SMT-BD1/m gb. SMT-BD1/m Positioner. See addendum at the end of the manual regarding the drives delivered with the Eprom version 7.

Transcription

1 See addendum at the end of the manual regarding the drives delivered with the Eprom version 7.08 SMT-BD1/m gb SMT-BD1/m Positioner INFRANOR SMT-BD1/m 1

2 SMT-BD1/m

3 This is a general manual describing a series of servo amplifiers having output capability suitable for driving AC brushless sinusoidal servo motors. This manual may be used in conjunction with appropriate and referenced drawings pertaining to the various specific models. Maintenance procedures should be attempted only by highly skilled technicians (EN standard) using proper test equipment. The conformity with the standards and the "CE" approval are only valid if the items are installed according to the recommendations of the racks and amplifiers manuals. Any contact with electrical parts, even after power down, may involve physical damage. Wait for 30 seconds after power down before handling the rack or the amplifiers (residual voltage). INFRANOR does not assume any responsibility for any physical or material damage due to improper handling or wrong descriptions of the ordered items. Infranor reserves the right to change any information contained in this manual without notice. This manual is a translation of the original document and does not commit INFRANOR's responsibility. The french manual is the only reference document. INFRANOR, November All rights reserved Index : 3.3 SMT-BD1/m 3

4 SMT-BD1/m

5 Contents PAGE CONTENTS...5 CHAPTER 1 - GENERAL DESCRIPTION INTRODUCTION CONFORMITY WITH EUROPEAN STANDARDS: CE APPROVAL GENERAL DESCRIPTION REFERENCE TO THE STANDARDS AFFIXING OF THE "CE" MARK...7 CHAPTER 2 - SPECIFICATIONS MAIN TECHNICAL DATAS MAIN PROTECTIONS STORED PROTECTIONS FUSE PROTECTION...10 CHAPTER 3 - INPUTS-OUTPUTS CONNECTORS X1 RESOLVER CONNECTOR X2 ENCODER CONNECTOR - SUB D 25 PINS FEMALE X4 COMMAND CONNECTOR - SUB D 25 PINS MALE X6 LOGIC OUTPUTS CONNECTOR - SUB D 9 PINS FEMALE X7 LOGIC INPUTS CONNECTOR - SUB D 9 PINS MALE X5 RS-232 CONNECTOR X3 TEST CONNECTOR SPECIFICATIONS OF THE LOGIC INPUTS-OUTPUTS DEDICATED LOGIC INPUTS: FC+, FC-, INDEX, RUN AND ENABLE LOGIC INPUTS START, STOP, JOG+, JOG-, IN1 TO IN LOGIC OUTPUTS SEQ, POS, SPEED, OK, OUT1 TO OUT CHAPTER 4 - CONNECTIONS CONNECTION DIAGRAMS POWER CONNECTION WITH SMT-BM 20 A SINGLE-AXIS RACK OR BF-RACK CONNECTION OF THE SERIAL RS WIRING RECOMMENDATIONS GND WIRING AND GROUNDING MOTOR AND RESOLVER CABLES SERIAL LINK CABLE...17 CHAPTER 5 - FUNCTIONAL FEATURES DESCRIPTION OF THE LOGIC INPUTS-OUTPUTS LOGIC INPUTS LOGIC OUTPUTS ADDRESSING REDUCTION OF THE PROGRAMMED SPEED VIA AN ANALOG INPUT...19 CHAPTER 6 - COMMISSIONING CHECKING THE AMPLIFIER CONFIGURATION INSTALLING THE PC SOFTWARE PUTTING INTO OPERATION AMPLIFIER COMMISSIONING AND ADJUSTMENT PARAMETER SETTING ENABLING MANUAL MOVE PROGRAMMATION GENERAL DESCRIPTION EDITION OF A SEQUENCE...29 Contents 5

6 6 - PROGRAMME EXECUTION USE OF THE OSCILLOSCOPE...32 CHAPTER 7 - FAULT FINDING SYSTEM FAULT STORED FAULTS "BUSY" FAULT "NovRAM" FAULT " C MOTOR" FAULT "UNDERVOLT" FAULT " C AMPLIFIER" FAULT "POWER STAGE" FAULT "RESOLVER" FAULT "R.D.C" FAULT "I 2 T" FAULT OPERATING PROBLEMS NO MOTOR MOVEMENT MOTOR SUPPLIED BUT NO TORQUE SHAFT LOCKED, ERRATIC OSCILLATIONS OR ROTATION AT MAXIMUM SPEED DISCONTINUOUS MOTOR ROTATION WITH ZERO TORQUE POSITIONS LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL LOUD NOISE IN THE MOTOR AT STANDSTILL AND WHEN RUNNING SERVICE AND MAINTENANCE...36 CHAPTER 8 - APPENDIX USING SMT-BD1/M WITH A DISPLAY TERMINAL CONFIGURATION USE SMT-BD1/M INSTRUCTIONS LIST OVERVIEW INSTRUCTIONS LIST HARDWARE ADJUSTMENTS ADJUSTMENT TO VARIOUS RESOLVERS ADJUSTMENT TO VARIOUS MOTORS MOTOR THERMAL SENSOR CURRENT LOOPS I 2 t PROTECTION LOGIC CONTROL ADJUSTMENT POSITIVE OR NEGATIVE LOGIC INPUTS USE OF THE «AMP. READY» AND «POWER READY» OUTPUTS SHIELD CONNECTIONS AMPLIFIER TYPES ADDENDUM 54 6 Contents

