OPERATION & INSTALLATION MANUAL. for. Glentek s Omega Series Digital PWM Brushless Servo Amplifiers. Model SMA9807 Model SMA9815 Model SMA9830

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1 OPERATION & INSTALLATION MANUAL for Glentek s Omega Series Digital PWM Brushless Servo Amplifiers Model SMA9807 Model SMA9815 Model SMA February Standard Street, El Segundo, California 90245, U.S.A. (310)

2 TABLE OF CONTENTS TABLE OF CONTENTS...2 OVERVIEW...5 PRODUCT DESCRIPTION...6 FULL FEATURE SERVO AMPLIFIER PHASE CURRENT MODE SERVO AMPLIFIER... 6 PULSE FOLLOWER SERVO AMPLIFIER... 6 Quadrature...6 Pulse (step) and Direction...6 CW/CCW Pulse mode...7 FEATURES...8 DIGITAL AMP CONTROL LOOP DIAGRAM...10 SOFTWARE...11 MOTIONMAESTRO INSTALLATION MOTIONMAESTRO AMPLIFIER SETUP FEATURES Opening of communications...13 Digital I/O setup...14 Amplifier mode setup...15 Commutation setup...16 Motor Parameters...17 Motor Safety...17 Amplifier Status...18 Control Panel...21 Motor Tuning...21 Saving parameters to non-volatile memory...22 Creating a backing up copy of amplifier parameters on disk...23 HARDWARE...26 STATUS DISPLAY CONTROLLER INPUT AND OUTPUT SIGNALS Command signal analog input...27 Analog output...28 Limits...29 Amplifier inhibit...29 Amplifier fault...29 Encoder output...30 Amplifier reset...30 External encoder power...30 POWER INPUT AND OUTPUT SIGNALS Bus power...30 Motor power...31 PC INTERFACE OPTIONAL RELAY I/O ENCODER FEEDBACK Encoder power, externally supplied March,

3 1 March, Encoder power, amplifier supplied...33 External event fault...34 Encoder channels A, B and Z...34 Hall channels 1, 2 and RESET SYSTEM SETUP...35 INITIAL WIRING OF THE AMPLIFIER Serial Port...35 Encoder Power...35 Encoder Logic...35 Power...35 APPLYING POWER TO THE LOGIC SECTION ENCODER CHECK PARAMETER SETUP PHASING THE MOTOR PARAMETER CHECK APPLYING POWER TO THE MOTOR TUNING...40 APPENDICES...41 A - ERROR CONDITIONS B GLENTEK SMA9800 SERIES AMPLIFIER COMMAND LIST, BY FUNCTION C -AMPLIFIER COMMANDS <CTRL-K> Kill...45 C Command...45 BV Bus Voltage...46 CA Commutation Angle...46 CAO Commutation Angle Offset...47 CCM Commutation Check Method...48 CER Commutation Encoder Remainder...49 CES Commutation Encoder Scale...50 CID Commutation Initialization recovery Distance...51 CIL Commutation Initialization current Limit...52 CIM Commutation Initialization Method...53 CIR Commutation Initialization rotation Rate...53 CIS Commutation Initialization Slew...54 CPL Commutation Phase Lead...55 CS Command Set...56 EC ECho On/Off...56 EN ENable/Disable Amplifier...57 FEP Feedback Encoder Position...57 FR Feedback Resolution...58 GL Gain, control Loop...59 GVC Gain, Velocity, Compensation...59 GVD Gain, velocity, Differential...60 GVF Gain, Velocity, Feedback...60 GVI Gain, velocity, Integral...61 GVP Gain, velocity, Proportional...61 IB Current Balance...62 IAD Input, Analog, Deadband...62 IAO Input, Analog, Offset...63 IAS Input, Analog, Scale...63 IL Current Limit...64 IUS Current User Scale...64

4 MC Motor Configuration...65 ML Motor Inductance...65 MOD amplifier operation MODe...66 MP Motor Poles...66 OAI Output Analog, source signal Index...67 OAO Output Analog, signal Offset...68 OAS Output Analog, signal scale (gain)...68 OAV Output Analog, test Voltage...69 RC Reload Configuration...69 RST ReSeT...70 SC Save Configuration...70 VER VERsion...70 D - SMA9800 RATINGS AND SPECIFICATIONS Power, Input And Output...71 Signal Inputs...71 Digital Inputs...72 Outputs...72 System...72 Notes...72 E MATCHING MOTOR PHASE LEADS TO AMPLIFIER COMMANDS USING HALL SENSORS F COMMUTATION TRACK SIGNALS AND PHASE-TO-PHASE BEMF G EUROPEAN UNION EMC DIRECTIVES Declaration of Conformity...90 H - AMPLIFIER TERMS AND TECHNOLOGY TERMS...91 TECHNOLOGY...95 I - AMPLIFIER MODEL NUMBERING SMA9807 Amplifier Model Numbering...97 SMA9815 Amplifier Model Numbering SMA9830 Amplifier Model Numbering J DRAWINGS SMA Amplifier module SMA9807-1A-1 Stand alone amplifier SMA9807-2A-2 2 axis base plate chassis installation SMA9807-4A-4 4 axis Installation SMA Amplifier module SMA9815-1A-1 Stand alone amplifier SMA9815-2A-2 2 axis base plate chassis installation SMA9815-4A-4 4 axis base plate chassis installation SMA9830 Amplifier March,

5 Overview This manual guides the application engineer through the steps necessary for a successful installation of an application using the SMA9800 series amplifiers. All features of the digital amplifier are explained and all necessary procedures for installation and tuning are covered. The following sections are presented in the order that would make installation easiest for most first time users of the amplifier. The Features and Product Description sections contain information for the application engineer to determine if the SMA9800 series amplifiers are appropriate for his application. Following these, MotionMaestro software is introduced. Enough material is given here to familiarize the application engineer with the tools necessary to setup and tune a motor using the SMA9800 series amplifiers. The hardware section outlines the hardware and connectors necessary to install a SMA9800 series amplifier into an application. Once these preliminaries are out of the way, the application engineer is brought through a step by step procedure that accomplishes system setup. In System Setup, the steps necessary to bring up and verify a fully functioning amplifier/motor combination is reviewed. Finally, Tuning is covered where the application engineer can use MotionMaestro to finetune the digital current or velocity loop to meet the specific demands of the application. 1 March,

6 Product Description Glentek s Omega Series Digital PWM Brushless Servo Amplifiers offer the latest in high performance DSP control of both rotary and linear brushless servo motors. With extensive utilization of surface mount technology and special heat transfer techniques, the Omega Series offers one of the world s most powerful products for a given form factor. The Omega Series is comprised of the following models: Full Feature Servo Amplifier The Full Feature servo amplifier operates in current (torque) or velocity (RPM) mode, accepts a +/-10V analog input as a command reference and commutates the motor sinusoidally for ultra smooth operation at low speeds. It requires an incremental encoder to derive the velocity signal and to commutate the motor. The absolute commutation angle is usually determined using Hall sensors or encoder Commutation tracks. However, in some cost sensitive applications where slight motor movement is acceptable upon power up, the amplifier can perform a power-on phase finding algorithm which eliminates the need for Hall sensors or Commutation tracks. Special versions are also available that decode Sanyo Denki and Yaskawa reduced wire encoders. 2-Phase Current Mode Servo Amplifier The 2-Phase Current Mode servo amplifier accepts two +/-10V analog inputs as current command references for two of the motor phases and derives the third command reference. This amplifier does not use any feedback devices and is used with controllers that provide the commutation. Pulse Follower Servo Amplifier The Pulse Follower servo amplifier incorporates all the features of the Full Feature servo amplifier and also accepts two digital pulse inputs as a position command reference. The two pulse inputs are high speed, differential and optically isolated digital inputs which can be configured to decode three pulse types and can be geared up or down (electronic gearing). The motor position and speed are a function of the number of pulses and the rate of the pulses respectively. The following pulse types can be decoded: Quadrature Two pulse inputs in quadrature, such as the output of an incremental encoder or an encoder pot determine both command distance and direction. This pulse decoding is useful to slave one motor to another by connecting the master motor s encoder output to the slave motor s pulse inputs. Pulse (step) and Direction The first input is a pulse train used to establish the absolute distance and velocity of the command and the second input is a direction signal used to establish the polarity of the command. This pulse type is output by many stepper motor controllers and allows upgrading a stepper motor system to a servo motor system without the need to change controllers. 1 March,

7 CW/CCW Pulse mode The first input is a pulse train to command positive moves and the second input is a pulse train to command negative moves. This pulse type is also generated by some older stepper motor controllers and may be useful in upgrading to a servo motor system. 1 March,

8 Features Digital current loops Current loop bandwidths up to 3 khz. Digitally tuned All parameters set digitally. No potentiometers to adjust. DSP control for the ultimate in high performance. Silent operation 25 khz PWM standard. Complete isolation Complete optical isolation between signal and power stage. Wide operating voltage VDC for Amplifier modules and 3U plug-in versions. All stand-alone and multi-axis versions can be ordered for operation from either VAC or VAC (single or 3-phase, 50/60 Hz). Direct AC operation No transformer required for stand-alone units or multi-axis chassis. The stand-alone units and multi-axis chassis include DC power supply, cooling fans, soft-start circuitry and a regen clamp with dumping resistor. Fault protection Short from output to output, short from output to ground, amplifier RMS over current, amplifier under/over voltage, amplifier over temperature, motor over temperature. RS-232 or RS-485 High speed (115.2K baud) serial communication interface for set-up and tuning. RS-485 multidrop with up to 31 amplifiers installed. Software configurable Glentek s Windows TM based MotionMaestro TM software provides ease of set-up and tuning with no previous programming experience required. This software is Windows TM 95/98/2000 and NT compatible and includes the ability to download upgrades. Non-volatile memory All parameters and positions are stored in non-volatile memory for reliable start up. In addition, up to two different configurations can be stored at one time. Dedicated inputs +/- limits, inhibit, fault, motor over temp & reset. Dedicated outputs Analog monitor, fault and divided encoder. Three basic models Covering almost all servo needs, the Omega Series includes a full feature current/velocity amplifier, a 2-phase input current amplifier, and a pulse following amplifier. Encoder output divider The frequency of the encoder output can be divided from the input by any integer 1-8. Note: Non-standard frequency divisors can be ordered on request. Encoder feedback Accepts encoder signals up to 4.3 Mhz. Special versions are also available that decode Sanyo Denki and Yaskawa reduced wire encoders. Status indicator 7-segment display indicates amplifier status and diagnostics. Sinusoidal commutation For the ultimate in efficiency and smooth motion. Commutates from almost any resolution linear or rotary encoder. SMT construction Provides ultra compact size, cost competitive package and high reliability. 1 March,

9 Parametric filtering Provides control engineers advanced filtering to eliminate unwanted system mechanical resonance. 1 March,

10 Digital Amp Control Loop Diagram Command Input IAO Current Loop Analog Input A-to-D 12 bit +/- 10 Volts 16 IAD IAS TRAJECTORY GENERATOR MOD 0 GL ƒ(s) ƒ(s) ƒ(s) Filter 1 Filter 2 Filter 3 ILA SVC MOD 1 Velocity Loop COMMUTATE SIC GVI/s GVC GII/s GVP GIP Current Feedback PWM MOTOR GVD s ƒ(s) Highpass Filter VELOCITY ESTIMATE GVS* Encoder SVS GVF * - Encoder counts/cycle are scaled by 2^(GVS). Glentek reserves the right to modify all or any part of this design without prior notification.

