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Digital Servo Amplifier

1. Index e nex index Enc X lt Receiver 12 b we X DU ndex EncA Phase A r 4 8 4 EncA lt t Phase A X Phase A Receiver lt 5 12 lt Phase B M4 7 lt Enc8 Phase B i Phase B pace Receiver ve t 1 Case Gnd B Shid Case Gnd Th 35V Encoder E n oV Gnd circuit power Copley Amplifier z 12 U N Figure 2 9 Quadrature Encoder Single ended Open Collector 2 12 Amplifier Connections Hall Sensors The controller performs a phase initialization routine using the encoder for proper commutation However improved phase initialization can be achieved using Hall sensors to determine initial positioning Typical Hall signals are shown in Figure 2 10 One Electrical Cycle All 6 states Phase U Phase V Phase W Typical 120 Degree Halls shown Figure 2 10 Hall Signals Hall Input Circuit The same Hall input circuit Figure 2 11 is used to receive Hall signals phase U phase V and phase W The circuit is designed to work with single ended TTL signals and single ended open collector signals Input circuit same for all Hall signals 45V 22k HCT14 10k 10nF Copley Amplifier Figure 2 11 Hall Input Circuit 7XX8 Series Digital Servo Amplifier User Guide 2 13 Motor 2 Phase U Hal i diennu e EE me to Case Gnd 5V Power 250mA max V Copley Amplifier Case Gnd Hall power Figure 2 12 Hall Connections Temperature Sensor Inpu
2. a LHS Heck 5 Ercacin Folat oos tee vier b See Tox Aso indes 58 e J Cepure Sauce Smal 55 Hj enem inne ease um Mes Le Temp Series iy Tuckng Window D Serum M Aea Bain Figure 5 6 Amplifier Status Now Screen Using Copley Motion Explorer Motor Status Note s Displays actual position count Max 22 1 Displays final position count target of preset profile Max 2 1 Actual velocity measured by amplifier and displayed in rotations per minute RPM Max 4MHz Counts Seconds Encoder Counts Revolutions x 60 RPM Max should not exceed motor specification Actual torque measured by amplifier Cont Limit Present value if continuous current limit Set in Motor gt Data gt Specification screen Calculated from contionuous torque 10 Amps Max Present value of peak current limit Set by external or internal values 20 Amps Max Limit Source Peak current limit source can be internal value or external voltage Range 0 20 Amps Mode Type Displays selected Operating Mode in a functional block diagram The type of status that follows i e position and current will vary depending upon mode of operation Set button Allows you to enter a pre determined actual position Table 5 4 Motor Status and Mode Beneath the current motor status and mode displays are a series of buttons and indicators which pertain to status errors etc Figure 5 7 Communication IL Am
3. Check box controls allow let you to select Automatic Connect on Startup and Status Query Status Query is the same as Status Update on the Amplifier Status Now screen When you select Status Query and Update Rate you are asking CME to interrogate the amplifier at a specified rate and display status in the Amplifier Status Now m Default Baud C 2400 C 9600 C 19200 C 57600 115200 Default Port Comm Port 1 C Comm Port 2 C Comm Port 3 C Comm Port 4 Automatic Connect on Startup Status Query Update Rate ms 1000 Dk Cancel Figure 5 31 Options gt Communications Screen 7XX8 Series Digital Servo Amplifier User Guide 5 43 Tools gt Options gt Directories The Directories screen shows the location of and allows access to various amplifier and motor files Loft 4 Options Figure 5 32 Options gt Directories Screen 5 44 Using Copley Motion Explorer Tools gt Options gt Advanced When you select Help gt Copley on the Web CME uses the address here to access the Copley Controls Web site Figure 5 33 Options gt Advanced Screen 7XX8 Series Digital Servo Amplifier User Guide 5 45 Tools Download Firmware In the future new features and enhanced functionality may be implemented in the amplifier s firmware When you receive a firmware release from Copley Controls save it to the Copley Motion Explorer folder You can use Copley Motion Explorer
4. Output Status circuit 5V DSP 10k 24V Coil suppl pply supply 4 8k 5mA Status 2 5V Status 2 10mA DSP 10k EXTREG3 _ V GND 24V supply Copley Amplifier Figure 2 27 Status Outputs 7XX8 Series Digital Servo Amplifier User Guide 2 25 Analog Monitor Output The analog monitor output Figure 2 28 is a 10V signal that can be used to monitor analog conditions measured inside the amplifier The output can be software configured to produce a voltage proportional to phase current in a motor winding motor velocity or other parameters DSP Analog output circuit J3 A mon n o Oscilloscope SPISMO Copley Driver 5 0V 10V 1k DAC gt inF at Signal Gnd al F 34 gt y 2 26 Amplifier Connections Figure 2 28 Analog Monitor Output Data Connector J4 The DSP Model 7XX8 supports RS 232 Jumpers on the amplifier s signal module set the configuration for the protocol Data connections should be made with wire that has a rating to support the signal current AWG 24 wire will support all data signals in this series Ribbon cable is acceptable for short distances and baud rates less than 9600 however to minimize coupling of PWM noise data signal wiring should be multiple conductor twisted pair shielded cable The amplifier looks like DCE Data Communications Equipment and does not req
5. to update firmware 1 From the Tools menu select Download Firmware 2 Select the cplyXXXX bin file that contains the latestfirmware 3 Selecting Open displays the message Erasing old firmware A bar graph which signifies the new firmware is being loaded is displayed When the bar graph is full the update is complete 4 Atthe Main menu verify the firmware version Select the Amplifier gt Connect to Host Note At the end of the download routine the amplifier is reset The Baud Rate changes to 9600 which results in a loss of communication if any other Board Rate was originally selected Reconnecting returns the Borad Rate to the desired value Warning If communication is lost while downloading firmware the amplifier must be returned to the factory 5 46 Using Copley Motion Explorer Tools Encoder Check Select Tools Encoder Check to access the Encoder Check screen Figure 5 34 The Encoder Checking routine verifies the integrity of the motor s encoder as follows Checksforthe presence of encoder quadrature pulses Verifies the presence of an index pulse Verifies that you have selected the correct A and B signal synchronization to the index pulse Aids youin verifying the number of encoder lines Perform the Encoder Checking routine before attempting to auto phase a new motor Also use this routine if you suspect problems with your encoder See Encoder Checking in Chapter 3 f
6. DC Model Power Connections 1 6 Diagnostics Meu 5 47 5 50 Diagnostics Com Log Screen 5 51 Diagnostics gt Special gt DSP Commands 5 50 Digital Position Input 5 24 Digital Positim M 4 11 Digital Rame Camectioms 2 18 Download Firmware 5 46 DSP Commands 5 53 E G Grounding 23 H Hl ipt cant 2 13 Hall Sewors 2 13 Help Menu 5 54 Home Switch Input 2 22 Homing 3 9 7XX8 Series of Digital Servo Amplifiers User Guide H I Initiate a Moe with the Revert 3 8 Installatian Using a Copley Motion Explorer Develgorent Kit Motor 3 6 Installatian Using a opley Motor Data File L Last Preset Icd 5 13 Line Filters for MI Reduction amp 24 M Main Menu 5 4 Main Window 5 3 Master Encoder Inputs 2 20 More Tess Button 5 13 Motor Data parameters 5 21 Motor Data gt Specification gt Electrical Scen 5 35 Motor Data gt Specification gt Feedback Stem 5 33 Motor Data gt Specification gt Mechanical Scream 5 36 Motor Data gt Specificatian gt Ratings Scen 5 344 Motor Data gt Specificatian gt Type Screen 5 32 Motor Menu 5 31 Motim Profile parameters 5 16 Motor Phase Wiring Comections 28 Motor Signal Wiring Comectims J2 2 9 Motor Temperature Sensor Screen 5 40 I 2 Index O Qn Line Gamectian Screen 5 5 Cperating Modes 4 1 5 15 atriy Cl P Parameter Coitrol Buttms 5 14 Pendant Module B 1 Performance Trace Screen 5 41 pese initializtim 3 7 Position
7. From the CME Main menu select the Amplifier pull down menu 2 Select Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button is displayed Select the button to display the full Amplifier Status Now screen 4 From the Operating Modes pull down menu select 10V gt Pos gt Torque 5 From the Motion Profile pull down menu select Velocity Note For proper operation always stop the motor before you select a before you select a different operating mode 4 10 Amplifier Operating Modes Digital Position Mode In Digital Position mode you configure the amplifier for a digital position loop driving a current loop Note The current loop gains and limits apply to the current loop operating inside the digital position loop In this mode some of the values for motion profile and all of the values for current loop are applicable Selecting Digital Position Mode 1 From the CME Main menu select the Amplifier pull down menu 2 Select Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button id displayed Select the button to display the full Amplifier Status Now Screen 4 From the Operating Modes pull down menu select Pos gt Torque 5 From the Motion Profile pull down select Gear 6 From the Digital Position Input Source pull down menu select one of the following A B Encoder where quadrature encoder pulses are us
8. J1 power and motor winding connections Figure 4 2 Typical Connections Position Mode 48 Amplifier Operating Modes Velocity Mode In Velocity mode you can configure the amplifier for a velocity loop in a position loop driving a current loop The velocity loop operates as a position loop that never reaches the destination position Note The torque loop gains and limits apply to the torque loop that operates inside the position loop In Velocity mode some of the values for motion profile and all of the values for position loop values are applicable In Velocity mode you can also set up the system to command velocity from a 10V reference This is described later in this section Selecting Velocity Mode 1 From the CME Main menu select the Amplifier pull down menu 2 Select Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button is displayed Select the button to display the full Amplifier Status Now screen 4 From the Operating Modes pull down menu select Pos gt Torque 5 From the Motion Profile pull down menu select Velocity Note For proper operation always stop the motor before you select a different operating mode 7XX8 Series Digital Servo Amplifier User Guide 49 Velocity Mode Using a 10V Reference In Velocity mode you can also set up the system to command velocity from a x10V reference Selecting Velocity Mode Using a 10V Reference 1
9. This group consists of the Preset signals Preset 1 Preset 2 Preset 3 Preset 4 and Reset For fail safe operation such as a disconnected or wire broken a software command controls the Preset and Reset inputs pull up or pull down level as a group This circuit Figure 2 25 works with single ended TTL signals and single ended open collector signals Input circuit same for all presets and reset Homa Common DSP Pull up to 5V or Pull down OV 22k for this group 22k HCT14 gt ANN o 10nF Ts V Copley Driver Figure 2 25 Preset and Reset Input Circuit Connections to a Remote Computer Preset 1 Preset 2 Preset 3 Preset 4 Reset Note Copley Driver Amplifier signal ground must be connected to controller ground Figure 2 26 Connections to a Remote Computer with Pull ups at 5 V 2 24 Amplifier Connections Status Outputs There are two status outputs that are used to indicate amplifier status or fault conditions The outputs are N channel MOSFET with 10k Ohms pull up resistors to 5VDC The specifications are Maximum off voltage 50VDC Maximum sink current 250mA On resistance 5 ohms The status outputs can be used to drive a relay opto coupler or PLC input See Figure 2 27 which contains a relay and optocoupler configuration with and external 24VDC supply 24V Coil supply RELAY CLOSED WHEN STATUS 1 IS LOW
10. cca amplifier file A file containing all amplifier FLASH values 16 presets and amplifier setup ccm motor file A file containing motor data CME uses cca file data to calculate values that can be stored in FLASH memory as part of preset data Pendant A module that selects presets and intercepts status and error signals from the amplifier on the signal bus It takes the place of auser equipment for purposes of application test and debug Preliminary motor Either a ccm file or a motor specification before it has been calculated data modeled by Copley Motion Explorer Preset A set of values stored in FLASH memory that contain all the information to operate the amplifier Up to 16 presets are available Table 1 2 New Terms 7XX8 Series Digital Servo Amplifier User Guide 1 5 1 6 Introduction CE Mark and UL Conformity In compliance with CE Mark the 7XX8 Series of Digital Servo Amplifiers are in conformity with the following standards EN 50081 1 1992 Electromagnetic Compatibility Generic Emission Standard EN 50082 1 1992 Electromagnetic Compatibility Generic Immunity Standard EN61010 1 1993 Safety Requirements for Electrical Equipment for Measurement Control and Lab Use The 7XX8 Series of Digital Servo Amplifiers are in conformity to the following UL standard UL 508C Standard for Safety Power Conversion Equipment Unpacking and Inspection Verify that the model number s of the product match
11. 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Q O 0 6 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 O O0 o00000000000000 0 o 000000000000000 0 0 0 0 0 0 0 0 0 0 0 070 0 0 0 0 o o 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 6 22 090999995959 595959 59595959 5959596 3 00 0 0 0 0 0 0 0 0 0 0 0 0 0 O 0 0 76 2 158 6 94 0 0 0 0 0 0 0 0 0 0 0 0 O0 O O 0 0 76 2 050 00 0000 OO O OO OO OO 176 3 o0 0000000000000 0 0 o o 0v0 0 0 0 0 070 0 0 0 0 0 0 o OO0 0000000000000 O o 0000000000000 00 O00000000000000000 v v T T v SE la 7 00 m 177 8 3 A A QUE LOC DC D 2 72 gt B a uU Figure A 1 Mechanical Outline AC Model Technical Specifications Moron eon 4 72 Wi Heat Sink Option 119 9 AC Model Connections J1 J2 J3 J4 Power and motor 9 position terminal strip Motor 15 position female Sub Dtype 4 40 standoffs for cable shell lock Use 15 pin Male Sub D solder cup amp backshell AMP 747904 2 amp 749915 2 or equivalent Signal 37 position female Sub D 4 40 standoffs for cable shell lock screws Use 37 pin Male D solder cup amp backshell AMP 747916 2 amp 749916 2 or equivalent RS 232 9 position female Sub D 4 40 standoffs for cable shell lock screws Use a 9 pin Male Sub D solder cup amp backshell AMP 747904 2 amp 749914 2 or equivalent Connector shells are connected to the amplifier chasis for ground ing shieldi
12. 5 36 displays various communications messages including the command Level 0 or Level 1 typeof message INFO WARNING ERROR The commands you can monitor in the Communiuctions Log screen are described as two levels Level O Level 1 When selected Level 0 commands that display Figure 5 36 are instruction mnemonics that describe the machine language commands in Copley Motion Explorer Instructions are 16 bit words the first eight bits consist of the hexadecimal code that represents the instruction For example in Figure 5 36 notice the Sent Get Acceleration command It s hexadecimal representation is 4C The Get Acceleration command reads the data in the Acceleration parameter under Motion Profile on the Amplifier Status Now screen for the preset that is currently selected Note To display commands in the Communications Log screen check Level 0 Then you must also access the Amplifier Status Now screen and select Status Updates When selected Level 1 commands are Get Presets hexadecimal representations of the active preset To display Level 1 commmands you must open the PreSet Manager screen Select a Preset in View select Make Active and select Interrogate 7XX8 Series Digital Servo Amplifier User Guide 5 51 Communication Log Screen FFFBOF87 lt 0 gt SENT GetSettlewindow 00 43 00 BD FFFB F87 0 RCVD GetSettlewindow 00 00 00 00 FFFB F87 0 SENT GetTrackingwindow 00 57 00 49
13. 97 Commutation Selects a commutation mode for the motor Mode Sinusoidal Used wirth ACBL motors Requires encoder on motor Halls optional but recommended The output of the trajectory generator is used to calculate the phase angle This angle is used to generate sinusoidally varying outputs to each motor phase Used with sinusoidal commutation Initialization routine required Halls not needed Counts per electrical cycle or counts per pole pair Phase Correct When enabled the encoder index signal is used to update the commutation Mode phase angle for each motor revolution Phase Prescale Divides in number of encoder counts by 64 for long moves with a large number of encoder counts Default Off 5 22 Using Copley Motion Explorer uL wemmnsmemmen O ro OOOO O o Grona NN NN Table 5 10 Motor Data Parameters 7XX8 Series Digital Servo Amplifier User Guide 5 23 Digital Position Input You use the Digital Position Input pull down menu Figure 5 15 in Gearing mode to select a command signal to drive the amplifier The Input Source may be A B Quadrature Encoder Pulse and Direction such as stepper commands Clockwise or Counterclockwise Polarity may be NonInverting or Inverting Gear Ratio is used to set the number of input pulses to the same count as the number of output pulses on the motor 65536 equals a 1 to 1 count Value slave counts master counts x 65336 To enter a value in the Gear Rati