7 Chapter 1 - General description 1- INTRODUCTION Series SMT-BD1/m servo modules are PWM servo amplifiers that provide speed control for AC sinusoidal motors (brushless) with transmitter resolver. The pluggable SMT-BD1/m system is available as a single-axis block version or as a multi-axis version that can receive up to six axes in a standard 19" rack. Both versions are including a power supply unit. The SMT-BD1/m servo amplifier can operate independently or in connection with a PLC (or a PC). It generates itself the positioning trajectory. After programmation, this amplifier is waiting for the START signal or a serial link command before starting the programme. 2 - CONFORMITY WITH EUROPEAN STANDARDS: CE APPROVAL GENERAL DESCRIPTION The SMT-BD1/m servo modules have their own DC/DC converter to provide appropriate logic voltage to the modules. This power supply can use, as a source, either the 310 V DC bus power voltage or an auxiliary supply which is necessary particularly when the position output information need to be saved, whatever the power supply statement. Each module is packaged as 6U "double Eurocard": one power board with IGBT transistors and one logic board with DSP (Digital Signal Processing). The SMT-BD1/m amplifier directly controls the motor torque, speed and position by means of the information provided by a transmitter resolver sensor. All control parameters are programmable by means of a serial RS 232 link and saved in a single EEPROM in the amplifier. The auto-configuration and auto-tuning functions allow quick and easy commissioning of the amplifier REFERENCE TO THE STANDARDS The SMT-BD1 amplifiers operating in the BF rack, which is equipped with the mains filter BF 35/70, have been approved with regard to their conformity with the Electromagnetic Compatibility standards - EN 55011, group 1, class A, regarding the conducted and radiated radioelectric disturbances, - CEI regarding immunity. The results and test conditions of the LCIE laboratory (Laboratoire Central des Industries Electriques), which is approved by the European Community, are referenced under the numbers , , and The results of the tests made according to the Low Voltage directive are referenced in the LCIE report nr Standard to be applied to the electrical equipment of industrial machines: EN AFFIXING OF THE "CE" MARK The CE mark has been affixed since Chapter 1 - General description 7

8 Chapter 2 - Specifications 1 - MAIN TECHNICAL DATAS Operating voltage Auxiliary voltage Motor phase-phase output voltage 310 VDC (270 V < Bus DC < 340 VDC) 310 VDC (200 V < Uaux < 340 VDC) 200 Vrms for DC bus 310 V Amplifier current ratings for an I 2 t protection in "fusing" mode (see chapter 8, section 3. 3) AMPLIFIER Urated (Vrms) Imax (Arms) Max. authorized rated current (Arms) the amplifier 1 s No fan* Fan 1* Fan 2* SMT-BD1/m-220/ ,4 2 SMT-BD1/m -220/ ,8 4 SMT-BD1/m-220/ ,8 6 SMT-BD1/m-220/ ,7 8,5 SMT-BD1/m-220/ , SMT-BD1/m-220/30r , SMT-BD1/m-220/ , SMT-BD1/m-220/45r , SMT-BD1/m-220/ SMT-BD1/m-220/60r SMT-BD1/m-220/ SMT-BD1/m-220/ Amplifier current ratings for an I 2 t protection in "limiting" mode (see chapter 8, section 3. 3) AMPLIFIER Urated (Vrms) Imax (Arms) Max. authorized rated current (Arms) the amplifier 1 s No fan* Fan 1* Fan 2* SMT-BD1/m-220/ ,4 2 SMT-BD1/m -220/ ,8 4 SMT-BD1/m-220/ ,8 6 SMT-BD1/m-220/ ,7 8,5 8,5 SMT-BD1/m-220/ ,8 8, SMT-BD1/m-220/30r , SMT-BD1/m-220/ ,6 8, SMT-BD1/m-220/45r , SMT-BD1/m-220/ , SMT-BD1/m-220/60r SMT-BD1/m-220/ SMT-BD1/m-220/ * Maximum ambient temperature = 40 C, fan 1 = 56 l/s, fan 2 = 90 l/s. NOTE Note : SMT-BD1-X/X r amplifier types are equipped with an additional heatsink in order to improve the heat dissipation and increase their rated current. The width of these amplifiers is then 18 TE instead of 12 TE. PWM switching frequency Minimum inductance between phases Current regulator (PI) Current loop bandwidth 10 KHz 1 mh adjusted to motor Cut-off frequency for 45 phase shift > 1 KHz 8 Chapter 2 - Specifications

9 Internal current limitation Imax: 20 % to 100 % and I rated: 20 % to 50 % Imax duration =1 second Speed and position regulators Speed loop bandwidth Max motor speed Encoder position output Analog outputs (test points) Logic inputs Optocoupled logic inputs Relay outputs Optocoupled logic inputs Fault display Motor and application parameter setting Automatic functions Sampling period = 0,5 ms Anti-wind-up system of the integrator Adjustable digital gains Cut-off frequency for 45 phase shift: 50 Hz, 75 Hz or 100 Hz Adjustable from 100 rpm to rpm Two A and B channels in quadradure + n zero pulses per revolution. Programmable resolution: max ppr up to 900 rpm max ppr up to rpm max ppr up to rpm Accuracy: 8 arc minutes +1/4 point (optional: 2 arc minutes + 1/4 point) Note: The total position accuracy must take into account the accuracy of the resolver used Speed input command (CV): ±10 V for ±max speed. Speed monitor (GT): ±8 V for ± rpm, linearity: 10% Current input command (Idc): ±10 V for ±current sizing, resolution 8 bits Current monitor (Imes): ±10 V for ±current sizing; resolution:8 bits Enable/Disable: ENABLE ON/OFF: RUN Limit switch +: FC+ Limit switch - : FC- Homing input: INDEX Fault reset: RAZ START, STOP, JOG+, JOG-, IN1 to IN8 Relay contact: Umax = 60 V Imax = 200 ma, Pmax = 10 W «Amp. ready»: closed if amplifier OK, open if fault «Power ready»: closed if power OK, open if fault Brake control SEQ, POS, SPEED, OK, OUT1 to OUT8 LEDs on front panel and diagnostic by serial link RS232 Serial link RS232 Amplifier adjustment to the motor (AUTO-PHASING) Automatic regulator tuning (AUTO-TUNING) Index research (HOME) Conformity with the standards: CE approval with EMC standards: multiaxis power supply configuration BF rack and - immunity : CEI mains filter BF35 or 70, or SMT-BM 20 A single- - conducted and radiated disturbances: EN 55011, axis rack and BF shield connection, Group 1, class A equipotentiality according to the wiring rules Electrical standards of industrial machines: - EN : insulator 1500 Vac / 1 min leakage current > 3 ma (EMI filters) Chapter 2 - Specifications 9