11 Software MotionMaestro is Glenteks Windows based application software that is used to communicate with the SMA9800 series digital amplifier. Although it is not necessary to use MotionMaestro, installation, setup and tuning is made easier through its use. MotionMaestro has many features that allow application engineers to easily configure a digital amp to an application. It has a terminal mode that operates at up to 115k baud transmission rates. It has an oscilloscope that can be used to monitor amplifier signals. It has a tuning dialog that can be used to step the motor. By using the oscilloscope and tuning dialog one can monitor step response to determine the correct parameters for optimal control loop performance. MotionMaestroª Installation MotionMaestro requires Windows95, Windows NT 4.0, or later software running on a PC. It is suggested that you have no less than 3 megabytes of disk space remaining on the hard drive prior to installation. Installation is performed by Install Shield. There are few options and in general you can press NEXT or YES until installation is complete. When installation is completed you will find a MotionMaestro shortcut on the windows Start\Programs menu. DO NOT RUN MOTIONMAESTRO UNTIL YOU HAVE READ ALL OF THIS SECTION. The MotionMaestro installation program is named Setup.exe. It is found on disk1 of the distribution floppies or in the MotionMaestro \disk1 directory of the distribution CD. The installation will create a Glentek folder in the Program Files folder. A MotionMaestro_x_x folder is created where _x_x matches the version number. You can have multiple versions of motion maestro installed, if you wish, and they will be placed into their own directories. When communications is established with the amp by MotionMaestro, the amp is queried for a model ID. MotionMaestro will select appropriate configuration files based on the model ID returned. You can run the program without an amplifier attached and inspect the menu options and dialogs. Do this by pulling down the Communications menu and selecting Demo. 1 March,

12 Demo Mode - For exploring MotionMaestro without an amplifier connected There are extensive help screens under the Help menu. Select Help Topics and you can read about the usage of MotionMaestro and it s features. MotionMaestroª amplifier setup features. This section is an introduction to MotionMaestro s features that are required for installation and setup of the SMA9800 series amplifiers. This section describes only those MotionMaestro features that are required for setting up a motor. This section is not a step by step tutorial. The System setup section is intended as a tutorial for motor setup. You may need to refer to this section when setting up a motor. The following features are reviewed here. 1.) Opening of communications. 2.) Digital I/O setup. 3.) Mode setup. 4.) Commutation setup. 5.) Motor Parameters. 6.) Motor Safety. 7.) Amplifier Status. 8.) Control Panel. 9.) Motor Tuning. 10.) Saving parameters. 1 March,

13 11.) Backing up a copy of amplifier parameters. Opening of communications Before MotionMaestro can be used, communications must be established between the amplifier and the PC that MotionMaestro is running on. Before opening communications in MotionMaestro you must have a serial communications cable wired as described in the hardware section of this manual. You will also need to make sure that the serial port on your computer is set as described in the system setup section. Open communications by selecting the Open option on MotionMaestro s main menu tool bar. Open Communications dialog box Select the COM port that you connected the serial port cable to and insure that a baud rate of is selected. When you press OK motion maestro will query the amplifier to determine what amplifier model is connected. If all goes well you should see a screen similar to the following with all green communications status indicators. 1 March,

14 MotionMaestro s main window when communications are open. When communications cannot be opened, a dialog is presented indicating so. If you cannot open communications you need to check your cable, PC COM port settings and power to the amplifier. Digital I/O setup You will probably have to modify the Digital I/O settings in order to insure that the amplifier does not come up in a fault condition. I/O can be active high or active low depending on the applications requirements. By selecting Digital I/O from the Setup menu you can modify what state the amplifier considers to be a fault condition, either high or low. Pressing OK in this dialog box will modify the amplifiers parameters. 1 March,

15 Dialog box for setting up digital I/O. Amplifier mode setup The amplifier can operate in either current/torque mode or velocity mode. By selecting the Setup Mode item on the Setup menu you can configure the amplifier to operate in one of these two modes. Dialog box for setting amplifier mode. When the SMA9800 series amplifiers are in current mode, parameters on the tuning dialog pertaining to the velocity loop are not available. 1 March,

16 Commutation setup The Commutation dialog allows you to define a motor s commutation characteristics. Here you can specify whether a motor is linear or rotary and what kind of encoder resolution the motor has. Select Commutation on the Setup menu to activate the following dialog. Dialog box for setting up motor commutation. Selecting linear instead of rotary will display parameters that are specific to a linear motor. Edit boxes that are not available are values that are calculated based on other parameters entered. Encoder scaling and remainder are automatically calculated based on the motor and encoder values that are entered. The working column represents modified values that are sent to the amplifier when clicking the Send Values to Amp button. In order to update the commutation values, the motor windings must be disabled. You can do this by clicking on the Disable Amp button. All edit box parameters are described in the help dialog at the bottom. You can activate this dialog by clicking on it and then you may scroll up and down through the help with the up or down arrows. Alternatively you can press F1 to view the dialog help text in notepad. After the values are sent to the amp you may test the values by enabling the windings. 1 March,

17 Motor Parameters This section does not apply to amplifiers with analog current loops. The Motor Parameters dialog is used to set digital current loop gains. Entering motor resistance, motor inductance, nominal DC bus voltage and desired current loop bandwidth accomplish this. MotionMaestro will calculate current loop gains based on the values entered. Select Motor Parameters on the Setup menu to activate the following dialog. Dialog box for entering motor parameters. Motor resistance and inductance are entered as phase to phase values. If these values are not indicated on the motor label you can determine these values by measuring the resistance or inductance between two motor wires connecting two phases of the motor. DC bus voltage is the regulated bus voltage. It is usually 160 or 320 volts. Current loop bandwidth is a measure of the current loops responsiveness. Generally you want this to be as high as possible. A good starting point is 1500 Hz. In order to update the motor parameters in the amplifier, the motor windings must be disabled. You can do this by clicking on the Disable Amp button. Pressing F1 displays the dialogs help text. After the values are sent to the amp you may test the values by enabling the windings. Motor Safety Once a motor is running you may want to set some limits that protect the motor. This can be done in the Motor Safety Setup dialog available from the Setup menu. Here you can setup a maximum current limit, current fold back and low speed ECB values. You must disable the windings before sending values to the amp. 1 March,

18 Dialog box for setting up motor safety parameters. Amplifier Status MotionMaestro has a variety of status dialogs that assists the application engineer in setting up or diagnosing a setup. Rather than showing all possible status on one dialog, MotionMaestro has been designed so that only those applicable to the situation at hand can be displayed. These dialogs continuously send queries to the amplifier to determine what the amplifiers current status is. The size and location of each status dialog is saved, thus allowing for productive setup conditions. When a dialog has the focus, F1 can be pressed to obtain help on the various items or status in the dialog. The following dialogs are described below. 1.) Control Loop Signals. 2.) Digital Inputs. 3.) Faults. 4.) Warnings. 5.) Status. Control Loop Signals This dialog is useful for determining if an amplifier control loop is responding properly. Commanded and absolute current through the motor can be displayed as well as the motors current velocity. Display this dialog by selecting Status\Control Loop Signals. 1 March,

19 Dialog for observing control loop status Digital Inputs This dialog indicates the state of digital inputs coming into the amplifier. Digital inputs are those inputs that can be characterized as being active or inactive. They are typically associated with one of the controller input and output signal pins. See the associated pin in the hardware section below for a description of the digital input of interest. Display this dialog by selecting Status\Inputs\Digital. Display for monitoring inputs to the amplifier. Faults Faults occur on conditions that make it impossible to operate the amplifier in a safe and stable condition. When a fault condition occurs the amplifier is halted and current is brought to zero. The amplifier must be reset either with the hardware reset switch or with software through the external reset pin. Conditions that cause faults are over currents, high or low bus voltages, excessive operating temperatures, and faulty sensors or amplifier hardware. An external fault can be generated by the controller through the /FAULT pin. See the hardware section below for addition information on /FAULT. Display this dialog by selecting Status\Faults. 1 March,

20 Amplifier fault status display. Warnings A warning status indicates that the amplifier is fully operational, but that it is operating in an unusual mode or in a condition that warrants attention. Current fold back is such a condition. Display this dialog by selecting Status\Warnings. The Warning dialog with the amplifier in fold back. Status All other amplifier status that is not a fault or warning is displayed on the Status dialog. These amplifier status are useful for diagnostics, setup or monitoring during operation. Display this dialog by selecting Status\System Status. 1 March,

21 The System status display. Control Panel A properly connected motor can be controlled using the control panel. The control panel displays the amplifiers commanded current or velocity along with the motors actual velocity. From the control panel you can easily command the motor without using a terminal window. The control panel can be accessed through the Tools pull down menu or from the control panel icon on the tool bar. Control Panel Motor Tuning Fine tuning of motor control loop parameters is accomplished with the Tuning dialog. This dialog is accessed through the Servo Tuning item on the Setup menu and is shown below. 1 March,

22 Dialog box for tuning the motor. This dialog has many tools and features for tuning a motor. Real time motor velocity is always available. One can activate the motor with the Continuous Step Response button. Then by viewing the response pattern on the scope you can see if changes to the tuning parameters improve or diminish performance. The Oscilloscope can query the amplifier down to a period of 4 milliseconds, which is adequate for most tuning requirements. The Tuning section below describes in detail how a motor is tuned. Saving parameters to non-volatile memory After a motor is configured and tuned to the applications satisfaction, the parameters must be saved to the amp s non-volatile memory. If this is done then the next time the amplifier is powered up, the amplifier will perform as desired. If the parameters are not saved then the power up parameters will be as they were when the parameters were last saved. The parameters can be saved to non-volatile memory by selecting the Save to NVM option on the setup menu, as illustrated below. 1 March,

23 Saving parameters to amplifier non-volatile memory. Creating a backing up copy of amplifier parameters on disk Backing up amplifier parameters to a file on disk. 1 March,