14. FFFBOF87 0 RCVD GetTrackingWindow 00 42 3E 80 FFFBOF87 0 SENT GetPosition 00 BB 00 44 FFFBOF87 lt 0 gt RCVD GetPosition 00 DF FF FF 63 CO FFFBOF87 lt 0 gt SENT Get amp cceleration 00 B4 00 4C FFFBOF87 lt 0 gt RCVD GetAcceleration 00 DD 00 00 03 20 FFFB F87 0 SENT GetDeceleration 00 6E 00 32 FFFB F87 0 RCVD GetDeceleration 00 00 00 00 00 00 FFFB F87 0 SENT GetJerk 00 A8 00 58 FFFBOF87 0 RCVD GetJerk 00 00 00 00 00 00 FFFBOF87 lt 0 gt SENT GetVelocity 00 B5 00 4B FFFBOF87 lt 0 gt RCVD GetVelocity 00 SE 00 0D AA AB FFFB F87 0 SENT GetProfileMode 00 5F 00 41 FFFB FS CVD GetProfileMo Figure 5 36 Diagnostics Comm Log Screen 5 52 Using Copley Motion Explorer Diagnostics gt Special DSP Commands Selecting Diagnostics gt Special gt DSP Commands displays the Copley DSP Commands screen Figure 5 37 You can use the DSP command pull down menu on this screen to select a specific command and send it to the amplifier You can read the commands hex code low byte which is initially displayed in a grey box In conjunction with the Communication Log screen Figure 5 38 you can verify that specific commands are sent and received Select Enable Logging to display data Many of the Set Commands are buffered Buffered commands must be followed by the update command to take effect For more information see the 7XX8 Series of Digital Servo Amplifier Programmer Referenc
15. LIN IO Penela na Phares Postres Em X dek 2278 Statua una i Picea et Tine 100 mS Seii Tene SE ka T IP De Hearn itn Selle Winds RMA Mask Tore PHa Sonn CE E 2 e F kine hao Mek IHI Bees Teno Line E a La Figure 5 18 Preset Manager Screen 7XX8 Series Digital Servo Amplifier User Guide 5 29 Make Active Loads the Preset In View to both temporary and fllash memory in the amplifier Make Actrive has the same effect as enabling a preset switch on the pendant The software will ask you to disable the amplifier in order to perform this task Loads the preset manager with the current values from the Amplifier Status Now screen Clears all the values in the current preset Uploads a preset from the amplifier to RAM in the PC Copy Makes a copy of the existing preset screen which you may paste into another preset screen Pastes a copy of a preset screen into another preset screen Download the Preset In View to flash memory on the amplifier Download All Download all presets 0 15 to flash memory on the amplifier NE Only available with preset 15 See the section that follows this table Table Preset Manager Screen Buttons 5 30 Using Copley Motion Explorer Motor Menu On the Main menu Figure 5 21 the Motor pull down menu has three options Motor Data Motor Temp Sense and Select M CopleyMotionE xplorer File View Amplifier Motor Tools Diagnostics Windo
16. Logo parameters 5 18 Positim I Timing 3 11 Position Mode 4 6 Pos Neg Enables 2 22 Preset defined 1 5 Preset and Reset Inout Circuit 2 24 Preset Mereger Screen 5 29 Pofiles 3 11 Q Quadrature encoders 2 10 R RS 232 Communications Mode 2 27 RS 485 Communications Mode 2 29 S Safety Gromding 23 Shielding 2 8 Software Parameter Notes 3 11 Secifictias Al Starting Copley Motio Explarer 3 3 gans Lie 53 Status Outputs 2 25 3 12 5 28 Status Update Checkbox 5 13 Stop Motor Window 5 57 T Temperature Sensor Input Circuit 2 14 Tem rology 1 8 Tools Auto Besing 5 4 Tools gt Download Fimware 5 46 Tools gt Encoder Check 5 47 Tools Menu 5 41 Tools gt Options Commicatios Screen 5 43 Tools gt Qotims gt Directories Screnm 5 44 Tools gt Optians gt Advanced Screen 5 45 TheMe 4 2 Trace Gah 541 Travel limit Ipits 2 22 U User ad trol Signals 73 2 16 user interface 5 1 Wiga cm File 3 3 V Velocity Mode 4 9 Vecifyirg Hardware Installatim 3 2 Verifying Software Parameters 3 6 View Menu 5 5 Voltage amp Current Ratings of Mains 24 W Window Menu 5 54 7XX8 Series of Digital Servo Amplifiers User Guide B NOTES
17. Make changes as needed When you re ready press Apply to Amp button to accept data m Motor Data r Current Loop m Position Loop Loop Gain Loop Gain Bandwidth m andwi Sinusoida Eabb p o Pp 286330 P OTT JHal Based asing Mor een D 1 185328 EE aa 8 Phase Counts Stiffness 16 Counts rev Bandwidth 9014310 p ETT EET Integrator Off s phas Cornet ode num Em Off Phase Prescale estan 15530 uz Meal AG 1000 ms Phase Init Time 1308 ap da rcm E CN v Encoder Polarity PS 0 Kout o HallOffset deg 0 Cont Curr Lim A 100 Integral Limit Ji AB Index o Peak Curr Lim 4 Derivative Time 4 99 High 1000 Peak Time ms 32000 Position Error Limit 25 Low I No Temp Sensor 97 PWM Limit B4 Tracking Window Apply to Amp amp Close window Apply to amp mp Cancel Figure 5 27 Apply Motor Data 7XX8 Series Digital Servo Amplifier User Guide Motor Temperature Sensor Screen From the Motor drop down menu you can access the Motor Temperature Sensor screen Use the adjustable slides to set upper and lower temperature thresholds lt a Motor Temperature Sensor Figure 5 28 Motor Temperature Sensor Screen 5 40 Using Copley Motion Explorer Selecting Tools from the Main menu provides access to the following features Trace Graph Options Download Firmware and Encoder Check Auto Phasing and Home
18. Specification screens and manually input the data from your motor s specification In the last two scenarios select Calculate Motor Data on the Motor Data gt Data Specification screen The modeled data should be displayed in the Apply Motor Data screen Selecting the Apply to Amp button displays the Motor Data on the Amplifier Status Now screen Tus Comnanidiadion Mode rote m Phang Mode 2000 Pia Count Ch Phase Covent Mode En E Phasa ce ono Phaea bet Tires ECs Hel Es uvu E H Bales Emm Posi m Abina bom Hl Tarp Samma pao f F Temp Series P Aeaee on Figure 5 14 Motor Data Amplifier Status Now Screen 7XX8 Series Digital Servo Amplifier User Guide 5 21 Current Limit Selects either an internal or external current limit control source for the motor Control Source Internal peak and continuous current limit values use Must be gt continuous current External voltage used to set peak current Range 0 10V Continuous Sets the continuous current limit for the motor Used to protect the motor in a Current Limit stalled condition Range 0 10 Amps Peak Current Sets the peak current limit for the motor Used to protect the motor from large Limit current commands Do not operate amplifier in a current limit this is for protection only Range 0 20 Amps PWM Limit Sets the pulse width modulation limit for the motor Used for limiting the average voltage applied to the motor Range 0
19. Tools gt Trace Graph This feature lets you select parameters Figure 5 29 to trace in real time on the Performance Trace screen Figure 5 30 Actual position lo ET position a Commanded position Commanded velocity Commanded acceleration Figure 5 29 Trace Parameters 7XX8 Series Digital Servo Amplifier User Guide 5 41 You can select up to four parameters to trace at a time Each one is represented on the trace screen by the color adjacent to your selection Selecting Immediate displays consistently refreshing trace parameters Selecting Update displays trace parameters after an update command or after applying a change Selecting Arm initiates a trace Selecting AutoArm repeatedly initiates a trace Select Torque displays a second chart representing U and V current on the X and Y axis Selecting Buffer Size sets the number of samples Selecting Interval re initiates and re displays traces at regulartime intervals BM e cub B Barranco 112 I Tem ERE p D pede erro pope Figure 5 30 Performance Trace Screen Using Copley Motion Explorer Tools gt Options On the Tools menu select Options to access the following features Communications Directories and Advanced Tools gt Options gt Communications Screen As with the On Line Connection screen the Communications screen lets you select a default port and baud rate for communications between the amplifier and a PC or laptop
20. Tuning Slides The Apply Motor Data screen has tuning slides Figure 5 27 You can use the slides to adjust the results of the data modeling The tuning slides affect Current and Position Loop The parameters associated with the slides Bandwidth Stiffness etc also have values resultant of the modeling process Increment the slides and check system response 5 38 Using Copley Motion Explorer C Bandwidth Used to increase or decrease the current loop response If proper values for motor inductance and resistance are entered the default current loop response is typically gt 1kHz Peaking Used to affect the amount of overshoot of the current loop response Typical peaking is about 5 The default current loop valuse calculated by the model are highly reliable so it is not necessaary to change them Bandwidth Used to change the system bandwith as it affects PID values I and D Used to change the overall system gain by affecting the Kout term Used to change system stiffness by affecting the P term Used to change the amount of inttegration I term Used to change the acceleration feed forward by affecting the Kaff term Used to reduce position error during acceleration Used to change the velocity feed forward fy affecting the K vff term Used to reduce position error during velocity Table 5 13 Tuning Slides zW Apply Motor Data These are the results of calculations using data from the MotorData form
21. be larger than the motor s nominal voltage rating for the absolute maximum voltage rating Consult the motor manufacturer for more information The current delivered by the supply can be calculated from the equation I P V Furthermore the power supply should be able to handle any current surge that occurs during power up The Copley amplifier limits the current surge to 37 Amps maximum on power up External Capacitance Required The capacitor used in the bridge rectifier circuit must be able to keep the voltage ripple or Vrip at sufficient levels and the capability of storing 10 times the energy regenerated from the load The capacitor C may be calculated from this equation C 1 120Hz Vrip DC Model r gt Ji o_o ei cg 4 e Inrush limiter dep e 3 iie Cw OT Qe 2 i Wht Blu Bik Brn jt Grn Grn Yel 120VAC Wiring for 72XXDC Copley Amplifier Fuses time delay 230VAC Wiring for 74XXDC Note All lines in this power stage are HOT At mains potential Figure 2 3 DC Model J1 Connector Note Circuits shown are typical connections and are not for design purposes Pin Signal Function el Amplifier output to V winding of motor Amplifier output to W winding of motor GND Chassis safety ground Also for cable shield of motor cable Table 2 2 DC Model J2 Pin s Description 7XX8 Series Digita
22. gt Gnd 34 X Vv Copley Driver Figure 2 23 Current Limit Input Note The values above are within 10 typically For greater accuracy measure current monitor and select parts for exact limit value 7XX8 Series Digital Servo Amplifier User Guide 2 21 2 22 Amplifier Connections Amp Enable Limit and Home Switch Inputs Amp Enable Input The Enable input functions as an on off switch for the drive When activated the drive functions normally When deactivated the output stages are disabled If the motor is turning and no brake is engaged the motor will coast to a stop The state of the Status LED is also affected by the Enable input If it is activated and there are no faults then the LED will be green Deactivating the Enable will cause the LED to flash green The active level and open circuit state of the enable lines can be software configured in the Amp Setup screen Travel limit Inputs Pos Neg Enables These inputs are typically used with end of travel limit switches When a PosEnable or NegEnable are activated the amplifier inhibits further driving into a travel limit but still enables the amplifier to back out Since motion in one direction is permitted changing the state of these inputs has no effect on the status LED Home Switch Input The Home input is used to detect the home position Enable Limit and Home Input Circuit The Enable Limit and Home input circuit Figure 2 23 is used to rec
23. initialization should be complete 10 Save the values to a Preset 7XX8 Series Digital Servo Amplifier User Guide 3 31 Tuning After Auto Phasing With a new motor applied to a load you may want to tune the system Select the Apply Motor Data screen and use the scale bars described below to adjust the System response Bandwidth Used to increase or decrease the current loop response If proper values for motor inductance and resistance are entered the default current loop response is typically gt 1kHz Used to affect the amount of overshoot of the current loop response Typical peaking is about 5 The default current loop valuse calculated by the model aare highly reliable so it is not necessaary to change them Position Loop Position Loop Bandwidth Used to change the system bandwith as it affects PID values I B D mainly Gan Used to change the overall system gain by affecting the Kout term Stiffness Used to e system stiffness by affecting the P term Integrator pe to change the acceleration feed forward by affecting the Kaff term Used to reduce position error during acceleration Used to change the velocity feed forward fy affecting the Kvff term Used to reduce position error during velocity Table 3 1 Tuning After Auto Phasing 3 32 Getting Started Chapter 4 Operating Modes This chapter describes operating modes that you may select to run with your amplifier and motor You
24. position as read from the encoder units of encoder counts The difference between the commanded and actual position encoder counts Commanded The commanded velocity encoder counts cycle 2 9 Velocity Actual Velocity The actual velocity encoder counts cycle 2 9 Commanded Torque The commanded motor torque Commanded Current Commanded current for winding 1 after commutation Max 25A 10V Winding 1 Actual Current Actual current for winding 1 as read from the A D converter Max 25A 10V Winding 1 multiplier 1 Actual Current Actual current for winding 2 as read from the A D converter Max 25A 10V Winding 2 multiplier 1 Current Error Difference between the actual and commanded current for winding 1 Max Winding 1 25A 10V multiplier 1 Commanded Current Commanded current for winding 2 after commutation Max 25A 10V Winding 2 multiplier 1 Current Error Difference between the actual and commanded current for winding 2 Max Winding 2 25A 10V multiplier 1 Output Command Output of current loop for winding 1 Max 25A 10V multiplier 1 Winding 1 Output Command Output of current loop for winding 2 Max 25A 10V multiplier 1 Winding 2 5 26 Using Copley Motion Explorer Analog Monitor Test dl and Phase Phase Angle Phase Phase angle used for commutation Range is 0 to Phase Counts 1 used for commutation Range is 0 to Phase Counts 1
25. postion buffer if motor shaft is out of Error position at initialization Thus the current destination position equals the actual postition Tracking Window Sets boundaries for actual motor position If the boundaries are crossed during trajectory then the tracking indicator is set Loop Sample Time Amplifier s digital control loop sampling time This parameter is factory set to 205 microseconds Table 5 8 Position Loop Parameters 7XX8 Series Digital Servo Amplifier User Guide 5 19 Current Loop You can use the Motor gt Data gt Specification screen to calculate initial current loop values Typical values produce 1kHz current loop bandwidth depending on power supply voltage motor resistance inductance and P andl values Current Loop Loop Gain 665 P 577 o Bias Figure 5 13 Current Loop Parameters A force proportional to error integrated or accumulated over time Sets the bias voltage of the digital servo filter Table 5 9 Loop Gain Parameters A force proportional to error between actual and commanded current 5 20 Using Copley Motion Explorer Motor Data You can set the Motor Data parameters Table 5 10 in several ways Obtain a cca file from Copley Controls Opening the file displays the Motor Data in the Amplifier Status Now screen Upload a ccm file provided by Copley controls to the Motor Data gt Specification screen Open the Motor Data
26. preset see figure 5 43 the CVM program will run the selected function after the preset is loaded TW reani Figure 5 43 CVM Sequence selection When the CVM program is running the program counter and CVM status can be viewed on the Amplifier Status Now screen To stop a CVM program while it is running press the Stop button see figure 5 44 Figure 5 44 CVM monitor 5 58 Using Copley Motion Explorer The Standard CVM Program loaded by the factory contains the homing routines The Standard CVM Program can be loaded by the user from the file menu by selecting load CVM and selecting the appropriate filename cvm file See the user guide for details on how to use the homing routines m View emplear Poto Mew i Open Saye S aval Ezt Figure 5 45 Loading CVM Custom CVM Programs may be documented and available for use by qualified customers New CVM Programs can be loaded by the user from the file menu by selecting load CVM and selecting the appropriate CVM file If the custom sequence is selected in a particular preset it will run after the preset is loaded See the associated document with the Custom CVM Program being used for details 7XX8 Series Digital Servo Amplifier User Guide 5 59 NOTES 5 60 Using Copley Motion Explorer Appendix A Technical Specifications The technical specifications were generated under the following test conditions 25 degrees C ambient Load 400 uH in s
27. screen brushless is defined as a sinusoidally or trapezoidally wound wye or delta connected brushless motor Two buttons Calculate Amp Data and Save As File are also important to retaining amplifier parameters See the next section 5 32 Using Copley Motion Explorer Motor Data Specification Feedback Screen Enter motor data on this screen if you are manually entering your motor specification in order to calculate amplifier parameters On this screen use the encoder data sheet to determine the number of Encoder lines Typical Encoder lines values are 500 1000 1024 etc During the Encoder Check Routine Chapter 3 CME multiplies the number of Encoder lines found by four to determine encoder counts per revolution of the motor shaft If the motor has an index signal check Index Then select the relative timing of the index pulse f the index is 1 4 of a line select the correct location Example Index Hi when A and B are Hi ELI Incremendal Encoder Encode ine in Lm ES F Indes On EE Ll E P a Temp Sensor C ve Ao Tupe Figure 5 23 Motor Data gt Specification gt Feedback Screen Linear Parameter s Linear Encoder Resolution um Magnetic Pair Length mm Save data as described earlier in this Motor menu section 7XX8 Series Digital Servo Amplifier User Guide 5 33 Motor Data gt Specification gt Ratings Screen If you are manually entering your moto