10 Temperature From 40 C, the rated currents must be reduced of - storage -20 C à +70 C 3%/ C. - operation +5 C à +40 C Maximum temperature: 50 C Altitude Moisture Cooling 1000 m < 50% at 40 C and < 90% at 20 C : EN standard Natural convection or forced air according to the rated current (see current table, chapter 2, part 1) 2 - MAIN PROTECTIONS STORED PROTECTIONS PROTECTION ERROR DISPLAY LED! " I 2 t " " Amplifier rated current overload * : - blinking display = Idyn signal (I 2 t threshold is reached) - continuous display = amplifier inhibited (I 2 t fault) Position following error Position " " "! Resolver cable interruption Resolver "! " " Power stage failure: - power supply overvoltage - internal switch protection - short circuit between phases - amplifier overtemperature for 4A to 60A current ratings Power stage!! " " Resolver converter failure R.D.C " "! " Amplifier overtemperature for 70A and 100A current ratings C Ampli! "! " Power supply undervoltage Undervoltage "!! " Motor overtemperature C Motor!!! " Fault of the amplifier parameter memory NovRAM! "!! Amplifier automatic procedure - blinking display = procedure operating - continuous display = operating error " : Led is unlit! : Led is lit * The operation mode of the I 2 t protection is described in chapter 8, section All these faults are stored in the amplifier, except for the "Undervoltage" fault. The reset of a stored fault can be made: - via the fault RESET input of X4, pin 13, - by switching off the amplifier power supply FUSE PROTECTION Busy!!!! F1 : Control of the average DC current of the power board supply (see chapter 8, Appendix). F2 : Control of the average DC current of the logic board supply (see chapter 8, Appendix). AMPLIFIER TYPE F1 POWER F2 LOGIC SMT-BD1/m-220/04 to AT 1 A SMT-BD1/m-220/17 and AT 1 A SMT-BD1/m-220/45 20 AT 1 A SMT-BD1/m-220/60 20 AT 1 A SMT-BD1/m-220/70 30 AT 5 AT SMT-BD1/m-220/ AT 5 AT 10 Chapter 2 - Specifications

11 Chapter 3 - Inputs-Outputs 1 - CONNECTORS Front panel connections X1 Resolver X5 Serial link RS-232 X6 Programmable logic outputs X2 Encoder X7 Logic inputs X4 Command X3 Test 2 - X1 RESOLVER CONNECTOR Sub D 9 pins female. PIN FUNCTION REMARKS 1 TC (pin H sensor connector) If thermal switch connected to X1 6 Shield connection If no "360 " connection on the connector 2 TC (pin I sensor connector) If thermal switch connected to X1 7 S1 (pin C sensor connector) MAVILOR motor with TAMAGAWA resolver 3 S3 (pin D sensor connector) MAVILOR motor with TAMAGAWA resolver 8 S4 (pin B sensor connector) MAVILOR motor with TAMAGAWA resolver 4 S2 (pin A sensor connector) MAVILOR motor with TAMAGAWA resolver 9 R2 (pin F sensor connector) MAVILOR motor with TAMAGAWA resolver 5 R1 (pin E sensor connector) MAVILOR motor with TAMAGAWA resolver For resolver connections other than the TAMAGAWA resolver on MAVILOR motors, see Resolver Wiring Table: Chapter 8, section 2. Chapter 3 - Inputs-Outputs 11

12 3 - X2 ENCODER CONNECTOR - Sub D 25 pins female PIN SIGNAL I/O DESCRIPTION 1 /CZ O Differential output of the encoder marker pulse (5 V 20 ma max.) 2 CZ O Differential output of the encoder marker pulse 3 /CA O Differential output of the encoder channel A (5 V 20 ma max.) 4 CA O Differential output of the encoder channel A 5 /CB O Differential output of the encoder channel B (5 V 20 ma max.) 6 CB O Differential output of the encoder channel B 7, 10, 11 0 V 14 START I Optocoupled logic input 15 STOP I Optocoupled logic input 16 WAIT I Optocoupled logic input 17 TEACH I Optocoupled logic input 24 5 V 5 V jumper must be closed 8 JOG+ I Optocoupled logic input 18 JOG- I Optocoupled logic input 9 SEQ O Optocoupled logic output 20 POS O Optocoupled logic output 21 SPEED O Optocoupled logic output 22 OK O Optocoupled logic output 23 GND (24 V) Mass of external 24 V V I 24 V input. This input must be used only if one of the outputs SEQ, SPEED, POS and OK is used and if the OUT1 to OUT8 outputs are not wired. 25 GND 12 Chapter 3 Inputs-Outputs

13 4 - X4 COMMAND CONNECTOR - Sub D 25 pins male PIN FUNCTION I/O REMARKS 1 Limit switch + I Positive or negative logic 14 Limit switch - I Positive or negative logic 24 0V limit switch I 20 ENABLE I Positive or negative logic 23 0 Volt ENABLE I 4 RUN I Positive or negative logic 7 INDEX/CLR I Positive or negative logic 25 0 V logic input 13 RESET I Fault RESET via 0 volt (contact between pins 13 and 12) 12 0V RESET I 15 Reserved 16 0 V analog I 17 Analog input I Speed reduction option 3 Reserved 10 Speed monitor GT O 2 Current monitor Imes (DAC OUT 2) O 11 0 Volt analog output O 18, 19 Amp. ready O Relay contact, closed when amplifier OK Pmax = 10 W with Umax = 60 V or Imax = 200 ma 8, 9 Brake control output O Relay contact. Pmax = 10 W with Umax = 60 V or Imax = 200 ma Volts O Max. 50 ma Volts O Max. 50 ma 5, 6 Unconnected 5 - X6 LOGIC OUTPUTS CONNECTOR - Sub D 9 pins female PIN SIGNAL DESCRIPTION 1 OUT1 Programmable output n 1 2 OUT2 Programmable output n 2 3 OUT3 Programmable output n 3 4 OUT4 Programmable output n 4 5 OUT5 Programmable output n 5 6 OUT6 Programmable output n 6 7 OUT7 Programmable output n 7 8 OUT8 Programmable output n V This 24 V must be used if one of the OUT1 to OUT8 outputs is wired Chapter 3 - Inputs-Outputs 13