24 An amplifier s current parameter settings can be saved to disk in a file that can be later used to configure another amplifier or to restore an amplifier s parameter settings. This is useful in production environments or where an application has several similar motors. Select Backup Card on the Backup item of the Tools menu to backup parameters. You will be presented with a Windows style Save File dialog. Here you can give the file a meaningful name and location to save the file to. Restore backed up files to an amplifier with the Restore Backup item. 1 March,

25 1 March,

26 Hardware This section describes the amplifier connections and how they are used in the typical application. Refer to the specific amplifier s installation drawing in appendix I. This drawing indicates the location of the pins described below along with what connector they can be found on. Status Display A diagnostic LED is provided for determining the general operating condition of the amp. It is a 7-segment LED display. When 5 volts are being supplied to the logic section of the amp, the decimal point is lit. When hall sensors are being used and the amp is operating normally, one of the outer six segments is lit. Each of the six outer segments represent one of the six hall states in a commutation cycle of a motor. A commutation cycle consists of two poles. In an 8-pole motor the LED will cycle through its six outer segments 4 times for one revolution of a rotary motor. When hall sensors are not being used the display will show a 0, all outer segments of the LED are lit. When the motors current is clamped, (i.e. held to zero), or the amplifier is in a fault condition, one of the following characters will be displayed as is appropriate to the fault or state. S. (fault) High-speed ECB tripped. (Short) L. (fault) Low speed ECB tripped. E. (fault) Encoder or Hall sensor fault detected. H. (fault) Heatsink or over temperature. h. (fault) Motor over temperature. b. (fault) Over Voltage fault. (bus) 3-bar (fault) power on commutation failed. Three horizontal bars. 2-bar (fault) invalid hall state detected. Top and Bottom horizonal bars. 1 (fault) eeprom checksum failed. C. (status) Clamp condition active. (Inhibit input) c. (status) Clamp condition active. (Fault Input) F. (status) Foldback condition active. O. (status) Normal operation. 8. (status) Amplifier is in reset. Controller Input and Output Signals Signals that typically are connected to an external controller are described in this section. These signals include: the primary command signal interface to the amplifier, an encoder output signal, limits, inhibits, analog output, reset and common. The following is a list and description of the possible controller I/O signals that can be found on an installation drawing. Each amplifier may have these on different types of connectors depending on the model that was ordered. It is important to refer to appendix I. 1 March,

27 Pin Name Description SIGNAL 1+ Command signal analog input, differential signal input. SIGNAL 1 - Command signal analog input, differential signal input. SIGNAL 2+ Command signal analog input 2, differential signal input. SIGNAL 2 - Command signal analog input 2, differential signal input. ANALOG OUT User configurable analog output. + LIMIT Inhibits the motor in the plus direction. - LIMIT Inhibits the motor in the minus direction. INHIBIT Inhibits the motor in both directions. /FAULT Active low fault, or inhibits the amplifier when forced low. RESET IN Resets latched faults. ENC + 5 IN External +5 volts input, encoder power supply ENCODER A+ Encoder A channel ENCODER A- Encoder A channel (NOT) ENCODER B+ Encoder B channel ENCODER B- Encoder B channel (NOT) ENCODER Z+ Encoder Z index (reference) ENCODER Z- Encoder Z index (reference) (NOT) + 15V OUT 15 volt source positive output - 15V OUT 15 volt source negative output + 5V OUT 5 volt source positive output - 5V OUT 5 volt source negative output TACH Analog output proportional to RPM PULSE+ Pulse signal of P & D interface, differential signal input. PULSE- Pulse signal of P & D interface, differential signal input. DIR+ Direction signal of P & D interface, differential signal input. DIR - Direction signal of P & D interface, differential signal input. COMMON Signal common N/C No Connection. Command signal analog input Pins SIGNAL 1+ and SIGNAL 1- are the command input. The command input takes a differential analog signal as referenced to the amplifiers ground. Input voltage is expected to range from -10 volts to +10 volts. The scale of the input is 5 amps/volt. The analog signal is converted using a 12 bit ADC. The analog input stage is a difference amplifier with a differential input impedance of 10Kohm. If a single-ended input is desired, then Signalshould be connected to Signal common, and the command input should be connected to Signal+. This will maintain the proper input gain for a +/-10V input range. In this configuration, the single-ended input impedance is 5Kohm. If the signal polarity is incorrect, the signal gain may inverted in the software setup using MotionMaestro (e.g. 50% instead of +50%.) 1 March,

28 Signal+ 4.99K K 10.0K 1.00K TLE KHz anti-alias filter To A/D converter TLE K 10.0K 10.0K REF 0.1 Signal- 4.99K.01 Command signal analog input design. Analog output Pin ANALOG OUT is an analog output. The output ranges from -10 volts to +10 volts and has 8 bit (256 step) resolution. The following signals can be selected through MotionMaestro as signals that can be monitored on ANALOG OUT. Test Voltage - A user defined constant test voltage. Command - ANALOG INPUT scaled, offsetted and dead band adjusted. Absolute Current - The absolute current that is being delivered by the amplifier. Encoder Velocity - A raw velocity, proportional to encoder counts per servo interrupt. Velocity - velocity scaled as Command, Encoder Velocity * Tach gain. Commanded Current - velocity compensated current command to the amplifier. R Phase - current being delivered to the R phase of the motor. S Phase - current being delivered to the S phase of the motor. By default the amplifiers absolute current is placed on ANALOG OUT at power up. The analog output can be used to monitor amplifier signals at the servo update frequency. By doing so, the application engineer can determine the amplifiers true response to commanded signals. The analog output is for reference use only. It is not intended for control purposes. At power on, its value is undetermined until the power on reset has completed. During some amplifier functions, this output is temporarily disabled. At the time of this writing, these functions include saving and recalling parameters from non-volatile memory. The output is filtered to minimize the switching noise from the PWM amplifier. The analog output is updated once per PWM cycle. 1 March,

29 From D/A converter 24.9K 100K TLE Analog Out REF 0 Analog output design. OMIT Limits Pins + LIMIT AND - LIMIT can be active low or active high based on a user selected setting, (See Digital I/O Setup). They are normally active low limits. If + LIMIT is brought low then positive current through the motor is brought to zero. If - LIMIT is brought low then negative current through the motor is brought to zero. These pins are normally high at 5 volts. Although the current is brought to zero the motor is free to rotate by externally applied forces. Amplifier inhibit An externally applied inhibit is available at pin INHIBIT. This is normally high, when brought low, positive and negative currents to the motor are clamped to zero. The display indicates C for clamped. The motor is free to rotate via externally applied forces. This pin can be configured as active high or low, (See Digital I/O Setup). Amplifier fault An externally applied fault is available at pin /FAULT. This is normally high; when brought low, positive and negative currents to the motor are clamped to zero. The display indicates lower case c for clamped. The motor is free to rotate via externally applied forces. An external fault does not require a reset. Instead removal of the external fault activity, is sufficient to bring the amp out of a fault condition. When the external fault is removed the amplifier resumes operation with whatever command is present. Internal faults, which are generated by unsafe operating conditions, must be cleared with a reset. 1 March,

30 Encoder output The Encoder output pins are a duplication of the motor encoder. 1,2,3,4,5,6,7 or 8 can divide the output. Dividing the encoder output by 1,2,4,8,16,32,64 or 128 can be ordered as an option. Encoder channels A, B and Z are available as pins ENCODER A+, ENCODER A-, ENCODER B+, ENCODER B-, ENCODER Z+ and ENCODER Z-. Amplifier reset The amplifier can be externally commanded to reset with the RESET IN pin. This pin can be configured as active high or low. The amplifier displays 8, all seven segments lit, while in reset. External encoder power To work reliably, some encoders require more current and/or a higher voltage than can be supplied by the amplifier. An external 5 or 12 volt source can be connected to the ENC + 5 IN pin. This power will be supplied to the encoder at the +V pin (see Encoder Feedback). Power Input and Output Signals The pin names for power are listed below: Pin Name Description B- Common side of DC buss voltage. B+ Positive side of DC buss voltage. PHASE T Motor phase T. PHASE S Motor phase S. PHASE R Motor phase R. Bus power DC bus power is received at pins B- and B+. DC bus power is used for both the logic and current section of the amplifier. It accepts 70VDC up to 340VDC on the B-/B+ terminals. 1 March,

31 Motor power Motor power is delivered on at pins PHASE T,S and R. NOTE: It is best not to connect the motor power pins until it is established that the logic section is working and operational. This means that with the DC bus pins connected, one should be able to communicate with the amplifier via serial cable and the motor encoder and hall sensors should be functioning properly. The LED display should sequence through the hall states, if hall sensors are being used, when the motor shaft is turned. This can all be determined without connecting the motor power. 1 March,

32 PC Interface The PC interface can be found at the HOST connector. An RS-232 (or optional RS-485) port is provided here. This port is the primary means of communication with the amplifier for setup and control. The port utilizes a DB-9 (or optional RJ/45 plug-jack) type connector. The HOST port, when configured as RS232 (independent of the connector type), is most reliable when a three wire cable is used. For a DB-9 connector, simply wire, DB-9 pins 2,3 and 5 straight through. A null-modem is not required. Using a fully wired DB-9 may cause some computers not to communicate properly. For the amplifier with an RJ/48 plug, A serial cable can be made or purchased for communicating with a PC by configuring a cable with one end being a male RJ/48 plug and the other end being a DB9 female connector. The pin-out names are below. Remember that there is no standard for an RS-485 connector. DB-9 female DB-9 Pin - Description Glentek Utilization Data Carrier Detect RX- (RS485) 2 - Received Data TX232/CLK- 3 - Transmitted Data RX232/RFS- 4 - Data Terminal Ready n/c 5 - Signal Common GND 6 - Data Set Ready RX+ (RS485) 7 - Request to Send n/c 8 - Clear to Send TX+ (RS485) 9 - Ring Indicator TX- (RS485) The pin-out for the RJ/45 connector on the amplifier is shown below. A cable wired to a DB-9 connector, as shown below, will work with most RS-232 connections. RS-485 wiring depends on the pin-out of the RS-485 card communicating with the amplifier. The chance is low that the below cable will work with your specific RS-485 card. DB-9 pins RJ/45 pins AMP Female Male Pin description < > RX+ 1 < > RX - 4 < > 3 n/c 5 < > 4 * GND 2 < > 5 * 232 TX 3 < > 6 * 232 RX 8 < > TX < > TX- 7 n/c Female RJ/45 pin-out Note: RS-232 requires connecting only the 3 pins marked with an asterisk above. RS-485 is an ordered option. 1 March,

