAPTER 7 SERVO MODE PHASE AND TUNE This chapter describes the general procedure for auto phasing and tuning an amplifier with a motor to operate in servo mode Step TAP AutoiPhase SOnvoiMOde EE 7 1 1 Auto Phase Warnings and Notes Ser 7 1
84. d after the time specified by the run to hold parameter has expired A small amount of jitter can occur when Stepper motors are at rest under hold current To prevent this the Stepnet features an optional voltage mode After the time specified in the hold to voltage parameter has expired the amplifier enters the voltage mode locking the duty cycle to prevent jitter An TT algorithm is used to protect the motor from overheating by basically averaging the amount of current applied to the motor and not allowing it exceed the run current setting If boost current is used then the motor must spend time with hold current applied so the average does not exceed the run setting See I2T Time Limit Algorithm p 167 NOTE Current loop operation in stepper mode is very similar to current loop operation in servo mode Reading the description of servo mode operation can be helpful in understanding stepper mode operation When doing so make the following substitutions where stepper mode uses run current servo mode uses continuous current where stepper mode uses boost current servo mode uses peak current Also there is no servo mode equivalent to the stepper mode hold current For more details about current loop operation see Servo Current Mode and Current Loop p 19 Copley Controls Corp 17 Operational Theory Stepnet Panel Amplifier User Guide 2 4 Servo Mode Operation 2 4 1 Servo Modes and Control Loops Nesting of Servo Mode Control Loops
85. d below Amplifier Response to Non Latched Following Error Fault In servo mode when a non latched following error fault occurs the amplifier drops into velocity mode and applies the Fast Stop Ramp deceleration rate to bring the motor to a halt The amplifier PWM output stage remains enabled and the amplifier holds the velocity at zero using the velocity loop In stepper mode when a non latched following error fault occurs the current move is aborted and the amplifier decelerates at the Trajectory Abort Deceleration rate The amplifier PWM output stage remains enabled and the Hold current is applied to the motor Resuming Operations After a Non Latched Following Error Fault The clearing of a non latched following error depends on the amplifiers mode of operation If the amplifier is operating as a CAN node starting a new trajectory using CANopen commands will clear the fault and return the amplifier to normal operating condition If the amplifier is receiving position commands from the digital inputs then the amplifier must be disabled and then re enabled using a hardware input or though CME 2 software commands After re enabling the amplifier will operate normally Amplifier Response to a Latched Following Error Fault When a latched following error fault occurs the amplifier disables the output PWM stage without first attempting to apply a deceleration rate Resuming Operations After a Latched Following Error Fault A latched following erro
86. d using the amplifier data management tools at the top of the Main screen shown below affect all data including motor feedback data CME 2 3 2 STM 075 07 Stepnet File Amplifier Tools Help mt mei A ET Easbat KI Amplifier Data Management Tools The amplifier data management tools are described below Icon Name Description a Save amplifier Saves save all user entered data represented on all screens from volatile and flash data to disk memory to a disk file with a ccx filename extension si Restore amplifier data from disk Restores amplifier and motor data from a ccx file to the amplifier s volatile and flash memory Note that only certain data is saved to flash by this operation the data described as Flash only on p 154 To assure that all data including the data described as Flash and is stored in flash use the Save amplifier data to flash tool 2 Save amplifier data to flash Saves contents of amplifier RAM to amplifier flash memory A Restore amplifier data from flash Restores contents the amplifier s flash memory to amplifier s volatile RAM To use a data management tool click the icon and respond to prompts Motor Data Management Tools Operations performed using the data management tools at the bottom of the Motor Feedback screen shown below affect only user entered data represented on the Motor Feedback screen Motor Feedback Data Management T
87. d with the actual position feedback to generate a position error Servo Position Loop Gains The following gains are used by the servo position loop to calculate the velocity command Gain Description Pp Position loop proportional The loop calculates the position error as the difference between the actual and limited position values This error in turn is multiplied by the proportional gain value The primary effect of this gain is to reduce the following error Vff Velocity feed forward The value of the profile velocity is multiplied by this value The primary effect of this gain is to decrease following error during constant velocity Aff Acceleration feed forward The value of the profile acceleration is multiplied by this value The primary effect of this gain is to decrease following error during acceleration and deceleration Gain Multiplier The output of the position loop is multiplied by this value before being passed to the velocity loop Servo Position Loop Feedback The feedback to the loop is the actual motor position obtained from a quadrature encoder attached to the motor Servo Position Loop Output The output of the servo position loop is a velocity command used as the input to the velocity loop 24 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 5 Input Command Types The amplifier can be controlled by a variety of external sources analog voltage inpu
88. dc output Total load current on J7 20 J6 2 and J6 4 not to exceed 250 mA 21 Multi Mode Port X 22 Multi Mode Port X 23 Multi Mode Port B Programmable differential input output port 24 Multi Mode Port B See Mode Dependant Dedicated Inputs p 80 25 Multi Mode Port A 26 Multi Mode Port A Copley Controls Corp Wiring 79 Wiring Stepnet Panel Amplifier User Guide Mode Dependant Dedicated Inputs These inputs are dedicated to specific functions depending on operating mode Mode Selected Command Source Function Digital Input Digital Input Multi Mode Single Ended Differential Port Current amp Velocity IN8 IN8 amp IN6 A amp A PWM Input PWM 50 Current amp Velocity IN8 IN8 amp IN6 A amp A PWM Input PWM 100 IN9 IN9 amp IN7 B amp B Direction Input Position IN8 IN8 amp IN6 A amp A Pulse Input Pulse amp Direction INQ IN9 amp IN7 B amp B Direction Input Position IN8 IN8 amp ING ASIA Count Up Up Down IN9 IN9 amp IN7 B amp B Count Down Position IN9 IN8 amp ING ASIA Channel A Quadrature IN8 IN9 amp IN7 B amp B Channel B 4 2 9 Stepnet Panel AC STX J7 Digital Inputs Wiring Diagram Typical i Motion ypica f Controller Circuit 5 Vdc 10 KQ pull up pull dow n Standard input R 10 KQ C 0 033 uf High speed input R 1KQ C 100 pf 80 Copley Controls Stepnet Panel Amplifier Use
89. detailed information see Following Error Fault Details p 40 2 11 3 Following Error Warnings When the position error reaches the programmed warning threshold the amplifier immediately sets the following error warning bit in the status word This bit can be read over the CAN network It can also be used to activate a digital output 2 11 4 Position and Velocity Tracking Windows When the position error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the position error remains within the tracking window for the programmed tracking time This bit can be read over the CAN network It can also be used to activate a digital output In servo mode a similar method is used to handle velocity errors For detailed information see Tracking Window Details p 41 Copley Controls Corp 39 Operational Theory Stepnet Panel Amplifier User Guide 2 11 5 Following Error Fault Details Position Error Reaches Fault Level As described earlier position error is the difference between the limited position output of the trajectory generator and the actual position When position error reaches the programmed Following Error Fault level the amplifier faults unless the following error fault is disabled As with a warning a status bit is set In addition the fault is recorded in the error log Additional responses and considerations depend on whether the fault is non latched or latched as describe
90. e 5 3 2 Starting CME 2 and Choosing an Amplifier NOTE Digital input 1 IN1 must be configured as a hardware disable It may be used to immediately disable the amplifier To software disable the amplifier at any time while running CME 2 press function key F12 5 3 2 1 Verify CME 2 installation and serial port configuration Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop If there are multiple ports the Copley Neighborhood root will be selected CME 2 5 1Betai3 amp File Amplifier Tools Help Ay a Ca P EX Copley Neighborhood GEB Virtual Amplifie EE 5 3 2 2 Select the desired amplifier to open the CME 2 Main screen varies with model and configuration CHE 2 5 2 STX unnamed 5 x File Amplifier Tools Help Tee oO EA 4 Copley Neighborhood en Input Output Virtual Amplifier CVM Control Program CAN Configuration L Pos Limits b eno conection L Detent Loop MotorFeedback Home Configure Faults Rotary Motor Fi2 To Disable If basic setup settings have not been chosen the Basic Setup screen opens 92 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 4 Basic Setup 5 4 1 Basic Setup Screen 5 4 1 1 To load a ccx file that was prepared for the amplifier motor combination see Quick Copy Setup Procedure p 156 5 4 1 2 si Click the Basic Setup button to display the Basic Setup
91. e Application 1 Amplifier Control Master Controller StepNet Local Control Amplifier CAN Network Copley Controls Corp 31 Operational Theory Stepnet Panel Amplifier User Guide 2 6 4 CAN Addressing A CANopen network can support up to 127 nodes Each node must have a unique and valid seven bit address Node ID in the range of 1 127 Address 0 is reserved and should not be used There are several methods for setting the CAN address using various combinations of the rotary CAN ADDR selector switch programmed values entered into flash memory and digital input signals Addressing Method Description Address selector switch If the address number lt 16 CAN address can be set using the CAN ADDR switch only Use programmed value Program address into flash only Ignore switch Use address switch with Use address switch and an offset value programmed into flash memory Address is the programmed offset value sum of the offset value and the switch setting Use inputs with Use inputs user selects how many lines 1 7 and an offset value programmed into flash programmed offset value This offset value is added to the value set by the inputs to determine the address Programmed value could be zero so that inputs alone determine address Ignore the CAN ADDR switch Use switch input lines Use switch inputs user selects how many lines 0 3 and an offset value programmed in and programmed offset
92. e amplifier on that port on CME 2 startup GG 8 075 ACME 2 3 2 STM 075 0 MECME 2 v3 2 STM 075 0 File Amplifier Tools Hell File Amplifier Tools Hell Aal kal 215 E 9 Copley Neighborhood BD Virtual Amplifier A Copley Neighborhood 5 Virtual Amplifier ES COM4 Xenus One amplifier Multiple amplifiers If as shown at right above multiple serial ports have been set up for communications with multiple amplifiers CME polls all the amplifiers and displays their names in the Copley Neighborhood To choose an amplifier click on the amplifier name 8 1 7 Renaming an Amplifier Each amplifier represented in the Copley Neighborhood amplifier tree has a name The default name for an amplifier is unnamed Use this procedure to rename an amplifier 8 1 7 1 Select the amplifier from the Copley Neighborhood 8 1 7 2 Choose Main Menu Amplifier gt Rename to open the Rename Amplifier screen Rename Amplifier xi Enter the new name for this amplifier WEE OOO OK Cancel 8 1 7 3 Enter the new name 8 1 7 4 Click OK to close the screen and save the new name or click Cancel to close the screen without saving the name Copley Controls Corp 153 Using CME 2 Stepnet Panel Amplifier User Guide 8 2 Manage Amplifier and Motor Data 8 2 1 Memory To maintain amplifier and motor settings the amplifier uses volatile RAM memory and non volatile flash memory Data can also be saved to disk for
93. e changes to amplifier flash close the screen and reset the amplifier Click Save amp Close to save changes to amplifier flash without resetting NOTE CAN address and bit rate changes take effect only after power up or reset Proceed to Stepper Mode Phase and Tune p 115 or Servo Mode Phase and Tune p 131 as appropriate Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 7 3 PWM Input Servo Mode Only For more information see PWM Input Servo Mode Only p 29 5 7 3 1 Temco Lan PWM Command to open the PWM Command screen Ke Command Of xi Configuration Scaling 3000 rpm at100 duty cycle PvM Input Type GG 50 Duty Cycle C 100 Duty Cycle Options Invert PWM input Allow 100 output ol nvert Sion input 5 7 3 2 Set the input options described below Option Description Scaling Current mode output current at 100 duty cycle Range 0 to 10 000 000 A Default Peak Current value Velocity mode output velocity at 100 duty cycle Range 0 to 100 000 rpm mm sec Default Maximum Velocity value PWM Input One wire 50 or two wire 100 with direction Type Options Invert PWM input Inverts the PWM logic Allow 100 output Overrides the 100 command safety measure See Failsafe Protection from 0 or 100 Duty Cycle Commands p 29 Invert Sign Input In 100 duty cycle mode inverts the polarity of the directional input
94. e equipment damage injury or death For more information on faults see Faults p 37 5 6 10 3 To restore factory defaults if needed click Restore Defaults 5 6 10 4 Click OK to save fault configuration settings to amplifier RAM and close the Fault Configuration screen OR click Cancel to restore to previous values and close the screen 5 6 10 5 Mon the Main screen click Save to Flash Copley Controls Corp 109 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 7 Command Input Choose the appropriate step for the input format Input Format Step Digital Position Digital Position Input p 111 CAN CAN Interface p 112 PWM servo mode PWM Input p 113 only Analog Analog Command Input STX Servo Mode Only p 114 To run the amplifier with Command Input set to Software Programmed or Function Generator see the CME 2 User Guide To run the amplifier with Command Input set to Camming see the Copley Camming User s Guide 110 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 7 1 Digital Position Input For more information see Digital Position Inputs p 27 5 7 1 1 Dati postion mous Click Digital Position Inputs to open the Digital Position Input screen Configuration tab Digital Input ioj xi Control Input Increment Position on ot Rising Edge Pulse Up Pulse Down Falling Edge Quadrature Stepping Resolution 1 Input
95. e example below Trace Status Waiting for Trigger Note that excessive Gain can introduce more error as shown below Trace Status Waiting for Trigger Copley Controls Corp 183 Detent Compensation Gain Stepnet Panel Amplifier User Guide D 1 2 Detent Gain Tuning Without Encoder With no encoder the trace display shows actual voltage instead of actual position With most motors the ouput voltage changes are subtle In these cases audible noise provides the best reference for tuning D 1 2 1 Make sure that amplifier and motor have been set up in stepper mode and tuned Detent D 1 2 2 On the CME 2 Main screen click Detent astepnet Advanced Tuning 15 xi Trace Status Trace Canceled Ready To Start New Trace Detent Velocity 1000 m rpm Gain 0 L IT Auto Scale Lock Trace Time 25 ms be D 1 2 3 With Gain set to zero adjust velocity from zero until worst noise is heard Error may peak at a certain velocity and then decrease at higher velocities so it may be necessary to reduce velocity to return to the velocity where the greatest noise is heard The trace image below was seen when the noise was loudest Trace Status Reading trace data from amplifier D 1 2 2 A the velocity where the worst noise is heard adjust Gain to find lowest noise level Trace Status Reading trace data from amplifier 184 Copley Controls APPENDIX E ORDERING GUIDE AND ACCESSOR