14 6 - X7 LOGIC INPUTS CONNECTOR - Sub D 9 pins male PIN SIGNAL DESCRIPTION 1 IN1 Logic input n 1 2 IN2 Logic input n 2 3 IN3 Logic input n 3 4 IN4 Logic input n 4 5 IN5 Logic input n 5 6 IN6 Logic input n 6 7 IN7 Logic input n 7 8 IN8 Logic input n 8 9 GND 24 V Mass of external 24 V 7 - X5 RS-232 CONNECTOR PIN FUNCTION REMARKS 5 0 V GND (shield connection if no "360 " connection on the connector) 3 TXD Transmit data RS RXD Receive data RS TXH Transmit data RS TXL Transmit data RS RXL Receive data RS RXH Receive data RS X3 TEST CONNECTOR PIN FUNCTION REMARKS Volt 2 Current input command I DC ± 10 V; resolution: 8 bits, linearity: 10 % (DAC out 1)* 3 Reversed analog input ± 10 V for ± max. speed 4 Speed monitor GT ± 8 V for ± rpm 5 Current monitor I mes ± 10 V; resolution: 8 bits, linearity: 10 % (DAC out 2)* * : 10 V for amplifier current rating. 14 Chapter 3 Inputs-Outputs

15 9 - SPECIFICATIONS OF THE LOGIC INPUTS-OUTPUTS DEDICATED LOGIC INPUTS: FC+, FC-, INDEX, RUN AND ENABLE Log Log - 5 V SMT-BD1/m 4,7 KΩ 47 KΩ Input impedance : 4,7 KΩ Response time : 500 µs 4,7 V 47 nf These inputs can be configurated in positive or negative logic by means of jumpers (see chapter 8, section 4.1 "Positive or negative logic inputs") LOGIC INPUTS START, STOP, JOG+, JOG-, IN1 TO IN8 5 V SMT-BD1/m Logic input 2.2 KΩ The input voltage corresponds to level 1 and is between 5 V and 24 V PC829 0 V The polarity of these inputs can be reversed by a software parameter (see chapter 6, section "Inputs - outputs configuration") LOGIC OUTPUTS SEQ, POS, SPEED, OK, OUT1 TO OUT8 24 V SMT-BD1/m 5 V The output current is 350 ma for the 8 outputs OUT1 to OUT8. Logic output PC829 0 V UDN2987A The polarity of these inputs can be reversed by a software parameter (see chapter 6, section "Inputs - outputs configuration"). The parallel connection of these outputs must be made by means of diods. IMPORTANT NOTE If the 24 V is available when the amplifier is off, the logic SEQ, POS, SPEED, OK, OUT1 to OUT8 are set at 24 V. Chapter 3 - Inputs-Outputs 15

16 Chapter 4 - Connections 1 - CONNECTION DIAGRAMS POWER CONNECTION WITH SMT-BM 20 A SINGLE-AXIS RACK OR BF-RACK K K.1 L1 L2 L3 GND N T/P P c 12/ Autotransf. 220 X T P N (*)Power relay N 1 ( ) N 2 Aux. relay Aux. "ON" Aux. "OFF" Aux. relay Power relay Amp. ready 24 V Power "ON" Power "OFF" Aux. relay Power relay ENABLE ON ENABLE OFF *POWER OK Power relay OF SD 0 V K.1 ENABLE relay K Power ON Amp. ready Filter BF 35/70 Aux. relay! * POWER OK: Only available on X5 of the rack back plane. If not using the POWER OK signal, make the jumper JK on the amplifier in order to have the AMP. READY signal taking into account the power statement. Power OFF Braking resistor connection +24V Aux. relay XA1 L1 L2 L XA2 Aux BF rack SMT-BM 20 A Pins 3 and 4 of XA2 Amplifier side X5 X4! Rack chassis grounding ENABLE GND AMP. READY GND U V W 4 cables + shield MOTOR 3 4 POWER READY AMPLIFIER X1 RES 6 pair shielded cables (+thermal probe) ( ): 3 A phase neutral circuit breaker curve C. (*): Differential circuit breaker remote controlled by safety voltage 12/24 V or 48 VAC and VDC. 16 Chapter 4 Connections

17 1.2 - CONNECTION OF THE SERIAL RS shield connection PC Serial port RxD 2 TxD 3 3 TxD 2 RxD SMT-BD1/m X5 GND 5 5 GND Sub D 9pts female Sub D 9pts female 2 - WIRING RECOMMENDATIONS (according to standards CEI 801 and EN see diagram "Shield connection on the connectors" - Chapter 8) GND WIRING AND GROUNDING The reference potential is the earth (ground). Motors and resolvers are grounded via their housing. If there is a potential reference, i.e. a main chassis or cabinet with a low impedance between the different elements, it should be used to connect ALL references to it and also connect this reference point to the earth (ground). Long reference potential connections are suitable ONLY if these connections have a very low impedance (< 0,1 Ω). Cables with low potential should NEVER run in the proximity of power lines. Every conductor cable (carrying a potential) MUST be shielded. Several wires in the same sleeve must be twisted and shielded. According to the CEI 801 standard, connectors must be made of metal or metal plated and must have a 360 shield connection (see chapter 8, section 6) MOTOR AND RESOLVER CABLES Cable ends should have a metallic collar allowing a 360 shield connection. The resolver cable must be twisted pair and shielded (sin, cos, ref.). Motor cables MUST also be shielded SERIAL LINK CABLE The serial link cable must also be shielded according to the above mentioned shielding recommendations. CAUTION! Command cables (serial link, resolver) and power cables must be connected and disconnected with amplifier OFF. Chapter 4 - Connections 17