33 Optional Relay I/O This 5 pin connector provides an interface for relay M1 and M2. Both relays are optional and not part of the standard product. Below the pins are described. Pin Name Description M1+ Relay 1 M function positive side M1 - Relay 1 M function common N/C No Connection M2+ Relay 2 M function positive side M2- Relay 2 M function common Encoder Feedback The following pin description defines the main encoder input port. Pin Name Description V Externally supplied 5 or 12 volt source (output) +5V Amplifier supplied 5 volt source (output) ENCODER A Encoder A channel input ENCODER A* Encoder A channel input (NOT) ENCODER B Encoder B channel input ENCODER B* Encoder B channel input (NOT) ENCODER Z Encoder Z channel input ENCODER Z* Encoder Z channel input (NOT) HALL 1+ Hall sensor 1 input HALL 1 - Hall sensor 1 input (NOT) HALL 2+ Hall sensor 2 input HALL 2 - Hall sensor 2 input (NOT) HALL 3+ Hall sensor 3 input HALL 3 - Hall sensor 3 input (NOT) COMMON Amplifier common MTR TEMP Motor over temperature switch input. Encoder power, externally supplied The encoder s power can be supplied externally via the ENC +5 IN pin (see Controller Input and Output Signals above). The external power is routed to the encoder via pin +V. Encoder power, amplifier supplied The amplifier can supply 5 volts of encoder power. It is accessible at the +5V pin. The source is rated at 150ma. 1 March,

34 External event fault The amplifier can be faulted on external event with the MTR TEMP pin. This pin can be configured as active high or low. The amplifier displays lower case h when this signal is active, latches the fault and disables the amplifier. Encoder channels A, B and Z The encoder input uses a 3-stage filter in determining if encoder inputs have changed. An encoder edge is considered valid if it holds a single state for three full encoder clock cycles. An encoder clock cycle is 1/26MHz. If an encoder clock is running at a perfect 50% duty cycle, then the shortest possible edge time is 1/26Mhz. Since the signal must pass through the 3-stage filter, the minimum edge time for an encoder signal is 3/26MHz or 115ns. This is equivalent to a single channel signal frequency of 8.67Mhz/2 (there are two edges in an encoder signal) or 4.33Mhz. Since encoder signals are not perfectly square or perfectly at a 50 percent duty cycle, the true signal frequency will be somewhat below this. If the Z channel on the encoder is being utilized, and the Z channel signal width is equal to ½ or a full quadrature pulse, then this signal rate is not affected. If the Z pulse is a quarter of a full quadrature pulse then the minimum edge time is increased to 231ns. The Z channel is edge sensitive such that swapping Z and Z* does not change the behavior of the amplifier. Hall channels 1, 2 and 3 Reset This switch performs a reset. A reset clears all faults, resets the DSP and initializes the amplifier. 1 March,

35 System Setup This section outlines how to connect an amplifier to a motor and how to insure that the amplifier is correctly connected to the motor. When this section is completed one should have a motor, which can be jogged and is ready to tune for the application. Initial wiring of the amplifier. Serial Port Purchase or manufacture a serial cable as described above under the description for PC Interface. Connect the female DB-9 connector to the PC that has your terminal software installed. Place the other end of the cable into the HOST port of the amplifier. The default serial settings for this amp are: Baud rate: Data bits: 8 Stop bits: 1 Parity: None There is no settable software protocol. Set your PC to raw ASCII. Encoder Power If the encoder requires an external power source, supply it at the amplifiers ENC +5 IN pin. Use one of the Encoder Feedback connector s COMMON pin for the 5 or 12 volt common. Encoder Logic Manufacture an encoder cable that will be connected to the encoder feedback port. Use the pin out description under Encoder Feedback above and the installation drawing as a guide. For the encoder, wire differential channels A, B and Z to the matching amplifier pins. Wire the encoder +5 volt to pin +V. Wire the encoder ground to a COMMON pin. Hall sensor wires should be wired to their matching amplifier pins HALL 1+, HALL 2+ and HALL 3+. A rotation of the motor should activate Hall 1,2 and 3 sequentially. Insure that 5 volts and ground are provided to the hall sensors through +V, either an external 5 Volts or from the amplifiers +5V pin. If encoder power is supplied from amplifiers +5V pin, make sure that the encoder s current draw is less than the current rating of the +5V pin. IMPORTANT: Use proper shielding for the encoder logic cable. Tie amplifier common to encoder ground and cable shield. DO NOT tie cable shield or encoder ground to motor case. Power Testing of the logic section requires that only the bus power terminals B+ and B- be connected. Connect an appropriate DC bus voltage, see Ratings and Specifications, to these pins. 28 February

36 DO NOT CONNECT THE MOTOR POWER CABLE. Applying Power to the Logic Section Turn on the DC bus voltage connected to the amplifier. A lit decimal point on the LED display indicates that 5 volts are being supplied to the logic section of the amplifier. Execute the communications software that is on your PC. Open a terminal window and press Enter on the keyboard. If the amplifier is communicating properly with the PC, the amplifier will respond with a > prompt. Each pressing of Enter will result with this prompt. NOTE: The amplifier is configured at the factory to work with your amplifier/motor combination. Occasionally the user needs to initialize the amplifier for a different motor. The following terminal commands can be used to initialize the amplifier. These factory defaults are generalized for the average motor so that after these commands are executed the user needs to insure that commutation and motor parameters are correct for the motor being used. All amplifiers are configured to default settings and you do not have to do the following procedure. It is included in the case that you need to initialize the amplifier to it s default settings. Enter the following commands to initialize an amplifier to default settings. The default settings may not work on the amplifier/motor combination shipped to you. Do this only if you are setting up the amplifier for a non Glentek supplied motor. EN 0 RC 0 SC ; disable windings. ; recall virgin parameters. ; save them to the amplifiers internal memory. Restoring an amplifier to factory default settings. Press the reset button on the amplifer. This resets the amplifier and loads the parameters. At this point, if all is wired correctly, the LED should have one of it s six external segments lit, (for amplifiers configured using hall sensor), or it may display a 0, (for amplifiers using other means to initialize commutation). 28 February

37 If a fault is visible on the amplifier s LED display, correct the fault before proceeding. You may have to apply a high or low voltage to one of the I/O pins to eliminate the fault. The most common of these are the external fault, and over temperature inputs. You may also be able to eliminate a fault condition by modifying the I/O configuration with the Setup Digital Inputs dialog as described above. Encoder Check As you face the motor flange where the motor shaft extends, turn the motor in a clockwise direction. For motors with hall sensors, as the encoder turns, the LED outer segments should be sequentially turned off and re-lit in a clockwise direction. If this is the case the hall wiring is correct. Parameter Setup Start MotionMaestro, establish communications with the amplifier, and enter the Setup\Select Mode dialog. Insure that the amplifier is configured for current mode. Motor/amplifier checkout is done in current mode. After checkout is completed you may change to velocity mode if your application requires that. Enter the Setup\Commutation dialog. Configure the amplifiers commutation characteristics as indicated on the dialog. For rotary motors enter the lines per revolution, not encoder counts. This should be found on the encoder nameplate. This number will need to be derived if linear scales are used. Disable the windings, if they are not already, and send the parameters to the amplifier. Select an appropriate commutation initialization method. (See Selection of a commutation initialization method in the appendix). NOTE: When any parameter that controls commutation is changed it is necessary to recommutate the motor. This very often is best achieved by executing RST from a terminal window or clicking the Fault Reset button on the control panel. NOTE: If you are using hall sensors to maintain commutation, you may want to fine tune your commutation. Hall sensors are typically not perfectly aligned with the motor windings. Set the Commutation Angle Offset to an appropriate value in MotionMaestros Setup\Commutation dialog. Enter the Setup\Motor Parameters dialog. (This is not available if your amplifier has an analog current loop). Enter the motor resistance, inductance, the bus voltage and the current loop frequency appropriate to the application. Disable the amplifier and send the parameters to the amplifier. Enter the Setup\Motor Safety dialog. Set Current limit to the rated limit of the motor or the rated limit of the amplifier, whichever is smaller. Set the fold back threshold to a value under the current limit. How much the threshold is set under the current limit depends on the dynamics of your application. Start with a value 5 percent under the current limit. If you are not using current fold back then set the fold back threshold to a value above or equal to the current limit. Set the Electronic Circuit Breaker (ECB) values. The low speed ECB protects the motor and amplifier from conditions when the current remains at the current limit for excessive periods of time. Set the LS/ECB threshold to about 60 percent of the amplifier 28 February

38 rated current or 90 percent of the motor rated current, whichever is smaller. Start with a 2 to 4 second filter time. Disable the amplifier and send the parameters to the amplifier. At this point you may want to save the parameters in non-volatile memory. Select Setup\Save to NVM from the menu bar. You may also choose to save the current parameters in the amplifier by saving them to hard disk. Select Tools\Backup Card from the menu bar. Phasing the motor If you are matching a motor to the amplifier and you have not received a motor with your amplifier from Glentek, then read Appendix E. Parameter Check Start MotionMaestro, establish communications with the amplifier, and enter the Setup\Servo Tuning dialog. Set the loop gain to zero. Set the signal gain to zero. Press Set. Then press Save. You are now ready to safely apply power to the motor in preparation for tuning. Applying Power to the Motor Turn the DC bus power off and wait for the bus to discharge. Connect the motor power leads phase R, S, and T (or phase A, B and C) to the amplifier. Be careful to follow the manufacturers phasing sequence when connecting these leads. Insure that the motor ground is properly grounded to the amplifiers chassis ground. NOTE: Turning power on may move the motor, do not have the motor shaft connected to the machine at this time. Turn the DC bus power on. Enable the amplifier if it is not already enabled. From the MotionMaestro Servo Tuning dialog, slowly increment the loop gain. First 1 percent. If the motor does not run away or lockup (i.e. hum), then the motor wiring is probably correct. If all appears to be ok, continue increasing the loop gain up to 100 percent. Open the control panel. 28 February

39 Slowly increase the commanded current in the positive (+) direction until the motor moves. Note the velocity. It should also be positive. If it is not, then check, or uncheck, the Tach Reverse checkbox. Zero the commanded current. Disable the amplifier and send the parameters to the amplifier. Save parameters to NVM. You are now ready for tuning. Before advancing further save these parameters to nonvolatile memory by pressing the SAVE button on the Servo Tuning dialog in MotionMaestro. 28 February