96. e of the amplifier Auto Tune CME 2 provides a current loop Auto Tune feature which automatically determines optimal Cp and Ci values for the motor For more information see the CME 2 User Guide 20 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 4 3 Servo Velocity Mode and Velocity Loop Servo Velocity Loop Diagram As shown below the front end of the servo velocity loop is a limiting stage This accepts a velocity command applies limits and passes a limited velocity command to the summing junction The summing junction takes the limited velocity command subtracts the actual velocity represented by the feedback signal and produces an error signal This error signal is then processed using the integral and proportional gains to produce a current command Optional filters can be used to reduce the excitation of any resonance in the system They are available on both the input command and the output current demand but most typically used on the output only Velocity Loop Velocity Integral Gain Vi Limited Velocity Limiter i Filter Current Demand JN Velocity Demand Limits e Velocity e Acceleration Feedback Derived Velocity e Deceleration e Emergency Stop Deceleration Not used w hen velocity loop is controlled by position loop See Velocity Loop Limits for details Inputs In servo velocity mode the velocity command comes from exter
97. e sous svavsi ovousbeana sages sasecessoatsussancnveasacsaesteenvasiasasanoceys CME 2 Installation and Serial Port Setup ln EE Ee EE elei EE Amplifier Configuration c ceecccerseereeeereetreeeeeeeneeeneeenees Command Input sert et ces n ea E AE S aE EE Aaea E O EO inane chats eE TA EEE AEA E sh anduutw seu a EEE Copley Controls Corp 85 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 1 Warnings DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death DANGER Make connections with power OFF Do not make connections to motor or drive with power applied Failure to heed this warning can cause equipment damage WARNING Spinning motor with power off may damage amplifier Do not spin motors with power off Voltages generated by a motor can damage an amplifier Failure to heed this warning can cause equipment damage WARNING 86 Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 2 CME 2 Installation and Serial Port Setup 5 2 1 Requirements Computer Requirements Minimal hardware requirements e CPU Minimum 400 MHZ e RAM Minimum 128 MB Using the minimum requirements will allow CME 2 to run but performance will be significantly reduced Communication Requirements For serial communications e Atleast one standard RS 232 serial port or a USB port
98. ederesiaedvlyncvedees 6 6 Completion Steps Servo Mode Phase and Tune 7 1 Auto Phase Servo Mode 7 2 Current Loop 7 3 Velocity Loop erg 7 4 Position Loop 1 59 COMM PISTON SUS DS ee Ee EE de cet Using CME 2 Stepper or Servo Mode 8 1 CME 2 Overview 8 2 Manage Amplifier and Motor Data 8 3 Downloading Firmware 8 4 Control Panel GEN Ges SS SES SN ON SS T 9 5 Home FUNCHOMN 6 EE Table of Contents Stepnet Panel Amplifier User Guide A VT Time Limit Algorithm seau doom eda ceased oes nea ann tenant A 1 T Algorithm o ceccscsessesseesesseeseteeeseeees A2 T Scope Trace Variables STX Only Thermal Considerations ss sissssesssnissssesnnnennnneennnennnnennnnnnennsnnenensneeeessneeensneeeneneeeesnneneneeenne C 1 Operating Temperature and Cooling Configurations C 2 Heatsink Mounting Instructions Detent Compensation Gain Dale Detent Gain TUNNELS LES ET RU ke ee eege de Meda de Ordering Guide and Accessories E 1 Stepnet Panel STP Amplifier E 2 Stepnet Panel AC STX Amplifier E 3 Stepnet Module STM Amplifier E 4 Stepnet Micro Module STL Amplifier Copley Controls ABOUT THIS MANUAL Overview and Scope This manual describes the operation and installation of the Stepnet Panel STP and Stepnet Panel AC STX amplifiers manufactured by Copley Controls The material in this manual applies to the entire Stepnet amplifier family with the
99. edure for the configuration Configuration Procedure Stepper mode no encoder Auto Phase Stepper Mode No Encoder p 117 Stepper mode with encoder Auto Phase Procedure Stepper Mode with Encoder p 118 6 1 3 Auto Phase Stepper Mode No Encoder 6 1 3 1 Click Auto Phase to open the Auto Phase Motor Direction Setup screen x Motor Direction Setup Make sure the motor is free to move Move motor and observe direction Motor direction can be changed by clicking Invert Motor output check box Velocity 50 rpm Ready Acceleration 16 65 tps Deceleration 16 65 tps Move NEG Invert Motor Output Hi Cancel 6 1 3 2 Activate the Enable Input 61 33 Verify the Velocity Acceleration and Deceleration values 6 1 3 4 Hold down Move POS to move the motor in the direction considered positive and observe the direction of movement If the motor does not move see Trouble Shoot Motor Wiring Setup p 119 6 1 3 5 If the motor did not move in the direction that you wish to program as the positive direction click Invert Motor Output and repeat 6 1 3 4 6 1 3 6 Click OK to save the direction setting 6 1 3 7 Proceed to Current Loop p 122 Copley Controls Corp 117 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 1 4 Auto Phase Procedure Stepper Mode with Encoder 6 1 4 1 6 1 4 2 6 1 4 3 6 1 4 4 6 1 4 5 6 1 4 6 6 1 4 7 118 iz Click Auto Phase to open the Auto Phase Mot
100. ehavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warning can cause equipment damage injury or death DANGER Using CME 2 can affect or suspend amplifier operations Use of CME 2 to change amplifier parameters while operating the amplifier can affect operations in progress Using CME 2 to initiate motion can cause operations to suspend The operations may restart unexpectedly when the CME 2 move is stopped Failure to heed this warning can cause equipment damage injury or death DANGER Latching an output does not eliminate the risk of unexpected motion with non latched faults Associating a fault with a latched custom configured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without operator intervention In this case motion may re start unexpectedly For more information see Clearing Non Latched Faults p 37 Failure to heed this warning can cause equipment damage injury or death 6 Copley Controls Stepnet Panel Amplifier User Guide About this Manual WARNING Do not ground mains connected circuits With the exception of the ground pins on the STX connectors J1 and J2 all of the other circuits on these connectors are mains connected and must never be grounded Failure to heed this warning can cause equipment damage WARNING WARNING Do not plug or unplug connectors with power applied
101. elative Type Trap Copley Controls Corp 145 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 4 2 2 7 4 2 3 7 4 2 4 7 4 2 5 146 6 _sm Click Start The Profile Generator executes a short move NOTES 1 The profile may not reach constant velocity during a short move 2 If following error occurs open CME 2 Control Panel el and click Clear Faults Adjust position proportional gain Pp to minimize following error Note that too much position loop proportional gain Pp might cause oscillation 1 On the Gains tab set velocity feed forward Vff and acceleration feed forward Aff to zero 2 On the Profile tab click Start On the Gains tab adjust position loop proportional gain Pp until best result is obtained 3 Click Start after each adjustment to test the new value on a new profile move NOTE If a following error occurs open the CME 2 Control Panel el and click Clear Faults Adjust velocity feed forward Vff Velocity feed forward Vff reduces following error in the constant velocity portion of the profile Often a velocity feed forward Vff value of 16384 100 provides best results 1 Click in the Vff field and adjust the value 2 Click Start after each adjustment to test the new value on a new profile move Adjust acceleration feed forward Aff Acceleration feed forward Aff reduces following error during profile acceleration and deceleration 1 Click in the Aff
102. emperature switch group 2 May be programmed to other functions 11 Encoder B Input 12 Encoder B Input Differential primary incremental encoder inputs 13 Encoder A Input 14 Encoder A Input 15 Signal Ground Signal and 5 Vdc ground Stepnet Panel AC STX J6 Quad A B Incremental Encoder Wiring Diagram With Index When the index pulse is used as in most applications wire the connection as shown here ns mn Sense se Se E erte Typical Circuit Incremental Encoder Case Ground Copley Controls Corp 75 Wiring Stepnet Panel Amplifier User Guide Stepnet Panel AC STX J6 Quad A B Incremental Encoder Wiring Diagram No Index In applications where the encoder index pulse is not used wire the connector as shown here Amplifier Incremental Encoder Encoder Power J6 1 LErame Gnd M Sg Case Ground 76 Copley Controls Stepnet Panel Amplifier User Guide Wiring Stepnet Panel AC STX J6 Single Ended Encoder Wiring Diagram The Stepnet Gnd terminal on the feedback connector J6 1 should be connected to the users system common ground through the shortest path so that signals between the controller and the Stepnet are at the same common potential and to minimize noise The system common ground should in turn be connected to an earthing conductor by the shortest wire possible so that the whole system is referenced to earth Encoder Stepnet Panel AC STX J6 Mo
103. ems 184 Copley Controls Corp 181 Detent Compensation Gain Stepnet Panel Amplifier User Guide D 1 Detent Gain Tuning Some stepper motors are susceptible to detent noise The detent gain tuning feature can be used to reduce that noise The detent tuning process is different with an encoder than without With an encoder actual position is displayed in a trace and used as the primary tuning reference Without an encoder actual voltage is shown in the trace With some motors voltage changes can be subtle In these cases audible noise can be a better tuning reference D 1 1 Detent Gain Tuning With Encoder D 1 1 1 Make sure that amplifier and motor have been set up in stepper mode and tuned D11 2 See On the CME 2 Main screen click Detent CETTE Advanced Tuning Trace Status Trace Canceled Ready To Start New Trace 101 x Detent Velocity 1000 G rpm Gain 0 m F Auto Scale Lock Trace Time 25 ms hd Start D 1 1 3 With Gain set to 0 adjust the velocity from 0 rpm until the greatest error is seen Error may peak and then decrease at higher velocities so it may be necessary to reduce velocity to return to the velocity where the greatest error is seen Trace Status Reading trace data from amplifier 182 Copley Controls Stepnet Panel Amplifier User Guide Detent Compensation Gain D 1 1 4 At the velocity which exhibits the worst position error adjust Gain until position error is minimized Se
104. epper motor Using motor encoder feedback the amplifier can monitor actual motor position and velocity and correct its output so the motor follows the commanded input precisely The amplifier can be configured to accept current velocity or position commands Use of the amplifier in servo mode can result in quieter operation and reduced power consumption 1 1 2 Amplifier Power The main power input HV to the Stepnet Panel STP amplifier can range from 20 to 75 Vdc This power can be supplied by an inexpensive unregulated DC power supply An auxiliary power input allows the digital processor to stay active when the main HV supply has been removed Mains input voltage to the Stepnet Panel AC STX can range from 100 to 120 Vac or 200 to 240 Vac single phase at 50 to 60 Hz This allows Stepnet the ability to work in the widest possible range of industrial settings Model Continuous Peak Current Voltage Current STP 075 07 5A 7A 20 75 Vdc STP 075 10 10A 10A STX 115 07 5A ZA 100 120 Vac STX 230 07 5A 7TA 100 240 Vac 10 Copley Controls Stepnet Panel Amplifier User Guide Introduction 1 2 Amplifier Commissioning with CME 2 Amplifier commissioning is fast and simple using Copley Controls CME 2 software All of the operations needed to configure the amplifier are accessible through CME 2 CME 2 communicates with Stepnet via an RS 232 link or CAN The multi drop feature allows CME 2 to use a single
105. er Actual Current 2 3 2 Full Stepping Full stepping is a traditional and simple approach to driving a step motor The motor moves when the amplifier stops applying current to one phase and applies it to the other The amplifier can apply current to either of these two phases in either direction e positive current into phase A negative into phase A positive into B negative into B This allows the amplifier to make the motor come to rest in 4 distinct positions for each magnetic poll pair of the motor Step motors typically have 50 or 100 poll pairs This means a full stepping amplifier can make the motor come to rest at 200 or 400 distinct positions or steps These motors are often described as being 1 8 degree step or 0 9 degree step 360 degrees 200 steps gives 1 8 degrees step The Stepnet amplifier can be set to full stepping mode by the programming the microsteps rev value equal to the motors step rev value 16 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 3 3 Microstepping Through microstepping Stepnet amplifiers provide a much higher degree of control over a motor s position than does an amplifier that only supports full stepping The Stepnet amplifier can apply varying amounts of current into both phases of the motor at the same time making it possible to rest the motor not only at the full step locations but at points or microsteps between them and thus allow a high degree of cont
106. ertia and boost current stepper mode or peak current servo mode Min 0 Max Decel Maximum trajectory deceleration Max value may depend upon the load inertia and boost current stepper mode or peak current servo mode Min O disables limit Abort Deceleration rate used by the trajectory generator Brake Operation p 34 Decel when motion is aborted Min 0 disables limit Clear Sets Max Velocity Max Accel and Max Decel to Limits zero disabling the trajectory generator Set Restores Max Velocity Max Accel and Max Default Decel to calculated defaults Limits Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 2 1 3 Open the Position Loop Values tab icix Trajectory Values Position Loop Values Following Error Fault ol uSteps Warning 0 uSteps IT Disable Fault Tracking Window D pSteps Time D ms 6 2 1 4 Set the following Position Loop Values options as needed Option Description For More Information Following Error Fault The level in Steps at which the following Following Error Fault Details p 40 error produces a fault We recommend raising the fault level before tuning the loop Warning The level in Steps at which the following error produces a warning Disable Prevents following error from triggering a fault Fault Tracking Tracking Width of the tracking window in Steps Tracking Window Details p 41 Window Tra
107. ervo current mode or a velocity command in servo velocity mode The PWM input can be programmed for two formats 50 duty cycle one wire or 100 duty cycle two wire 50 Duty Cycle Format One Wire The input takes a PWM waveform of fixed frequency and variable duty cycle As shown below a 50 duty cycle produces zero output from the amplifier Increasing the duty cycle toward 100 commands a positive output decreasing the duty cycle commands a negative output a _ Decreasing Duty Cycle Increasing Duty Cycle 2 PWM Input 50 Duty Cycle Amplifier Output 0 Max The command can be inverted so that increased duty cycle commands negative 100 Duty Cycle Format Two Wire One input takes a PWM waveform of fixed frequency and variable duty cycle and the other input takes a DC level that controls the polarity of the output 0 duty cycle creates a zero command and a 100 duty cycle creates a maximum command level The command can be inverted so that increasing the duty cycle decreases the output and vice versa 100 Duty Cycle 0 Duty Cycle 100 Duty Cycle PWM Input Direction Input Amplifier Output 0 Min Failsafe Protection from 0 or 100 Duty Cycle Commands In both formats the amplifier can be programmed to interpret both O and 100 duty cycle as a zero command This provides a measure of safety in case of a controller failure or a cable break Copley Controls Cor