18 Chapter 5 - Functional features 1 - DESCRIPTION OF THE LOGIC INPUTS-OUTPUTS LOGIC INPUTS ENABLE RUN Enabling authorized. This signal is a necessary conditions for the motor enabling (see also signal RUN). Enabling signal. The motor can be enabled only when the signals ENABLE and RUN are activated. Use in priority the RUN signal if using the brake control. RUN Motor enabled BRAKE Brake OFF delay Brake ON delay INDEX/CLR FC+ FC- START Index input for the axis homing. This input can be used for resetting the position counter. Limit switch input, positive direction. Limit switch input, negative direction. This signal starts the sequence which number is defined by the inputs IN1 to IN7. This signal must be disabled before the sequence is over. Combination of the logic inputs IN1 to IN7 6 ms / min. 1,5 ms / min. START 4 ms / min. STOP CLR WAIT TEACH JOG+ JOG- This input stops the motor with a programmed deceleration This input resets the position counter when this function is configurated. When this signal is activated, it inhibits the execution of a sequence. The sequence will start when this signal is disabled. This input allows to read the value of the current motor position and to program the sequence defined by the logic inputs (IN1 to IN7) with this value. If the sequence contains an index research procedure (HOME), this function has no effect. Manual movement in positive direction. Manual movement in negative direction. 18 Chapter 5 Functional features

19 IN1 to IN8 These inputs allow to define, in natural binary code, the sequence that will be executed. They also allow to define a sequence starting condition LOGIC OUTPUTS Amp OK Power OK This signal indicates that the amplifier is ready (without error). This signal indicates that the power supply is OK. BRAKE This output controls the brake. SEQ POS SPEED OK This signal indicates that a sequence is presently executed. This signal is activated when the motor reaches the position, and remains enabled until the next motor movement. In case of a forced movement, this signal remains enabled This signal indicates that the speed stage is reached during a movement of the motor. This signal indicates that the amplifier is ready for a movement (no error and amplifier enabled). sequence 1 with Tdec = 0 and link = 2 sequence 2 Delay time POS SEQ SPEED OUT to OUT8 Programmable logic outputs. These outputs are operating only during a programmed sequence. 2 - ADDRESSING Each amplifier can have an address 0. The amplifier has 4 micro-switches (SW1) allowing to define an address from 0 to 15 (see location of these switches in chapter 8, section 1: Hardware adjustments). The allocation of an address to an amplifier allows to communicate, from one single host, with several amplifiers via the serial link (RS-232 or RS-422). 3 - REDUCTION OF THE PROGRAMMED SPEED VIA AN ANALOG INPUT It is possible to get an optional analog input allowing to reduce the programmed speed. The displacement speed is reduced with regard to the programmed speed, inversely proportionally to the analog input value. This speed reduction is applied to the programmed speed of all sequences as well as the manual movement speeds. Chapter 5 - Functional features 19

20 Chapter 6 - Commissioning 1 - CHECKING THE AMPLIFIER CONFIGURATION The amplifier standard configuration for MAVILOR motors with TAMAGAWA resolver is the following: - Resolver adaptation card P RES: 4 x 12,7 KΩ 1%. - Current loops adjustment according to table of chapter 8, section 1. - Motor thermal probe PTC: Jumper MN. - Positive control logic: Jumpers E. F. G closed. - No auxiliary supply: Jumper JK closed and jumper KL open. For the amplifier adjustment to other motor or resolver types, or to another control logic, see chapter 8, sections 2, 3 and INSTALLING THE PC SOFTWARE Connect at first the serial link RS232 between PC and amplifier. The BD1M software is running under DOS. For installing the software, insert the disk in drive A and start the installation by entering A:INSTALL Enter the communication port (COM1 or COM2) and start the installation by pressing [INSTALL]. 3 - PUTTING INTO OPERATION Check the secondary voltage of the power transformer. Rated value: 220 V rms between phases, max. value without load < 260 V rms (including all authorized variations, especially mains variations). Check the DC bus voltage on the back of the rack: U DC 310 V, U DC max < 370 V, U DC min > 200 V. The braking resistor must remain cool (CAUTION! This resistor is under high voltage). Turn power off and wait until voltage drops below 10 V before plugging in the first amplifier. ENABLE and RUN signals must be disabled. Plug in the amplifier and apply power. 1st CASE Use without auxiliary supply. When applying power, the green LED "ON" must light and the red "ERROR" LEDs must be off after the AUTOTEST procedure of the amplifier. 2nd CASE Use with auxiliary supply (Chapter 8, section 4.2). When applying power, the "Undervolt." fault may be displayed. Apply main power: the fault is cancelled. CAUTION When turning the off amplifier, wait for at least 5 seconds before turning power on again. 20 Chapter 6 Commissioning

21 4 - AMPLIFIER COMMISSIONING AND ADJUSTMENT In the directory C:\BD1M, start the software by entering BD1M. The software screen is divided into 2 areas: - one menu area, accessible by means of function keys (F1 to F10) of the PC keyboard, - an area displaying the information regarding the axis (position, speed, logic inputs/outputs). The function keys F1 to F10 allow the access to various functions of the software. The menu tree structure is shown below: - F2: Parameters - F2: Motor - F2: Motor list - F3: Auto-phasing - F4: Motor parameters - F5: Phase lead calculation - F6: Current limit - F7: Speed limit - F3: Controller - F2: Auto-tuning - F3: Controller parameters - F4: Stability gain - F4: Encoder output - F5: Input/Output configuration - F6: Scale parameters - F7: General parameters - F8: Manual move parameters - F2: Jog/Move parameters - F9: Save parameters - F10: File - F2: Load parameters - F3: Save parameters - F4: Save report - F5: Print report - F3: Single move Chapter 6 - Commissioning 21