40 Tuning For Glenteks digital amplifiers, you can use MotionMaestro to tune the amplifier for best response in your application. Select the Servo Tuning dialog from the Setup pull down menu. Press the Scope button. This will display the Oscilloscope setup screen. For tuning the digital amplifier you will want one of the scope s traces to be set for Actual Velocity. This is equivalent to monitoring the tach test point on Glenteks analog amplifiers. Make sure that the trace is active and that it has an appropriate scale. Press OK and the scope will be displayed. You should see a trace scanning across the scope. If you do not, press the scopes setup button and adjust the scope until a trace is visible. The scope setup needs to be performed only once. Your settings will be saved for the next tuning session. To continue with the tuning, you can apply a step input voltage to the analog inputs, or you can choose to use MotionMaestro for applying a step input through its bias. Your application may require that you use an analog input that is slewed properly by your applications external control. Insure that the compensation is at a known conservative value, if you do not know what this means set the compensation to zero. Apply a continuous step response and observe the waveform on the oscilloscope. Compare the Oscilloscope waveform with the below illustrations. Figure B, a one hook over shoot signal is a practical target to aim for. A.) Critically Damped Signal. B.) 1 Hook Overshoot Signal C.) Under Damped Signal. D.) Over Damped Signal. Increase the compensation until the oscilloscope waveform is critically damped or has just one hook overshoot. This should be achieved without the system becoming unstable. You 28 February

41 can increase and decrease the compensation with the up and down arrow on the keyboard when the compensation edit box in MotionMaestro has the focus. When you are satisfied with the tuning you can save the parameters to non-volatile memory with the Save button on the Tuning Dialog. You have now tuned the amplifier and motor with no load. At this time you can attach the motor to your application and redo the tuning procedure. When tuning is complete you can save the amplifier parameters to an ASCII text file with MotionMaestros Backup command. You will find this command under the Tools pull-down menu, under backup. Select Backup Card. You will be prompted for a file name. The file can later be found under the application directory with a bk filetype descriptor. At a later time this file can be used to quickly load default parameters for an application. Appendices 28 February

42 A - Error Conditions APPENDIX A This appendix contains definitions of error codes read from an amplifier. Errors may be returned in response to a command sent via a serial line. MotionMaestro displays the following response when the amplifier returns an error. ERROR= nn > where nn is a number that is explained in the following list. Error # Definition 1 Invalid command 2 Reserved 3 Reserved 4 Invalid command argument 5 Reserved 6 Reserved 7 Reserved 8 Reserved 9 Reserved 10 Reserved 11 Reserved 12 Reserved 13 Reserved 14 Reserved 15 Motor is enabled 16 Inhibit is active 17 Parameter is locked 1 March,

43 1 March,

44 APPENDIX B B Glentek SMA9800 Series Amplifier Command List, By Function This appendix is intentionally left blank. 1 March,

45 APPENDIX C C -Amplifier commands Appendix C contains commands that can be used to setup a SMA98xx series amplifier from a terminal window. They are sent to the amplifier via the host port, a serial communications line. This is a subset of the commands that are available. Most of these commands are available through some feature within the MotionMaestro environment. <CTRL-K> Kill This is a synonym for EN 0. It basically disables the amplifier. Syntax: NVM: press CTRL and K key simultaneously No Examples: CTRL-K PWM is disabled. C Command Sets or reports the amplifier s command. This command can be used for immediately commanding the amplifier. This acts like an additional offset to the analog input. If you wish to eliminate any signal coming from the input, set IAS to 0. To see what the analog input command is, use SVC. Syntax: C <value> Value: Units of value are different depending on the mode of operation, MOD. MM: NVM: The Tools/Control Panel allows easy access to this command via a slide bar and buttons. Amplifier units are converted to engineering units so that one can easily determine what is being commanded to the amplifier. No Examples: C Report the amplifiers currently set command, this does not report the analog input signal. 1 March,

46 BV Bus Voltage Reports the DC bus voltage that the amplifier is tuned for. This is a static value. For the actual DC bus voltage measured by the amplifier use SBV. All amplifiers are designed to operate in a range of voltages. BV should be set within that range. See the Ratings and Specifications appendix for your particular amplifier model. Syntax: Value: MM: NVM: BV <value> Reports DC volts as an integer value Volts This value can be set on the Motor Parameters dialog. It is used to derive GIP. Yes Examples: BV Report the value of BV currently stored in the amp. BV 320 Records the value of the DC Bus Voltage that is to be attached to the B+ and B- terminals of the amplifer. CA Commutation Angle Reports the amplifiers current commutation angle. Angles reported range from 180 to 180 degrees. This command is useful for diagnostics. It is a read only command. Syntax: Value: MM: NVM: CA Reports scaled signed integer representation of degrees. Where: = degrees and: = degrees Use the CUSTOM data trace attribute in the oscilloscope to view the Commutation angle during setup. No Examples: CA may report as 90 degrees. 1 March,

47 CAO Commutation Angle Offset Constant angle that is used to offset the current commutation position in order to adjust for misaligned or offsetted commutation sensors. Permissible angles range from 180 to 180 degrees. Syntax: Value: MM: CAO <value> Scaled signed integer representation of degrees. Where: = degrees and: = degrees The Setup\Commutation dialog converts scaled integer units to degrees so that the user can enter values in degrees. NVM: Yes Default: CAO 0 0 degrees Examples: CAO degrees. CAO degrees. CAO degrees. 1 March,

48 CCM Commutation Check Method Sets or reads the method used to check commutation. This can be disabled, set to Hall PLL or set to Z PLL. Commutation can drift if an encoder is faulty or if encoder resolutions do not exactly match the placement of motor windings. The PLL methods generally will use a secondary signal to compare against the position sensors reported commutation angle. If the commutation angle does not agree with the alignment obtained at commutation initialization, then the commutation angle is updated accordingly. It is assumed that the secondary signal is accurate. The Hall PLL method senses hall signal edge transitions to determine if the commutation angle has drifted. The Z PLL uses the encoder signal Z channel to determine if the commutation angle has drifted. Syntax: Value: MM: CCM <value> Integer number representing which method is selected. Where: 0 = Commutation checking is disabled. 1 = Hall PLL checking is enabled. 2 = Z PLL checking is enabled. The Setup\Commutation dialog allows setting of this via check boxes. NVM: Yes Default: CCM 1 Hall PLL selected. Examples: CCM 2 Set commutation check method to Z PLL. CCM report current setting. 1 March,

49 CER Commutation Encoder Remainder Sets or reads the encoder remainder. The encoder remainder is an adjustment that the amplifier adds to the internally maintained commutation angle, every 360 degrees of commutation. The commutation angle is an internally maintained value such that is 360 degrees of commutation. This internal value is scaled to encoder counts. Encoders that consist of 2^n counts do not require remainder adjustment, that is CER=0. All others require a remainder adjustment in oder to insure that commutation remains aligned with the poles of the motor. CER is a value based on the number of motor poles, the resolution of the encoder, and the encoders scaling to the commutation angle. It is best to allow MotionMaestro to determine this value for you. MotionMaestro calculates encoder scaling (CES) and the number of encoder counts per commutation cycle. If the number of encoder counts per commutation cycle has a fractional component, non-integer, then commutation checking, (a PLL), must be enabled. This command is obsolete as of firmware 2.4. CER can be verified using the following formula: CER = ((2^32 - A)/(2^PRESCALE)) Where: A= (counts per commutation cycle) * [(encoder scale) * (2^PRESCALE) * 2] PRESCALE = 8 Syntax: Value: MM: CER <value> Scaled signed integer representing fractions of encoder counts The Setup\Commutation dialog automatically calculates this value when motor and encoder information is entered. NVM: Yes Default: CER 0 no remainder required. 1 March,

50 CES Commutation Encoder Scale Sets or reads the encoder scale. The encoder scale, along with an internal value of 512, scales the number of encoder counts per commutation cycle to 2^32 counts which is the internal value used to measure a commutation cycle. This command is supplied so that the scale can be saved in a backup file. Syntax: Value: MM: CES <value> Integer representing scale applied to encoder counts The Setup\Commutation dialog automatically calculates this value when motor and encoder information is entered. NVM: Yes Default: 1024 Example: CES pole motor, 8192 lines per revolution. Gives 8192 counts per commutation cycle. 2^32 = 8192 * 512 * March,

51 CID Commutation Initialization recovery Distance Sets or reads the commutation initialization recovery distance. This is the distance (in degrees of a commutation cycle) and direction that the amp will move a motor when a limit switch is triggered during commutation initialization. A positive value of CID indicates that when a positive limit switch is triggered, recovery motion will cause encoder counts (FEP) to increment, for a negative limit switch activation recovery will cause encoder counts to decrement. When CID is negative, the recovery movement away from the limit switch is in the opposite direction as described above. If limit switch activity is not released (broken wire), the amplifier will rotate the motor 4 * CID and then fault. This command is valid for twang commutation initialization. This feature allows the amp the move a motor away from a limit switch so that twang can be performed. Recovery is attempted up to three times and then will fault. In this case a larger value of CID may correct the problem. Syntax: Value: MM: CID <value> Integer representing distance as degrees of a commutation cycle. The distance represents the amount of additional movement in the recovery direction, once the limit switch signal goes inactive degrees. The Setup\Commutation dialog has an edit box labeled Recovery Distance through which CID can be set. Values are in degrees of commutation. NVM: Yes Default: 0 Limit switch recovery attempt is disabled. Example: CID 360 When a positive limit switch is detected during commutation initialization, a recovery movement is attempted to eliminate the limit switch activation. When the limit switch is deactivated, an additional 360 degrees of commutation are traversed. Recovery movement increments encoder counts for recovery from a positive limit switch. CID -360 Same as CID 360, except that movement decrements encoder counts for recovery from a positive limit switch. CID 0 Disable limit switch recovery during commutation initialization. 1 March,

52 CIL Commutation Initialization current Limit Sets or reads the commutation initialization current limit. This is the maximum current that an amplifier will be permitted to command a motor during commutation initialization. Twang and Dither initialization methods use this parameter. The value of CIL needs to be high enough to move a motor and commutate it reliably at any given powerup position. This is best determined at the time of setup by trial and error. It is dependent upon the motors back EMF, uncommutated cogging torque and system friction. Syntax: Value: MM: CIL <value> Integer representing scaled current The Setup\Commutation dialog converts this value to amps. NVM: Yes Default: 1000 represents 1.53 amps on a peek 50 amp amplifier. Example: CIL /32767 * 50 = 3.0 amp current limit. 1 March,

53 CIM Commutation Initialization Method Sets or reads the commutation initialization method. This specifies how the amplifier determines what the initial commutation angle is after power up. The options are Hall, dither and twang methods. Refer to the Amplifier Terms and Technology appendix for an explanation of these initialization schemes. Syntax: Value: MM: CIM <value> Integer selector representing method to use. Where: 1 = Twang method 2 = Dither method 3 = Hall method The Setup\Commutation dialog provides selection of these via radio buttons. NVM: Yes Default: 3 Hall Method. Example: CIM 1 Amplifier will use twang method to determine what the initial commutation angle is when the amplifier is enabled for the first time after power up. CIR Commutation Initialization rotation Rate Sets or reads the commutation initialization rotation rate. This command is applicable to twang mode only. Specifies the rate at which the second movement of twang initialization moves a motor to 0 degrees. This also specifies the rate of recovery away from a limit switch should a limit switch be triggered during twang. Syntax: Value: MM: CIR <value> Integer representing degrees per second, of a commutation cycle. 1 to 400 degrees/second. The Setup\Commutation dialog has an edit box labeled Rotation Rate through which CIR can be set. Values are in degrees per second. NVM: Yes Default: 60 Twang s second move is 2 seconds (120 degrees). Example: CIR 30 Twang will move to 0 degrees in 4 seconds. 1 March,