108. escribed below Control Description Enable Click to software enable the amplifier Disable Click to software disable the amplifier Set Zero Position Click to set the amplifier s actual position counter to zero Clear Faults Click to clear all amplifier faults and latched outputs Reset Click to reset the amplifier Risk of unexpected or uncontrolled motion Using the CME 2 Set Zero Position function while the amplifier is operating under CANopen control or other command sources could cause unexpected or uncontrolled motion Failure to heed this warning can cause equipment damage injury or death DANGER 162 Copley Controls Stepnet Panel Amplifier User Guide 8 4 5 Jog Mode Using CME 2 Jog mode provides a simple way to generate forward or reverse commands as described here 8 4 5 1 8 4 5 2 8 4 5 3 Copley Controls Corp To put the amplifier in jog mode set the Enable Jog option Set up a jog move by setting the following mode specific parameters Mode Parameter Description Current Current Current applied to the motor Limited by current loop Continuous Current servo Warning Unloaded motors may depending on torque setting ramp up in mode speed very quickly only Current Ramp The rate at which the current will increase and decrease Velocity Jog Speed Velocity of the jog move Limited by velocity loop Vel Limit servo mode only Position Velocit
109. field and adjust the value 2 Click Start after each adjustment to test the new value on a new profile move NOTE If after tuning the position loop the motor makes a low frequency audible noise while enabled but not moving the velocity loop gains Vp and Vi may be lowered to reduce the noise If the gain values are set too low the response to instantaneous rates of change might be reduced i e slow correction to disturbances or transients Try multiple sets of profiles representing typical moves that might be executed in the application Starting with Set up a trapezoidal profile repeat the process as needed Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Phase and Tune 7 4 3 Test S Curve Profile NOTE Skip this step unless the amplifier will perform S Curve profile moves Jerk is the rate of change of acceleration S Curve moves reduce jerk to provide a smooth profile To tune the level of jerk run an S Curve profile and adjust velocity acceleration deceleration and jerk levels until the desired profile is obtained Trace Status Ready w Profile Type Trap 5 curve 7 4 3 1 On the Profile tab click the S Curve button 7 4 3 2 Set up an S curve profile by adjusting the following options Set values that represent a typical move under normal operation Trajectory Limits Tab Maximum Velocity Maximum speed of the profile Maximum Acceleration Maximum acceleration deceleration
110. fier motor pair by copying configuration files that were prepared for the amplifier motor combination 8 2 4 1 Make sure the amplifier is connected to the PC serial port Lee 8 2 4 2 ES Start CME 2 by double clicking the CME 2 desktop shortcut icon 8 2 4 3 8 2 4 4 8 2 4 5 8 2 4 6 8 2 4 7 8 2 4 8 CME 2 5 1Beta13 STM 075 07 Step Net 1A lol x Fie Amplifier Tools Help ye OR S aie EX Copley Neighborhood CAN Network Address 1 State Pre operational 5 Virtual Amplifier n ETES Input Output CVM Control Program CAN Configuration P Loop h V Loop Configure Faults Rotary Motor Amp Software Disabled F12 To Disable Ki On the Main screen click Restore amplifier data from disk When prompted navigate to the folder containing the appropriate ccx file Highlight the file name and then click Open to load the file data into amplifier RAM E On the Main screen click Save to Flash If you do not need to load a CVM Control Program skip to Step 8 2 4 7 To load a CVM Control Program choose File gt Restore CVM Control Program When prompted navigate to the folder containing the appropriate ccp file Highlight the file name and then click Open to load the file data into flash memory This step also results in the setting of the Indexer 2 Program option Enable Control Program on Startup This configures the program to auto start when the amplifier is powered up or reset If you do not need
111. ft of the trace NOTE For information on the alternate Auto Tune feature see the CME 2 User Guide 6 3 2 1 Click the Scope Tool Apply To Current 6 3 2 2 Choose Current from the Function Generator Apply To list e On the Settings tab make sure Auto Setup is selected Auto Setup automatically sets the following parameters Function Generator Tab Function Square Wave Amplitude 50 of current loop Run Current setting Frequency 100 Hz Amplitude Offset 10 percent of current loop Run Current setting Settings Tab Channel 1 Commanded Current green Channel 2 Actual current white 6 3 2 3 SE iil Verify that the Amplitude value is not excessive for the motor 6 3 2 4 Click Start 6 3 2 5 On the Gains tab adjust current loop proportional gain Cp 1 Set current loop integral gain Ci to zero 2 Raise or lower Cp until desired step response is obtained Typically this means little or no overshoot with a 100 Hz square wave at 50 percent of Run Current If the Cp value is too large ringing may occur If the Cp value is too low bandwidth decreases Make sure gain values don t produce excessive ring TIP r To change a value highlight the value Then enter value directly use mouse and arrow controls OR use Page Up Page Down keys to move in increments of 10 Copley Controls Corp 123 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 3 2 6 Adjust current loop i
112. gured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without operator intervention In this case motion may re start DANGER unexpectedly Failure to heed this warning can cause equipment damage injury or death Click OK to save changes to volatile memory and close the Custom Output Configuration screen Copley Controls Corp 105 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 6 6 Custom Digital Output Settings Custom Trajectory Status Any of the amplifier s digital outputs can be programmed to respond to a combination of amplifier trajectory status conditions The output goes active when one or more of the conditions is met 5 6 6 1 5 6 6 2 5 6 6 3 5 6 6 4 106 OUT2 ARE Eee eet Hi Configure Custom Choose Custom Trajectory Status for an output and then click Configure Custom to open the Trajectory Status Configuration screen aoo o IT Homing Error IT Referenced Homed F Homing In Progress F Move Aborted IT Trajectory Generator Running PF Camming Buffer Error C Output Active High Output Active Low i Cancel Select one or more trajectory status conditions described below Multiple functions are OR ed together so any status match activates the output Trajectory Status Functions Status Description Homing Error Activate output if an error occurred in the last homi
113. h The HV power supply should be connected to the system common ground only at the Stepnet power connector In this way voltage drops across the power conductors due to high motor currents will not appear at the Stepnet ground but at the HV power supply negative terminal where they will have less effect Connection to the case is provided on the Chassis Ground terminal of the power connector J1 1 This terminal should connect to the system chassis ground keeping the wire as short as possible 58 Copley Controls Stepnet Panel Amplifier User Guide Wiring This maximizes the shielding effect of the case and provides a path to ground for noise currents that may occur in the cable shields Stepnet Panel STP Shielding It is recommended that connections to the Stepnet motor power and signal connectors be made using shielded cables Shields on cables reduce emissions from the amplifier and help protect internal circuits from interference due to external sources of electrical noise The shields shown in the wiring diagrams are also required for CE compliance Cable shields should be tied to earth or system ground Provisions are made on each Stepnet connector for connecting the shield to the chassis ground of the Stepnet which in turn is connected to the system ground 4 1 2 Stepnet Panel STP Connector Locations Connector locations are shown below J3 Signal J2 Motor J4 RS 232 gt E J5 CAN J6
114. he integral and proportional gains to produce a command This command is then applied to the amplifiers power stage Current Loop Current Integral Gain Ci Command ne I Current Demand gt Current Limiter Limited Current Current Proportional Gain Cp Current Offset gt fs Limits Feedback Actual Current e Peak Current e Continuous Current e Peak Current Limit Time Inputs In servo current mode the current command comes from external sources such as the amplifier s PWM inputs or internal sources such as a Copley Virtual Machine CVM program See PWM Input Servo Mode Only p 29 In servo velocity or position modes the current command is generated by the velocity loop Offset The servo current loop offset is intended for use in applications where there is a constant force applied to or required of the motor and the system must control this force Typical applications would be a vertical axis holding against gravity or web tensioning This offset value is summed with the current command before the limiting stage Limits The current command is limited based on the following parameters Limiter Description Peak Current Limit Maximum current that can be generated by the amplifier for a short duration of time This value cannot exceed the peak current rating of the amplifier Continuous Current Maximum current that can be constantly generated b
115. he output current to the Continuous Current Limit When current limiting is active the output current will be equal to the Continuous Current Limit if the commanded current is greater than the Continuous Current Limit If instead the commanded current is less than or equal to the Continuous Current Limit the output current will be equal to the commanded current 168 Copley Controls Stepnet Panel Amplifier User Guide IT Time Limit Algorithm A 1 3 IT Current Limit Algorithm Application Example IT Example Parameters Operation of the l T current limit algorithm is best understood through an example For this example a motor with the following characteristics is used e Peak Current Limit 12 A e PT Time Limit 1 S e Continuous Current Limit 6 A From this information the TT setpoint is PT setpoint 12 A 6 A 1 S 108 AS See the example plot diagrams on the next page Copley Controls Corp 169 IT Time Limit Algorithm Stepnet Panel Amplifier User Guide Ur Example Plot Diagrams The plots that follow show the response of an amplifier configured w PT setpoint 108 A S toa given current command For this example DC output currents are shown in order to simplify the waveforms The algorithm essentially calculates the RMS value of the output current and thus operates the same way regardless of the output current frequency and wave shape T current limit _commanded _actual Current A
116. here is one exception if a non latched following error occurs in position mode then the amplifier goes into velocity mode and the Fast Stop Ramp is used For more information see Following Error Fault Details p 40 Copley Controls Corp 21 Operational Theory Stepnet Panel Amplifier User Guide Diagram Effects of Limits on Velocity Command The following diagram illustrates the effects of the servo velocity loop limits Limited Velocity Commanded Velocity e Vel Limit A I Gesn l Accel Limit Fr Decel Limit gt Servo Velocity Loop Gains The servo velocity loop uses these gains Gain Description Vp Velocity loop proportional The velocity error the difference between the actual and the limited commanded velocity is multiplied by this gain The primary effect of this gain is to increase bandwidth or decrease the step response time as the gain is increased Vi Velocity loop integral The integral of the velocity error is multiplied by this value Integral gain reduces the velocity error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the velocity error value over time Servo Velocity Gains Shift The Velocity Gains Shift feature adjusts the resolution of the units used to express Vp and Vi providing more precise tuning If the non scaled value of Vp or Vi i
117. high input voltage gt 2 45 Vdc General purpose input 12 Type 74HC14 Schmitt trigger w RC filter RC time constant 500uSec 5 kQ resistor pull up to internal 5 Vdc Input voltage range 0 V 24 Vdc Logic low input voltage lt 1 35 Vdc Logic high input voltage gt 3 65 Vdc 48 Copley Controls Stepnet Panel Amplifier User Guide Specifications 3 9 Digital Outputs Channels 4 Type STP 1 4 Current sinking MOSFET open drain with 1 kQ pullup to internal 5 Vdc STX 1 3 through diode STX 4 Brake Opto isolated current sinking MOSFET with flyback diode to 24Vdc Maximum voltage 30 Vdc Low level output resistance lt 0 10 Function Programmable Maximum sink current STP 1 4 STX 1 3 STX 4 1A Total current of outputs 1 4 not to exceed 2A 1A Total current of outputs 1 3 not to exceed 1A 1A 3 10 Encoder Power Supply Output Voltage output 5 Vdc 5 Maximum current output 250 mA Short circuit protection STX only Fold back current limiting Note collapsing this supply will put the amplifier in a fault condition Function Provides power for motor encoder Copley Controls Corp 49 Specifications Stepnet Panel Amplifier User Guide 3 11 Incremental Quadrature Encoder Inputs 3 11 1 Incremental Differential Encoder Inputs Channels 3 Type Differential RS 42
118. i drain modifies the effect of velocity loop integral gain The higher the Vi Drain value integral the faster the integral sum is lowered Range 0 to 32 000 Default 0 bleed Command For more information see the CME 2 User Guide Filter Output Filter Copley Controls Corp 139 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 3 2 Manually Tune the Velocity Loop To tune the velocity loop apply square wave excitation to the velocity loop and adjust velocity loop proportional gain Vp and velocity loop integral gain Vi to obtain a desired waveform Trace Status Trace Canceled Ready To Start New Trace NOTE During tuning observe any warnings that appear to the left of the trace 7 3 2 1 Click the Scope Tool to open the Oscilloscope window T f locit 7 3 2 2 S Choose Velocity from the Function Generator Apply To list ee On the Settings tab make sure Auto Setup is selected Auto Setup automatically sets the following parameters Function Tab Function Square Wave Amplitude 10 velocity loop Vel Limit setting Frequency 5 Hz Settings Tab Channel 1 Limited velocity green Channel 2 Actual motor velocity white Amplitude l 200 rpm 7 3 2 3 7 3 2 4 _sm Click Start 7 3 2 5 On the Gains tab adjust velocity loop proportional gain Vp 1 Set velocity loop integral gain Vi to zero Verify that the Amplitude value is not exce
119. ial Ports screen xi Configure Serial Ports Select one or more serial ports from the list then selectthe baud rate Selected Ports COMS Baud Rate fi 15200 z lt Back 5 2 5 6 Configure the selected ports 1 Highlight a port in the Selected Devices list 2 Choose a Baud Rate for that port 3 Repeat for each selected port Cancel 5 2 5 7 Click Finish to save the choices Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 0 5 3 1 5 3 1 1 5 3 1 2 5 3 1 3 5 3 1 4 Prerequisites Hardware and Equipment Verify that all power is OFF Verify wiring to all amplifier connectors Secure the motor 1 Make sure motor is securely fastened 2 Make sure that no load is connected to the motor STP Apply Aux voltage if available If the Aux supply is not wired verify that the amplifier enable input IN1 is in the disabled state and then apply HV power The factory default setting for the enable input is open or pulled high for disable STX Apply 24 V only Risk of unexpected or uncontrolled motion CME 2 can be used while the amplifier is under other control sources such as CANopen and DeviceNet However some changes made with CME 2 could cause unexpected or uncontrolled motion Failure to heed this warning can cause equipment damage injury or death DANGER Copley Controls Corp 91 Mode Selection and General Setup Stepnet Panel Amplifier User Guid
120. ier model and configuration Pele Hi Lo state of output Digital Inputs 1 5 Digital Inputs 6 12 Digital Outputs e H Grey light Output is not active IOUT 11 FETE Lo lt 4 OUT2 Not Configured ji Hi a OUT3 Not Configured he Hi a Gontigure Custom Red light Output is active OUT4 Brake Active High e D Hold position when limit switch is active Restore Defaults Close 5 6 4 2 Choose any of these functions for any output OUT4 is recommended for brake function Output Function Description For More Information Not Configured No function assigned Output remains high Fault Active High Output goes high when one or Faults p 37 more faults are detected Fault Active Low Output goes low when one or more faults are detected Brake Active High Output goes high to activate the Brake Operation p 34 brake Brake Active Low Output goes low to activate the brake PWM Sync Output The PWM synchronization output OUT1 only Custom Event See Custom Digital Output Settings Custom Event p 104 Custom Trajectory See Custom Digital Output Settings Custom Trajectory Status p Status 106 Custom Position See Custom Digital Output Settings Position Triggered Output p Triggered Output 107 Program Control Output state controlled by CVM or external program Active High Program Control Output state controlled by CVM or external prog