22 - F4: Sequence setup - F5: Down load - F2: Copy sequence - F3: Paste sequence - F4: Compare sequences - F7: Edit sequence - F8: Delete sequence - F9: Up load - F10: File - F2: Load - F3: Save - F4: Save report - F5: Print report - F5: Run sequence - F7: Reset error - F8: Oscillo - F9: Misc. - F2: Address - F5: Serial port - F9: Error display - F10: Exit Notes - The ESC key makes it possible to go up one level in the menu hierarchy. - Dialog window: - the arrow keys allow to move between the various elements, - the ENTER key then allows to quit and confirm the modifications, - the ESC key or «F1: Return» key allow to quit without confirmation, - the SPACE key allows to change a displayed selection on an element with multiple selection PARAMETER SETTING Select the appropriate amplifier and fan types according to the motor used (see current ratings table in chapter 2, section 1) CURRENT LIMITATION Menu "F2: Parameters" then "F2: Motor" then "F6: Current limit". Select the amplifier current limitation mode (Menu "Current limit"). When putting into operation, the "Fusing" mode is recommended. In "Fusing" mode, the amplifier is disabled when the current limitation threshold is reached (see chapter 8, section 3.3). In "Limiting" mode, the current is only limited at the value defined by the parameter Rated current when the limitation threshold is reached (see chapter 8, section 3.3). The parameter Maximum current (%) defines the amplifier maximum current. It can vary between 20 % and 100 % of the amplifier current rating. This parameter is defined according to the amplifier and motor specifications (see chapter 2, section 1). The parameter Rated current (%) defines the limitation threshold of the amplifier RMS current (I 2 t). It can vary between 20 % and 50 % of the amplifier current rating. This threshold is defined according to the amplifier and motor specifications (see chapter 2, section 1). Check that the parameter values for maximum current and rated current are compatible with motor and amplifier. Otherwise, adjust them according to the motor and amplifier specifications. 22 Chapter 6 Commissioning

23 APPLICATION SPEED LIMITATION Menu "F2: Parameters" then "F2: Motor" then "F7: Speed limit". The parameter Maximum speed (rpm) defines the maximum rotation speed of the motor. The variation range is between 100 and rpm and the resolution is 5 rpm. The function Reverse movement allows to reverse the motor rotation direction with regard to the sign of the position counter. Regarding the encoder position output, the counting direction is not modified according to the motor rotation direction. Check that the parameter value "max. speed" (Menu "Speed limit") is compatible with motor and application. Otherwise, modify it according to the motor and application specifications MOTOR PARAMETERS Menu "F2: Parameters" then "F2: Motor". The menu "F2: Motors list" allows the selection of a motor in the motor list. If the motor used is not in the motor list, please proceed as described below AMPLIFIER ADJUSTMENT TO A NEW MOTOR Uncouple the motor from the mechanical load and check that the motor shaft has free rotation for one revolution that is not dangerous for the operator. Execute the Auto-phasing procedure (the RUN signal must be disabled and the ENABLE signal activated) in order to get the parameters Pole pairs, Motor phase and Resolver adjustment. Note that during the autophasing procedure, the motor is automatically enabled and then disabled after the procedure. Calculate the parameter "current phase lead" (Menu "F2: Motor" then "F4: phase lead calculation") from the motor specific parameters (the effects of this parameter are useful for low inductance motors running at high speeds). The motor parameters menu gives the parameters calculated by means of the auto-phasing procedure and the "current phase lead calculation" parameter. - The parameter Pole pairs defines the number of motor pole pairs. - The parameter Phase order defines the sequence order of the motor phases. - The parameter Resolver offset defines the mechanical shift between the motor reference and the resolver reference. - The parameter Current phase lead defines the currents phase lead for the motor maximum speed. This phase lead is proportional to the motor speed and compensates the current loops phase shift in order to keep a maximum torque/current ratio in the motor SPEED LOOP PARAMETERS Menu "F2: Parameters" then "F3: Controller" The auto-tuning procedure identifies the motor and load specifications and calculates the gain parameters of the regulator. During the execution of the procedure, the operator can select a regulator bandwidth (Low = 50Hz, Medium = 75 Hz and High = 100 HZ). These values correspond to the cut-off frequency for a 45 phase shift of the speed loop. For executing the auto-tuning procedure with disabled motor, the ENABLE signal must be activated and the RUN signal disabled. For executing the auto-tuning procedure with enabled motor (i.e. vertical load), both ENABLE and RUN signals must be activated. Chapter 6 - Commissioning 23

24 Make sure that the motor shaft has free rotation for one revolution that is not dangerous for operator and machine before starting the auto-tuning procedure with Filter = standard. After the auto-tuning procedure, check that the motor is correctly running in both directions. Check the response for a small displacement without IDC saturation. In case of loud noise in the motor at standstill or when running, check the rigidity of the mechanical transmission chain between motor and load (backlashes and elasticities in motor and couplings). If the problem remains, execute again the auto-tuning function with a lower bandwidth. If the problem still remains, execute again the auto-tuning function by activating the antiresonance filter. Adjust more accurately the loop response stability by adjusting the stability gain (menu Controller parameters and then Stability gains) SPEED LOOP ADJUSTMENT WITH A VERTICAL LOAD In the case of an axis with an unbalanced load (constant torque due to a vertical load), proceed as follows: Select the current limitation mode Limiting. Initialize the regulator gains corresponding to the unloaded motor by executing the auto-tuning procedure with the motor uncoupled from its mechanical load. Couple the motor to the load. If possible, make a control in speed loop via the NC; otherwise close the position loop with a stable gain. Move the shaft in manual control until a safe position is reached. Check for free rotation over one revolution that is not dangerous for operator and machine (far enough from the mechanical stops). Execute the auto-tuning procedure with the motor at standstill (see part 4.1.5). If the motor shaft is moving, the amplifier does not execute the procedure ENCODER OUTPUT PARAMETERS Menu "F2: Parameters" then "F4: Encoder output The parameter Encoder resolution defines the equivalent encoder resolution on channels A and B of the encoder position output for one motor shaft revolution. Binary and decimal values are both accepted. The maximum encoder resolution is limited by the motor rotation speed as shown in the table below. Max. possible speed (rpm) Max. encoder resolution The parameter Number of zero pulses defines the number of marker pulses on channel Z for one motor shaft revolution. The adjustment range is between 1 and 16. The parameter Zero pulse origin shift defines the shift between the first marker pulse on channel Z and the reference zero position of the resolver. The adjustment range is between 0 and The value corresponds to one motor shaft revolution. The parameter Zero pulse width defines the width (as a resolution) of the marker pulses on channel Z. The adjustment range is between 8 and The value corresponds to one motor shaft revolution. The ENABLE signal must be disabled before validating these parameters by "OK". The amplifier will then execute the programmation of the encoder output (which lasts about 5 s). 24 Chapter 6 Commissioning