54 CIS Commutation Initialization Slew Sets or reads the commutation initialization slew for dither mode commutation. This specifies the rate that current is ramped upto the commutation current limit, CIL, during commutaion initialization. This parameter can be used to make fine adjustments to the dither routine. CIS limits acceleration during commutation initialization. The value of CIS cannot be so low that the amplifier will timeout during a commutation probe. If the amplifier times out, a commutation fault will result. CIS is used along with CIL to provide reliable commutation after powerup. Syntax: Value: MM: CIS <value> integer representing rate at which current ramps up to CIL. The higher the number the quicker ICL will be achieved. Valid Values: 1 thru 7 Note: DO NOT set CIS outside this range. The Setup\Commutation dialog provides an edit box with which to set this value. MotionMaestro also checks the value prior to commanding the amp. NVM: Yes Default: 4 median slew rate for initialization current. Example: CIS 1 Set the initializtion slew rate to the minimum rate. 1 March,

55 CPL Commutation Phase Lead Sets or reads the commutation phase lead. Refer to the Amplifier Terms and Technology appendix for an explanation of phase lead. Syntax: Value: MM: CPL <value> Scaled signed integer that represents degrees per thousand rpm (degrees/trpm) or (degrees/mpm. Units are dependent on the encoder resolution The Setup\Commutation dialog provides an edit box for setting the phase lead. MotionMaestro automatically converts amplifier units to degrees/trpm taking encoder resolution into account. NVM: Yes Default: 0 most applications do not use phase lead. Example: CPL 4000 For an 8 pole motor with an 8192 line encoder, this represents 2.0 degrees/trpm = (2.0 * 1000 * 65536)/(4*8192) 1 March,

56 CS Command Set Reports a number identifying the command set that an amplifier is configured for. This number identifies the commands and features that are available through the host interface. Syntax: Reports: CS Integer identifying the commands available to the Amplifier. Currently available command sets are listed below. 3: 93xx amplifier 5: Digital amplifier supporting position loop commands 6: 9615 amplifier. Reduced command set. 7: 97xx amplifiers. Analog amplifier with digital logic board. 8: 98xx amplifiers. Fully digital amplifier with extended memory. 9: 98xx Two phase analog input amplifiers. MM: NVM: Uses the CS command to determine what dialogs to make available and what features an amplifier has. Yes, Read-only. Examples: CS May report 8 indicating a standard 98xx with extended memory. EC ECho On/Off Turns console terminal echo on or off. Anything sent to the amplifier is sent back (echoed) to the terminal when this option is on. Syntax: EC <parameter> Parameters: Null Query current state 0 Echo off. 1 Echo on. NVM: Yes Default: EC 0 Off Examples: EC Returns 1 indicating echo on, 0 indicating echo off. EC 0 Echo Off. EC 1 Echo On. 1 March,

57 EN ENable/Disable Amplifier Controls enabling and disabling of current to the motor windings. Motor commutation will occur if the motor has not yet been initialized. Once the commutation for the motor is established, the motor windings can be disabled, the motor shaft moved and the motor re-enabled with no loss of commutation or position information. Syntax: EN <parameter> Parameters: Null Query current state 0 Disable amplifier. 1 Enable amplifier. NVM: No Examples: EN Returns 1 indicating enabled, 0 disabled. EN 0 Disable amplifier. EN 1 Enable amplifier. FEP Feedback Encoder Position Reports current encoder position in encoder counts. Encoder counts are independent of the physical encoder counts per revolution. The encoder counter rolls over at to Syntax: NVM: FEP N/A Examples: FEP Returns number from to March,

58 FR Feedback Resolution Sets or reports the feedback resolution. For rotary encoders, this is the number of encoder lines per revolution. For linear encoders, this is the distance between encoder counts. Syntax: Value: MM: FR <value> Rotary: Unsigned integer representing lines per revolution of encoder. Range: 1..2^32 lines. Linear: Scaled unsigned integer specifying the distance between encoder counts. Each unit represents.01 um. Range: 1..2^32. This can be set on the Commutation dialog. NVM: Yes. Default: FR 8192 Lines per Revolution for a rotary encoder. Examples: FR Reports the feedback resolution. FR 1024 Sets feedback resolution to 1024 lines for rotary motor. FR 30 Sets feedback resolution to.3 um for a linear motor. 1 March,

59 GL Gain, control Loop Sets or reads the control loop gain. This gain scales the commanded current to the current loop. Syntax: Value: MM: GL <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. The Tuning dialog refers to this as Loop Gain. NVM: Yes Default: GL percent. Examples: GL percent. GVC Gain, Velocity, Compensation Sets or reads the velocity loop compensation gain. This gain scales the velocity loop error compensated command. It is used to roughly tune an amplifier in a quick manner. This is equivalent to the compensation gain pot on Glentek s analog amplifiers. It is a non-linear gain. Syntax: Value: MM: GVC <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. (non-linear) The Tuning dialog refers to this as Compensation. NVM: Yes Default: GVC percent compensation. Examples: GVC percent compensation. GVC percent compensation. GVC 6 25 percent compensation. GVC 2 10 percent compensation. 1 March,

60 GVD Gain, velocity, Differential Sets or reads the velocity loop differential gain. Differential gain advances the phase of the velocity loop. A derivative introduces 90 degrees of phase lead, thus reducing phase lag. GVD increases the amplifiers responsiveness, thus increasing bandwidth. Derivative gain tends to increase ringing by increasing gain at higher frequencies. This is sometimes referred to as tach lead. Syntax: Value: MM: GVD <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. The Tuning dialog refers to this as Derivative. NVM: Yes Default: GVD percent. Examples: GVD Amp reports the present differential gain. GVD percent. GVD 0 No Differential gain. GVF Gain, Velocity, Feedback Sets or reads the velocity loop feedback gain. This gain attenuates the estimated velocity derived from sensors on the motor. This is sometimes referred to as tach gain. Syntax: Value: MM: GVF <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. The Tuning dialog refers to this as Tach. NVM: Yes Default: GVF percent attenuation. Examples: GVF Query amp for present value. GVF percent attenuation. 1 March,

61 GVI Gain, velocity, Integral Sets or reads the velocity loop Integral gain. Integral gain improves DC and low frequency stiffness. The higher the gain, the higher the DC stiffness. Integral gain increases phase lag and contributes to increased instability, overshoot and ringing. Syntax: Value: MM: GVI <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. The Tuning dialog refers to this as Integral. NVM: Yes Default: GVI percent. Examples: GVI Amp reports the present integral gain. GVI 0 0 percent, no integral gain. GVP Gain, velocity, Proportional Sets or reads the velocity loop Proportional gain. Proportional gain adjusts the commanded velocity in proportion to the feedback error. Proportional control tends to drift at low frequency or at DC command signals. Syntax: Value: MM: GVP <value> Scaled signed integer representation of percent gain, percent. Null Query amp for present value = percent. The Tuning dialog refers to this as Proportional. NVM: Yes Default: GVP percent gain. Examples: GVP Amp reports the present proportional gain. GVP 0 No Proportional gain. 1 March,

62 IB Current Balance When commanded, automatically balances the R, S, and T current loops. When auto balancing is completed, the three current balance offsets, ISO, IRO and ITO will have been updated. In order to execute this command, parameters must be unlocked and the amplifier must be disabled. Parameters should be locked after this command is executed. This command is performed at Glentek after a warm-up period and prior to shipping an amplifier. Syntax: MM: NVM: IB N/A. N/A Examples: IB Amplifier current loops are automatically balanced. IAD Input, Analog, Deadband Sets or reads the analog input deadband. Dead band is a window, centered on zero. Any input that is inside the deadband window translates to zero. Output IAD Input Syntax: Value: MM: IAD <value> Scaled signed integer representation of volts. Where: = Volts The Tuning dialog refers to this as Dead Band. NVM: Yes Default: IAD volts Examples: IAD 0 0 volts. IAD -32 Invalid, do not use negative deadband. 1 March,

63 IAO Input, Analog, Offset Sets or reads the analog input offset. The analog input signal is offsetted by the amount that IAO represents. Syntax: Value: MM: IAO <value> Scaled signed integer representation of volts. Null Query amp for present value = Volts The Tuning dialog refers to this as Signal Offset. NVM: Yes Default: IAO 0 0 volts. Examples: IAO volt offset. IAO volt offset. IAS Input, Analog, Scale Sets or reads the analog input offset. The analog input signal is scaled from 0 to 100 percent. Syntax: Value: MM: IAS <value> Scaled signed integer representation of percentage. Null Query amp for present value = percent = percent. The Tuning dialog refers to this as Signal Gain. The user can enter Percentage and MotionMaestro automatically converts the the amplifiers scaled representation. NVM: Yes Default: IAS percent signal attenuation. Examples: IAS 0 0 percent signal attenuation, no signal passes. This is useful to eliminate input noise during tuning and diagnostics. IAS invert signal with 50 percent attenuation.. 1 March,

64 IL Current Limit Sets or Reports the amplifiers current limit. This is the maximum current that will be allowed through the amplifier regardless of any command given. Syntax: Value: IL <value> Scaled signed integer representation of the current limit. This value can be converted to appropriate engineering units as follows: * (current limit in amps) / (IUS/100) where: is the maximum value ov the scaled representation for current. IUS is the value obtained when IUS (Current User Scale) is queried. NVM: Yes Default: IL = * 20 amps/(5000/100). Examples: IL Returns the current value the the current limit is set to. IL 5243 Set the amplifiers current limit to 8 amps = * 8 amps peeak/50. IUS Current User Scale Reports a number representing the full scale value, in amps, that can be reported by the amplifier. Typical values for IUS would be 5000 representing 50 amps or 2500 for 25 amps. External programs, such as MotionMaestro, will use this value to convert values reported by an amplifier to amps. Syntax: IUS Reports: The value returned is 100 times the maximum full scale amps that can be reported by the amp. NVM: Yes, read-only Default: IUS Amps. Examples: IUS Amplifier reports 2500 meaning that any current value returned is on a scale where represents 25 amps. 1 March,