28. use the slide bar to increase the current that is applied to the motor The maximum output current of the amplifier is limited to 20 amps You can also use the Command Current in Position mode Pos gt Torque with algorithmic phasing In this mode the command value is used by the motor as a reference point when you perform algorithmic phasing Enables The Amplifier Status Now screen contains check box controls several Enable lines Figure 5 10 Select the enables as you would set digital logic on a controller For example if the polarity is reversed set the enable lines low Operating Mode The Amplifier Status Now screen contains the Operating Mode pull down menu Figure 5 10 For more information see Chapter 4 Operating Modes The pull down menu provides the following modes Torque Torque mode use Command Current 10V gt Torque Position mode Pos gt Torque Velocity mode 10V Pos gt Torque Digital Position mode Note For proper operation always stop the motor before you select a different operating mode 7XX8 Series Digital Servo Amplifier User Guide 5 15 Motion Profile Initial Motion Profile parameters Figure 5 11 are calculated from data you input on the Motor gt Motor Data gt Specification screens or parameters that you upload from a cma file to the Motor gt Motor Data gt Specification screens You can manually change adjust these parameters Tabl
29. 0 0 0 0 s O0000000000000000 au SEIT gt e ET Y st Y J3 sinn Ut 0 0 O amp O s J 2 se v Bt Hi 2 s U 4 Ee 7 00 B lt W 6 177 8 g J2 S O A 15 o9 8 0 5 EC ee L 2 OQ r r FH Copley 55 E c Y 2 00 Cases 1 00 50 0 Westwood MA USA 25 0 Y 4 00 w Heat Sink Option Heat Sink Option 100 0 Figure A 2 Mechanical Outline DC Model Technical Specifications DC Model J1 J2 J3 Signal J4 RS 232 Connectors Power and motor 7 position terminal strip Motor 15 position female Sub Dtype 4 40 standoffs for cable shell lock Use 15 pin Male Sub D solder cup amp backshell AMP 747904 2 amp 749915 2 37 position female Sub D 44 40 standoffs for cable shell lock screws Use 37 pin Male D solder cup amp backshell AMP 747916 2 amp 749916 2 9 position female Sub D 4 40 standoffs for cable shell lock screws Use 37 pin Male D solder cup amp backshell AMP 747916 2 amp 749916 2 7XX8 Series Digital Servo Amplifier User Guide A 5 A6 Other Technical Specifications for DSP Model 7XX8 Load inductance Minimum inductance Maximum inductance Bandwidth Small signal PWM outputs PWM frequency Modulation Reference inputs Torque or velocity Position pulses Preset 400UH No maximum Maximum varies with inductance and supply 3dB 2kHz with minimum load at nominal supply voltage Varies with load ind
30. Amplifier OK Indicators 7XX8 Series Digital Servo Amplifier User Guide 5 11 Enables Button Select the Enables button to display the Enable Inputs Screen This screen allows you to view the Enable Positive Enable and Negative Enable input lines to Switches on the pendant board Switching the Pos or Neg enable to off halts the motor s rotation When properly connected to a motor the Enable Pos and Neg indicators should be green If not use the Amplifier Status Now More screen to change the active levels of the Enable Inputs Or if the Enable indicator is red set the ENAB switch on the pendant down ON LI nable Inputs AS PORTS f eH X por Opes Herm dE AEEA pa heed MON EB ioc Aces B8 H i Feni n BH H 1 Enabled MOT Enabled Aciwe Level Selectnn Enablis Inpa Line Figure 5 9 Enable Inputs Screen 5 12 Using Copley Motion Explorer Amp Setup Button This button Figure 5 10 displays the Amp Setup screen described earlier in this section Last Preset Loaded This indicator Figure 5 6 displays the number of the last preset loaded displayed More Less Button Clicking this button Figure 5 6 changes the Amplifier Status Now screen by increasing or decreasing the displayed portion of the window Status Update Checkbox Check this box Figure 5 6 to update the status information in the Amplifier Status Now screen Updates occur at pre determined intervals defined in the Too
31. B A I3 7 lt on e ue Enc B past Enc X E Enc X 5V y Group Prog gt Ly logic Ly Ly Pull up down Preset input Active state Prog Power 12 ov 1 Shld Motemp Sensor H 9 ADC Gnd Group Prog _ Pull upidown Enable gt input logic Active state aa rog PWM Stage ph Bridge amp Current Sense Monitor DAC Status FETS Internal See Figure 2 4 for DC 2 information regarding Inrush limiter Functional Diagram Amplifier Connectors Note Circuits within dashed line are HOT At mains potential Motor Overtemp Ri E a A Grounding A single point star ground should be used with all device grounds converging Do not daisy chain the connections to ground The ground connections should be as short a distance as possible The motor ground should be connected directly to the amplifier Safety Grounding For safety it is important that amplifier frame ground on J1 be connected to earth ground typically through the power cable Note Frame ground on AC models is at J1 3 Frame ground on DC models is at J1 1 The connections on the power board such as the motor phase are at line potential Signal Grounding The signal board is full
32. Commanded The commanded position units of encoder counts clipped to 16 bits Position clipped Actual Position The actual position units of encoder counts clipped to 16 bits clipped Position Error The difference between the commanded and actual position encoder counts clipped clipped to 16 bits Commanded The commanded velocity encoder counts cycle 2 5 clipped to 16 bits Velocity clipped Actual Velocity The actual velocity encoder counts cycle 2 clipped to 16 bits clipped Runing Current The sum of the differences between the commanded torque squared and the Summary torque threshold squared This is the sum that is compared ti the programmable current limit Running Current Same as above but clipped to 16 bits for better resolution Summary clipped Table 5 11 Analog Monitor Signals 7XX8 Series Digital Servo Amplifier User Guide 5 27 Status Outputs On the Amplifier Status Now screen there is a segment Figure 5 17 that lets you program the Status Outputs lines from the Amplifier to be read on pendant You can program the pendant indicators STAT 0 and STAT 1 to indicate whether a motion profile is active or a fault has occurred Select the Status Output button to open the Status Output screen Check the appropriate status box True False button and On Hi LO option STAT 0 and STAT 1 have mask and sense bytes Hex Mask data is sent to the amplifier Sense data is read fromthe amplifier S
33. Figure 3 4 which is a segment of the Amplifier Status Now screen Chapter 5 1 Adjust the integral limit to 0 or set the integration term I to 0 2 Increase the derivative term D for a sufficiently low position error 3 Increase the proportional gain P for a sufficiently stiff position loop 7XX8 Series Digital Servo Amplifier User Guide 3 11 3 12 Getting Started 4 Increase the Integration Limit and integration term I to keep the torque at a sufficient value while under load The Position Error Limit is the number of encoder counts allowed before a position error occurs Kout is a multiplier at the end of the digital position loop so it must not be set to zero See Chapter 5 for other position loop values Position Loop Loop Gain 21 47483547 Integral Limit 4 Derivative Time 32000 Position Error Limit 15530 Kaff 1308 Kwff 21 Kout index Capture Source Command Motion Done Mode pr Clear Position fisooo Tracking Window ps Servo Loop Sample Time Figure 3 5 Position Loop Tuning Trace You can use the Performance Trace screen to tune the system while the load is attached by exciting a profile On the Main menu select Tools gt Trace to display the Performance Trace screen See the Tools section in Chapter 5 for details Status Output You can use the Status Output feature to program Stat 1 and Stat 2 on the pendant to indicate motion profile active or an e
34. R5 200 R1 1 21k R6 200 28 10 5k Current n Limit cw R3 20 10V 17 35 18 36 19 37 27 34 11 SSSS SSSSSSS 45V Reset Preset 0 Preset 1 Preset 2 Preset 3 Analog Mon Enable Pos Enable Neg Enable Home Signal Gnd Stat 0 Stat 1 412V Ext Curr Lim Ref Input Ref Input Signal Gnd Ch A Ch A Ch B Ch B Ch X Ch X 5V OV Signal Gnd Signal Gnd B1 Figure B 2 Pendant Schematic B 4 Operator Pendant Appendix C Ordering Information Refer to this appendix when ordering accessories cables and development kits 7228AC 20A peak 10A continuouse from 32 132VAC 50 60Hz AC mains 7428AC 20A peak 10A continuouse from 32 264VAC 50 60Hz AC mains 7228DC 20A peak 10A continuouse from 45 186VDC 32 132VAC rectified 7428DC 20A peak 10A continuouse from 45 373VDC 32 264VAC rectified Software CD CD rom with Copley Motion Explorer Software Printed Users Manual for the 7XX8 Digital Amplifier Series Control Pendant Hand controller with switches potentiometers and connections for testing D Sub 9 pin 15 pin and 37 pin Male Solder Cup with Backshell mus ee jm ea bwcue m je emeweenem O 7XX8 Series Digital Servo Amplifier User Guide C 1 34MS 10 Military Style Twisted shielded c
35. User Guide Digital Servo Amplifier Models 7228AC 7228DC 7428AC 7428DC Chapter 1 Chapter 2 Table Of Contents iie miao b olo M RR 1 1 luz ibl C 12 Model Sai ieoa nis a Eare EA N ei 13 P selkio imica opm 13 Copley Motion Explorer Software 14 Software Requirements c ceeeeeeeee eene 14 Termnolody isveeex eese eeveseesee suave stavanvesancousdeveneesss 1 5 CE Mark and UL Conformity ccce 1 6 Unpacking and Inspection ccce 1 7 Technical SUDDOELU i i esee es een rte heroe aeneae psu si adn 1 7 CaP By co A oe iei Let oie ants repe adeak 1 8 Amplifier Connections cesses nennen 2 1 ico bise Kho o ETE 2 3 J1 AC amp DC Power and Motor Phase 24 DC Model Power Connections eee 2 6 Motor Phase Wiring Connections 2 8 J2 Motor Signal Wiring Connections 2 9 Amp Enable Limit anf Home Switch Input 2 22 Data Connector UA 14 5 eere rere ede rene etae 2 27 Amplifier Status Indicator eese 2 30 Signal Module eiie notat ea rab esee a Ire bae nha a eine 2 31 7XX8 Series Digital Servo Amplifier User Guide H 1 2 Chapter 3 Chapter 4 Getting Stated unte dc Ud diese tutes 3 1 Starting Copley Motion Explorer 3 2 Installation using Copley Motion Explorer Development Kit Motor ou eeeeeececeeeseeeceesee
36. a file filename ccm Motor connected to amplifier When using a new vendor motor the Encoder Checking and Auto Phasing routines should be executed to establish proper phasing Values for current loop gain terms P and I are calculated or configured General Rules Algorithmic phasing should only be used if it is known that the motor is free to move in both directions and that a brief uncontrolled move can be tolerated by the motor mechanism and load If this extra motion is not desired then use Hall sensors and Hall based phase initialization Use caution if connecting a load The Phase Init Time is used to set the duration of the phase initialization algorithm The value used during auto phasing is sufficient If set too fast then improper phasing may result 7XX8 Series Digital Servo Amplifier User Guide 3 29 The Command Current is used to move the motor The value derived during auto phasing is sufficient If set to low then improper phasing may result The value for Phase counts must be correct The Phase correction mode can be turned on This will use the encoder index to correct thecommutation phase angle This will correct for noise on the encoder line or a non integer number of phase counts Use PWM limit current limits and slow blow fuses o protect high cost motors Encoder Polarity normally low pulse high index or normaly high pulse low index must be set correctly for proper algorithm
37. a files Table 5 2 On Line Connection Screen Amp Setup Screen The Amp Setup screen Figure 5 5 has the following options Serial Port Amp Data Active Level Selection Preset Inputs Preset Input Resistors Reset Edge Apply to Amplifier Store to Amplifier Flash and Clear Changes Note These parameters are global amplifier settings and apply to all presets 56 Using Copley Motion Explorer Inga Lese autem o o o a HN Whna connecions E MOU MIN MN MI LL D Preset o E Prost Inputs p l S Pup Lemi E Figure 5 5 Amplifier Setup Screen Set the Baud Parity Stop bits and Protocol If using RS 485 set the Network Address Displays unit serial and model numbers Remarks user defined mnemonic Active Level Select active levels as you might configure hardware on a controller Also Selection displays present input level detected hex Result and decimal Preset results Debounce Time Sets the time required for the Preset switches to have complete closure i e ms switch noise complete When disabled ignore Preset iput lines J3 5 J3 24 J3 6 J3 250n pendant Preset Input Sets Preset Input Level to 1 or 0 1 Pull up to 5V 0 Pulldown to Gnd Resistors Reset Edge Select Reset line signal active on either rising of falling edge Apply to Amplifier Store parameters in RAM on amplifier for temporary use Store to Amplifier Apply amplifier global setup to flash memory o
38. ables for motor power and signal Amp i Plug 7228AC CBL 162BE 001 6000rpm 1 4 round 7428AC CBL 232AE 001 4500rpm 3 8 round 7228AC CBL 232BE 001 6000rpm 3 8 round nc m rond 7228AC 6000rpm sues fur keyway Notes 1 Kit Includes Power cord Data cable Motor signal cable Motor power cable Connector Kit Pendant cable Pendant Software CD and Users Manual 2 Size 16 amp 23 motors have flying leads with connector Size 34 motors have military style connectors C 2 Ordering Information Index A AC amp DC Power amp Motor Phase J1 24 Adjusting Calculated Motor Data 3 19 Algorithmic Has Initializatim 3 29 Amp Enable Input 2 22 Amp Enable Limit 2 22 Amp Enable Limit and Home Switch Ipis 2 2 Amp Ok Button 5 10 Amp Setup Buttm 5 13 Amp Setup Screen 5 6 Amplifier Comectios 21 Inplifier Men 5 5 Analog Mm tor 5 25 Analog Monitor Output 2 26 Amplifier Explorer Window 5 56 Amplifier Status Now Screen 5 8 Applicatims 13 Apply Motor Data Screen 5 38 Apply to Amp Buttons 5 37 Auto Hesing 3 A 5 48 C Calaulate Anplifier Data Button 5 37 CE Mark and UL Conformity 1 6 Copley Motion Explorer Software 14 51 Copley Virtual Machine CWM 5 58 Command Option 5 15 Comunications Button 5 10 Communications Log Screen commutation 2 13 Connections to a Remote Computer 2 24 Current Loop parameters 5 20 Digital command receiver 1 19 5 51 D Data Comector J4 1 28
39. al Servo Amplifier User Guide 3 7 3 8 Getting Started Enabling the Amplifier 1 On the pendant board set the Enable switch to the down position This is the default fail safe mode if the line is cut the amplifier is disabled 2 Observe that the amplifier s Status indicator turns solid green Initiate a Move with the Pendant 1 Observe the Amplifier Status Now screen Make sure all the indicators Communications Amp OK and Enable are green If they are not see the section called Amplifier Status Now screen in Chapter 5 2 You can initiate a move by switching the desired preset on the pendant Refer to the Application Note that you received with the development kit Homing Sequence The Homing routine s can be used in conjunction with a preset to perform a predefined homing routine You can access the Homing Sequence screen Figure 3 4 from the Tools menu by selecting Homing Make Current Position Home If you manually select a home position select Make Current Position Home and Apply to download the home position to the amplifier This is a medium accuracy routine that requires manual interface Home to Limit Switch Using the preset velocity the motor drives into the stop until the limit switch is hit The motor is then backed off until the limit switch transitions back The actual home position is dependant upon these switch characteristics This is a medium to high accuracy routine requiri
40. and you want to use this data and the data on the other Motor Data Specification screens 1 Selecting Calculate Amp Data to generates model amplifier parameters Note To fully generate amplifier parameters you must input data to each of the Motor Data Specification screens Type Feedback Ratings Electrical and Mechanical 2 The CME software models the data you ve input then displays the recommended parameters on the Apply Motor Data screen Figure 5 27 Save As File button Use the Save As File button to save the motor data as a Copley Controls Motor ccm file Apply to Amp Status Buttons When you select an Apply to Amp Status button the motor data is applied to the Amplifier Status Now screen Using the Amplifier Status Now screen temporarily load the data into the amplifier s volatile memory or permanently into the flash memory 7XX8 Series Digital Servo Amplifier User Guide 5 37 Apply Motor Data Screen You use CME to access this screen Figure 5 27 if you are a Manually inserting motor specifications into the Motor Data Specification screens b Uploading a ccm file automatically inserts motor data into the Motor Data Specification screen When you select Calculate Amp Data CME software models the data and displays the results in the Apply Motor Data screen Note The parameters on this screen are detailed in the previous section describing the Amplifier Status Now screen