25 INPUTS-OUTPUTS CONFIGURATION Menu "F2: Parameters" then "F5: Input/Output configuration". Inputs pol. defines the polarity of the optocoupled inputs START, STOP, JOG+, JOG-, IN1 to IN8: a signal that is not checked off with an X corresponds to an active 24 V input. Sequence control: The inputs IN1 to IN7 can be used for selecting sequences (checked off with an X). There are maximum 128 sequences that can be selected this way by the inputs IN1 to IN7 (in binary code). The other inputs can be used for the starting condition. Output pol.: defines the polarity of the optocoupled outputs SEQ, POS, SPEED, OK, OUT1 to OUT8: a signal that is not checked off with an X, corresponds to an active 24 V output. Output pulse: the outputs OUT1 to OUT8 can be defined as pulse outputs (checked off with an X) which duration is defined by the parameter output pulse duration (1 to ms) POSITION RESOLUTION PARAMETERS Menu "F2: Parameters" then "F6: Scale parameters". This menu defines the following parameters: Position resolution: defines the position resolution for one motor revolution according to the desired number of decimals and the desired unit. The value range is between 16 and 65536/rev. Decimal: number of decimals. Unit: defines the unit used. Example: For a resolution of 4 mm/motor rev., if the number of decimals = 3, the parameters are: Resolution = 4000 Decimal = 3 Unit = mm Following error threshold: defines the triggering threshold of the following error. Dead band : defines the dead band for the position control. CLR input enable: when activated (checked off), allows to use the INDEX input for re-initializing the position counter: at the inactive-active transition of this signal, the value 0 will be loaded again in the position counter. Reset counter: this function allows to reset the position counter when it reaches a pre-defined value. If the value is set at 0, this function is not activated. Forward: with the function "Reset counter" activated, - if this parameter is activated (ticked off), the motor turns in positive direction for an absolute displacement lower than the value of the "Reset counter" parameter, - if this parameter is not activated (not ticked off), for an absolute displacement lower than the value of the "Reset counter" parameter, the motor follows the shortest way GENERAL PARAMETERS Menu "F2: Parameters" then "F7: General parameters". This menu allows to define the following parameters: Speed profile: trapezoidal or S-curve. Chapter 6 - Commissioning 25

26 "Brake ON" delay: defines the time between the brake enabling and the amplifier disabling: - brake ON (contact open), - delay time, - amplifier disabled. "Brake OFF" delay: defines the time between the brake enabling and disabling: - amplifier enabling, - delay time, - brake OFF (contact closed). Analog input limitation: validates, by an analog input, the option "programmed speed reduction"; this is possible only when the option "analog input" is available. The displacement speed is then limited with regard to the programmed speed value in an inversely proportional way to the analog input value. This speed reduction is applied to the programmed speed : - modulation of the programmed speed for positioning sequences (ABS, REL), - limitation for speed and torque sequences. When the analog input is 0 V, the motor runs at the programmed speed. A 5 V input controls the motor at half of the programmed speed. A 15 V signal is available on the X4 connector and allows to realize a "speed reduction" potentiometer MANUEL MOVE PARAMETERS Menu "F2: Parameters" then "F8: Manual move parameters", then «F2: Jog/Move parameters» This menu defines the parameters movement speed, acceleration time and deceleration time during a movement via JOG+, JOG- or via the serial link (function F3 Single move in the main menu). The parameters acceleration time and deceleration time define the time with regard to the maximum speed (defined by the parameter "Speed limitation"). When the movement speed is lower than the maximum speed, the trajectory acceleration and deceleration times are proportionally smaller. Max. speed movement speed parameter acceleration time parameter deceleratiion time parameter PARAMETERS SAVING Menu "F2: Parameters" then "F9: Save parameters". When all adjustments are made, the parameters must be saved in the amplifier non volatile memory. This is made by executing the menu Save parameters with the ENABLE signal inhibited. 26 Chapter 6 Commissioning

27 PARAMETER FILES The menu "F10: File" allows the access to following functions: - parameters saving on the disk (F3: Save parameters). - loading of the saved parameters on the disk (F2: Load parameters). - parameters saving as a text file (F4: Save report). - parameters printing (F5: Print report) ENABLING The amplifier can be enabled only when the ENABLE and RUN signals are enabled. ENABLE is a "hardware" signal that allows the amplifier inhibition in critical situations. RUN is a "software" signal that allows the delay time control via the BRAKE output. During the Auto-phasing procedure, this signal must be inhibited and the ENABLE signal enabled. If the brake is not used, the potential of the RUN signal should be set and the ENABLE signal should be used for the enabling/disabling (and not the contrary). The brake control signal (BRAKE) is a low power signal that cannot directly control the brake. It must be connected to an external power relay for controlling the motor brake. The brake control is enabled (contact open) or disabled (contact closed) according to the amplifier statement (disabled or enabled) MANUAL MOVE The manual move can be made as follows: - via the inputs JOG+ and JOG-: the motor moves at the programmed speed (see section "Manual move parameters) or - via the serial link: the BD1m software allows a single move by giving the home position (Menu "F3: Single move"). Chapter 6 - Commissioning 27

28 5 - PROGRAMMATION GENERAL DESCRIPTION The sequences programmation is accessible via the menu "F4: sequence setup". Function "F2: Copy sequence" : allows to copy the highlighted sequence. Function "F3: Paste sequence" : allows to "paste" the sequence copied before (by F2) instead of the highlighted one. Function "F5: Download": allows to transfer the programme (128 sequences) from the amplifier to the PC. The amplifier must be inhibited during the transfer. Function "F7: Edit sequence" edits the highlighted sequence. Function "F8: Delete sequence" deletes the highlighted sequence. Function "F9: Upload": allows to transfer the programme (128 sequences) from the PC to the amplifier. The amplifier must be inhibited during the transfer. Function "F10: File": allows the access to following functions: - saving of a programme (sequences list) on a disk (F3: Save sequences). - loading of a programme saved on the disk (F2: Load sequences). - saving of the sequences list as a text file (F4: Save report). - printing of the sequences list (F5: Print report). CAUTION! When the "Resolution" parameter is modified, all position values in the sequences are also modified. When the parameter "Max. motor speed" is modified, all speed parameters in the sequences are also modified. Consequently, when a sequence file is sent to the SMT-BD1/m amplifier, it must be programmed before with the correct parameters "Position resolution" and "Max. motor speed". 28 Chapter 6 Commissioning