65 MC Motor Configuration Sets or reports the current motor configuration. Possible configurations are linear and rotary. Syntax: MC <parameter> Parameters: Null Query current setting 0 Rotary motor. 1 Linear motor. NVM: Yes Default: MC 0 Rotary Motor. Examples: MC Returns 0 indicating rotary motor, 1 indicating linear motor. MC 0 Amplifier expects a rotary motor. ML Motor Inductance Sets or reports the motor inductance. Values can be entered from.01 to 327 millihenries. Syntax: ML <value> Value: Values are scaled millihenries. 1 unit equals.01 millihenries. NVM: Yes Default: ML millihenries Examples: ML Report the value entered in the amplifier specifying the motors measured millihenries. MC 500 Set the motors millihenry rating to 5 mh. 1 March,

66 MOD amplifier operation MODe Sets or reads the mode that the amplifier is currently configured to operate in. Syntax: MOD <parameter> Parameters: Null Query current setting 0 Analog current mode. Commands at the analog input are sent to the current control loop. The velocity loop is not active. 1 Analog velocity mode. Commands at the analog input are used as input to the velocity loop. The velocity loop controls current based on velocity feedback. NVM: Yes Default: MOD 0 Analog current mode. Examples: MOD Query amp for the present operating mode. MOD 1 Configure amp for analog velocity mode. MP Motor Poles Sets or reports the number of motor poles specified for a rotary motor or the pole pitch of a linear motor. For any motor there are two poles per electrical cycle. One north pole and one south. For a rotary motor MP will always be an even number. Typical values are 4, 6 and 8. For a linear motor MP represents the distance, in.01 millimeters, from one north pole to a neighboring north pole. This distance is called the pole pitch. Syntax: MP <value> Value: Rotary motor pole count. An even number less than Linear motor pole pitch. 1 unit represents.01 mm. Range.01mm mm. NVM: Yes Default: MP 8 Rotary motor 8 poles. A very typical value. Examples: MP Report the value entered in the amplifier specifying the motors number of poles or pole pitch. MP 3000 For a linear motor, Specify the pole pitch to be 30 mm. 1 March,

67 OAI Output Analog, source signal Index Sets or reads the index of the signal being place on the analog output. The analog output uses an 8 bit DAC to convert internal digital signals to the analog output. See the hardware section of the manual for details. Syntax: OAI <parameter> Parameters: 0 Test voltage, a user can output a desired voltage level to the analog output using OAV. 1 Absolute Current, the absolute current that is being delivered by the amplifier. Scaling is 5 amps per volt. 2 Velocity scaled the same as command, OAI 5. This is raw encoder velocity * GVF. 3 The raw encoder velocity, no scaling. Proportional to encoder counts per servo interrupt. 4 Commanded current, this is the velocity compensated and filtered current command to the amplifier, SIC. 5 This is the present command to the amplifier. If the command comes from the analog input, it is the scaled, offsetted, dead band adjusted and accel/decel limited command. If the command originates from the host, i.e. rs232 command, then it is only the accel/decel limited command. 6 R Phase current. Scaling is 5 amps per volt. 7 S Phase current. Scaling is 5 amps per volt. NOTE: Glentek reserves the right to modify the signals associated with the above indeces. MM: The Setup/Analog I/O dialog allows for easy entry of this amplifier setting. NVM: Yes Default: OAI 1 Absolute Current. Examples: OAI 0 Analog Output will place the test voltage OAV at the analog output pin. OAI report what signal is currently at the analog output. 1 March,

68 OAO Output Analog, signal Offset Sets or reports the present offset being applied to the analog output pin. This can be used to balance a signal. Hardware deviations or generated noise may introduce bias into the analog output circuitry. This command can be used to adjust for this. Syntax: OAO <value> Value: Where: is 10 volts MM: The Setup/Analog I/O dialog automatically converts amplifier units to volts for the user. NVM: Yes Default: OAO 0 No offset applied to analog output. Examples: OAO 164 apply a.05 volt offset to the analog output. 10*164/32767=.05. OAO report the currently applied offset. OAS Output Analog, signal scale (gain) Sets or reports the present scaling being applied to the analog output. Scaling can range from.004 to 128 times the signal value. Syntax: OAS <value> Value: Where: 256 is no scaling or 100 percent of signal. MM: The Setup/Analog I/O dialog converts the amplifier number into a percent for easy adjustment and to coincide with control terminology where signals are modified by gains. NVM: Yes Default: OAS % signal gain, no scaling. Examples: OAS 512 output is amplified by 2. This is 200% gain. OAS report the currently applied signal gain. 1 March,

69 OAV Output Analog, test Voltage Sets or reports the test voltage applied to the analog output pin. This can be used to determine if the analog output is working properly and is capable of driving its full range, -10 volts to 10 volts. Syntax: OAV <value> Value: Where: is 10 volts on the analog output. MM: The Setup/Analog I/O dialog converts the amplifier number into a voltage. NVM: Yes Default: OAV 0 0 Volts. Examples: OAV volts is placed on the analog output. OAV report the test voltage currently applied to the analog output. RC Reload Configuration Reloads factory defaults or a users saved configuration stored in non-volatile memory with the SC command. The amplifier must be disabled in order to execute this command. Syntax: RC <parameter> Parameters: Null Reload Configuration 1 saved to NVM. This is a synonym of RC 1. 0 Reload Factory defaults. 1 Reload Configuration last saved to NVM with the SC command. Same as RC NVM: N/A Examples: RC Reload parameters last saved with SC. RC 0 Restore Factory Default configuration. 1 March,

70 RST ReSeT Executes a Kill (CTRL-K) and then a warm start. A warm start clears state variables and integral sums then commutates the motor. Syntax: NVM: RST No Examples: RST Resets the amplifier. SC Save Configuration Saves the parameters that defines the current amplifier configuration to Non-volatile memory (NVM). Commands that have NVM defined as Yes are saved to NVM. This command is executed only if the amplifier has been disabled. Syntax: NVM: SC N/A Examples: SC Save current configuration to NVM. VER VERsion Reports the firmware major and minor version along with the date of the firmware. The reported string has the following form. Vxx.zz mm/dd/yyyy Where:V is constant. xx is the major version. zz is the minor version. mm is the month dd is the Day yyyy is the year 2000 Syntax: NVM: VER N/A Examples: VER Returns a string that looks like this: V1.2 4/18/ March,

71 APPENDIX D D - SMA9800 Ratings and Specifications This appendix contains specifications for the application engineer which are necessary to utilize the SMA9800 series amplifiers. (1) Power, Input And Output Amplifier Input power Output Power (2) Model (Buss Voltage B+) (Current) Standard Power RMS Peak High Power RMS Peak SMA (3) 70 VDC / 340 VDC 15A 25A 20A 40A SMA9816-1A VAC / 130 VAC 15A 25A 20A 40A SMA9816-1A VAC / 240 VAC 15A 25A 20A 40A NOTE: Multi-axis chassis have the same input power and output power of the SMA9816-1A-1 stand alone packages. Signal Inputs Input Maximum Minimum Current Source Voltage Impedance Gain VDC Ohms Amp/Volt Differential 13 10, Single Ended 13 10, March,

72 Digital Inputs Input Source Specification Limit + See * Limit - See * Inhibit See * Reset See * Fault (as input) See * Motor Temp See * * 40V max. -.5V min. Teminated by 10k Ohms. Digital inputs have hysteresis with thresholds at 1/3 and 2/3 of 5V. Outputs Output Fault (as output) Analog Out Encoder Outputs: Specification Active low, open collector output can sink 500 ma max. User selectable D/A. Output capable of driving 2K ohm load at 5 Volts. EIA-422-A differential line driver, 2631 compatible. System Feature Drift offset over temperature referenced to input: Frequency response Velocity Loop: Current Loop: Dead band: Specification 0.01mV/1 degree C max. Implementation dependent. Typical, depending on motor inductance, 2kHz typical. (Bandwidths available up to 3 khz.) Parameterized. Notes 1) All data in this section is based on the following ambient conditions: 120 degrees F (50 C) maximum. 2) Forced air cooling is required to meet the maximum power ratings specified. 3) The amplifier module(s) (SMA9815) require an external DC power supply which must include a bridge rectifier, buss capacitor, solid state relay and shunt regulator. 1 March,

73 APPENDIX E E Matching motor phase leads to amplifier commands using hall sensors. Below you will find the steps necessary insure that the command phases of a digital amplifier are properly matched to any three-phase motor that has hall sensors. This method applies to a fully digital amplifier with digital current loops. Please read this procedure prior to working with the motor and amplifier. It is intended that this procedure be done once by the engineering staff, whereupon they will incorporate the findings into production drawings, wiring labels and procedures. A) Locate or prepare the required equipment. A 2 channel oscilloscope A 3-phase Y-connected resistive load as illustrated below. A computer with MotionMaestro (MM) installed. R1 R2 R3 R1, R2 and R3 = 20K 10watt resistors. (Specification for resistive load) B) With the power off, connect the motor encoder and the halls to amplifier. Leave the motor power leads disconnected. Connect the RS232 serial cable from the amplifier to the MM serial port on the computer. C) Apply power to the amplifier and establish communications between the amplifier and MM. D) Prepare the amplifier using the following dialogs. 1.) Unmark the Encoder Reverse checkbox on the Commutation dialog. This insures that the encoder feedback is NOT reversed. 28 February

74 2.) Unmark the Tach Reverse checkbox on the Control Panel dialog. This insures that the Tach feedback is NOT inverted. 3.) Insure that the amplifier is disabled. The Enable disable button should read Enable Amp 28 February

75 4.) Insure that the amplifier is in current mode. Select current mode on the Setup Mode dialog. 5.) Set the analog command input signal gain to zero. Use the Setup Analog Input/Output dialog as shown. E) From the MM Setup menu, open the Commutation dialog and setup the following items: Motor type. Are you phasing a rotary or linear motor? Number of Poles. Encoder resolution. Commutation angle offset = 0 (-30 degrees if halls aligned phase to neutral?) Commutation phase advance gain = 0 Commutation method = Hall 28 February

76 F) Open the Control Loop Signals dialog from the MM Status menu, and check the Actual velocity and the Commanded current boxes for monitoring. G) While monitoring the actual velocity on MM, rotate the motor by hand in the direction that causes the 7-segment display to rotate clockwise as viewed from the top of the amplifier. The actual velocity should be positive. If it is negative, reverse the encoder direction by marking the Encoder Reverse checkbox on the Commutation dialog. 28 February

77 H) Save the new settings by selecting Save to NVM from the Setup menu. Answer Yes when prompted to save. I) Connect the 3-phase Y-connected resistor load to the motor power leads for monitoring motor back EMF (BEMF). NOTE: do not connect the motor leads or the resistor load to amplifier. Motor Leads Y-Connected Resistor load Connecting the channel 1 scope probe. J) Connect the channel 1 probe to the amplifiers Analog Out pin. Connect the channel 1 common to the amplifiers Common pin. Set the channel 1 vertical scale to around 2V per division. From the Setup Analog Input/Output dialog, Set the Analog Output Signal Source to Phase R. 28 February