41. ata in the file calculates new data and displays it in the Apply Motor Data screen Figure 3 8 You may make adjustments to data in this screen as necessary See the section later in this chapter called Adjusting Calculated Motor Data 7 Select Save As File if you d like to save the calculated data to your PC as a ccm file Select Save to Amp if you d like to save the data to the amplifier 8 Select Apply to Amp The Amplifier Status Now screen displays 9 Select More The data modeled from the ccm file is now associated with the appropriate amplifier and motor parameters on the Amplifier Status Now screen 10 Select Save As Preset if you want to save the data in the Amplifier Status Now screen to the flash memory on the amplifier 11 After saving data as a preset you can select File Save As at the Main menu to save the data as a cca file 12 Proceed to the section called Adjusting Calculated Motor Data E Apply Motor Data a SUM Figure 3 8 Apply Motor Data Screen 7XX8 Series Digital Servo Amplifier User Guide 3 15 NOTES 3 16 Getting Started Installation Using a Vendor Specification and Motor If you are using a vendor specification to install a new motor follow the instructions below Using a Motor Specification 1 Perform Verifying Hardware Installation p 3 1 2 Perform Starting Copley Motion Explorer p 3 3 3 From the Main menu select Motor gt Mo
42. cca or by applying calculated values using a motor data file filename ccm The motor must be connected to the amplifier When using a new vendor motor the Encoder checking and Auto phasing routines should be executed in order to establish proper phasing Procedure 1 Disconnect the load from motor when testing Torquemode operation 2 Set the Operating mode to torque and Command to 0 3 Verify Current Loop Gain P gt 0 and I gt 0 Current Limits Phasing Mode Hall Based Set commutation mode to Trapezoidal 5 Apply changes then enable the amplifier 6 Increase the command torque by 250mA and click Apply Repeat until motion occurs Reverse direction using a negative current Change commutation mode to Sinusoidal Apply command torque and verify the same direction of motion Check Current Loop Bandwidth Optional for properly calculated values Save settings to desired preset and an amplifier file filename cca 7XX8 Series Digital Servo Amplifier User Guide 43 Application Example Simple drive torque mode Preset 0 Command 1 Amp PWM Limit 10 Drive to neg limit with 1 25Amps torque and 16Vavg speed limit Preset 1 Command 1 Amp PWM Limit 10 Drive to pos limit with 1 25Amps torque and 16Vavg speed limit Preset 2 Command 4 Amps PWM Limit 97 Drive to pos limit with 5Amps torque and no voltage limit Figure 4 1 illustrates typical connections in Torque mod
43. ce with the tems of such license The information in this manual is furnished for informational use only is subject to change without notice and should not be construed as a committment by Copley Controls Corpo ration Copley Controls assumes no responsibility or liability for any Except as permitted by such license no part of this publication may be reproduced stored in a retrieval system or transmitted in any form without prior written permission of Copley Control Corp Copley Motion Explorer is a trademark of Copley Controls Corp Microsoft Windows 98 is a registered trademark of Microsoft Corpora tim pley Gmtxols Gap mks ro warranties epes or ilia iridiy without limitation te inplied wratis oC necimtauility ad fites fo a pertiadar prt regmr ding te Ge Mtin Explorer software Written and designed by Copley Controls Corporation 410 University Avenue Westwood MA 02090 Printed in the U S A Revision 1 1 Chapter 1 Introduction The 7XX8 Series of Digital Servo Amplifiers are high performance DSP Digital Signal Processor controlled amplifiers They control AC brushless motors with full sinusoidal commutation AC models operate directly from AC mains DC models operate from DC power sources which directly rectify the line All models have full isolation between signal and power stages No power transformers are required Built using surface mount technology these amplifiers offer a full complement of featur
44. coder input receives encoder pulses phase A phase B and index This circuit is designed to work with differential signals single ended TTL signals and single ended open collector signals Software supports the master encoder to perform position commands Electronic gearing can be used to ratio the master encoder command Receiver circuit same for all digital channel inputs PhaseA 4 gt Phase A N chA J17 gt Channel A m Phase A Ch A gt 35 gt Receiver Ea Ch B Phase B 18 gt Channel B PhaseB i Di gt Phase B gt lt x X Ch B 5 Receiver P Ch X Index J gt Pus b d cpm 19 Channel X Lg i naex 37 y Receiver S Case Gnd sma Case Gnd 1 Encoder circuit power ax isi 155 45V Power Gnd DY ov 250mA max s Mis Copley Driver 2 20 Amplifier Connections Figure 2 22 Differential Master Encoder Connections Current Limit Input The current limit can be controlled externally via connector pin J3 10 Figure 2 23 A resistor can be connected between this pin and signal ground J3 11 26 or 34 or the pin can be driven by a voltage between 0 and 10VDC Using this technique the current limit can be controlled over a range of 100 to 0 of the peak J3 Analog input circuit DSP 0OM0VDC Gurr Limit 200k ADCN2 gt 10 NVV n eink R 2 200k eT
45. d descriptions of the Copley Motion Explorer screens see Chapter 5 7XX8 Series Digital Servo Amplifier User Guide 3 1 32 Getting Started Verifying Hardware Installation Perform the following preliminary checks during all motor installations 1 Make sure all connectors are properly secured Figure A 3 2 Make sure the Status indicator on the amplifier is flashing green while power applied 3 On the pendant board Figure B 1 a Make sure all the switches are up b Make sure the Current Limit potentiometer is set fully clockwise c Make sure the 10 V potentiometer is set fully counter clockwise Starting Copley Motion Explorer 1 In Windows select Start Programs gt Copley Motion Explorer Copley Motion Explorer 2 The Welcome screen Figure 3 1 displays Select On Line button by clicking on it 3 The On Line Connection screen Figure 3 2 displays 4 Select the COMM port that connects the PC to the amplifier 5 Select the Desired Baud rate 6 Select Connect button to establish communication with the amplifier A successful connection is indicated by the following The Amplifier Found indicator turns green The bar graph fills to indicate that the presets are uploading from the amplifier to the PC The Model number Serial number and Firmware version of the amplifier display The Status indicator on the amplifier continues to flash green 7 Selecting the C
46. de to Algorithmic and Phase Correct Mode to ON Also set a Phase Init Time and set Commutation Mode to Sinusoidal Proceed to the next sections Encoder Checking Auto Phasing and Algorithmic Phasing Bi e e Fass v 2000 or wj or wj 1000 uvw sl E ps WP o oo Lof m Hm Figure 3 8 1 Adjusting Motor Data Encoder Checking The Encoder Checking routine verifies the integrity of the motor s encoder as follows Checks for the presence of encoder quadrature pulses Verifies the presence of an index pulse Verifies that you have selected the correct A and B signal synchronization to the index pulse Aids you in verifying the number of encoder lines Perform the Encoder Checking routine before attempting to auto phase a new motor You may also use this routine if you suspect problems with your encoder Encoder Checking Routine Warning Before proceeding make sure that the motor is free to move bi directionally and not connected to a load 1 Enable the Amplifier 2 To access the Encoder Check screen Figure 3 8 go to the Main menu and select Tools gt Encoder Check Amps Motor Command EN Conus Counts Rev EN Measured Counts Rev EN 5 Phase counts Measured Approx Phase Counts 4 Number of Poles f Check Encoder _ _ Z Encoder Polarity Jr xas mese Cm Index Sensed J Index captured Figure 3 9 Encoder Check Screen 7XX8 Serie
47. e Preset 0 Preset 1 I O Logic Encoder A Encoder A Encoder B Encoder B Encoder X Encoder X 5V Status 0 Enable Signal ground C 5V Note Amplifier signal ground must be connected to controller ground For J1 details on AC or DC model see J1 power and motor winding connections Figure 4 1 Typical Connections in Torque Mode 44 Amplifier Operating Modes Torque Mode Using a 10V Reference In Torque Mode you can also set up the system to command torque from a 10V reference In Torque Mode using a 10V reference the following apply current loop gains and limits currentloop values The values for Command Current Motion Profile and Position Loop are not applicable Selecting Torque Mode Using a 10V Reference 1 Select the Amplifier pull down menu from the CME Main menu 2 Click Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button is displayed Click the button to display the full Amplifier Status Now Screen 4 Select 10V Torque from the Operating Modes pull down menu 7XX8 Series Digital Servo Amplifier User Guide 4 5 Position Mode By selecting Position mode you can configure the amplifier for a position loop driving a current loop Note The current loop gains and limits apply to the torque loop that operates inside the position loop Within the position loop t
48. e 5 7 to satisfy your application requirements You can save all of the parameters on the Amplifier Status Now screen as one of 16 possible presets You may also save the parameters on the Amplifier Status Now screen as a cca file r Motion Profile Trapezoid Profile No Stop Stop o Position 500 RPM Velocity 200 mS Acceleration 200 mS Deceleration 12 2 Jek fi 0 mS Settle Time fi D Settle Window None Seq Figure 5 11 Motion Profile Parameters On execution of a preset the data assigned to a motion profile parameter is used to perfrom the motion profile 5 16 Using Copley Motion Explorer me LL Trapezoid A Trapezoid profile has a specified maximum acceleration deceleration and velocity They are used to calculate trajectory to a position A Velocity profile is is a position loop that never gets to the destination S Curve If you select a sinusoidal S curve then you must set a Jerk value S Curve is used to reduce positive error during acceleration and deceleration Also reduces mechanical distortion to the system Gear The ratio of Digital input counts to motor encoder counts Value slave counts master counts E Used to turn off a previously set stop comand Abrupt Stop Instantly without deceleration stops the motor without any deceleration phase Smooth Stop Uses programmed deceleration value and profile shape for the current mode to stop the axis Not used with Gear profil
49. e Manual Copley DSP Commands x SetVelacity Y 11 SetSignalSense ry SetStatusOutput SetStop SetT emperatureLimit SetTraceMode SetTracePeriod Figure 5 37 Copley DSP Commands Communication Log Screen x FFFA TSF 0 RCVD Update 00 00 FFFA019F lt 0 gt SENT Update 00 EB 00 14 FFFAO19F 0 RCVD Update 00 00 FFFAO18F 0 SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFA019F lt O gt RCVD SetVelocity 00 00 FFFA019F lt 0 gt SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFA019F lt O gt RCVD SetVelocity 00 00 FFFAO18F 0 SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFA019F lt O gt RCVD SetVelocity 00 00 FFFA019F lt 0 gt SENT SetVelocity 00 DF 00 11 00 00 10 00 FFFAO19F 0 RCVD SetVelocity 00 00 FFFA019F lt 0 gt SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFAQ18F 0 RCVD SetVelocity 00 00 FFFA019F lt 0 gt SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFAQ19F 0 SENT SetVelocity 00 EF 00 11 00 00 00 00 FFFAO19F 0 RCVD SetVelocity 00 00 2 IV Enable Logging Close Refresh Figure 5 38 Set Velocity Sent and Received 7XX8 Series Digital Servo Amplifier User Guide 5 53 The Window menu provides you with standard Window controls Cascade Tile Horizontal Tile Vertical Arrange Icons and Amplifier Status Now Help Menu The Help menu provides you with on line Help for the Copley Motion Explorer software Some limited Help is availab
50. e for a voltage rating of 300 V DC and a temperature range of 80 C To minimize coupling of PWM noise encoder signal wiring should be multiple conductor twisted pair shielded cable Furthermore all cable shields should be case grounded at both ends for compliance with CE emissions limits Cm Sm rmm mem C i I E E 4 E Table 2 3 J2 Hall and encoder Connections Note 1 5VDC 250mA also connects to J3 15 J3 27 and J2 11 Combined not to exceed 250mA 7XX8 Series Digital Servo Amplifier User Guide 2 9 15 J2 MOTOR o o o o o o o 00000000 Hall Receiver Case Gnd l Encoder Receiver amp Home pulse logic 4 k Case Gnd 5V Power 250mA max A Q N o 14 Case Gnd v ADC Sensor La 9 Motemp a Gnd Copley Driver V Figure 2 5 J2 Signal Connector Motor Overtemp Switch The J2 connector is a female Sub D 15 position with 4 40 standoffs for the cable shell More About Encoder and Hall Sensor Connections Encoder Sensor Quadrature encoders typically provide three signals Figure 2 6 two square waves phase A and B that are 90 apart and an index pulse which will typically occur once per revolution 2 10 Amplifier Connections There are several ways to configure the encoder interface However differential signals are reco
51. e mode Position Sets the trajectory destination of the motor Used with Trapezoid and S curve profile modes Max 2 1 Values lt 0 only in Velocity mode Velocity RPM Sets the maximum velocity for the motor Do not change with a motor in motion in S curve profile mode RPM Max 4MHz Counts Seconds Encoder Counts Revolutions x 60 Sets the maximum acceleration Not used with Gear profile mode Deceleration Sets the maximum deceleration Not used with Gear profile mode If 0 then Acceleration value is used Jerk Sets the Jerk value rate of change of acceleration for S curve profile only The 1 value approaches a Trapezoid profile Settle Time Sets the time in number of cycles to reach the steady state position within the settle window 1 servo cycle equals 205 microseconds Range 0 to 29 1 servo cycles Settle Window Sets the position range within which the motor must remain for the duration specified by SettleTime Range 0 to 2 1 counts Table 5 7 Motion Profile Parameters 7XX8 Series Digital Servo Amplifier User Guide 5 17 Position Loop An amplifier may use a Position Loop to hold a position You can use the Motor gt Data gt Specification screen to calculate initial position loop values Using the tuning slides on the Apply Motor Data screen adjust the values until they are within a usable range Table 5 8 describes Position Loop parameters Position Loop Loop Gain Integral Li
52. ected to controller ground Figure 2 16 Connections to a Controller Digital Command Inputs Digital input commands the same use with stepper motors can be used to command position See the waveforms Figure 2 17 Electronic gearing can be used to ratio the input command Positive direction Negative direction Channel A Pulse and Direction ChannelB Channel A Pulse CW and Pulse CCW Channel B L Channel A Quadrature Pulses Channel B Figure 2 17 Digital Command Inputs 7XX8 Series Digital Servo Amplifier User Guide 2 17 Digital Command Receiver The Digital command receiver Figure 2 19 receives the Channel A Channel B and Channel X inputs The circuit works with differential signals single ended TTL signals and single ended open collector signals Receiver circuit same for all Channel inputs Copley Driver Figure 2 18 Digital Command Receiver Digital Remote Connections The next several figures illustrate possible configurations to a remote computer controller J3 Pulse and Direction Receiver circuit differential configuration Case Gnd same for all digital channel inputs Pulse Ch A gt 17 l Channel A m Pulse XK X XxX Ch A ss k Receiver P Di Ch B 4s
53. ed Latches unit OFF will reset if Reset input is connected to Gnd or when power is recycled Latches unit OFF at 70 C on heatplate will reset if Reset input is connected to Gnd or when power is recycled Shutdown at internal DC buss lt 45VDC Shutdown buss gt 195 VDC Model 7228 or buss gt 390VDC Model 7428 Output current peak continuous and peak time limits programmed via RS232 port 7XX8 Series Digital Servo Amplifier User Guide A 9 120VAC Line Cord Fuse Black White Green Motor Power Cable Refer to the application note for connection details for this kit Brushless Motor 4 A 10 Connection Diagram You can use the connection diagram when connecting a user supplied motor See Chapter 4 Using a New RS 232 Cable PC or Laptop Pendant Signal Cable f Encoder Hall cable Motor Driver Model 7428AC input a2 26avac STATUS 50 60Hz ol oe A 8 c Jk aH OQ JU 2 SN OP Qe n sita Ojoj 38 ss erek B 5 Lo js 2s 3 ZU s 38 sox Sg EH SEA Ig IW ssk E Eley A hL sf HE IE cn gp id Westwood MA USA I zm ono M LI LT i Technical Specifications o Ll F z 2 fon 7xx8 Penda
54. ed as a master encoder to position the motor e CW CCW where pulses on the clockwise line produce CW rotation and pulses on the counter clockwise line produce CCW rotation e Pis Dir where stepper pulse and direction are used to position the motor 7 Under Digital Position Input set the Gear Ratio value to scale the number of digital input counts to the number of encoder counts 7XX8 Series Digital Servo Amplifier User Guide 4 11 Digital Mode Using a Master Encoder Use this procedure for master encoder mode operation Prerequisites Amplifier configured for motor either by downloading an amplifier file filename cca or applying calculated values using a motor data file filename ccm Motor connected to amplifier When using a new vendor motor the Encoder checking and Auto phasing routines should be executed to establish proper phasing Torque mode operation verified and functioning properly Position mode operation verified and functioning properly Procedure 1 Disconnect load from motor when testing master encoder mode operation Set the operating mode to Pos Torque mode and enter Motion Profile values Set profile to Gear and Digital Position input to A B encoder Set the Gear Ratio value 5 Set Kaff and Kvff to 0 These terms can produce noise at the motor 6 Apply changes then enable the amplifier The motor should be in a stationary position loop Rotate the mast