121. imit switches will no longer function Failure to heed this warning can cause equipment damage Copley Controls Corp 33 Operational Theory Stepnet Panel Amplifier User Guide 2 8 Brake Operation 2 8 1 Digital Output Controls Brake Many control systems employ a brake to hold the axis when the amplifier is disabled Any of the digital outputs can be programmed for brake control 2 8 2 Event and Mode Specific Brake Stop Sequences Braking sequences vary depending on the amplifiers operating mode In current mode disabling the amplifier activates the brake output and disables the amplifier output stages immediately In position or velocity mode a hardware or software disable starts a sequence of events e The motor begins to decelerate at Abort Deceleration rate in position mode or Fast Stop Ramp rate in velocity mode At the same time the Brake Stop Delay Time count begins e When the motor slows to Brake Stop Activation Velocity OR the Brake Stop Delay Time expires the brake output activates and PWM Delay Brake Stop Response Time count begins e When response time has passed the amplifiers output stages are disabled 2 8 3 Brake Settings As shown below the brake settings available in position and velocity mode provide control over the braking sequence Enable Input Brake Stop delay time Se U Speed H SR Brake Stop activation velocity D U Drake Ouptput Enable he PVM delay Power Section Brake Stop
122. ipment damage injury or death Clearing Latched Faults A latched fault is cleared only after the fault has been corrected and at least one of the following actions has been taken e power cycle the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel El and press Clear Faults or Reset e clear the fault over the CANopen network Example Non Latched vs Latched Faults For example the amplifier temperature reaches the fault temperature level and the amplifier reports the fault and disables the PWM output Then the amplifier temperature is brought back into operating range If the Amplifier Over Temperature fault is not latched the fault is automatically cleared and the amplifiers PWM outputs are enabled If the fault is latched the fault remains active and the amplifiers PWM outputs remain disabled until the faults are specifically cleared as described above Copley Controls Corp 37 Operational Theory Stepnet Panel Amplifier User Guide Fault Descriptions The set of possible faults is described below For details on limits and ranges see Fault Levels p 52 Fault Description Fault Occurs When Fault is Corrected When Amplifier Over Temperature Amplifier s internal temperature exceeds Temperature falls below specified specified temperature temperature Motor
123. is Failure to heed this warning can cause equipment damage injury or death 2 6 1 CAN Network and CANopen Profiles for Motion In servo or stepper position mode the amplifier can take instruction over a two wire Controller Area Network CAN CAN specifies the data link and physical connection layers of a fast reliable network CANopen is a set of profiles specifications built on a subset of the CAN application layer protocol These profiles specify how various types of devices including motion control devices can use the CAN network in a highly efficient manner Stepnet supports the relevant CANopen profiles allowing it to operate in the following modes of operation profile torque profile velocity profile position interpolated position and homing 2 6 2 Supported CANopen Modes In profile torque mode the amplifier is programmed with a torque command When the amplifier is enabled or the torque command is changed the motor torque ramps to the new value at a programmable rate When the amplifier is halted the torque ramps down at the same rate In profile velocity mode the amplifier is programmed with a velocity a direction and acceleration and deceleration rates When the amplifier is enabled the motor accelerates to the set velocity and continues at that speed When the amplifier is halted the velocity decelerates to zero In profile position mode the amplifier is programmed with a velocity a relative distance or ab
124. ital Output Settings Custom Event p 104 The amplifier stops driving motion in the direction of an active limit switch with the mode dependent and configurable variations described below Mode Response to Active Limit Switch Servo Amplifier stops driving motion in the direction of the active limit switch The amplifier will drive motion Current in the opposite direction if commanded Servo Velocity Stepper Responses depend on the setting of Hold position when limit switch is active p 101 rai Hold Position not set The amplifier aborts the trajectory in progress and stops the axis using reverse current only at the Abort Deceleration rate After the axis has stopped the amplifier will not drive current in the direction of the activated limit switch In any command mode other then a digital input mode the amplifier will respond to commands in the opposite direction If in digital input mode the amplifier must be disabled and re enabled to command motion in the opposite direction Hold Position set The amplifier aborts the trajectory in progress and stops the axis at the Abort Deceleration rate After the axis stops the amplifier servos to hold that position The amplifier will respond to commands in the opposite direction WARNING WARNING Limit switches may be disabled If the amplifier is switched back to current or velocity mode with Hold position when limit switch is active p 101 set the l
125. k current in current mode or maximum velocity in velocity mode increasing the resolution of control Dead Band To protect against unintended response to low level line noise or interference the amplifier can be programmed with a dead band to condition the response to the input signal voltage The amplifier treats anything within the dead band ranges as zero and subtracts the dead band value from all other values For instance with a dead band of 100 mV the amplifier ignores signals between 100 mV and 100 mV and treats 101 mV as 1 mV 200 mV as 100 mV and so on Copley Controls Corp 25 Operational Theory Stepnet Panel Amplifier User Guide Dead Band Output 100 200 200 100 0 100 200 Input Offset To remove the effects of voltage offsets between the controller and the amplifier in open loop systems CME 2 provides an Offset parameter and a Measure function The Measure function takes 10 readings of the analog input voltage over a period of approximately 200 ms averages the readings and then displays the results The Offset parameter allows the user to enter a corrective offset to be applied to the input voltage The offset can also set up the amplifier for bi directional operation from a uni polar input voltage An example of this would be a 0 to 10 Vdc velocity command that had to control 1000 rpm CCW to 1000 rpm CW Scale would be set to 2000 rpm for a 10 Vdc input and Offset set to 5V After this
126. k signals When a fault in any of the differential pairs is detected a feedback error occurs To enable or disable this protection see Enter Motor Feedback Brake Settings Manually p 96 In applications where Encoder Loss Detection is enabled and the encoder does not have an index channel or the index channel is not wired to the amplifier the amplifier s index channel connector pins must be jumpered as shown in Stepnet Panel AC STX J6 Quad A B Incremental Encoder Wiring Diagram No Index p 76 38 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 11 Position and Servo Velocity Errors 2 11 1 Error Handling Methods In stepper mode with encoder or servo position mode any difference between the limited position output of the trajectory generator and the actual motor position is a position error The servo or stepper position loop uses complementary methods for handling position errors following error fault following error warning and a position tracking window Likewise in servo velocity or servo position mode any difference between the limited velocity command and actual velocity is a velocity error The servo velocity loop uses a velocity tracking window method to handle velocity errors There is no velocity error fault 2 11 2 Following Error Faults When the position error reaches the programmed fault threshold the amplifier immediately faults The following error fault can be disabled For
127. l STP J5 and J6 Pin Description Pin Signal Function 1 CAN_H CAN_H bus line dominant high 2 CAN L CAN_L bus line dominant low 3 CAN_Gnd Ground 0 V V 4 Pass though to second connector no internal connection 5 Pass though to second connector no internal connection 6 CAN_SHLD Pass though to second connector no internal connection 7 CAN_Gnd Ground 0 V V 8 CAN V Pass through to second connector no internal connection Stepnet Panel STP CAN Bus Wiring Diagram Amplifier CAN CAN Network Opto isolation CAN Gnd CAN Network Note 1 If this is the last amplifier on the network use Copley Terminator Plug PN STP NT to terminate the bus Copley Controls Corp Wiring 65 Wiring Stepnet Panel Amplifier User Guide 4 1 7 Stepnet Panel STP RS 232 Serial Communications J4 Stepnet Panel STP J4 Mating Connector 6 position modular connector RJ 11 style Copley Controls provides a prefabricated cable and modular to 9 pin sub D adapter in RS 232 Serial Cable Kit PN SER CK A diagram of the female connector is shown below 0 0 00 1 2 3 4 5 6 Stepnet Panel STP J4 Pin Description Pin Signal Function 1 N C No connection 2 RxD Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply ground 5 TxD Transmit data output to computer 6 N C No connection Stepnet Panel ST
128. ld current levels in stepper mode or by using servo mode it is often possible to use a smaller power supply then would normally be required Operation from regulated switching power supplies is possible if a diode is placed between the power supply and amplifier to prevent regenerative energy from reaching the output of the supply If this is done there must be external capacitance between the diode and the amplifier 2 1 2 Stepnet Panel STP Auxiliary Power Stepnet has an Auxiliary Power input which can keep the amplifier communications and feedback circuits active when the PWM output stage has been disabled by removing the main HV supply This can occur during EMO Emergency Off conditions where the HV supply must be removed from the amplifier to ensure operator safety The Auxiliary Power input operates from any DC voltage that is within the operating voltage range of the amplifier The higher of the two voltages HV or Auxiliary will power the DC DC converter that supplies operating voltages to the amplifier DSP and control circuits As long as the HV voltage is greater than the auxiliary power voltage it will power the DC DC converter and the auxiliary power input will draw no current Connection of an Auxiliary power supply is optional 14 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 2 Amplifier Power Stepnet Panel AC STX Power distribution within the Stepnet Panel AC STX is divided into three
129. ltage and current in a 45 C ambient environment Maximum Ambient Temperature vs Current Output 50 L te EE ECH Sa e 40 SSC Ber Le 5 3 2 X e 0 2 4 6 8 10 Output Current Arms Thermal Resistance Stepnet Panel STP Configuration Thermal Resistance No Heat Sink Convection Cooled 2 8 C W No Heat Sink Fan Cooled 100 LFM minimum 1 3 C W With Heat Sink Fan Cooled 100 LFM minimum 0 8 C W With Heat Sink Fan Cooled 200 LFM minimum 0 6 C W Copley Controls Corp 175 Thermal Considerations Stepnet Panel Amplifier User Guide C 1 2 Stepnet Panel AC STX Power Dissipation Stepnet Panel AC STX The following chart shows the internal power dissipation for of the Stepnet Panel AC STX amplifiers versus output current levels at different HV voltages The output current is calculated from the motion profile motor and load conditions The values on the chart represent the rms root mean square current that the amplifier would provide during operation Drive Power Dissipation vs Output Current 45 40 Vi to an aa e STM 115 07 ad se STX 230 07 No a Power Disipation W 20 15 a es ae 0 _ o Output Current Arms 176 Copley Controls Stepnet Panel Amplifier User Guide Thermal Considerations Max Ambient Temperature vs Current Output Stepnet Panel AC STX 120 The following chart shows the maximum allowable
130. lti drop feature allows CME 2 or other ASCII serial controller to use an RS 232 serial connection to one amplifier as a gateway to other amplifiers linked together by CAN bus connections The Stepnet can also be controlled by a Copley Virtual Machine CVM program running on the amplifier Stepnet amplifiers can be networked with Copley Accelnet and Xenus digital servo amplifiers When operating as a stand alone amplifier Stepnet can accept incremental position commands from step motor controllers in Pulse and Direction or Count Up Count Down formats as well as A B quadrature commands from a master encoder Pulse to motor position ratio is programmable for electronic gearing In servo mode Stepnet can also accept PWM torque or velocity commands The amplifier features 12 programmable digital inputs and four programmable digital outputs The Stepnet amplifier is ROHS compliant 1 1 1 Stepper and Servo Modes Stepper Mode In stepper mode the amplifier operates as a traditional open position loop stepper amplifier With the addition of optional encoder feedback in stepper mode the amplifier can monitor and report actual motor position and optionally apply a proportional gain to correct following error Also a position tracking window can be set up along with a programmable following error warning and fault Servo Mode In servo mode with motor encoder feedback the amplifier operates as a true closed loop servo amplifier controlling a st
131. manded Motor Phase Angle The software will now micro step the motor in 150 80 a5 the negative direciton Make sure the motor is free to move Press Start when ready 150 30 480 e o Auto Phase Current 117 A 210 aan 240 37 300 Increment Rate 90 elec deg s Actual Motor Position D counts Stop Read Configuration Settings cacy counts per rev 4000 Poles 4 lt Back Skip gt Cancel Click Start to begin the Phase Count Test Observe status messages See the prompt x i Observe motor motion and verify that it moves 1 full turn before any gearing When you are ready to observe motion click OK See the prompt Phase Counts xj K Did motor move 1 full turn If motor did not turn 1 full turn click No and verify that in the Motor Feedback screen the following parameters have been set correctly Number of Poles for rotary motors Magnetic Pole Pair Length for linear motors Encoder Lines or Fundamental Lines for rotary encoders Encoder Resolution for linear encoders Copley Controls Stepnet Panel Amplifier User Guide 7 1 3 10 7 1 3 11 7 1 3 12 7 1 3 13 7 1 3 14 Servo Mode Phase and Tune If motor turned 1 full turn click Yes Click Next to open the Motor Phase Initialize screen x Motor Phase Initialize The amplifier will perform phase intialization Make sure the motor is free to move Press Initialize Phase when ready lt Back Finish Cancel Click I
132. mplifier RS232 Circuit J4 Serial d Auxillary 7 V Power Supply DC DC FX Converter uo optional 7 Se BEA Power VO f l j t Controller FN Circuit Ek 4 AUX m HV KA m DC t n GND V es Ne of Fa at 7 Power Supply T Y a j S 7 ga J Encoder TIT El 7 ig ee ot ed Y Ka A x T 5V 9 LT y 250 ma J3 Signal i ti l Connections to system ground should e V PR FR N be kept as short as possible J L E Pay Sle Cl Motor inverter VU VI j J5 amp J6 CAN i j l Y Ny Isolation Barrier T 8 Y a e CAN Bus T J2 Motor 7 CAN Network Transceiver As shown above power and control circuits in the Stepnet share a common circuit ground Digital inputs are referenced to this common circuit ground as are the digital outputs encoder inputs and serial communications port The CAN ports are electrically isolated from this common circuit ground The Stepnet case Chassis Ground is also isolated from any of the internal circuits The Stepnet Gnd terminal on the power connector J1 4 should be connected to the users system common ground through the shortest path so that signals between the controller and the Stepnet are at the same common potential and to minimize noise The system common ground should in turn be connected to an earthing conductor by the shortest wire possible so that the whole system is referenced to eart