78 K) Connecting the channel 2 scope probe. Connect the channel 2 probe to one of the motors leads. Connect the channel 2 common to the center of the Y-connected resistor load. Set the channel 2 vertical scale to around 2V per division. Set the horizontal scale to around 100 ms per division. Scaling may need to be changed to in order to best see the data. L) Verify that the amplifier is enabled. Open the Control Panel. If there is a button labeled Disable Amp, then the amplifier is enabled, otherwise press the Enable Amp button. 28 February

79 M) From the Control Panel, apply a digital current command of 10 amps to the amplifier. To do this you may have to expand the range that can be commanded from the control panel by selecting the Options button. (Actually it would be best to command the max current, but the current limit and foldback threshold would need to opened up. There is no load connected to the amplifier so no power is delivered) N) Find the phase R motor lead. Rotate the motor by hand and verify the trace on channel 1 (phase R current command) follows a sinusoidal pattern. Move the channel 2 scope probe to each motor lead to determine which BEMF waveform is in phase or 180 deg out of phase with the phase R command. Label this lead Phase R. NOTE: For each phase, R S and T, one direction of rotation should cause the back EMF (BEMF) to be in phase with the command while a reverse rotation direction should cause the BEMF to be 180 degrees out of phase. Determine which direction gives you 180 degrees out of phase for the phase R motor lead. Then rotate the motor in that same direction when determining the phase of the S and T motor leads. Once the phases are labeled, double check that the phase R, S and T motor leads result in waveforms that are 180 degrees out of phase with the corresponding digital current commands on the amplifier when rotating the motor in the same direction for all three. ALSO: This method of matching motor leads to the amplifier requires that the motors hall sensors be aligned with the motor phase to phase BEMF. If the motor hall sensors are aligned with the motors phase to neutral BEMF, then the commutation offset angle must be set to + or 30 degrees (you have to try both) before comparing the commands to the BEMF waveforms. O) Find the phase S motor lead. In MotionMaestro, change the Analog Output Signal Source to Phase S. Place the channel 2 scope probe on one of the two remaining motor leads. Rotate the motor in the same direction that was used for phase R above. Determine which of the remaining two leads of the motor result in a waveform that is 180 degrees out of phase with the phase S command. Move the channel 2 probe to the remaining motor lead if necessary. Label this lead Phase S. P) Find the phase T motor lead. If phase R and phase S where properly found, phase T will be the remaining motor wire. Label this lead phase T. Q) Set the current command back to 0 by clicking the ZERO button on the Control Panel. Reset any current limits, foldback thresholds to the desired operational settings. Reset the Control Panel options to appropriately safe values. R) Disable the amplifier by clicking the Disable Amp button on the Control Panel, and save the settings by selecting Save to NVM from the Setup menu. S) Remove the amplifiers power. Remove the scope probes. Connect the motors lead R, S, and T to the amplifiers command phase R, S, and T, respectively. 28 February

80 T) Apply power to amplifier. The amplifier should still be in current mode and enabled (unless the external inhibit is active). From the Control Panel, see following picture, issue a digital current command of.5 to 2 amps, enough so the motor to begins to rotate. U) While the motor is rotating, verify that the sign of the actual velocity matches the sign of the commanded current. If NOT, disable the amplifier, and mark the Tach Reverse checkbox on the control panel. Enable the amplifier and verify that the signs now match. Command the opposite polarity current to the motor, -.5 to -2.0 amps and verify that the motor reverses direction and runs at approximately the same speed. The signs of the current command and actual velocity should still match. V) Set the current command back to 0 by clicking on the ZERO button of the Control Panel. Disable the amplifier by pressing Disable Amp and save the settings by selecting Save to NVM from the setup menu. The motor should now be properly phased and ready to operate in current or velocity mode. 28 February

81 28 February

82 APPENDIX F F Commutation track signals and phase-to-phase BEMF. Commutation track signals and phase-to-phase BEMF T to R(gnd) R to S(gnd) S to T(gnd) U track V track W track -180 to 180 degrees As measured turning motor CW looking at face of motor. When in hall pll mode and with a standard wound Glentek motor, LED display will transition in a CW direction. Encoder Outputs The following illustrates the encoder signals for a standard Glentek motor that is correctly commutated where the encoder is not reversed (FER=0) and the tach feedback is reversed (TR=1). A+ Encoder channel B+ Encoder channel Z+ Encoder mark 28 February

83 APPENDIX G G European Union EMC Directives 28 February

84 Electromagnetic Compatibility Guidelines For Machine Design This document provides background information about Electromagnetic Interference (EMI) and machine design guidelines for Electromagnetic Compatibility (EMC) Introduction Perhaps no other subject related to the installation of industrial electronic equipment is so misunderstood as electrical noise. The subject is complex and the theory easily fills a book. This section provides guidelines that can minimize noise problems. The majority of installations do not exhibit noise problems. However, these filtering and shielding guidelines are provided as counter measures. The grounding guidelines provided below are simply good grounding practices. They should be followed in all installations. Electrical noise has two characteristics: the generation or emission of electromagnetic interference (EMI), and response or immunity to EMI. The degree to which a device does not emit EMI, and is immune to EMI is called the device s Electromagnetic Compatibility (EMC). Equipment, which is to be brought into the European Union legally, requires a specific level of EMC. Since this applies when the equipment is brought into use, it is of considerable importance that a drive system, as a component of a machine, be correctly installed. EMI Source-Victim Model shows the commonly used EMI model. The model consists of an EMI source, a coupling mechanism and an EMI victim. A device such as servo drives and computers, which contain switching power supplies and microprocessors, are EMI sources. The mechanisms for the coupling of energy between the source and victim are conduction and radiation. Victim equipment can be any electromagnetic device that is adversely affected by the EMI coupled to it. Figure 1- EMI Source-Victim Model EMI SOURCE RADIATED EMI CONDUCTED EMI EMI VICTIM EMI VICTIM Immunity to EMI is primarily determined by equipment design, but how you wire and ground the device is also critical to achieving EMI immunity. Therefore, it is important to select equipment that has been designed and tested for industrial environments. The EMI standards for industrial equipment include the EN X series (IEC X and IEC8O1-X), EN55011 (CISPR11), ANSI C62 and C63 and MIL-STD-461. Also, in industrial environments, you should use encoders with differential driver outputs rather than single ended outputs, and digital inputs/outputs with electrical isolation, such as those provided with optocouplers. The EMI model provides only three options for eliminating the EMC problem: 28 February

85 Reduce the EMI at the source, Increase the victim s immunity to EMI (harden the victim), Reduce or eliminate the coupling mechanism, In the case of servo drives, reducing the EMI source requires slowing power semiconductor switching speeds. However, this adversely affects drive performance with respect to heat dissipation and speed/torque regulation. Hardening the victim equipment may not be possible, or practical. The final and often the most realistic solution is to reduce the coupling mechanism between the source and victim. Filtering, shielding and grounding can achieve this. Filtering As mentioned above, high frequency energy can be coupled between circuits via radiation or conduction. The AC power wiring is one of the most important paths for both types of coupling mechanisms. The AC line can conduct noise into the drive from other devices, or it can conduct noise directly from the drive into other devices. It can also act as an antenna and transmit or receive radiated noise between the drive and other devices. One method to improve the EMC characteristics of a drive is to use isolation AC power transformer to feed the amplifier its input power. This minimizes inrush currents on power-up and provides electrical isolation. In addition, it provides common mode filtering, although the effect is limited in frequency by the interwinding capacitance. Use of a Faraday shield between the windings can increase the common mode rejection bandwidth, (shield terminated to ground) or provide differential mode shielding (shield terminated to the winding). In some cases an AC line filter will not be required unless other sensitive circuits are powered off the same AC branch circuit. NOTE: Common mode noise is present on all conductors that are referenced to ground. Differential mode noise is present on one conductor referenced to another conductor. The use of properly matched AC line filters to reduce the conducted EMI emitting from the drive is essential in most cases. This allows nearby equipment to operate undisturbed. The basic operating principle is to minimize the high frequency power transfer through the filter. An effective filter achieves this by using capacitors and inductors to mismatch the source impedance (AC line) and the load impedance (drive) at high frequencies. For drives brought into use in Europe, use of the correct filter is essential to meet emission requirements. Detailed information on filters is included in the manual and transformers should be used where specified in the manual. AC Line Filter Selection Selection of the proper filter is only the first step in reducing conducted emissions. Correct filter installation is crucial to achieving both EMIL attenuation and to ensure safety. All of the following guidelines should be met for effective filter use. 1. The filter should be mounted to a grounded conductive surface. 2. The filter must be mounted close to the drive-input terminals, particularly with higher frequency emissions (5-30 MHz). If the distance exceeds 600mm (2 feet), a strap should be used to connect the drive and filter, rather than a wire. 3. The wires connecting the AC source to the filter should be shielded from, or at least separated from the wires (or strap) that connects the drive to the filter. If the connections are not segregated from each other, then the EMI on the drive side of the filter can couple over to the source side of the filter, thereby reducing, or eliminating the filter effectiveness. The coupling mechanism can be radiation, or stray capacitance between the wires. The best method of achieving this is to mount the filter where the AC power enters the enclosure. AC Line Filter Installation shows a good installation and a poor installation. 28 February

86 Figure 2- AC Line Filter Installation POOR GOOD DRIVE DRIVE FILTER FILTER When multiple power cables enter an enclosure, an unfiltered line can contaminate a filtered line external to the enclosure. Therefore, all lines must be filtered to be effective. The situation is similar to a leaky boat. All the holes must be plugged to prevent sinking. If the filter is mounted excessively far from the drive, it may be necessary to mount it to a grounded conductive surface, such as the enclosure, to establish a high frequency (HF) connection to that surface. To achieve the HF ground, direct contact between the mounting surface and the filter must be achieved. This may require removal of paint or other insulating material from the cabinet or panel. The only reasonable filtering at the drive output terminals is the use of inductance. Capacitors would slow the output switching and deteriorate the drive performance. A common mode choke can be used to reduce the HF voltage at the drive output. This will reduce emission coupling through the drive back to the AC line. However, the motor cable still carries a large HF voltage and current. Therefore, it is very important to segregate the motor cable from the AC power cable. More information on cable shielding and segregation is contained in the section on shielding. Grounding High frequency (HF) grounding is different from safety grounding. A long wire is sufficient for a safety ground, but is completely ineffective as a HF ground due to the wire inductance. As a rule of thumb, a wire has an inductance of 8 nh/in regardless of diameter. At low frequencies it acts as constant impedance, at intermediate frequencies as an inductor, and at high frequencies as an antenna. The 28 February

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