55. ed externally Power stage optically isolated 7XX8 Series Digital Servo Amplifier User Guide A 7 A 8 Motor encoder Inputs A B X Buffered outputs Enc Buffout A Enc Buffout B Enc Buffout X Hall inputs Logic inputs Enable Pos enable Neg enable Reset Technical Specifications 2 2kW internal pull up to 5V Differential or single ended 4 meg Counts Sec maximum HCMOS differential line driver buffered encoder output A HCMOS differential line driver buffered encoder output B HCMOS differential line driver buffered encoder output X U V W Single ended 10k Ohms internal pull up to 5V TTL 28V max Group programmable 22k Ohms internal pull up to 5V or pull down to OV Software pro grammable active Lo or Hi Enables amplifier within 5ms when active Enables positive rotation Enables negative rotation Resets latching fault condition recovers in 1ms Thermal Requirements Storage temperature range Operating temperature range 30 C to 85 C 0 to 70 C baseplate temperature Thermal resistance heatplate to ambient No heatsink or fan 2 7 deg C W No heatsink w fan 1 0 deg C W With heatsink no fan 1 6 deg C W With heatsink and fan 0 4 deg C W Protection Output to output short Output to ground short Overtemperature Undervoltage Overvvoltage Current limiting Latches unit OFF will reset if Reset input is connected to Gnd or when power is recycl
56. eeeeees Verifying Software Parameters Ikea alio f RIT EN Enabling the Amplifier oo eee eeeceseeceeeeeeeeeeeeees Initiate a Move with the Pendant Homing Sequence sororis i eieae oei ait aliate Software Parameter Notes Ecertion Loop TNG s 2 cesce esee ette unes Dr tree ves Installation Using a Copley Motor Data File and a New Copley Motor e eeeeee ee eee ene enne 3 13 Installation Using a Vendor Specification enclMOLUOE ete eeteotee mte a tne tes ne Pese te ee t ns e eet A 3 17 Adjusting Calculated Motor Data 3 19 Encoder Checking cc eeeeeeeeeee rennen 3 21 Auto PHASING zo eee e Re Ie RM 3 24 Algorithmic Phrase Initializatian 3 29 Operating Modes eeeeeeeeeeeeee eene eene 4 1 TOLQUE MODE ss csseicsidecccas tone deates cas T rh ao ecaeestes 42 Positron MOE L5 eicere eR cuneo e pestectee thee sese 4 6 Velocity MODE ere 4 9 Digital Position Mode e irite har eene 4 11 Chapter 5 Using Copley Explorer Motion Controller 5 1 M in WIndOW 3 eR decesteseiwastewensesesssenboed iaa 53 Exle Men ol Ideen ti tente ER EOS ER eA EVE 5 4 Mew Menu 4 secti iiecsed edes sepeseese siden s s iena Pede ses du dens 5 5 Amplifier Mer eo eerte Eran ea e EE e EY ee ea FR eu Rad 5 5 On Line Connection Screen esee 5 5 Amp Setup Screen dieere ere 5 6 Amplifie
57. eive the Enable signals Enable Pos Enable Neg Enable and Home For fail safe operation such as a disconnected or wire broken a software command controls the Enable and Home inputs pull up or pull down level as a group This circuit is designed to work with single ended TTL signals single ended open collector signals and PLC s that switch to 24V max or ground J3 Signal Gnd 26 Enable 3 21 Note Pos enable Amplifier signal ground Neg enable 22 must be connected to controller ground Home 4 Copley Amp Input circuit same for all enables and home nie Common DSP gt Pull up to 5V or Pull down OV 22k for this group 22k HCT14 gt N ie Y Figure 2 23 Enable Limit Home Input Circuit Copley Driver Figure 2 24 Enable Configuration Reset Inputs The Reset input can be used to clear a fault condition caused by over temperature or output short circuit The Reset line should be activated after the fault is removed In the case of over temperature fault the amplifier can be re enabled after the case temperature cools to lt 70 C In the case of a short circuit the drive can be re enabled every 50ms and will be shutdown as long as the short remains Digital Preset and Reset Inputs You can use the four Preset inputs to initiate 16 predefined velocity torque or motion profiles 7XX8 Series Digital Servo Amplifier User Guide 2 23 Preset and Reset Input Circuit
58. er encoder and verify that the slave encoder follows Motion profile limits apply The Trace can be used to monitor the profile source Encoder source 4 12 Amplifier Operating Modes 8 Check Position Loop Bandwidth 9 Verify that there is no current or voltage limiting during motion with a load 10 Save to an amplifier file filename cca Application Simple Gearing with Phase Advance and Retard Preset 0 Gear ratio 1 1 Slave Master ratio 1 1 tracking Preset 1 Gear ratio 1 2 1 Slave Master ratio 1 2 1 advancing Preset 2 Gear ratio 1 1 2 Slave Master ratio 1 1 2 retarding I O Logic Preset 0 Encoder A Slave Status 0 Encoder Ses Enable 5V Hall V NEM Encoder B Hall W J Master Encoder Gnd A Phase V Phase W For J1 details on AC or DC model see Signal Gnd J1 power and motor winding connections Figure 4 3 Digital Position Mode Using a Master Encoder 7XX8 Series Digital Servo Amplifier User Guide 4 13 Notes 4 14 Amplifier Operating Modes Chapter 5 Using Copley Motion Explorer This chapter describes the Copley Motion Explorer CME user interface The Copley Motion Explorer program is powerful software that enables you to optimize servo parameters for your application High level tasks that you perform with CME are described in Chapter 1 CME features and functions are available to you via a
59. eries with 1 Ohm Model Output power Peak power Peaktime Continuous power Output voltage On resistance Ro ohms Max PWM Peak Output Voltage Maximum effective output voltage at continuous power Maximum effective output voltage at peak power 7228AC 7428AC 20A 110VAC 20A 205VAC 1 second at peak power or 2 seconds after polarity reversal 10A 130VDC 10A 250VDC 0 2 0 15 VAC x 1 41 2 x 0 97 Ro x lo 130V 10ADC 250V 10ADC 110V Q 20ADC 205V 20ADC 7XX8 Series Digital Servo Amplifier User Guide A 1 A 2 Model Input Power Mains Voltage Mains current continuous output rating Inrush current on startup External mains fuse rating 7228AC 32 132VAC 47 63Hz 16A 19A max 20A 125V Time delay 7428AC 32 132VAC 47 63Hz 16A 37A max 20A 250V Time delay Mechancial Weight 3 71 Ib 1 69kg without optional heatsink Add 3 2 Ib 1 47kg for heatsink Y ek 1 46 Heat Sink Option 69 1 v a 7 50 gt 190 5 A A A 0 0 0 0 0 0 0 0 6 6 0000 00 0 Oo 0O 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 93 23 62 o 0000000000000 0 0 959595959595959595959595959595959 v ES 959595959595959595959595959595959 SA 0 0 0 0 0 0 0 0
60. es for AC brushless motor control All models use industry standard 10V analog control signals for torque or velocity control A two signal digital input takes step motor command pulses for position control in either CW CCW or PLS DIR format or fromquadrature encoder A B signals Digital preset inputs can be used to initiate 16 predefined velocity torque or position indexes Athree phase MOSFET bridge output stage delivers power in four quadrants for smooth and efficient bidirectional acceleration and deceleration of motors Windows software is used to configure the various gain and current limit settings and to customize the amplifiers for a wide range of loads and applications Settings are held in nonvolatile flash memory Communication with the 7XX8 Series Digital Servo Amplifier User Guide 1 1 12 Introduction amplifier is done through an RS 232 port for easy interface to most computers Software settings permit compensation over a wide range of load inductances to maximize bandwidth with different motors Individual peak and continuous current limits allow high acceleration without sacrificing protection against continuous overloads All models are protected against output short circuits output to output and output to ground and heatplate overtemperature With Reset input open the amplifier will latch off until powered down or the Reset input is toggled If reset from such conditions is desired the Reset inp
61. for the position value located in the more screen in the motion profile section 5 Apply changes then enable the amplifier The motor should be in a stationary position loop 6 Enter a new Target Position then click Apply A motion profile should execute 7 Savethe settings to Preset 0 Any will do 8 Enter Target Position 0 and click apply The profile should return to the 0 position Save settings to preset 1 9 Toggle between presets 0 and 1 The Trace can be used to monitor the profile 10 Check Position Loop Bandwidth 11 Verify that there is no current or voltage limiting during motion profiles 12 Save to an amplifier file filename cca Application Simple pick and place Preset 0 Velocity 0 Position loop values set for soft tuning Stay in position with no count jitter Preset 1 Position 0 Position loop values set for aggressive tuning Move to pick position Preset 2 Position X Position loop values set for aggressive tuning Move to place position 7XX8 Series Digital Servo Amplifier User Guide 4 7 Figure 4 2 illustrates typical Position mode connections connected to controller ground I O Logic Preset 0 Encoder A Status 0 Encoder B X Encoder X gt y Enable note Hall V Amplifier signal ground must be Hall W Gnd Phase V Phase W Pos Enable Neg Enable Signal Gnd For J1 details on AC or DC model see
62. g new motors you may want to adjust the calculated Motor Data Figure 3 8 in the Amplifier Status Now screen This section takes this scenario into account Note Calculated data is defined as motor data which is displayed in the Amplifier Status Now screen It was previously preliminary motor data which was entered into the Motor Data gt Specification screen and calculated when the Calc Amp Data button was selected The Current Limit Source can be external or internal When set to External a voltage or resistance is used to set the peak current limit When Internal the continuous current limit and peak current limit values are used The average voltage can be limited to the motor by setting the PWM Limit Phase Counts or the number of encoder counts per electrical cycle pole pair is an important value which must be set accurately The value may be determined using this equation Phase Count Counts per rev no of pole pairs In this example Figure 3 8 4000 counts per revolution divided by 2 pole pairs equals 2000 phase counts Halls Present Commutation Mode can be set to either Trapezoidal or Sinusoidal If the motor has Hall sensors The Phase Mode can be set to either Hall based or Algorithmic You should proceed to the next sections Encoder Checking and Auto Phasing 7XX8 Series Digital Servo Amplifier User Guide 3 19 3 20 Getting Started No Halls If no Halls are present then set Phasing Mo
63. gative direction enable 5 Preset 0 1 of 4 preset mode select lines Reset Amplifier fault reset input 6 Preset 2 1 of 4 preset mode select lines Preset 1 1 of 4 preset mode select lines 7 Status O Out Amplifier status output 1 Preset 3 1 of 4 preset mode select lines 9 Analog Mon Programmable monitor output 27 5V Output 5VDC 250mA output 10 Curr Limit External current limit input 28 12V Output 12VDC 25mA output 11 0V Sgnd Signal Ground 12V Output 12VDC 25mA output 12 Ch A out Buffered encoder output Ch A 30 Ch A out Buffered encoder output Ch A 14 Ch X out Buffered encoder output Ch X Ch X out Buffered encoder output Ch X 15 5V Output 5VDC 250mA Ch A Encoder input Chan A 16 N C No connection OV Sig Gnd Signal Ground 17 Ch Ain Encoder input Chan A Ch A in Encoder input Chan A 18 Ch Bin Encoder input Chan B Ch Bin Encoder input Chan B 19 Ch Xin Encoder input Chan X 37 Ch X n Encoder input Chan X Table 2 4 Signal Connections J3 Note 5VDC 250 mA connects to J3 15 J3 27 and J2 11 Combined current from all pins must not exceed 250mA 7XX8 Series Digital Servo Amplifier User Guide 2 15 Pull up to 5V or pull down to GND are selectable and may be stored in a preset In addition the active level Hi or Lo may also be selected and store as a preset Comma
64. he selected values for the motion profile and position loop are applicable Selecting Position Mode 1 From the CME Main menu select the Amplifier pull down menu 2 Select Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button is displayed Select the button to display the full Amplifier Status Now Screen 4 From the Operating Modes pull down menu select Pos gt Torque Position Mode with Encoder and Halls Use this procedure for position mode operation Applications include programmable logic controllers PLC s that require profiled moves from the amplifier in response to logic levels at the inputs Prerequisites e The amplifier must be configured for the motor either by downloading an amplifier file filename cca or applying calculated values using a motor data file filenam ccm Motor connected to amplifier When using a new vender motor the Encoder checking and Auto phasing routines should be executed to establish proper phasing Torque mode operation should be verified and functioning properly 4 6 Amplifier Operating Modes Procedure 1 Disconnect load from motor when testing position mode operation 2 Set the Operating mode to Position Torque mode enter Motion Profile 3 Verify Position Loop tuning parameters 4 Set Actual Position to 0 by pressing set top left hand corner of Status Now screen Then set Target Position to 0 by entering 0
65. ic phasings or phase correction Also the location of the index pulse A B Index must be set correctly for proper detection of the index pulse Example If the index pulse is high during the time that encoder line A and B are high then select 11 for proper A B Index Method A Software Phase Initialization o c 5 oO ND Start with no load Set Commutation mode to Sinusoidal Set Phase mode to algorithmic Set Phase Correct mode to On Set Phase Init Time to 4000 ms Set Command to sufficient value On Amplifier Status Now screen select Amp OK gt gt Phase initialized gt gt Attempt Phase initialzation 3 30 Getting Started 00000000000000 8 The motor should wiggle with in 1 electrical cycle for 4 seconds Phase initialization should now be OK Repeat this function several times to verify the operation 10 Save the values to a preset Method B Phase Initialization on Power up Oo RB w m oS Start with no load Set Commutation mode to Sinusoidal Set Phase mode to algorithmic Set Phase init time to 400 ms Set Phase correct mode to On Set Command Current to a sufficient value usually provided during Auto Phasing routine This value will be set to 0 after algorithmic phasing Save to a Preset that will be used on power up Power down completely Power up The motor should wiggle within 1 electrical cycle for 4 seconds Phase
66. l Servo Amplifier User Guide 2 7 Motor Phase Wiring Connections Motor Protection Fusing amp Circuit Breakers To protect the motor during the prototype phase it is the recommendation of Copley Controls Corp to use time delayed fusing in line with the motor To protect the motor from an unintentional event the current rating should be no greater than the motors continuous stall current Shielding To minimize noise radiation from the motor cabling wires should be twisted and shielded Furthermore all cable shields should be case grounded at both ends for compliance with CE emissions limits DC Model AC Model N Perso 4 Ji Sme deayed Mu Ph U 4 U e v L PhaseU Phase V 5 v 7 Lv es Ww Phase W Motor a eu F Case Gnd 7 DX V gt OR Shield i 2 Buss 1 L1 L2 3 Buss 2 3 4 EL Copley Driver UU T 4 Buss Note All lines in this Buss power stage are HOT At mains potential Copley Drivery 2 8 Amplifier Connections Figure 2 4 Motor Phase Wiring Note Circuits shown are typical connections and are not for design purposes Motor Signal Connector J2 Connectors amp Cabling Motor signal connections should be made with wire that has a rating to support the signal current AWG 24 wire will support all motor signals in this series Additional recommendations for wire insulation ar
67. le as of this printing From the Main menu select Help gt Contents to open the help files 5 54 Using Copley Motion Explorer Help gt About On the Main menu select Help gt About to display the software release version of Copley Motion Explorer Figure 5 39 Select Information About to display Microsoft System Information Figure 5 40 About CopleyMotionE xplorer Copley ES Controls oo cw Corp Figure 5 39 A Microsoft System Information File Edit View Test Help System Info ET About Copley Motion Explorer Bm E uj amp i sj System DLL s Font Proofing Graphic Filters Text Converters Display Audio Video CD ROM Applications Running OLE Registration Active Modules Ee Select a category to displ Figure tf vl xd Operating System Windows version Processor Total physical memory Available physical memory USER memory available GDI memory available Swap file size Swap file usage Swap file setting Available space on drive C Windows directory TEMP directory See Memory in Help Index lay the associated items 5 40 Windows 95 410 Pentium 129500 KB 5858 KB 53 64 53248 KB 1 Dynamic 2096832 KB CAWINDOWS CNWINDOWSNTEMP Microsoft System Information Screen 7XX8 Series Digital Servo Amplifier User Guide 5 55 Amplifier Expl
68. load Note Before you begin auto phasing you must have completed the steps in the earlier sections Installation Using a Vendor Specification and Motor and Encoder Checking On the Amplifier Status Now Screen Motor Data should be complete Amplifier Status Now screen Current Loop parameters P and I should have assigned values Operating Mode should be set to Torque Command Amps should be set to 0 After phasing you can reset this to a small current to check operation in Torque mode When executing auto phasing you define positive direction in the system Accessing and Using the Auto Phasing Screen 1 On the Main menu select Tools Auto Phase The Auto Phasing screen Figure 3 9 displays 2 Check Auto Update to display the Hall States 3 Select Attempt Phasing to initiate the routine ET Phasing AW a fi oei fhi Figure 3 10 Auto Phasing Screen 7XX8 Series Digital Servo Amplifier User Guide 3 25 3 26 Getting Started Auto Phasing Routine The auto phasing routine sequences through a number of subroutines During this process the auto phasing routine is dependent upon the validity of the specification data you entered into the Motor Data gt Specification and calculated and applied to Amplifier Status Now screen If you do not know the Hall state inversion or Hall offset set them to no inversion and no Hall offset respectively The routine will provide y