133. n STP models the thermal interface between the amplifier and heat sink is a phase change material pad On STX models the thermal interface is a dry film interface pad G24 G22 C 2 3 C 2 4 STX Remove the blue protective sheet from one side of the pad Place the phase change material on the amplifier taking care to center the pad holes over the holes in the amplifier Remove the clear protective sheet from the pad Clear Protective Sheet Discard Dry Film Interface Pad Blue Protective Sheet Discard STP Place the phase change material STP on the amplifier taking care to center the pad holes over the holes in the amplifier STP and STX Mount the heatsink onto the amplifier taking care to see that the holes in the heatsink phase change material or interface pad and amplifier all line up STP and STX Install and torque the four 6 32 mounting screws to 8 10 Ib in 0 9 1 13 Nm STP diagram shown here Copley Controls Corp 179 Thermal Considerations Stepnet Panel Amplifier User Guide 180 Copley Controls APPENDIX D DETENT COMPENSATION GAIN This chapter describes the detent compensation gain feature that can be used in stepper mode to reduce detent noise D 1 Detent Gain Tuning S EE EE canoe setae eae eme ln due eta penne aa 182 D 1 1 Detent Gain Tuning With Encoder seems 182 D 1 2 Detent Gain Tuning Without Encoder se
134. n attributes Loop Attribute Description Command input Every loop is given a value to which it will attempt to control For example the velocity loop receives a velocity command that is the desired motor speed Limits Limits are set on each loop to protect the motor and or mechanical system Feedback The nature of servo control loops is that they receive feedback from the device they are controlling For example the position loop uses the actual motor position as feedback Gains These are constant values that are used in the mathematical equation of the servo loop The values of these gains can be adjusted during amplifier setup to improve the loop performance Adjusting these values is often referred to as tuning the loop Output The loop generates a control signal This signal can be used as the command signal to another control loop or the input to a power amplifier 18 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 4 2 Servo Current Mode and Current Loop Servo Current Loop Diagram As shown below the front end of the servo current loop is a limiting stage The limiting stage accepts a current command applies limits and passes a limited current command to the summing junction The summing junction takes the commanded current subtracts the actual current represented by the feedback signal and produces an error signal This error signal is then processed using t
135. nal sources such as the amplifier s PWM inputs or internal sources such as a Copley Virtual Machine CVM program See PWM Input Servo Mode Only p 29 In servo position mode the velocity command is generated by the position loop Servo Velocity Loop Limits The velocity command is limited based on the following set of parameters designed to protect the motor and or the mechanical system Limiter Description Velocity Limit Sets the maximum velocity command input to the servo velocity loop Acceleration Limit Limits the maximum acceleration rate of the commanded velocity input to the servo velocity loop This limit is used in servo velocity mode only In servo position mode the trajectory generator handles acceleration limiting Deceleration Limit Limits the maximum deceleration rate of the commanded velocity input to the servo velocity loop This limit is used in servo velocity mode only In servo position mode the trajectory generator handles deceleration limiting Fast Stop Ramp Specifies the deceleration rate used by the servo velocity loop when the amplifier is hardware disabled Fast stop ramp is not used when amplifier is software disabled If the brake output is active the fast stop ramp is used to decelerate the motor before applying the brake Note that Fast Stop Ramp is used only in servo velocity mode In servo position mode the trajectory generator handles controlled stopping of the motor T
136. ndow 597 rpm Time 100 ms Close 7 3 1 1 Enter the following options as needed Option Description Velocity Limit Top speed limit Max value may depend upon the back EMF amp the Encoder resolution Min value 0 Acceleration Maximum acceleration rate Max value may depend upon load inertia amp peak current Limit Min value 1 Does not apply in position mode Deceleration Maximum deceleration rate Max value may depend upon load inertia amp peak current Limit Min value 1 Does not apply in position mode Tracking Width of the tracking window in rpm or mm s for linear Window Tracking Position must remain in the tracking window for this amount of time to be considered Time tracking Vp Velocity loop proportional gain Range 0 to 32 767 Vi Velocity loop integral gain Range 0 to 32 767 Fast Stop Deceleration rate used by the velocity loop when the amplifier is hardware disabled Ramp Range 0 to 100 000 000 Default velocity loop Decel Limit value For more information see Servo Velocity Loop Limits p 21 Low Gains Increases the resolution of the units used to express Vp and Vi providing more precise Shift tuning For more information see Servo Velocity Gains Shift p 22 High Gains Decreases the resolution of the units used to express Vp and Vi providing more precise Shift tuning For more information see Servo Velocity Gains Shift p 22 Vi Drain V
137. nel Amplifier User Guide Servo Mode Phase and Tune 7 2 2 Manually Tune Current Loop To tune the current loop apply square wave excitation to the current loop and adjust current loop proportional gain Cp and current loop integral gain Ci to obtain a desired waveform Trace Status Reading trace data from amplifier M Ap Aw y din y AA Vidala An NOTE During tuning observe any warnings that appear to the left of the trace and take appropriate action NOTE For information on the alternate Auto Tune feature see the CME 2 User Guide 7 2 2 1 Click the Scope Tool to open the Oscilloscope window Apply To Current 7 2 2 2 Choose Current from the Function Generator Apply To list a On the Settings tab make sure Auto Setup is selected Auto Setup automatically sets the following parameters Function Generator Tab Function Square Wave Amplitude 10 of current loop Continuous Current Limit setting Frequency 100 Hz Settings Tab Channel 1 Commanded Current green Channel 2 Actual current white d 0 47 3 o 7 2 2 3 ae S Verify that the Amplitude value is not excessive for the motor 7 2 2 4 Click Start 7 2 2 5 On the Gains tab adjust current loop proportional gain Cp 1 Set current loop integral gain Ci to zero 2 Raise or lower Cp until desired step response is obtained Typically this means little or no overshoot with a 100 Hz low cu
138. ng attempt Referenced Homed Activate output if the most recent homing attempt was successful Homing in Progress Activate output when a homing move is in progress Move Aborted Activate output if move is aborted Trajectory Generator Activate output while trajectory generator is generating a move Running Camming Buffer Error A camming buffer error has occurred Choose Output Active High to have the output go high when active or Output Active Low to have the output go low when active Click OK to save changes to volatile memory and close the screen Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 6 7 Custom Digital Output Settings Position Triggered Output Any of the amplifier s digital outputs can be programmed to respond in certain ways to the position of the controlled axis The output goes active when the axis position meets the specified criteria OUT2 Custom Position Triggered Output Hi Configure Custom 5 6 7 1 5 6 7 2 Choose Custom Position Triggered Output for an output and then click Configure Custom to open the n Position Configuration screen Position Triggered Output x Configuration In Position Window Trigger At Position Trigger Positive Motion Trigger Negative Motion C Output Active High Output Active Low Upper Position 0 counts Lower Position 0 counts Use Actual Position C Use Limited Position Cancel 5 6 7
139. ng error When any fault occurs with the exception of a following error the amplifier s PWM output stage is disabled the fault type is recorded in the amplifier s internal error log which can be viewed with CME 2 and the status LED changes to indicate a fault condition exists A digital output can also be programmed to activate on a fault condition The following error fault behaves with slight differences as described in Following Error Fault Details p 40 The amplifiers PWM output stage can be re enabled after the fault condition is corrected and the amplifier faults are cleared The process for clearing faults varies depending on whether the fault is configured as non latched or latched The fault clearing descriptions below apply to all faults except for the following error fault which is described in Following Error Fault Details p 40 Clearing Non Latched Faults The amplifier clears a non latched fault without operator intervention as soon as the fault condition is corrected Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against DANGER unexpected motion Failure to heed this warning can cause equ
140. nitialize Phase The screen will display completion messages Test Complete Phasing has been initialized Click Finish to close the screen and save values to amplifier flash If the Auto Phase algorithm does not produce desired results try adjusting the Auto phase Current and Increment Rate values 7 1 4 Trouble Shoot Motor Direction Setup If motor direction setup step failed 7 1 4 1 7 1 4 2 If an encoder is used check Encoder power and signals Check shielding for proper grounding 7 1 5 Trouble Shoot Motor Wiring Setup If motor wiring setup step failed 7 1 5 1 7 1 5 2 7 1 5 3 7 1 5 4 7 1 5 5 Copley Controls Corp Verify that amplifier is disabled Check for mechanical jamming Check for good connections to the motor power wires Disconnect motor power wires Measure for proper motor resistance 135 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 2 Current Loop Initial current loop proportional gain Cp and current loop integral gain Ci values were calculated during general amplifier setup For an introductory overview of the control loops see Servo Modes and Control Loops p 19 NOTE For Copley Controls digital amplifiers the current loop gain is independent of the power supply voltage 7 2 1 Current Loop Settings For more information see Servo Current Mode and Current Loop p 19 7 2 1 1 item Click Loop to open the Current Loop screen current Loop f ll x
141. nt the algorithm protects the motor by limiting the output current A 1 2 IT Formulas and Algorithm Operation Calculating the FT Setpoint Value The FT setpoint value has units of Amperes seconds A S and is calculated from programmed motor data The setpoint is calculated from the Peak Current Limit the IT Time Limit and the Continuous Current Limit as follows PT setpoint Peak Current Limit Continuous Current Limit CT Time Limit FT Algorithm Operation During amplifier operation the VT algorithm periodically updates the T Accumulator Variable at a rate related to the output current Sampling Frequency The value of the IT Accumulator Variable is incrementally increased for output currents greater than the Continuous Current Limit and is incrementally decreased for output currents less than the Continuous Current Limit The IT Accumulator Variable is not allowed to have a value less than zero and is initialized to zero upon reset or 24 Vdc logic supply power cycle Accumulator Increment Formula At each update a new value for the IT Accumulator Variable is calculated as follows CT Accumulator Variable n FT Accumulator Variable n Actual Output Current Continuous Current Limit Update period After each sample the updated value of the IT Accumulator Variable is compared with the IT setpoint If the IT Accumulator Variable value is greater than the TT Setpoint value then the amplifier limits t
142. ntegral gain Ci until desired settling time is obtained 6 3 2 7 _sw Press Stop to stop the function generator 6 3 2 8 E On the Main screen click Save to Flash to avoid losing the changes 6 3 3 Optimize Hold and Run Current Ratings 6 3 3 1 Reduce Hold Current if possible to reduce heat generation 1 Test with load OR 2 Calculate Hold Current requirement gt hold torque x rated current rated torque 6 3 3 2 Reduce Run Current if possible to reduce heat generation 124 Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 4 Profile Move Tests Test the system with various gains limits and load conditions Trace Status Ready me A EN AL LL LL A LE LL CPU NOTE During profile tests observe any warnings that appear to the left of the trace Click the Scope Tool 6 4 1 2 Select the Profile tab 6 4 1 1 6 4 1 3 M zeg On the Settings tab make sure Auto Setup is selected Auto Setup automatically sets the following parameters Profile Tab Move Relative Type Trap Distance 2 revolution rotary or 2 cm linear Reverse and repeat Not checked Settings Tab Channel 1 Profile velocity green Channel 2 Actual current white Channel 3 Commanded current purple Copley Controls Corp 125 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 4 1 4 Set up a trapezoidal profile by setting the trajectory limits
143. ompted save the file to the MotorData folder in the CME 2 installation folder The default installation folder is C Program Files Copley Motion CME 2 MotorData Extract the contents of the zip file to the same location The folder should now contain the new motor data file with a ccm filename extension If desired delete the zip file to save disk space 5 5 1 2 To load motor data from a motor data file _Motoreavac Click Motor Feedback to open the Motor Feedback screen On the Motor Feedback screen click Restore Motor Data from Disk Sal When prompted navigate to the folder containing the file then click on the file name and then click Open Verify motor data files against manufacturer s specifications Proceed to The Calculate Function p 99 Copley Controls Corp 95 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 5 2 Enter Motor Feedback Brake Settings Manually 5 5 2 1 Meta Click Motor Feedback to open the Motor Feedback screen A Motor Feedback screen representing a typical rotary motor is shown below Parameters vary with amplifier model Stepper Motor Encoder Rotary Motor x Motor Feedback Brake Stop Units Manufacturer Jacmel Metric English Model Number JPK264 018 Motor Inertia O12 Kgcm x Resistance 57 ohms Inductance 54mH Rated Torque 0 3813 Nm x Rated Current 14 Basic Step angle 1 8 degrees Step 200 Full Stepsirev uStep
144. on 7 5 mm female Manufacturer Part numbers Wago 721 203 026 045 RN01 0000 Insert extract lever Wago 231 131 Wire size 12 AWG maximum Connector housing and terminals are included in connector kit STX CK Stepnet Panel AC STX J1 Pin Description Pin Signal Function 1 L1 AC power input hot or L1 2 Frame ground Chassis safety ground 3 L2 AC power input neutral or L2 Stepnet Panel AC STX J1 AC Mains Fuse Recommendation Recommended fuse type Class CC 600 Vac rated Ferraz Shawmut ATDR Littelfuse CCMR Bussman LP CC or equivalent Stepnet Panel AC STX J1 AC Mains Wiring Diagram Single Phase Fuses L1 Line 19 47 63 Hz L2 Neut 100 240 VAC Earth Ground Keep wire length Corcom 10VN1 as short as or equivalent possible Not to k used for CE compliance exceed 1 Meter Not required on a neutral line Note A clamp on ferrite Fair Rite PN 0431164951 was used on the AC input cable between the filter and drive single turn to meet EMC requirements during qualification testing 70 Copley Controls Stepnet Panel Amplifier User Guide 4 2 4 Stepnet Panel AC STX Motor J2 Stepnet Panel AC STX J2 Mating Connector Wiring Description Receptacle Single Row 5 Position Manufacturer Part numbers Wago 721 605 000 043 RN01 0000 Insert extract lever Wago 231 131 Wire Size 28 12 AWG Connector housing and terminal
145. on and deceleration rates Pulse and Direction Format In pulse and direction format one input takes a series of pulses as motion step commands and another input takes a high or low signal as a direction command as shown below Pulse Input JU UU JTUUUL Direction Input __ Velocity de D N The amplifier can be set to increment position on the rising or falling edge of the signal Stepping resolution can be programmed for electronic gearing Count Up Count Down Format In the count up count down format one input takes each pulse as a positive step command and another takes each pulse as a negative step command as shown below Up Input JUUUL Velocity Command The amplifier can be set to increment position on the rising or falling edge of the signal Stepping resolution can be programmed for electronic gearing Copley Controls Corp 27 Operational Theory Stepnet Panel Amplifier User Guide Quadrature Format In quadrature format A B quadrature commands from a master encoder via two inputs provide velocity and direction commands as shown below Alnput CL LI LL B Input III ITT Velocity Command The ratio can be programmed for electronic gearing 28 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 5 3 PWM Input Servo Mode Only Two Formats The amplifier can accept a pulse width modulated signal PWM signal to provide a current command in s
146. ools Caleulate OK Cancel The motor data management tools are described below Icon Name Description ES Save motor data to disk Saves only motor feedback data from the PC s RAM to a disk file with a ccm filename extension Amplifier data that is not represented on the Motor Feedback screen is not saved in this file si Restore motor data from disk Restores only motor data from a disk file with a ccm filename extension to the amplifier s flash memory Amplifier data that is not represented on the Motor Feedback screen is not affected 4 Save motor data to flash Saves the contents of the Motor Feedback screen from a buffer in the PC s RAM to the amplifier s flash memory Amplifier data that is not represented on the Motor Feedback screen is not saved Can be used to assure that all changes are saved to flash without closing the Motor Feedback screen A Restore motor data from flash Restores only motor data from amplifier flash to amplifier RAM Amplifier data that is not represented on the Motor Feedback screen is not affected Can be used before closing the Motor Data screen to restore settings to the previously saved values To use a data management tool click the icon and respond to prompts Copley Controls Corp 155 Using CME 2 Stepnet Panel Amplifier User Guide 8 2 4 Quick Copy Setup Procedure Use this procedure to configure an ampli
147. or Direction Setup screen auto Phase x Motor Direction Setup Move the motor in the direction that you want to be positive Press Next when done Motor Actual Position D counts Release Brake Skip gt Cancel Activate the Enable Input Move the motor at least three counts in the direction considered positive If the Motor Actual Position count does not change see Trouble Shoot Motor Direction Setup p 119 Click Next to open the Motor Wiring Setup screen x Motor Wiring Setup The software will move the motor Make sure the motor is free to move Press Startwhen ready Motor Actual Position 0 counts Velocity 10 rpm Ready Stop lt Back Finish Cancel Verify the Velocity setting Click Start to begin motor wiring setup The software displays messages Configuring Initial Settings Microstepping Test Complete Motor Wiring has been configured During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate causing the motor to move If you chose to Skip the motor direction setup step Auto Phase will prompt for confirmation of correct motor direction If the step fails see Trouble Shoot Motor Wiring Setup p 119 Click Finish to close the screen and save values to amplifier flash Copley Controls Stepnet Panel Amplifier User Guide Stepper Mode Phase and Tune 6 1 5 Trouble Shoot Motor Direction Se
148. ounded Attach the metal motor case to the metal machine frame or connect the ground wire of the motor to the metal frame of the machine e Grounding of the motor frame through the motor power cable to amplifier J2 1 The ground wire should be of the same gauge as the power wires Cable shields because of their smaller wire size must not be used as part of a safety ground system Stepnet Panel AC STX Signal Grounding The amplifier signal ground must be connected to the control system signal ground The amplifier signal ground is not connected to earth ground internal to the amplifier Therefore the control system signal ground can be connected to earth ground without introducing a ground loop Stepnet Panel AC STX Shielding Shields on cables reduce emissions from the amplifier and help protect internal circuits from interference due to external sources of electrical noise The shields shown in the wiring diagrams are also required for CE compliance Cable shields should be tied at both ends to earth or chassis ground The housing and pin 1 of both J6 and J7 are connected to the amplifier s chassis 4 2 2 Stepnet Panel AC STX Connector Locations Connector locations are shown below oo ed do le OC ge 2 a tal E ui 1 3 J4 15 Copley Controls Corp 69 Wiring Stepnet Panel Amplifier User Guide 4 2 3 Stepnet Panel AC STX Power J1 Stepnet Panel AC STX J1 Mating Connector Description Plug 3 positi
149. p 29 Operational Theory Stepnet Panel Amplifier User Guide 2 6 Communication As described below the amplifier features multiple communication interfaces each used for different purposes Interface Description RS 232 port The amplifier features a three wire RS 232 port Control commands can be sent over the RS 232 port using Copley Controls ASCII interface commands In addition CME 2 software communicates with the amplifier using a binary protocol over this link for amplifier commissioning adjustments and diagnostics For RS 232 port specifications see Serial Interface p 51 For RS 232 port wiring instructions see Stepnet Panel STP RS 232 Serial Communications J4 p 66 or Stepnet Panel AC STX RS 232 Serial Communications J8 p 83 Note that CME 2 can be used to make adjustments even when the amplifier is being controlled over the CAN interface or by the digital inputs CAN interface When operating as a CAN node the amplifier takes command inputs over a CANopen or DeviceNet network CAN communications are described in the next section Using CME 2 can affect or suspend CAN operations When operating the amplifier as a CANopen or DeviceNet node use of CME 2 to change amplifier parameters can affect CANopen or DeviceNet operations in progress Using CME 2 to initiate motion can cause CANopen or DeviceNet operations to suspend The operations may restart unexpectedly when the CME 2 move
150. p tuning values Min 0 00001 kg cm Max 1 000 kg cm Default 0 00001 kg cm Resistance Motor resistance line to line Used for calculating the initial current loop tuning values Min 0 019 Max 327Q Default 0 010 Inductance Motor inductance line to line Used for calculating the initial current loop tuning values For inductance range see Power Output p 45 Rated Torque Motors rated operating torque Min 001 N m Max 1000 N m Rated Current Motor s rated continuous current Min 0 001 A Max 1000 A Basic Step Angle Fundamental stepper motor step in degrees Min 0 225 Max 22 5 Default 1 8 UStep Rev stepper mode only Number of microsteps per revolution of the motor Min 4 Max 100 000 000 Default 4000 Note When using encoder feedback it is desirable to set this value equal to the number of encoder counts per rev 5 5 4 Linear Motor Setup Parameters View or change the settings described below Options vary with amplifier model Metric units are shown here Setting Description Manufacturer Motor manufacturer s name Saved for reference in the motor data file Model Number Motor model number Saved for reference in the motor data file Units Selects whether the parameters entered in this screen are in Metric or English units Motor Mass The mass of the moving component of the motor Used in servo mode for calculating initial velocity loop
151. pper Mode Operation 2 3 1 Stepper Mode Control The amplifier receives target position commands from the digital inputs or over the CAN interface When using the digital inputs the amplifier s internal trajectory generator calculates a trapezoidal motion profile based on the trajectory limit parameters The trajectory generator updates the calculated profile in real time as additional position commands are received The output of the generator is an instantaneous limited position command The vector generator accepts this command and calculates a limited current command which is the input to the current loop For information on the current loop see Servo Current Mode and Current Loop p 19 Refer to Copley Controls CANopen Programmer s Manual for position loop operation while under CAN control In stepper mode the trajectory generator accepts a target position and provides a current demand to the current limiter The current limiter provides a limited current to the stepper current loop The stepper current loop outputs a PWM command to drive the motor Actual current feedback is used to close the current loop in the amplifier Position feedback from an optional encoder can be used to provide position maintenance data to the external controller program Target Position Limited PWM Position FRE SEN Command Control Trajectory Vector Stepper Motor Program Generator Generator Current Loop Encoder Actual Position with optional encod
152. programmed following warning level Actual Current Shows actual current being applied to windings during homing Actual Position Shows actual position during homing 164 Copley Controls Stepnet Panel Amplifier User Guide Using CME 2 8 5 2 3 Optionally click Home to begin a homing sequence 8 5 2 4 To stop the homing sequence before it is completed click Stop 8 5 2 5 Click Save to save the settings to flash memory Click Exit to close the screen Copley Controls Corp 165 Using CME 2 Stepnet Panel Amplifier User Guide 166 Copley Controls APPENDIX A I T TIME LIMIT ALGORITHM This chapter describes the algorithm used to implement the PT limit NOTE This chapter uses servo mode examples and terminology to describe how the PT limit works It works the same way in stepper mode with the following exceptions e servo mode continuous current stepper mode run current e servo mode peak current stepper mode boost current Copley Controls Corp 167 IT Time Limit Algorithm Stepnet Panel Amplifier User Guide A 1 IT Algorithm A 1 1 IPT Overview The TT current limit algorithm continuously monitors the energy being delivered to the motor using the ET Accumulator Variable The value stored in the IT Accumulator Variable is compared with the TT setpoint that is calculated from the user entered Peak Current Limit IT Time Limit and Continuous Current Limit Whenever the energy delivered to the motor exceeds the I T setpoi
153. r Guide Wiring Stepnet Panel AC STX J7 Digital Outputs Wiring Diagram EE Typical Output Loads Typical Circuit Motion Controller External Power Supply Flyback diode required for inductive loads Copley Controls Corp 81 Wiring Stepnet Panel Amplifier User Guide Stepnet Panel AC STX J7 Multi Mode Port Interface Diagram Typical Circuit 26C32 Motion Controller or Position Motion Controller 82 Copley Controls Stepnet Panel Amplifier User Guide Wiring 4 2 10 Stepnet Panel AC STX RS 232 Serial Communications J8 Stepnet Panel AC STX J8 Mating Connector 6 position modular connector RJ 11 style Copley Controls provides a prefabricated cable and modular to 9 pin sub D adapter in RS 232 Serial Cable Kit PN SER CK A diagram of the female connector is shown below 0 0 00 1 2 3 4 5 6 Stepnet Panel AC STX J8 Pin Description Pin Signal Function 1 N C No connection 2 RxD Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply ground 5 TxD Transmit data output to computer 6 N C No connection Stepnet Panel AC STX J8 RS 232 Serial Communications Wiring Diagram ground To PC ground RS 232 Port Copley Controls Corp 83 Wiring Stepnet Panel Amplifier User Guide 84 Copley Controls CHAPTER 5 MODE SELECTION AND GENERAL SETUP The Stepnet
154. r fault can be cleared using the steps used to clear other latched faults e power cycle the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel el and press Clear Faults or Reset e clear the fault over the CANopen network 40 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 11 6 Tracking Window Details Proper Tracking Over Time As described earlier position error is the difference between the limited position output of the trajectory generator and the actual position In servo mode velocity error is the difference between commanded and actual velocity When the position or velocity error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the error remains within the tracking window for the programmed tracking time Servo Mode Velocity Tracking Illustration The following diagram illustrates the use of tracking window and time settings in servo velocity mode Actual Velocity Limited Velocity V D J N t Tracking Window ri j E d Pa N 4 ff i H t E ra d Ee 7 fe J Da oe Tracking ff l m Time 7 Tracking Window Output Copley Controls Corp 41 Operational Theory Stepnet Panel Amplifier User Guide 2 12 Inputs 2 12 1 Digital Inputs The amplifier has 12 digital
155. r latched faults and outputs AMP Enable LO Enables with reset A low input will enable the amplifier A low to high transition will reset the amplifier AMP Enable HI Enables with reset A high input will enable the amplifier A high to low transition will reset the amplifier AMP Enable A low input will enable the amplifier LO Enables AMP Enable A high input will enable the amplifier HI Enables Not Configured No function assigned to the input NEG Limit HI Inhibits A high input will inhibit motion in negative direction NEG Limit LO Inhibits A low input will inhibit motion in negative direction POS Limit HI Inhibits A high input will inhibit motion in positive direction POS Limit LO Inhibits A low input will inhibit motion in positive direction Reset on LO HI Transition A low to high transition of the input will reset the amplifier Reset on HI LO Transition A high to low transition of the input will reset the amplifier Motor Temp HI Disables A high input will generate a Motor Over Temperature fault Motor Temp LO Disables A low input will generate a Motor Over Temperature fault Home Switch Active HI A high input indicates the home switch is activated Home Switch Active LO A low input indicates the home switch is activated Motion Abort Active HI A high input stops motion but amplifier remains enabled Motion Abort Active
156. ram Active Low Copley Controls Corp 103 Mode Selection and General Setup Stepnet Panel Amplifier User Guide 5 6 5 Custom Digital Output Settings Custom Event Any of the amplifier s digital outputs can be programmed to respond to a combination of events including faults warnings and status indications The output goes active when one or more of the selected events take place 5 6 5 1 5 6 5 2 104 Custom Event Configure Custom Choose Custom Event for an output and then click Configure Custom to open the Event Configuration screen Event Triggered Output x IT Amplifier Fault 7 Amp Over Temperature IT Latch Output IT Feedback Error Motor Over Temp Clear IT Under Voltage IT Over voltage Short Circuit F Current Limited F Voltage Limited F Positive Limit Switch pm Output Active High Ze Output Active Low Cancel Help Select one or more of the faults described in Fault Descriptions p 38 or any of the following warnings or status conditions described below Note that multiple functions are OR ed together so any event activates the output Custom Events Warnings Warning Description Current Limited The current output is being limited by the T algorithm or a latched current fault has occurred See TT Time Limit Algorithm p 167 Voltage Limited The current loop is commanding full bus voltage in
157. ration The amplifier status indicator color blink codes comply with CAN Indicator Specification 303 3 as described below Note that green and red codes are often interlaced each indicating a different set of conditions The green codes indicate the CANopen state machine mode of operation pre operational operational or stopped The red codes indicate the status of the physical bus warning or error conditions CANopen State Machine Mode of Operation Indicator State Diagram Blinking green Pre operational 200 green off Steady green Operational green off Single flash green Stopped 1 second green off H 200 ms Physical Bus Status Single flash red Warning Limit 1 second Reached red i off 200 ms Double flash red Error Control Event 1 second red off KR 200 200 ms ms Triple flash red Sync Error 1 second red j off h KR 200 200 200 ms ms ms Steady red Bus Off red off J In addition the CAN status indicator is turned off when the CAN node ID selector CAN ADDR is set to 0 A setting of 0 which is an invalid CAN address shuts down most operations on the CAN interface and the light is shut off to indicate this status 36 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 10 Protection 2 10 1 Faults Overview Stepnet detects and responds to a set of conditions regarded as faults such as amplifier over temperature and excessive followi