69. ls Options Communications screen 7XX8 Series Digital Servo Amplifier User Guide 5 13 Parameter Control Buttons On the Amplifier Status Now screen Figure 5 10 there are five parameter control buttons Table 5 6 Clear SaveAs Load Void Evecute gt Enables Changes Preset Preset Preset Home v Pull Up 45V Enable 5 Command Operating Mode v Pos Limit Gnd 1 00 A huir nnt Iv Neg Limit Gnd 7 r Current Loop Motion Profile Loop Gain Profile r 258 A Figure 5 10 Amplifier Status Now Screen Segment Buton Function Apply Now When amplifier connected loads the current parameters in the Amplifier Status Now screen to active registers or active RAM on the amplifier Clear Changes Deletes changes highlighted in yellow displayed in Amplifier Status Now screen Save as Preset Saves parameters currently displayed in Amplifier Status Now screen to flash memory for selected preset on amplifier Load Preset Uploads a specified preset from amplifier flash memory of selected preset and displays it locally in Amplifier Status Now screen Void Preset e Preset Void Preset Deletes specified preset prameters in flash memory on the amplifier Table 5 6 Parameter Control Buttons 5 14 Using Copley Motion Explorer Command Current The Command Current option Figure 5 10 is normally used in Torque mode You manually insert or
70. mit Derivative Time 32000 Pasition Error Limit 5530 Kaff 308 Kwvff Kout Index v Capture Source Off 16000 Tracking Window Clear Position ioo o0 zu xs pr m 205 Loop Sample Time Figure 5 12 Position Loop Parameters 5 18 Using Copley Motion Explorer h occ A force proportional to error between actual and commanded positions A force proportional to error integrated or accumulated over time a A force proportional to the derivative or rate of change of error Integral Limit Sets the integration limit of the digital servo filter for the motor Must be gt 0 Derivative Time Sets the sampling time in number of servo cycles for the servo filter to use in calculating the derivative term for the specified axis Must be 70 Position Error Sets the absolute value of the maximum position error allowed by the digital Limit servo filter for the motor If the position error exceeds this limit a motion error occurs Max 2 1 Sets the acceleration feed forward gain of the digital servo filter for the motor Sets the velocity feed forward gain ofthe digital servo filer for the motor Output gain at end of tPID transfer function Must be 70 Capture Source Determines which encoder signal is used to trigger the high speed capture of the actual position of the motor Encoder index pulse Default capture source Reserved for future use Clear Position When set to on clears position error in
71. mmended for their inherently large CMRR common mode noise rejection ratio For more information about encoder formats see Chapter 3 Index E Phase A Phase B Figure 2 6 Quadrature Encoder Pulses Encoder Receiver The same encoder receiver circuit Figure 2 7 is used to receive the quadrature encoder pulses phase A phase B and index This circuit is designed to work with differential signals Figure 2 8 single ended TTL signals and open collector circuits Figure 2 9 Receiver circuit same for all encoder inputs A B X A B X 47pF T Copley Driver Figure 2 7 Encoder Receiver Circuirt 7XX8 Series Digital Servo Amplifier User Guide 2 11 Figure 2 8 Quadrature Encoder Differential Configuration Receiver circuit same for all encoder inputs J2 Receiver circuit Motor same for all encoder inputs J2 l l 6 Enc X Index Enc X Index 4 I Index Receiver la 13 J Enc X Index Enc A Phase A lt Enc A 4 Phase A in KI I Phase A Receiver 15 4 Enc A Phase A Phase B lt 7 Enc B Phase B Si dis EncB lt Enc B X X1 Prase ie Receiver q 14 k Hase 1 Pase Gnd Shld Case Gnd 45V Encoder 5V Power gt 11 EN O circuit power m 250mA max oV Gnd Copley Amplifier J 12 2 Motor
72. n this chapter provides specifics about amplifier connectors including Ground AC DC Power and Motor Phase Connector J1 Motor Connector J2 Signal Connector J3 Data Connector J4 Figure 2 1 is a functional diagram of amplifier connections At the end of this chapter you ll find information about the amplifier s signal module and Status indicator 7XX8 Series Digital Servo Amplifier User Guide 2 1 Note L gt Amplifier signal ground must be connected to controller ground Buffered Enc A out Pulse and gt Direction Format Logic Mode Selects Jumper Selects RS 232 Data Port 3 RS 485 Driver 5 Gnd Receiver Dif Amp P amp ADC Mode Selects DSP FLASH RAM le 8 4 Buffered Enc A out Buffered Enc B out Encoder Buffered Enc B out buffer kA AAS Buffered Enc X out Buffered Enc X out Inputs Preset 0 Preset 1 Preset 2 Preset 3 Reset Signal Gnd Enable Pos enable Neg enable Home Outputs Analog monitor Status 0 Status 1 2 2 Amplifier Connections I logic it 6 e a Hall U Hall Hall V Receiver ig i lt Hall W I 414 Enc A Enc A Encoder 115 4 Receiver Enc
73. n amplifier for permanent use Flash Clear Changes Clear changes to parameters displayed on screen Table 5 3 Amplifier Setup Screen Options 7XX8 Series Digital Servo Amplifier User Guide 5 7 Amplifier Status Now Screen The Amplifier Status Now screen displays amplifier status and parameters which contain adjustable data Initially only the top third of the screen displays to indicate Motor status including Actual Position Target Position RPM Torque Cont Limit Peak Limit Limit Source and Mode Table 5 4 Select More to display the entire screen LIT SI axi St bs Howl xix 1 Ei Minter Us 4 Made gt Torque pemo mm Motes Rt Se Em o ER EN reve MM Peek Lene TI S i Mote command daa mola Taa oani Dren IM i soo RII Seperate IND eee coo EHE MY enses pd NETTE EAE SLE E Ead pr EET Carer Lini F EES iaa E Donii oa E Palita lind 153 A Corvinus Lus Lint WERT Tongue FF HagLin Gnd 16 A Fask ueri Linie Cutat Loop luc ma Peak Cusi Tine Motion Panis Position Loop Loop Bain v eee pese Loop ba Pp mue s Stm lE F 74 Tapara c Conwaimbon Made F i or Heels E rn pm mo Phasing E RIP Velo Anak Honba Fhia Counts m Apoelm stor X Indeges Lind un Lllz co Phan Comet e GE o m he F Chiaie Tiree f Midhiphas Jor Pharm Prrcala Cum p d 3 Poimi Ovi iXX Phan ira Tira M bi 553 kam Statue Dui We o LITE HTH F DT ma np
74. nd Inputs s 19 Ch A ei ChA 5 o o T Ch B I 9o Ch B 36 o9 CX jio o 06 Ch X o 5 J3 o Ref gt 9o SIGNAL Ref 9 il SO y ao E ete o 0 L ji Signal 9 Copley Driver Note Amplifier signal ground must be connected to controller ground Inputs J3 J3 Preset 0 I 5 9 IPreset 1 o o gt 24 7 Preset 2 oTo gt 6 8 Preset 3 oTo 25 x Reset P o 23 13 Signal Gnd 9 26 i Enable amp o 70 3 32 Pos enable amp o 70 21 34 Neg enable o 70 22 Home o 70 4 Curr Limit 10 Copley Driver Figure 2 15 J3 Connector and Cabling Outputs Amon Status 0 Status 1 Ch Aout Ch A out Ch B out Ch B out Ch X out Ch X out Signal Gnd The J3 connector is a female Sub D 37 position with 4 40 standoffs for cable shells 2 16 Amplifier Connections Analog Command Inputs 10V The analog input circuit Figure 2 16 receives analog torque or velocity commands from the controller in the range of 10V The differential configuration reduces common mode noise CN 10V Analog J3 50k Analog input circuit Case Gnd C DAC 10V Ref o9 50k 220pF em Analog Gnd XC X Reto a ANN Ac Ram 50k 50k AURA Sig ground Shld Note Signal ground H Amplifier signal ground must be wee va Copley Driver conn
75. ng Model 7228DC 7428DC Output power Peak power 20A 180VDC 20A 370VDC Peaktime 1 second at peak power or 2 seconds after polarity reversal Continuous power 10A 180VDC 10A 370VDC Output voltage On resistance Ro ohms 0 2 0 15 Max PWM Peak Output Voltage HV x 0 97 Ro x lo 7XX8 Series Digital Servo Amplifier User Guide A4 Model Input Power High Voltage HV current continuous output rating Inrush current on startup External mains fuse rating 7228DC 45 186VDC 16A 19A max 20A 125VDC Time delay 7428DC 45 373VDC 16A 37A max 20A 250VDC Time delay Mechancial Weight 2 71 Ib 1 23kg without optional heatsink Add 3 2 Ib 1 47kg for heatsink 7 50 190 5 v 093 A 9595959595959 595959595959595959 23 62 0 070 07070 0 0 0 0 0 0 0 0 0 0 0 e SAC 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 o o o o 0 0700 00 00 0 0 0 0 O 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 4 91 0 070 0 0 0 0 070 0 0 0 0 0 0 0 O o o o0 0 0 0 0700 070 9 0 010 155 5 9595999995959 995959 99595999 995959 3 00 959595959595959595959595959595959 5 55 959595959595959595959595959595959 176 2 EZAN 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 138 75 0 0 0 0 0 0 0 0 0 0 0 0
76. ng no manual interface Home to Index Pulse Using the preset velocity the motor drives into the stop until the limit switch is hit The motor is then backed off the limit past the limit switch recovery until the index pulse transition occurs The actual home position is dependent upon the location of the index pulse This is a very high accuracy routine that requires no manual intervention Custom This is an optional routine pre programmed by Copley Controls that you may execute from a Preset 7XX8 Series Digital Servo Amplifier User Guide 3 9 CM Preset Manager Home to Index Figure 3 4 Homing Sequence 3 10 Getting Started Software Parameter Notes Here are some notes about software parameters All of the software parameters are defined in Chapter 5 Profiles The Profile mode selections are trapezoidal S curve or velocity If you choose a sinusoidal S curve then you must set a Jerk value See the Amplifier Status Now screen in Chapter 5 The Velocity Profile is actually a position loop that never gets to the destination If you do not enter a value for Deceleration then the Acceleration value is used Position Loop Tuning The position loop tuning parameters are determined by a mathematical model They are initialized soft and with loading of the motor For proper operation with a load the PID values for the Position Loop may need to be changed A tuning method follows Refer to
77. nt 2 mmmm 9 ipsu mea c 9 t SFL status RESET sv ka lt Ad scno cno HOM NEG POS AMP ENABLES Analog Monitor 5v bz jcHHHH g ou wg PRESETS 100 i0 100 rw oPen REV b CURRENT LMT Control Pendant Appendix B Operator Pendant The Operator Pendant Figure B 1 is a module that connects to the signal bus in place of a Programmable Logic Controller PLC You can use the pendant in a system to test and debug your application The pendant has a number of components that you can use Switches for initiating signals and presets Connectors for auxilliary encoder inputs and monitoring with a scope Potentiometers for adjusting current and voltage LEDs for status display Table B 1 describes pendant components 7XX8 Series Digital Servo Amplifier User Guide B 1 ENABLE POS and NEG REV FWD Switch Current Limit Potentiometer 10 V Potentiometer Analog Monitor Auxiliary Encoder Inputs Stat 1 Stat 0 Leds Function When GND resets the system to a default state Functions as an on off switch for the amplifier Toggling the switch from on to off will cause the amplifier Status indicator to go from steady to flashing green Normally GND enables the amplifier Enable rotation in one direction while inhibiting it in the other A 5V signal enables and GND disables motion in the indicated direction Dependent upon the Active Le
78. o field position the cursor over the field and left click once The Gear Ratio window should open The Digital Input field sets the pulses for the Master Amplifier while the Amp Motor field sets the number of output pulses for the Slave Amplifier PDC a0 Counts Digital Input 00 Counts Calculate Gear Ratio M Apply Cancel Figure 5 15 Digital Position Input 5 24 Using Copley Motion Explorer Analog Monitor The Analog Monitor pull down menu configures the analog output to monitor a specified signal Table 5 11 The Multiplier in Gearing mode for example can be used to amplify a small monitored signal The Offset can be 10 volts Analog Monitor Test Output and fi Multiplier o Offset Figure 5 16 Analog Monitor Note The monitored signal is adjusted before writing to the Digital to Analog Converter as follows For 32 bit signals Output signal offset x 2 x multiplier For 16 bit signals Output signal offset x 26 x multiplier In Table 5 11 signals are 32 bits unless denoted as winding 1 winding 2 or clipped 7XX8 Series Digital Servo Amplifier User Guide 5 25 Analog Monitor Test Output and None No signal is selected The DAC output will only reflect the offset and multiplier This may be used to test the DAC output Commanded The commanded position units of encoder counts Position Actual Position The actual
79. ontinue button should display the Amplifier Status Now screen Figure 3 3 7XX8 Series Digital Servo Amplifier User Guide 3 3 Figure 3 1 Welcome Screen Figure 3 2 On Line Connection Screen 34 Getting Started The Amplifier Status Now screen displays the status information most recently retrieved from the amplifier You can check the Status Updates box to continuously update the Amplifier status Now screen This screen displays the amplifier s current preset operating mode and motor data 4 Amplifier Status Now KIT 002 motor 5 17 ctua Position Set PG Target A REI Posion BIER Cont Linit ERI m atus RPM NEN Peek Lirit ETO e Current rmm A Limit Source Im L r Mode Torque MotorCmd Current CM e 3 10 00 Motor command drives motor Torque current Communication LI Amp OK Enables Enn Pos neo Amp Setup M Status Updates Clear Save As Load Void Changes Preset Preset Preset Command 0 25 A iniit Profile id v Position 500 RPM Velocity 200 mS Acceleration o mS Deceleration fi Jek fi 0 mS Settle Time 10 Settle Window None Z Seq r Digital Position Input A B Encode Y Input Source Noninvertin z Polarity Gear Ratio Motion Profile r Operating Mode v PosLimit Gnd 21 A Torque v Neg Limit Gnd 1048 A ER Cu
80. or details on executing the encoder checking routine Da fou have d0DO pauses per Fer LOO Line P carcde 7 Tam Harcr im mot anablad plese enable chan click cn E ah ndm emend i dni capiusad Figure 5 34 Encoder Check Screen 7XX8 Series Digital Servo Amplifier User Guide 5 47 Tools gt Auto Phasing Select Tools gt Auto Phasing to access the Auto Phasing screen Figure 5 35 Usually you use the Auto Phasing routine when wiring a new vendor motor to the amplifier You can use the Auto Phasing routine to phase Hall sensors the encoder and motor output wires Execution of the routine enables you to achieve proper phasing for sinusoidal and trapezoidal commutation See the Auto Phasing section in Chapter 3 for details on executing auto phasing r ni ga Alo Phazinsg Figure 5 35 Auto Phasing Screen 5 48 Using Copley Motion Explorer Tools Homing Sequence The options available forthe Homing Sequence are described in Chapter 3 Homing Sequence 7XX8 Series Digital Servo Amplifier User Guide 5 49 Diagnostics Menu The Diagnostics menu contains the features Amp OK Trace Comm Log Groups and Special You do not have access to the Amp Ok Trace and Group items They are for use by Copley Controls personnel 5 50 Using Copley Motion Explorer Diagnostics gt Comm Log gt Communication Log When you check Enable Logging and follow some other steps described below this screen Figure
81. orer Window This window Figure 5 41 displayed to the left of the Main window contains icons for Amplifier Status Now and each of the 0 15 presets Selecting an icon opens the Amplifier Status Now screen or a Preset Manager screen for a specific preset View gt Explorer located on the Main menu acts as a toggle control for the Amplifier Explorer Window and determines if the window is open viewed or closed not viewed ti Copley Motion Explorer File View Amplifier Motor To Amplifier EB Amp Status Now G Amp Setup Presets Preset 0 Preset 1 Preset 2 Preset 3 Preset 4 Preset 5 Preset 6 Preset 7 Preset 8 Preset 9 Preset 10 Preset 11 Preset 12 Preset 13 Preset 14 Preset 15 Figure 5 41 Preset Select Window 5 56 Using Copley Motion Explorer Stop Motor Window Use the Stop Motor window Figure 5 42 to halt a motor If you close this window you must restart CME to re display it Selecting Stop Motor overrides the Enable Overide indicator button on the Amplifier Ok screen If Enable Overide is red slelect it and then select Clear Enable Overide Figure 5 42 Stop Motor Window 7XX8 Series Digital Servo Amplifier User Guide 5 57 Copley Virtual Machine CVM The CVM is a program area that stores and runs CVM Programs The Standard CVM Program is used by the Copley 7xx8 Amplifier to perform the homing function If a sequence is selected in a particular
82. ou with these parameters and prompt you to save them in the Amplifier Status Now screen Warning Whenever the routine prompts you to re wire the motor turn the power to the motor off The auto phasing routine has three main subroutines First the routine checks for proper direction and commutation You will notice the Hall Angle indicators turn on and off as the auto phasing routine cycles through the Hall state combinations CME prompts you to determine if the wiring at J2 and J1 is proper relative to motor s rotational direction Figure 3 10 If necessary the routine prompts you to re wire the motor Figure 3 11 With respect to direction CME asks you to swap a pair of wires The swap combinations are motor wires UW VW and UV With respect to commutation CME asks you to rotate motor wires Rotate left is the equivalent of shift U to W W to V and V to U Rotate right is the equivalent of shift W to U Uto Vand V to W Next the auto phasing routine checks Hall timing You may again be prompted to reconfigure motor wires Finally the auto phasing routine re analyzes the timing data and determines if either a Hall Offset value is required or achange in the active level of the Hall states is detected If necessary the routine generates a Hall Offset value and or displays the required Hall states Enter these value in the Amplifier Status Now screen and use them for all presets The offset value is