158. response time The pre braking delay controlled by the deceleration rate and delay timer allows the amplifier to slow the motor before applying the brake PWM Delay Brake Stop Response Time makes it possible to ensure the brake has time to lock in before disabling the power section 34 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 9 Status Indicators 2 9 1 Amplifier and CAN Interface Status Indicators Stepnet Panel STP The amplifier s status indicator is a bicolor LED labeled STATUS on the J5 connector The CAN interface status indicator is a bicolor LED on the J6 connector Stepnet Panel AC STX The amplifiers status indicator is a bicolor LED labeled STATUS on the front panel The CAN interface status indicator is a bicolor LED on the J4 connector 2 9 2 Amplifier Status Indicator Operation Amplifier status indicator color blink codes are described below Color Blink Code Meaning Not illuminated No power to amplifier Steady green Amplifier is enabled and operational Slow blinking green Amplifier is disabled No faults or warnings are active Fast blinking green A limit switch is active The amplifier is enabled Steady red A non latched fault has occurred Blinking red A latched fault has occurred Copley Controls Corp 35 Operational Theory Stepnet Panel Amplifier User Guide 2 9 3 CAN Interface Status Indicator Ope
159. rol over the motor s position There is virtually no limit on the number of microsteps rev that can be programmed into the Stepnet amplifier The practical limit depends on the motor but a value on the order of 4096 microsteps electrical cycle is generally reasonable Programming a very high value will limit the maximum velocity of the motor When a high resolution encoder is connected to the motor it is sometimes advantageous to program the number of microsteps to be equal to the number of encoder counts Some drive manufacturers require that the number of microsteps rev be an integer multiple of the number of electrical cycles The Stepnet amplifiers do not have such a limitation 2 3 4 Current Control in Stepper Mode The Stepnet amplifier uses three programmable current settings to control the current applied to the motor boost run and hold Boost current is applied to motor while it is accelerating or decelerating Since it is only applied for a short amount of time it can typically be set higher then the motor s continuous rated value Another parameter time at boost specifies how long the boost current may be applied to the motor If acceleration or deceleration time exceeds this limit the current will decrease to the run value even though the motor is still accelerating decelerating The run current is applied to the motor while it running at a constant velocity The hold current is used after the motor has stopped running an
160. rrent square wave If the Cp value is too large ringing may occur If the Cp value is too low bandwidth decreases Make sure gain values don t produce excessive ring en TIP To change a value highlight the value Then enter value directly use mouse and arrow controls OR use Page Up Page Down keys to move in increments of 10 Copley Controls Corp 137 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 2 2 6 7 2 2 7 7 2 2 8 7 2 2 9 138 Adjust current loop integral gain Ci until desired settling time is obtained _sm Press Stop to stop the function generator ol On the Main screen click Save to Flash to avoid losing the changes If the amplifier is to be operated in current mode skip the velocity and position loop setup procedures and go to Completion Steps p 148 Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Phase and Tune 7 3 Velocity Loop Initial velocity loop proportional gain Vp and velocity loop integral gain Vi values were calculated during general amplifier setup 7 3 1 Velocity Loop Settings For more information see Servo Velocity Mode and Velocity Loop p 21 V Loop Click V Loop SE Commanded Commanded Veloch Current Actual Velocit 333 rps vp 117 Output Filter Decel Limit 333 rps Vis 26 Fast Stop Ramp 333 rps Low Gains Shift vel Limit 2000 rpm Tracking Dre Command Filter goa 0 Wi
161. s are included in connector kit STX CK Stepnet Panel AC STX J2 Pin Description Pin Signal Function 1 Frame Ground Motor frame ground and cable shield 2 Motor B Phase B output of amplifier 3 Motor B Phase B output of amplifier 4 Motor A Phase A output of amplifier 5 Motor A Phase A output of amplifier Stepnet Panel AC STX J2 Motor Wiring Diagram Typical wiring for a 4 lead motor Amplifier J2 Note A clamp on ferrite Fair Rite PN 0431164281 was used on the motor cable single turn installed close to the amplifier to meet EMC requirements during qualification testing Typical wiring alternatives 8 lead motor coils in parallel 8 lead motor coils in series eS ee AN gt lt 2i i l B Bet 4 ee a Bo 2 B J er CT ae er Le 3 2 S Copley Controls Corp 6 lead motor D ei ve SH Bot lt we bi f 2 No JI Connection _ J lt J SEI SS e KL f 71 Wiring Stepnet Panel Amplifier User Guide 4 2 5 Stepnet Panel AC STX Aux HV and Brake J3 Stepnet Panel AC STX J3 Mating Connector Description Plug 3 position 5 0 mm female Manufacturer Part numbers Wago 721 103 026 047 RN01 0000 Insert extract lever Wago 231 131 Wire Size 12 AWG maximum Connector and backshell are included in connector kit STX CK Stepnet Panel AC STX J3 Pin Description Pin Sign
162. s 64 or less the Low Gains Shift option is available to increase the gains adjustment resolution Such low values are likely to be called for when tuning a linear motor with an encoder resolution finer than a micrometer If the non scaled value of Vp or Vi is 24001 or higher the High Gains Shift option is available to decrease the gains adjustment resolution Servo Velocity Loop Command and Output Filters The servo velocity loop contains two programmable digital filters The input filter should be used to reduce the effects of a noisy velocity command signal The output filter can be used to reduce the excitation of any resonance in the motion system Two filter classes can be programmed the Low Pass and the Custom Bi Quadratic The Low Pass filter class includes the Single Pole and the Two Pole Butterworth filter types The Custom Bi Quadratic filter allows advanced users to define their own filters incorporating two poles and two zeros For more information see the CME 2 User Guide Servo Velocity Loop Outputs The output of the servo velocity loop is a current command used as the input to the servo current loop 22 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 4 4 Servo Position Mode and Position Loop Servo Position Loop Diagram The amplifier receives position commands from internal sources such as a Copley Virtual Machine CVM program or external input sources such as the amplifier s digi
163. s and Methods of Measurement of Radio Disturbance Characteristics of Industrial Scientific and Medical ISM Radio Frequency equipment EN 61000 6 1 2007 e Electromagnetic Compatibility generic immunity Requirements Following the provisions of EC Directive 2004 108 EC EMC Directive EN 61010 1 2001 e Safety Requirements for Electrical Equipment for Measurement Control and Laboratory use Following the provisions of EC Directive 2006 95 EC Low Voltage Directive UL 508C 3rd Ed 2002 UL Standard for Safety for Power Conversion Equipment UL 61010 1 2nd Ed 2004 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use 3 2 Power Input 3 2 1 Stepnet Panel STP Power Input Specification Model STP 075 07 STP 075 10 HV min to HV max 20 to 75 Vdc transformer isolated Peak current 8 Adc 1 Sec 11 Adc Continuous current 5 5 Adc 11 Adc Auxiliary power optional 20 to 75 Vdc 3W typical when auxiliary power gt HV OW when auxiliary power lt HV 3 2 2 Stepnet Panel AC STX Power Input Specification Madel STX 115 07 STX 230 07 Mains voltage 100 120 Vac 100 240 Vac Mains frequency 50 60 Hz Mains current 8 Arms continuous Logic supply required 20 32 Vdc 500 mAdc maximum 44 Copley Controls Stepnet Panel Amplifier User Guide Specifications 3 3 Power Output 3 3 1 Stepnet Panel STP Power Output
164. s command input See Input Command Types p 25 Function Generator current and velocity mode only Internal function generator provides command input Software Programmed The amplifier is controlled by software commands from either the Copley Virtual Machine CVM or an external source See Copley Indexer Program User s Guide or the Copley ASCII Interface Programmer s Guide Digital Input position mode only Command input is provided via the Input Source selected from the choices described below See Digital Position Inputs p 27 CAN position mode only Command input is provided over the CANopen network See Communication p 30 and the CANopen Programmer s Guide Camming position mode only Amplifier runs in Camming Mode See Copley Camming User Guide Click Finish to close the Basic Setup screen Copley Controls Stepnet Panel Amplifier User Guide Mode Selection and General Setup 5 5 Motor Setup Motor Feedback and Brake settings can be loaded from a file or entered manually into the fields Choose the appropriate method and perform the steps described e Load Motor Feedback Brake Data File p 95 e Enter Motor Feedback Brake Settings Manually p 96 5 5 1 Load Motor Feedback Brake Data File 5 5 1 1 To download motor data files from the website 1 5 In an internet browser navigate to http Awww copleycontrols com Motion Downloads motorData htm Click the appropriate motor name When pr
165. screen x Settings Stepper Motor Motor Type Rotary Motor Encoder None Encoder Correction Off Run in Servo Mode Off Operating Mode Stepper CAN I Load cex File ServoTube Setup Cancel 5 4 1 3 Click Change Settings to start the Basic Setup wizard Use Back Next to navigate screens Screen details vary depending on amplifier model and mode selection 5 4 1 4 Select the Motor Type Rotary or Linear 54 15 View or change the Feedback settings described below Setting Options Motor Primary Incremental or none Encoder is required for servo mode operation In stepper Encoder mode operation it can provide position maintenance information Run in Servo When checked amplifier runs in closed loop servo mode See Stepper and Servo Modes Mode p 10 Enable When checked amplifier runs in stepper mode and uses a programmable proportional Encoder gain to correct following errors See Encoder Correction p 128 Correction Copley Controls Corp 93 Mode Selection and General Setup 5 4 1 6 5 4 1 7 94 Stepnet Panel Amplifier User Guide View or change the Operating Mode settings described below Setting Options Operating Stepper mode Position See Stepper Mode Operation p 16 Mode Servo mode Current Velocity Position See Servo Mode Operation p 18 Command PWM Command current and velocity mode only Digital pulse width modulated signal Source provide
166. solute position and acceleration and deceleration rates On command a complete motion profile is executed traveling the programmed distance or ending at the programmed position The amplifier supports both trapezoidal and s curve profiles 30 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory In interpolated position mode the controller sends a sequence of points to the amplifier each of which is a segment of a larger more complex move rather than a single index or profile The amplifier then uses cubic polynomial interpolation to connect the dots so that the motor reaches each point at the specified velocity at the programmed time Homing mode is used to move the axis from an unknown position to a known reference or zero point with respect to the mechanical system The homing mode is configurable to work with a variety of combinations of encoder index home switch limit switches and mechanical stops 2 6 3 Architecture As shown below in a CANopen motion control system control loops are closed on the individual amplifiers not across the network A master application coordinates multiple devices using the network to transmit commands and receive status information Each device can transmit to the master or any other device on the network CANopen provides the protocol for mapping device and master internal commands to messages that can be shared across the network g StepNet Local Control Softw ar
167. ssive for the motor 2 Raise or lower velocity loop proportional gain Vp until desired step response is obtained Typically this means little or no overshoot on a 5 Hz small slow speed square wave 7 3 2 6 Adjust velocity loop integral gain Vi until desired settling time is obtained 7 3 2 7 _sm Press Stop to stop the function generator 7 3 2 8 E On the Main screen click Save to Flash to avoid losing the changes 7 3 2 9 If the amplifier is to be operated in velocity mode skip the position loop setup procedures and go to Completion Steps p 148 140 Copley Controls Stepnet Panel Amplifier User Guide Servo Mode Phase and Tune 7 4 Position Loop Initial position loop proportional gain Pp velocity feed forward Vff and acceleration feed forward Aff values were calculated during general amplifier setup 7 4 1 Position Loop Settings For more information see Servo Position Mode and Position Loop p 23 7 4 1 1 Foon Click P Loop to open the Position Loop screen Position Loop Copley Controls Corp 141 Servo Mode Phase and Tune 7 4 1 2 142 Set the following Trajectory Values as needed Stepnet Panel Amplifier User Guide Option Description For More Information Max Velocity Maximum trajectory velocity Max value may depend upon the back EMF and the Max feedback count servo mode or maximum number of microsteps stepper mode Min 0 Default 0 25 x motor velocity
168. t STX only digital inputs CAN network CANopen or DeviceNet or over an RS 232 serial connection using ASCII commands The amplifier can also function as a stand alone motion controller running an internal CVM program or using its internal function generator 2 5 1 Analog Command Input STX Servo Mode Only Overview The amplifier can be driven by an analog voltage signal through the analog command input The amplifier converts the signal to a current velocity or position command as appropriate for current velocity or position mode operation respectively The analog input signal is conditioned by the scaling dead band and offset settings A programmable filter is also available on the analog input See the Low Pass and Bi Quad Filters appendix in the CME 2 User s Guide Scaling The magnitude of the command generated by an input signal is proportional to the input signal voltage Scaling controls the input to command ratio allowing the use of an optimal command range for any given input voltage signal range For example in current mode with default scaling 10 Vdc of input generates a command equal to the amplifier s peak current output 5 Vdc equals half of that Scaling could also be useful if for example the signal source generates a signal range between 0 and 10 Vdc but the command range only requires 7 5 Vdc of input In this case scaling allows the amplifier to equate 7 5 Vdc with the amplifier s pea
169. tal inputs or a CANopen or DeviceNet network When using the digital inputs the amplifier s internal trajectory generator calculates a trapezoidal motion profile based on the trajectory limit parameters The trajectory generator updates the calculated profile in real time as additional position commands are received The output of the generator is an instantaneous position command limited position In addition values for the instantaneous profile velocity and acceleration are generated These signals along with the actual position feedback are processed by the position loop to generate a velocity command The following diagram summarizes the servo position loop Position Loop Profile Velocity Velocity Feed Forw ard Vff Target Trajectory il i P Position Gonorator Profile Acceleration Acceleration Feed Forw ard Aff uae gt Kee Pas Limited Position gt Position Proportional Gain Pp Limits e Max velocity e Max accel Max decel Feedback Actual Position e Abort decel The Clear Limits feature is described in Position Loop Settings p 141 Servo Position Mode Inputs In servo position mode various input sources can drive the amplifier e The amplifier receives position commands directly from the digital inputs For more information see Digital Inputs p 100 e The amplifier receives position commands over a CANopen or DeviceNet network via the amplifier s CAN interface For more
170. termination plug is installed in second connector Function Real time motion control Copley Controls Corp 51 Specifications Stepnet Panel Amplifier User Guide 3 15 Status Indicators Amplifier status Stepnet Panel STP LED is integrated in connector J5 Stepnet Panel AC STX LED on front panel CAN status Stepnet Panel STP LED is integrated in connector J6 Stepnet Panel AC STX LED is integrated in connector J4 Conforms to CAN Indicator Specification CiA DR 303 3 3 16 Fault Levels Amp over temperature gt 70 C DC bus under voltage Stepnet Panel STP lt 20 Vdc Stepnet Panel AC STX lt 60 Vdc DC bus over voltage Stepnet Panel STP gt 90 Vdc Stepnet STX 115 07 gt 200 Vdc Stepnet STX 230 07 gt 400 Vdc Encoder power STX only lt 4 55 Vdc 3 17 Power Dissipation 3 17 1 Stepnet Panel STP Power Dissipation STP 075 07 STP 075 10 Output HV Dissipation Current 0 Adc 75 Vdc 3W Maximum 25 Vdc 6 0 W continuous 75 Vdc 7 5 W 3 17 2 Stepnet Panel AC STX Power Dissipation STX 115 07 STX 230 10 Output Power 0 Adc 1W AW Maximum continuous 30W 40W 3 18 Thermal Impedance See C Thermal Considerations p 173 52 Copley Controls Stepnet Panel Amplifier User Guide Specifications 3 19 Mechanical and Environmental Stepnet Panel
171. the files Stepnet_Firmware zip and the latest cff file If desired delete Stepnet_Firmware zip to save disk space 157 Using CME 2 Stepnet Panel Amplifier User Guide 8 3 2 Downloading Firmware to Amplifier 8 3 2 1 8 3 2 2 8 3 2 3 8 3 2 4 8 3 2 5 158 On the Main screen choose Tools gt Download Firmware to open the Download Firmware window Download Firmware x 9 Doyouwantto save your data before downloading new firmware No Cancel To download new firmware without saving amplifier and motor data click No and then proceed to Step 8 3 2 4 To back up amplifier and motor data before downloading firmware click Yes x M Save Data To Disk M Save Data To Flash Cancel 1 Use check marks to select whether to save to disk flash both or neither 2 Click OK to save data and continue to select a firmware image or click Cancel to continue without saving data 3 If Save Data to Disk was checked use the Save Amplifier Data to Disk screen to browse to the folder where you want to save the ccx file Then enter a name in the Name field Then click Save When the Firmware Images window appears proceed to Step 8 3 2 4 Use the Firmware Images window to locate and select a firmware image file Click Open to begin the download Or click Cancel to close the screen without downloading new firmware A message window displays a series of progress messages Writing new firmware image E 8
172. to flash memory Switch provides the lower four bits inputs provide the next 0 3 bits The value offset is added to the value set by the switch and inputs to determine address If programmed value is zero switch and inputs alone determine address For more information on CAN addressing see CAN Interface p 112 For more information on CAN communications see Communication p 30 For more information on CANopen operations see the following Copley Controls documents e CANopen Programmer s Manual e CML Reference Manual e Copley Motion Objects Programmer s Guide 32 Copley Controls Stepnet Panel Amplifier User Guide Operational Theory 2 7 Limit Switches 2 7 1 Use Digital Inputs to Connect Limit Switches Limit switches help protect the motion system from unintended travel to the mechanical limits Any of the digital inputs 2 12 can be can be programmed as positive or negative limit switch inputs An input can also be programmed as a home limit switch for homing operations The amplifier also supports software limits as configured in Homing Functions Settings p 164 2 7 2 How the Amplifier Responds to Limit Switch Activation In all modes in response to an active limit switch The amplifier status indicator flashes green at fast rate A warning is displayed on CME 2 Control Panel and the CME 2 Control Panel limit indicator turns red Optional Appropriately configured digital outputs go active See Custom Dig
173. to load a set of Cam Tables skip to Step 8 2 4 8 To load a set of Cam Tables choose File gt Restore Cam Tables When prompted navigate to the folder containing the appropriate cct file Highlight the file name and then click Open to load the file data into flash memory If you do not need to load a Gain Scheduling Table the process is complete To load a Gain Scheduling Table choose File gt Restore Gain Scheduling Table When prompted navigate to the folder containing the appropriate ccg file Highlight the file name and then click Open to load the file data into flash memory TIP When copying amplifier data to multiple amplifiers consider locking CME 2 to prevent accidental changes to settings See the CME 2 User s Guide 156 Copley Controls Stepnet Panel Amplifier User Guide Using CME 2 8 3 8 3 1 8 3 1 1 8 3 1 2 8 3 1 3 8 3 1 4 8 3 1 5 Copley Controls Corp Downloading Firmware Acquiring Firmware Updates from Web Site In an Internet browser navigate to http Awww copleycontrols com Motion Downloads firmware html Click on the appropriate Stepnet firmware icon When prompted save the file to the Firmware Image folder in the CME 2 installation folder The default installation folder is C Program Files Copley Motion CME 2 Firmwarelmage The folder should now contain a file named Stepnet_Firmware zip Extract the contents of the zip file to the same location The folder should now contain
174. tor Over Temperature Wiring Diagram Motor Over Temperature Switch 74HC14 Case Ground Copley Controls Corp 77 Wiring Stepnet Panel Amplifier User Guide 4 2 8 Stepnet Panel AC STX Control J7 Stepnet Panel AC STX J7 Mating Connectors Description Manufacturer PN Wire Size 26 Position 0 1 x 0 09 High Density D Sub Male Solder Style Norcomp 180 026 24 30 AWG Connector 103L001 Back shell Norcomp 979 015 020R121 Solder style connector included in Connector Kit PN STX CK Pin connections are shown here 1 10 19 J7 pin connections 78 Copley Controls Stepnet Panel Amplifier User Guide Stepnet Panel AC STX J7 Pin Description Pin Signal Function Frame Ground Cable shield connection Ref Input Analog command negative input Ref Input Analog command positive input Speed Pull Up Pull Down 4 IN1 Enable Standard Group 1 5 IN2 Standard Group 1 6 IN3 Standard Group 1 7 IN4 Programmable inputs Standard Group 2 8 IN10 Standard Group 4 9 IN11 Standard Group 4 10 INS HS Group 3 11 IN6 HS Group 3 7 nr EE mn LT 13 IN8 HS Group 4 14 IN9 HS Group 4 15 Signal Ground Signal ground reference for inputs and outputs 16 OUT1 17 OUT2 Programmable outputs 18 OUT3 19 Signal Ground Signal ground for 5Vdc inputs and outputs 20 5 Vdc 5 V
175. tual Position value on the screen should change If it does not change see Trouble Shoot Motor Direction Setup p 119 Click Next to open the Motor Wiring Setup screen x Motor Wiring Setup Commanded Motor Phase Angle The software will now micro step the motor 120 H o Make sure the motor is free to move 150 30 Press Start when ready 180 a Auto Phase current 075 A 210 VA 330 240 35 300 Increment Rate 4500 elec deg sec Motor Actual Position 0 counts Ready lt Back MEX Cancel Click Start to begin the motor wiring setup The software displays messages Configuring Initial Settings Microstepping Test Complete Motor Wiring has been configured During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate causing the motor to move If you chose to Skip the motor direction setup step Auto Phase will prompt for confirmation of correct motor direction If the step fails see Trouble Shoot Motor Wiring Setup p 119 NOTE If incorrect values were entered for inductance and resistance the calculated Cp and Ci values may produce current loop oscillation evidenced by an audible high frequency squeal during auto phasing Copley Controls Corp 133 Servo Mode Phase and Tune Stepnet Panel Amplifier User Guide 7 1 3 6 7 1 3 7 7 1 3 8 7 1 3 9 134 Click Next to open the Phase Count Test screen x Phase Count Test Com
176. tup If motor direction setup step failed 6 1 5 1 6 1 5 2 If an encoder is used check encoder power and signals Check shielding for proper grounding 6 1 6 Trouble Shoot Motor Wiring Setup If motor wiring setup step failed 6 1 6 1 6 1 6 2 6 1 6 3 6 1 6 4 6 1 6 5 Verify that amplifier is disabled Check for mechanical jamming Check for good connections to the motor power wires Disconnect motor power wires Measure for proper motor resistance Copley Controls Corp 119 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 2 Position Limits Stepper Mode with Encoder Position Limits 6 2 1 1 Click Position Limits to open the Position Limits screen 6 2 1 2 120 Position Limits Trajectory Values Position Loop Values Commanded Commanded Position ie Fu Current Max Velocity 1000 rpm Clear Limits Set Default Limits Max Accel 167 rps Max Decel 167 rps Abort Decel 167 rps Set the following Trajectory Values options as needed ls Option Description For More Information Max Maximum trajectory velocity Max value may Servo Position Mode and Position Loop Velocity depend upon the back EMF and the Max p 23 feedback count servo mode or maximum number of microsteps stepper mode Min 0 Default 0 25 x motor velocity limit Max Accel Maximum trajectory acceleration Max value may depend upon the load in
177. uide Gain Scheduling Indicates whether Gain Scheduling is active See the CME 2 User Guide x The fault indicator goes red when a fault is active Check the status message box for a description of the most recent fault Fault Under voltage Check the Error Log for a full history of faults and warnings The warning indicator goes yellow when a warning is active Check the status message box for a description of the most recent Warning Pos Outside of Tracking Window Check the Error Log for a full history of faults and warnings Message Box The message box below the indicators displays the most recent active fault or warning message 160 Copley Controls Stepnet Panel Amplifier User Guide 8 4 3 Monitor Functions Using CME 2 The Control Panel Monitor channels can display real time values on up to three separate variables Monitor Commanded Position hd counts Actual Motor Position D ES counts Limited Position v ES o s Mode Position Digital Input To set up a monitor display box click in the list box and select a variable from the list Disabled disables the display Other options represent the following amplifier variables Note that some variables are only applicable when an encoder is present in stepper or servo mode Variable Description Commanded Current Command input to the internal current loop Actual Current Actual current output
178. utton 6 4 2 2 Set up an S Curve profile by adjust the following options Set values that represent a typical move under normal operation Trajectory Limits Tab Maximum Velocity Maximum speed of the profile Maximum Top acceleration deceleration of the profile Deceleration acceleration Acceleration Deceleration Maximum Jerk The jerk value set by Calculate procedure gives an S Curve whose maximum slope the trapezoidal profile slope This value gives a maximum acceleration no greater than the initial acceleration Small values produce less jerking but take longer to complete move Large values produce more jerking and a more trapezoidal profile but complete the move faster Profile Tab Distance Increase the move distance to produce a complete trajectory profile Use an acceptable value the does not exceed mechanical limits of the system Move Relative Type S Curve 6 4 2 3 Verify that the boost run and hold currents are appropriate for the move 6 4 2 4 Try multiple sets of profiles representing typical moves that might be executed in the application Starting with Set up an S Curve profile repeat the process as needed Copley Controls Corp 127 Stepper Mode Phase and Tune Stepnet Panel Amplifier User Guide 6 5 Encoder Correction Optionally set encoder correction options 6 5 1 1 Make sure the Encoder Correction option has been set See Basic Setup Screen p 93 Encoder Corre
179. ve the right to modify our products The information in this document is subject to change without notice and does not represent a commitment by Copley Controls Copley Controls assumes no responsibility for any errors that may appear in this document Copley Controls Corp 5 About this Manual Stepnet Panel Amplifier User Guide Product Warnings Observe all relevant state regional and local safety regulations when installing and using Copley Controls amplifiers For safety and to assure compliance with documented system data only Copley Controls should perform repairs to amplifiers DANGER Hazardous voltages Exercise caution when installing and adjusting Copley Controls amplifiers Failure to heed this warning can cause equipment damage injury or death DANGER DANGER Risk of electric shock High voltage circuits are connected to DC or AC power Failure to heed this warning can cause equipment damage injury or death DANGER Motor voltage rating Be sure that the motor is rated for the voltage provided by the amplifier s outputs Failure to heed this warning can cause equipment damage injury or death DANGER Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched b
180. with a USB to RS 232 adapter e Atleast one serial communication cable Available from Copley Controls Copley Controls cable part number SER CK For CAN communications e One Copley Controls CAN PCI network card part number CAN PCI 02 CME 2 also supports CAN network cards made by these manufacturers KVaser Vector and National Instruments e One PC to amplifier CANopen network cable Software Requirements Copley Controls CME 2 software Version 5 2 or higher Operating System Requirements Operating Systems Supported Windows NT 2000 XP Vista users see Special Notes for Windows Vista Users 5 2 2 Special Notes for Windows Vista Users When the CME 2 installer starts running under Windows Vista a message will be displayed stating that an unidentified program is trying to access the computer Click the button to allow the installer to continue and CME 2 will be installed properly On previous versions of Windows the user data for CME 2 like ccx ccm files etc were stored in C Program Files Copley Motion CME 2 Because of Windows Vista security the CME 2 user files are stored on Vista systems in C Users Public Public Documents Copley Motion CME 2 5 2 3 Downloading CME 2 Software from Web Optional 5 2 3 1 Choose or create a folder where you will download the software installation file 5 2 3 2 In an internet browser navigate to http Awww copleycontrols com Motion Downloads index html Under Software Releases
181. y Velocity of the jog move Limited by velocity loop Vel Limit Acceleration Acceleration rate of the jog move Deceleration Deceleration rate of the jog move Command the move Mode Steps Current Hold Pos to apply positive current to the motor or hold down Neg to apply negative current to servo the motor Le Release the button to command zero current Velocity Hold Jog Pos to command a forward velocity or hold down Jog Neg to command a negative servo velocity de Release the button to command zero velocity Position Hold Move Pos to generate a forward move profile or hold Move Neg to generate a negative move profile Release the button to stop movement NOTE A position mode jog move continuously updates the commanded position If a following error develops with Following Error Fault is disabled motion will not stop on button release Instead it stops when actual position commanded position 163 Using CME 2 Stepnet Panel Amplifier User Guide 8 5 Home Function 8 5 1 Overview The CME 2 Home function can be used to set and test homing parameters 8 5 2 Homing Functions Settings Home 8 5 2 1 oome On Main screen click Home to open the Homing screen xl Software Limits Positive 0 pSteps Deceleration Rate D rps Negative 0 pSteps Disable Method set Current Position as Home SA Direction of Motion fe Positive f Negative Offset uSteps
182. y the amplifier Limit CT Time Limit Maximum amount of time that the peak current can be applied to the motor The amplifier can be programmed to fold back the current to the continuous current setting or generate a latched fault when this time is exceeded For more details see TT Time Limit Algorithm p 167 Note Although the current limits set by the user may exceed the amplifier s internal limits the amplifier operates using both sets of limits in parallel and therefore will not exceed its own internal limits regardless of the values programmed Copley Controls Corp 19 Operational Theory Current Loop Gains Stepnet Panel Amplifier User Guide The current loop uses these gains Gain Description Cp Current loop proportional The current error the difference between the actual and the limited commanded current is multiplied by this value The primary effect of this gain is to increase bandwidth or decrease the step response time as the gain is increased Ci Current loop integral The integral of the current error is multiplied by this value Integral gain reduces the current error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the current error value over time Current Loop Output The output of the current loop is a command that sets the duty cycle of the PWM output stag

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