83. p OK m Enables Enable Pos Nea _Amp Setup_ ESAT v Status Updates Figure 5 7 Status Buttons and Error Indicators Amp Status Now Screen 7XX8 Series Digital Servo Amplifier User Guide 5 9 Communications Button Selecting the Communication button Figure 5 6 displays the ON Line Connection screen When the Communication indicator is green there is a good connection When Status Updates is on the indicator refreshes at the same rate as the updates Amp Ok Button The Amp OK button is a useful troubleshooting tool If an AMP OK indicator is not green during operation of the amplifier select it to display a series of indicators Table 5 5 Each indicator also serves as a button which you may select for options and information emcehe ec QN E iAmplim DE Figure 5 8 Amplifier OK Screen 5 10 Using Copley Motion Explorer Amp Internal A loss of internal regulator power has occurred Check connections at J1 on the PWM Outputs Indicates problem with power board Attempt to clear with this button or reset and possibly wait for assembly to cool down Phasing Initialized Indicates that sinusoidal commutation has not been initialized Use alogrithmic phasing if Halls not present If Halls present then use Hall based phasing Phasing OK Phasing has been lost When green Indicates that a move can be made No Following Error Indicates that the position error is greater than tthe set limit Table 5 5
84. plifier Motor Tools Diagnostics Window Help Figure 5 3 Main Menu File Menu The File pull down menu provides you with file managementoptions Create a new motor file ccm using the motor form or an amplifier file cca using the preset manager and the Amp Setup screens Opens a motor ccm amplifier cca or axis cxa file from the Copley Motion Explorer folder The cxa file contains all the amplifier and motor data together with the axis name to form a single axis file for replicating an axis Save presets as a cca file motor data as a ccm file or complete axis data as a cxa file You must use the Save As Preset button on the Amplifer Status Now screen before you can Save data as a file Save As Save cca ccm or cxa files as another name Table 5 1 File Menu 54 Using Copley Motion Explorer View Menu The View menu has one option Explorer When it is selected the Preset Select window is displayed You can use the Preset Select window to access the Amp Status Now and Preset Manager screens Amplifier Menu The Amplifier menu has the following options Connect to Host for On Line Connection Amp Setup Status Now and Preset Manager Selecting an option opens the related screen s On Line Connection Screen The On Line Connection screen has the following option buttons Comm X Desired Baud Connect Upload Continue and Work Offline T ait On Line Connection x Double click Serial Comm
85. r Status Now Screen ccce 5 8 Preset Manager Screen c eceeeeeeeeeeeee 5 29 M tor Men MN EP PE S RE Motor Data Screens Motor Data Specification Screen 5 32 Motor Data gt Specification Feedback Screen 5 32 Motor Data gt Specification Ratings Screen 5 32 Motor Data gt Specification Electrical Screen 5 35 Motor Data gt Specification Mechanical Screen 5 36 Apply Motor Data Screen ine teeth 5 32 Motor Temperature Sensor Screen 5 40 Tools Menu une ptr Re IR 5 41 TOOLS gt Trace Graph 22 3 susretne ian 5 41 TOOLS SQOELGHS gt S 5 43 Tools gt Options gt Directories 5 44 Tools gt Options gt Directories eese 5 45 Tools Download Firmware TOOLS gt Encoder Check 5 2 ue denne eei Tools Auto PHASING 2 43 2 e neant nnne Re rhone Tools gt Home Sequence eret rene Diagnostics Menus eeeeeeese esee seen neant een Diagnostics gt Comm Log 25 2 ee eerie throno Diagnostics gt SPECIAL 2 teret trennen eere Help Menu atte dee e Ree E E e ER Ete Amplifier Explorer Window Stop Motor WINAOW eee eee etae rina t Ras Copley Virtual Machine cessent 7XX8 Series Digital Servo Amplifier User Guide B 1 4 NOTES This manual as well as the software described in it is fumished under license and may only be used or copied in accordan
86. r specification in order to calculate amplifier parameters enter your motor data on this screen F i a Motor Data Figure 5 24 Motor Data gt Specification gt Ratings Screen Linear Parameters Linear Continuous Force N Lb or Oz Linear Peak Force N Lb or Oz Save data as described earlier in this Motor menu section 5 34 Using Copley Motion Explorer Motor Data gt Specification gt Electrical Screen Enter motor data on this screen if you are manually entering your motor specification in order to calculate amplifier parameters ii Maur Data Figure 5 25 Motor Data gt Specification gt Ratings Screen Linear Parameters Linear Force Constant N Lb or Oz Linear Back emf Constant V mm V in Save data as described earlier in this Motor menu section 7XX8 Series Digital Servo Amplifier User Guide 5 35 Motor Data gt Specification gt Mechanical Screen If you are manually entering your motor specification in order to calculate amplifier parameters enter motor data on this screen G Motor Data 1 30E 00 9396 02 Figure 5 26 Motor Data gt Specification gt Mechanical Screen Linear Parameters Linear mass Kg Lb Oz Linear Static Friction Kg Lb Oz Save data as described earlier in this Motor menu section 5 36 Using Copley Motion Explorer Calculate Amplifier Data Button If you ve input motor parameters to a Motor Data Specification screen Type for example
87. rom the mains For low voltage units install the fuse on the hot line For high voltage units install fuses on both hot lines Line Filters for EMI Reduction amp CE A line filter such as the Corcom P N20VDK6 must be installed no more than three feet from the amplifier s power entry terminal strip for compliance with CE emissions limits 2 4 Amplifier Connections AC Model Fuses 20A time delay Bik Brn Grn Grn Yel e 120VAC Buss Fuses 20A time delay Bik Brn Buss Motor U Motor V Grn GrivYel 230VAC Wiring for 74XXAC Motor W 4 Note All lines in this power stage are HOT At mains potential Figure 2 2 AC Model J1 Connector Cre see Ce Sd a ES Amplifier output to U winding of motor 8 Motorw Amplifier output to W winding of motor o xb os sate an Ato br cabe omar Table 2 1 AC Model J1 Pin s Description D Negative terminal of internal DC power supply D 7XX8 Series Digital Servo Amplifier User Guide 2 5 26 Amplifier Connections DC Model Power Connections No Transformer Required This model operates from power supplies that rectify the line directly with full optical isolation between signal and power stages Voltage amp Current Ratings of Power Supplies The power supply should deliver sufficient power P to supply the power delivered to the motor and the power lost in the amplifier In general the supply voltage V should
88. rrent Loop 1000 mS m Position Loop Loop Gain x Loop Gain 561 P d he wl 364 l fis D 8i 4 D poste RUDI m Analog Monitor 2000 100 00 Integral Limit Cur U z E ot zl D Derivative Time fi Multiplier ot Position Error Limit Offset 1000 Kaff Status Out 3 oj o 308 m Status Uvw w SUS Kyvff m e amp H40 Mask cusan o Sense 1 Indes hf Capture Source Status 1 250 Hi Jor z Clear Position tH80 Mask 0 00 0 Tracking Window fo Sense 1 Trapezoi x Commutation Mode Hal Base x Phasing Mode Lo Temp Sensor Reference Gain Last Preset Loaded Lue Enables Motor Data v Pull Up 5v Current Limit Tl Enable 45V n Data E Control Source Continuous Curr Limit Peak Current Limit Peak Current Time PWM Limit Phase Counts Phase Correct Mode Phase Prescale Phase Init Time Hall Offset Hall States Encoder Polarity A B Index Temp Sensor Figure 3 3 Amplifier Status Now Screen 7XX8 Series Digital Servo Amplifier User Guide 35 3 6 Getting Started Installation Using a Copley Motion Explorer Development Kit Motor Follow this procedure if you are installing a motor that accompanied a Copley Motion Explorer Development Kit Verifying Software Parameters Accompanying the Copley Motion Explorer Development Kit you received an Application Note The note contains software parameters specific to the motor that shipped wi
89. rror condition has occurred See the section called Amplifier Status Now screen Chapter 5 Installation Using a Copley Motor Data File and a New Copley Motor If you do not have a Copley Motion Explorer Kit Copley can supply you with a Copley Controls motor ccm data file These files contain preliminary motor data Save the file to your Copley folder in the Copley Motion Explorer directory Using a ccm File 1 Perform Verifying Hardware Installation p 3 1 2 Perform Starting Copley Motion Explorer p 3 3 3 On the Main menu Select File Open to display the Open Publication screen Figure 3 5 4 Select File Type ccm to display a list of ccm files in the folder 5 Open the ccm file The Motor Data gt Specification screen displays Figure 3 6 The data can be viewed by selecting the appropriate tab Look in cx CopleyMotionE xplorer amp Al ce a CBL232BE 001 ccm Files of type fat ERAN E aet Cancel Open as read only Z Figure 3 6 Open Publication Screen 7XX8 Series Digital Servo Amplifier User Guide 3 13 3 14 Getting Started Feedback m Selection Manufacturer Copley Controls Model CEL232AE 001 Electrical Type Mechanical Type Brushless C DIEBUS Rotary Poles 4 C Linear Save As Save To File Amplifier Figure 3 7 Motor Data Specification Screen 6 Select Calculate Amp Data Copley Motion Explorer models the d
90. s Digital Servo Amplifier User Guide 3 21 3 22 Getting Started Checking the Auto Update feature enables the Encoder Counts gauge Verify the Number of Poles and make sure the value entered is correct for the motor you are using The default value is 4 On the Amplifier Status Now screen Figure 3 3 verify the data entered is complete A percentage of the Continuous Current Limit will be used to drive the motor shaft Select the Check Encoder Counts button The motor shaft should rotate one revolution The Encoder Check screen should display Configured Counts Rev and Measure Aprox Counts Rev As the shaft rotates the Encoder Counts gauge reflects rotation and encoder counts If the motor shaft did not rotate use the Motor Command tuning slide to apply more current Select Check Encoder Counts again The amount of current applied is a percentage of the Continuous Current Limit Tune and select Check Encoder Counts as necessary For a more precise method of measuring Approx Counts see Manual Encoder Check in next section Successful completion of the Encoder Checking routine is signified by a The near match of data displayed in Configure Counts Rev and Measure Approx Counts Rev boxes b The Index Sensed indicator alternates between red and green as the index pulse is detected c The Index captured indicator turns green to signify that an index pulse was detected after one full re
91. select these modes using the Copley Motion Explorer software Operating modes include Torque mode Position mode Velocity mode Digital Position mode For detailed descriptions of the Copley Motion Explorer screens see Chapter 5 7XX8 Series Digital Servo Amplifier User Guide 4 1 42 Torque Mode By selecting Torque mode you can configure the amplifier for a torque current loop Note In torque mode the following apply current loop gains and limits command current and current loop values The values for motion profile and position loop are not applicable Selecting Torque Mode 1 From the CME Main menu select the Amplifier pull down menu 2 Select Status Now to display the Amplifier Status Now screen 3 Scroll right until the More button is displayed Select the button to display the ful Amplifier Status Now Screen 4 Select Torque from the Operating Modes drop down menu Note For proper operation always stop the motor before you select a different operating mode Amplifier Operating Modes Torque Mode with Encoder and Hall Use this procedure for torque mode operation Applications include microprocessor control systems that get position feedback from the motor encoder and require current from the amplifier in response to a control voltage at the inputs Prerequisites The amplifier must be configured for the motor by downloading an amplifier file filename
92. series of easy to use Windows based screens To open the initial CME Welcome screen 1 In Windows Select Start Programs Copley Motion Explorer Copley Motion Explorer 2 The CME Welcome screen Figure 5 1 should open Selecting either On Line or Off Line provides access the CME Main window Figure 5 2 Note This chapter is organized as if you were accessing Screens sequentially from left to right on the Main menu 7XX8 Series Digital Servo Amplifier User Guide 5 1 Figure 5 1 Welcome Screen 52 Using Copley Motion Explorer Main Window The Main window consists of the Main window controls the Main menu the Amplifier Explorer window the screen display area and the Status Line The Main window controls are located in the top row of the window and consist of the CME icon and the minimize maximize and close window buttons Selecting the CME icon pull down menu provides access to the standard window controls Restore Move Minimize Maximize and Close Main Menu 1 re see gas e D Main Window Controls EL sl Amplifier Explorer Window Screen Display Area mmi ul Status Line Mem i Fa Bamian Z N Figure 5 2 Main Window 7XX8 Series Digital Servo Amplifier User Guide 5 8 Main Menu The Main menu has a number of pull down menus They are File View Amplifier Motor Tools Diagnostics and Help ed CopleyMotionE xplorer Jox File View Am
93. t Circuit The temperature sensor input circuit Figure 2 13 receives signals from sensing devices such as thermal sensors The circuit works with resistive sensors or an open closed switch to ground The 7XX8Series work well with N O Normally Open N C Normally Closed or resistive sensors The overtemp threshold s are adjustable with CME and may be stored as part of a preset Input circuit Motor Sensor signal 5V Motor Overtemp DSP Switch oe eee 100nF Normally Case Gnd Closed Copley Amplifier Figure 2 13 Temperature Sensor Input Circuit 2 14 Amplifier Connections Signal Connector J3 Control signal connections should be made with wire that has a rating to support the current signal AWG 24 wire will support all motor signals in this series Additional recommendations are for a voltage rating of 300 V DC and a temperature range of 80 C To minimize coupling of PWM noise sensor signal wiring should be multiple conductor twisted pair shielded cable Further more all shielded cables should be case grounded at both ends for compliance with CE emissions limits Pin Signal Function Pin Signal Function 1 Safety GND Chassis frame ground 2 Ref 10V analog command input Ref 10V analog command input 3 Enable input Amplifier enable Pos Enable Positive direction enable 4 Home Home switch input Neg Enable Ne
94. tatus Out 8 o Status 0 P amp H40 Mask o Sense Status 1 amp H80 Mask 0 Sense Figure 5 17 Status Outputs Screen Segment 5 28 Using Copley Motion Explorer Preset Manager Screen On the Main menu select Amplifier Preset Manager to display the Preset Manager screen Figure 5 18 The Preset Manager screen displays amplifier and motor data associated with parameters for a selected preset 0 15 A preset is an instance of all the necessary motor and amplifier data necessary to make a motor perform a predefined task When you select Preset Manager Preset 0 displays in the screen by default The screen displays all the parameters described earlier under Amplifier Status Now screen In addition the screen has buttons Table 5 12 to facilitate management of the presets Feet Io Wons J i s gp anten m oa Eni mery aje Pulp e lod Core F Erabi v E Clear Save Pret aen A Presea B riri i e een m La Lini Girl Pl Opmatng Minds I Arop Cone Ling lt a Pas Tenn sae Dm 153 A Coninupur Curent B lp m E 106 A Pask Cuners Mohnn Prn ln ep T a itr m Peak Cuneri Times E P BI xPsMLe iue m top Made a o Me Traper n tardan 6 Punon mi o P Horan Hasse e Praag Mode am RPM velop ix negara Tes Cusp ord 200 Phase Counts TE mf Acoma 1 Deienive Tim Mare ni m Pharm Comet Meds E127 mi Deceinusion D
95. th the kit These parameters include Operating mode Enable Motor Data Current Loop Position Loop and Motion Profile 1 On the Amplifier Status Now screen select More to display expanded software parameters 2 Verify that the software parameters displayed on the Amplifier Status Now screen are identical to the software parameters in the Application Note 3 If the parameters match proceed to First Move in the next section Changing Software Parameters You can change the settings in the Amplifier Status Now screen 1 Make changes as necessary in the Amplifier Setup Now screen to match the Application Note Changes will be highlighted in yellow 2 Select Apply Now stores the changes in the amplifiers volatile memory 3 Select Save as Preset Select the desired preset number to save the parameters into flash memory on the amplifier Select Void Preset to delete the values in an amplifier preset Select Load Preset to display a preset in the Amplifier Status Now screen First Move 1 To verify that the motor is generating encoder pulses rotate the motor shaft 2 Observe the Motor Actual Position count change in the Amplifier Status Now screen If the amplifier is using Hall based phasing and the Halls are connected properly then phase initialization is complete If you are not using Halls see the section about No Halls under Adjusting Calculated Motor Data later in this chapter 7XX8 Series Digit
96. tor Data The Motor Data Specification screen displays 4 The Motor Data Specification screen Figure 3 6 has four tab selectable screens Type Feedback Ratings Electrical and Mechanical Enter motor data from the specification into those screens 5 Select Save File As to save the specification data as a ccm motor file for future use 7 Select Calculate Amp Data Copley Motion Explorer models the data performs calculations and displays new calculated data in the Apply Motor Data screen Figure 3 7 After you complete Auto Phasing discussed later in this chapter you may make adjustments to data in this screen using the slide bars 8 Select Apply to Amp The Amplifier Status Now screen displays 9 Select More The data modeled from the ccm file is now associated with the appropriate amplifier and motor parameters on the Amplifier Status Now Screen 7XX8 Series Digital Servo Amplifier User Guide 3 17 3 18 Getting Started 10 Select Save As Preset to save the data in the Amplifier Status Now screen to flash memory on the amplifier 11 Selecting Save File As saves the data contained in the Amplifier Status Now screen to the PC as a cca file 12 Review the next section Adjusting Calculated Motor Data 13 Go to the following section Encoder Checking 14 Go to the Auto Phasing section at the end of this chapter to verify electrical connections Adjusting Calculated Motor Data When configurin
97. trollers Applications include Sinusoidal brushless motors Linear brushless motors X Y stages Robotics Automated assembly machinery 7XX8 Series Digital Servo Amplifier User Guide 1 3 14 Introduction Motion Explorer Software You can manage the 7XX8 Series of Digital Servo Amplifiers from the Windows based Copley Motion Explorer CME software Some ofthe high level tasks that you can perform from the CME screens include Create a new motor file or load an existing motor file Generate a new amplifier file or load an existing amplifier file Adjust motor phasing e Fine tune current and position loops with trace feature Selectoperating modes Generate new presets that you can store in flash memory on the amplifier Execute diagnostics that display statistical or graphical data about system performance Software Requirements The Copley Motion Explorer software is recommended for Windows 98 systems The 7XX8 Series Digital Servo Amplifier interfaces to a PC via a simple RS 232 connection For more information about the Copley Motion Explorer software see Chapter 5 Terminology Some new terminology is introduced herein with this product The terms are defined below and may be added to as necessary Calculated motor Consists of amplifier and motor data generated by Copley Motion Explorer data based on preliminary data from either ccm files or motor specifications
98. typically a multiple of 30 for example 0 30 or 60 degrees Any other Hall offset value means there may be a problem with the alignment of the Halls on the motor Select Apply to Amp to save the values generated by auto phasing to flash memory on the amplifier After Auto Phasing 1 Open the Amplifier Status Now screen Set Operating Mode to Torque Apply a small amount of current using the Current command and select Apply Now to test the Torque mode operation 2 Check the Motion Profile on the Amplifier Status Now screen a Input data to the Position parameter b Input data to the Velocity parameter c Input data to the Set Accelertation parameter d Input data to the Set Deceleration parameter 3 Select the Apply Motor Data screen which you should not have closed earlier Test the amplifier and motor using the Position Loop slide bars with servo loop active 7XX8 Series Digital Servo Amplifier User Guide 3 27 CopleyMotionE xplorer Define Positive Direction eee DENTES Figure 3 11 Encoder Check CopleyMotionE xplorer Figure 3 12 Encoder Check 3 28 Getting Started Algorithmic Phase Initialization For motors that have quadrature encoders and no Hall sensors algorithmic phase initialization can be used to initialize the phase for commutation Prerequisites Amplifier configured for motor either by downloading an amplifier file filename cca or applying calculated values using a motor dat
99. uctance and filter values 25kHz Center weighted 50 duty cycle at OV output Analog 10V Differential 94KW between inputs X20V maximum Digital 2 signal TTL any of three formats CW CCCW Pulse Dir A amp B quadrature Digital 4 line TTL 28V max Group programmable 22k Ohm internal pull up to 5V or pull down to OV The four inputs initiate 16 pre defined prests Motor overtemp input Analog input Technical Specifications 5kW internal pull up to 5V for thermistor or IC sensor Thresholds programmable Logic Outputs Status output Status LED Blinking green Green Red Blinking red Analog monitor DC power outputs Data Port Ground Signal Power Two Stat0 Stat1 Software function programmable N channel MOSFET 10k pull up to 5V Max 50V off voltage Max 250mA sink 5 Ohm On resistance Bi color LED changes color and flashes to indicate amplifier operating status Ready Amplifier OK Amp will run when enabled Normal Amplifier enabled and AMP OK Buss fault non latching over or under volage condition Amplifier recovers when in normal range Latching fault Output overcurrent short circuit or overtemp condition Ground Reset or power amp off on to clear condition 10V full scale 1k Ohm source resistance Programmable monitor functions 5VDC 250mA 12VDC 25mA 12VDC 25mA RS232 RS232 3 wire TxD RxD Gnd Ground Floating Ground
100. ud di 22 Flashing Red Latching Fault Ground Reset input or cycle AC power OFF ON Table 2 7 Amplifier Status Indicator Note 1 Fault Output short circuit or heatplate overtemperature Amplifier latches off and stays off until reset Amp OK Internal buss voltage is within limits AND NOT Fault Ready Amp OK AND NOT enabled Normal Amp OK AND enabled 2 30 Amplifier Connections Signal Module This section illustrates the amplifier s signal module layout Figure 2 32 and jumper settings Figure 2 33 JP3 JP6 JP4 DSP amp Internal Flash RAM J3 Signal J2 Encoder Hall Figure 2 32 Signal Module Layout Jumpers Settings Function Factory installed JP13 Do not move DSLIBBBH S 8522 enun JP1 JP3 JP6JP4 87654321 e Force JP2 Analog Scale Default Ead Range 20Vmax Figure 2 33 Signal Module Jumper Settings 7XX8 Series Digital Servo Amplifier User Guide 2 31 Chapter 3 Getting Started This chapter introduces you to the Copley Motion Explorer software CME In conjunction with CME screens there are step by step procedures enabling you to install a Copley supplied motor or your own motor In this chapter there are procedures for several motor installation scenarios Installation Using a Copley Motion Explorer Development Kit Installation Using a Copley Motor Data File and a New Copley Motor Installation Using a Vendor Specification and Motor For detaile
101. uire a null modem cable RS 232 Communications Mode RS 232 communications mode is the default The default settings for the communications port are 9600 baud eight data bits no parity 1 stop bit no flow control RS 232 Serial Data Output Amp gt Controller RD RS 232 Serial Data Input Controller gt Amp Table 2 5 RS 232 Connector Pin Out ee 7XX8 Series Digital Servo Amplifier User Guide 2 27 RS 232 Cable and Connector RS 232 C 02 J4 RS 232 comm port D HRe ME BT 1 pm o5 DATA Driver e Receiver Copley Amplifer Figure 2 29 Data Connector J4 Connector type 9 pin Sub D female 4 40 locking standoffs for connector cable clamps Notes 1 Signals in Bold amp Italics are for standard 3 wire RS 232 connection 2 Do not use ribbon cable for connection to multiple amplifiers when operating amplifier in RS 232 mode RS 232 x ad Receiver y E q a Transmitter QI nS RS 232 Q g Tg Ribbon Cable 3 s 14 2 TXD 3 RXD qo 7 GND 000000000000 10000009000 DB 9 Female Copley Driver Connector DB 9 Male DB 25 Male Front view Front view Figure 2 30 RS 232 Cable and Connnector 2 28 Amplifier Connections NOTES 7XX8 Series Digital Servo Amplifier User Guide 2 29 Amplifier Status Indicator The Amplifier Status indicator is an LED that depending on color reflects operating conditions Table 2 7 Flashing nid p
102. unications Port buttons below to test for amplifier present at that port Serial Port to test COMM COMM COMM COMM T 2 3 4 fi 15200 Baud Rate Detected at E 15200 Baud Rate Set to Desired Baud C 2400 9600 C 18200 57600 115200 eye Found 7228AC Model Number Connect 01000001 Serial Number Upload 1 5 Firmware Version Work OffLine Figure 5 4 On Line Connection Screen 7XX8 Series Digital Servo Amplifier User Guide 5 5 Normally you use the On Line Connection screen during installation of or re connection to an amplifier Comm X Select a communications port on your PC Comml to Comm4 from which your PC is physically connected to the amplifier Desired Baud Select a baud rate 2400 thru 115200 for communications between the PC and amplifier Connect Select connect to initialize full communications between the PC and CM E and the amplifier Upload Interrogate amplifier and upload presets from the amplifier to the PC or laptop Continue After successful connection select Continue to open the Amplifier Status Now screen Successful connection indicated when Amplifier Found indicator turns solid green and the correct Model Serial Number and Firmware Version display on the screen Work Offline Provides no connection to the amplifier but allows for the following tasks to be performed entering and saving motor data files and using the preset manager to manipulate amplifier dat
103. ut can be momentarily connected to ground A red green status LED speeds diagnostics when the amplifier is put into operation Features The Digital Servo Amplifier Model 7XX8 Servo works with DSP controlled torque velocity or position modes using only encoder feedback from the motor It is programmable for S curve and trapezoidal motion files You can select up to 16 preset modes using a PLC or Logic Hi Lo line Otherfeatures include No transformer required AC version operates directly from AC mains DC version operates from rectified line with full optical isolation between signal and power stages RS 232 digital interface used to store all settings in internal FLASH memory for selecting preset modes Separate motor signal and control signal Sub D type connectors for simpler cabling Terminals for DC Buss connect to an external regenerative energy dissipator Input for motor temperature sensor with settable thresholds and logic to protect motor windings Command sources Analog 10V inputs Digital PLS DIR CW CCW Digital presets and Data RS 232 Fault protections short circuits from output to output output to gnd over under voltage motor or amplifier overtem temperatur Models The following table describes the 7XX8 Series Digital Servo Amplifiers model variations Table 1 1 7XX8 Models Applications The 7XX8 Series of Digital Servo Amplifiers are compatible with a wide range of con
104. vel on Amplifier Status Now screen The status of the Home line determines the status of the In Home switch This is the actual zero position only if Homed to the Home switch In Torque mode or Velocity 10V Pos Torque you can change the bias voltage In any mode when an external current is selected you can control the peak current In Torque mode you can adjust 10 V for current peak programed In Velocity mode you can adjust 10V for Velocity programed Test point for signal selected with Analog Monitor parameter on the Amplifier Status Now screen Test point for ground Used for auxiliary encoder input signals master encoder and other digital input modes including Pulse and Digital Used to indicate whether a motion profile is active or a fault has occurred Table B 1 Pendant Components NOTE The default switch setting consists of all switches up position B 2 Operator Pendant t gt E gt i E L dn Figure B 1 Pendant Module 7XX8 Series Digital Servo Amplifier User Guide B 3 J3 15 Reset hd b s1 o Po x 23 o P o e 5 of gee 24 0 LPS P 8 25 re Gnd j e e hd Analog q 9 Mon Enable PosEn oA 2 NegEn o e 21 Home Ke 22 o s DS
105. volution of the shaft Also there is proper synchronization of the index pulse to the A and B encoder pulses 9 If the Encoder Check routine is unsuccessful check physical connections verify motor specifications re calculate the data and apply the data to amplifier The routine may direct you to re adjust Encoder Polarity and A B Index in the pull down menus provided on the screen Linear Motor Encoder Check You may perform a Linear Motor Encoder Check This operation is performed using linear measurements Note the differences between the screen using rotary measurements and the screen using linear measurements which is shown below Qu Encoder Check x Configured Phase counts Motor Command Measured Approx Configured Counts Elec Cycle mm Index Index per Cycle a bier Check Encoder Ea Encoder Polarity m z ee me 76 J Index Sensed J Index captured Figure 3 9 1 7XX8 Series Digital Servo Amplifier User Guide 3 23 3 24 Getting Started Auto Phasing Refer to this section when wiring a new vendor motor to the amplifier You can use the Auto Phasing feature for proper connection of three Hall signals three motor phase wires and proper phasing of encoder wires Execution of the auto phasing routine enables you to achieve proper phasing for trapezoidal and sinusoidal commutation Warning Before proceeding make sure that the motor is free to move bi directionally and not connected to a
106. w Help Figure 5 21 Main Menu Motor Data Screen s olx When you select Motor Data the Motor Data Specification screen which contains a series of tabs used to access other screens is displayed Figure 5 22 Motor Type is the first screen displayed K1 CopleyMotionE xplorer Eile View Amplifier Motor Tools Diagnostics Window Help Amplifier 2 43 Presets Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Preset Figure 5 22 BE Amp Status Now como cUm m uto oc L4 Amplifier Status Now Motor HTa Motor Data Specification P f fme Feedback Ratings m Selection Mode Pos Torque x Med s SOCS T Manufacturer Copley Controls m Electrical Type Brushless Poles 4 DE Brush Mechanical Hj Rotary near Calculate Amp Data Save As File Motor Data gt Specification gt Type Screen Note The parameters captured in the motor data screens reflect selection of Mechanical Type Rotary Linear parameters are documented under each Motor Data screen in the section that follows 7XX8 Series Digital Servo Amplifier User Guide 5 31 Motor Data gt Specification Type Screen On the Motor Data gt Specification gt Type screen Figure 5 21 you can input information about the motor s manufacturer model and type On this
107. x 18 Channel B x be Ch B sfs p Receiver P EE 1 ona 11 Sig ground w Note T U Amplifier signal ground must be Copley Driver connected to controller ground Figure 2 19 Differential Pulse and Direction Configuration 2 18 Amplifier Connections J3 Pulse and Direction Gii Receiver icut single ended open collector 1 same for all digital channel inputs configuration gt Channel A eae Receiver Vv V j gt Channel B Ute N Receiver V HE Copley Driver Figure 2 20 Single Ended Open Collector Pulse andDirection Configuration The single ended configuration is most susceptible to noise and therefore is the least desirable Pulse and Direction single ended TTL configuration Receiver circuit same for all digital channel inputs Pul Channel A eae Receiver M vie Dir 1 Channel B Per Receiver i V Case Gnd 5V TTL circuit power O 3 45V Power Gnd 250mA max Y X Copley Driver Single Ended TTL Pulse and Direction Figure 2 21 Configuration The single ended configuration is most susceptible to noise and therefore is the least desirable 7XX8 Series Digital Servo Amplifier User Guide 2 19 Quadrature master encoder differential configuration Master Encoder Inputs The master en
108. y isolated from the power section in this series of amplifiers For proper operation connect the signal ground on J3 to the controller ground Chassis amp Cable Shield Grounding for EMI Reduction amp CE To minimize noise radiation from the motor and power cabling wires should be twisted and shielded Motor sensor signals are often routed near the motor phase winding cables To minimize coupling of PWM noise sensor signal wiring should be multiple conductor shielded cable Further more all cable shields should be case grounded at both ends for compliance with CE emissions limits See Figure s 2 1 through 2 4 for details 7XX8 Series Digital Servo Amplifier User Guide 2 3 AC amp DC Power amp Motor Phase J1 Power supply and motor connections Figure 2 2 should be made with wire that has a rating to support the amplifiers continuous current AWG 14 wire supports all amplifiers in this series Additional recommendations use wire insulation with a voltage rating of 600V DC and a temperature range of 105 C Voltage amp Current Ratings of Mains The mains for high voltage units that use 240V AC 50 60Hz 1 phase should be rated for a current of 20 amps The mains for low voltage units that use 120V AC 50 60Hz 1 phase should be rated for a current of 20 amps Fusing Model 7228AC 7228DC 7428AC 7428DC Fuse 120V 20A 120V 20A 250V 20A 230V 20A Fusing should be time delayed and installed on any hot lines coming f
109. your order Refer to the Read Me First document for a parts checklist cabling connections and Copley Motion Explorer software installation instructions Technical Support For technical support you may contact us in several ways Online at our web site www copleycontrols com Email sales copleycontrols com Telephone 781 329 8200 Fax 781 329 4055 7XX8 Series Digital Servo Amplifier User Guide 1 7 1 8 Introduction Safety Review the safety guidelines provided below DANGER HAZARDOUS VOLTAGES Exercise caution when installing and adjusting WARNING DO NOT make connections to motor or drive with power applied WARNING DO NOT spin motors with power off Voltages generated by the motor can damage drives WARNING DO NOT switch operating modes with out using precautions Values set for one operating mode may not be proper for another DO connect drives using good wiring and workmanship practices DO operate drives within specifications provided in this manual DO disconnect motors from loads while setting up or servicing systems Chapter 2 Amplifier Connections In general use the Copley Motion Explorer Kits Read Me First sheet for connection of the amplifier to AC or DC power A 3 phase brushless motor Quadrature encoders The control pendant or controller PC or laptop running Copley Motion Explorer Should you require it during installatio

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