29 5.2 - EDITION OF A SEQUENCE Parameters of a sequence: Move Defines the movement type. ABS: positioning in absolute dimension. REL: positioning in relative dimension. HOME: research procedure of the axis origin. SPEED: motion in speed mode. TORQUE: motion in speed mode with torque limitation. Procedure diagram of the origin research: Switch research (programmed speed) Switch detection First marker pulse out of the switch Start Positioning on the origin (marker pulse) Withdrawal from the switch (speed/4) When sequence 0 includes a homing procedure (HOME), no other sequence can be executed before sequence 0 at power up. Pos Speed Tacc Tdec Delay or TimeOut Next Counter Counter link Dimension to be reached, absolute or relative according to the parameter above. If Move is the origin research procedure, Pos is the value to be loaded into the position counter for the origin position found. The value range is between ( x resolution) and ( x resolution -1). Defines the movement speed in rpm. Defines the acceleration time in ms. Defines the deceleration time in ms. This parameter can be = 0 when a chaining can be made without stopping the motor. See also section "Manual move parameters" for the definition of the parameters Movement speed, Acceleration time and Deceleration time. Defines, in ms, the delay time at the end of the positioning. If the movement is the origin research procedure, this parameter defines, in seconds, the "time out" after which the amplifier releases an error (if it does not find the index position). If this value is set at 0, the "time out" protection is not activated. Defines the sequence to be executed after the current one. Defines how many times the sequence must be executed. This counter will be decremented at each executed sequence. Defines the number of the sequence to be executed if the above counter is not at zero. Example : sequence 1: Next = 2 Counter = Counter link = sequence 2: Next = 3 Counter = 2 Counter link = 1 sequence 3: Next = Counter = Chapter 6 - Commissioning 29

30 Counter link = If the execution starts at sequence 1, the programme course will be the following: Sequence 1 Sequence 2 Sequence 1 Sequence 2 Sequence 3 start at sequence n 1 then link (parameter "Next") to sequence n 2. first execution of sequence n 2, then connection to sequence n 1 (parameter "Counter link"). execution of sequence n 1, then link to sequence n 2 (parameter "Next") second execution of sequence n 2, then connection to sequence n 3 (parameter "Next"). execution of sequence n 3, then programme over. Output Output trigger Defines the statement of the 8 outputs:. do not change the output statement 1 set the output at 1, 0 set the output at 0, T reverse the output (toggle). Defines the triggering moment of the outputs according to one of the five solutions below: BEGIN: logic output at the beginning of the sequence SPEED: logic output when the speed is reached POS: logic output when the motor passes a position HOLD: logic output at the end of the trajectory END: logic output at the end of the sequence The outputs can also be preset as pulse outputs (cannot be modified by means of a programme) with a preset duration. This type of output only concerns the outputs set at 1 or "toggle" (see section "Inputs - outputs configuration"). Regarding the origin research, the parameters are: Dir Research direction, "+" for the positive direction and "-" for the negative direction Switch Origin research with switch detection. Zero Origin research with marker pulse direction. Origin In the case with switch, this parameter allows to come back to the origin position (movement reversal); otherwise, the motor will be stopped after the braking. Reset Load the Pos value in the position counter at the origin position. 30 Chapter 6 Commissioning

31 Procedure diagram with switch: Switch research (programmed speed) Switch detection (origin position) Start Load the Pos value in the position counter Return to origin position (speed/4) If Switch = Y and Zero = Y or Origin = Y, the speed reversal is made by the switch detection or by a limit switch. Output pos. Start condition Example : Defines the position where the output must be triggered if it has been programmed (see above). The inputs that are not defined as sequences selection inputs can be programmed here in order to define a starting condition for the programmed sequence. Example : As the inputs 1 to 5 are sequences selection inputs, the inputs 6 to 8 can be used for the starting condition. Conditions: inputs 6 to 1 inputs 8 to 0 input 7: unused "Start conditions "0.1..." (inputs 7 and 1 to 5 are not concerned by the starting condition). In these conditions, this sequence can only be executed if input 6 is set at 1 and input 8 at 0. A conditional sequence connection can be programmed via the inputs by combining the «start condition» for the inputs with the «counter link» parameter. The counter parameter must be empty. The sequence will be executed if the «start condition» inputs are ready. Otherwise, it will not be executed and the programme directly switches on to the sequence indicated by the «counter link» parameter. Sequence 1 Next = 2 Counter = Counter link = 4 Start condition = 1... (IN8 input) When executing this sequence: if IN8 input = 1, sequence 1 will be executed and the programme switches on to sequence 2. if IN8 input = 0, sequence 1 will not be executed and the programme directly switches on to sequence 4. If, in the example above, the parameter "counter link" is empty, the programme waits until the "start condition" inputs are ready for executing sequence PROGRAMME EXECUTION The execution of a sequence can be made: - via the logic input START: this input triggers the execution of the sequence defined by the inputs IN1 to IN7 (in natural binary code), - via the serial link. The BD1m software allows the execution of any sequence: menu "F5: Run sequence". Then, enter the number of the sequence to be executed. NOTE : A sequence execution requires the enabling of the OK signal. Chapter 6 - Commissioning 31

32 7 - USE OF THE OSCILLOSCOPE Oscilloscope screen (F8 of the main menu): Function keys Channel cursor Triggering instance cursor Triggering level cursor (trigger) Keys F1 and F2 allow to change the time base. Keys F3 and F4 allow to change the amplitude of the channel indicated by the "channel selector". Key F5 allows to put the "channel selector" on channels 1, 2 or 3. Key F6 allows to allocate a signal (Imon, Iref, Speed ref, Speed mon...) to the channel indicated by the "channel selector. Key F8 allows to change the operation mode: - Continuous. - By single trigger. - By auto-trigger. The 3rd channel is only available in «Auto trigger» or «Single trigger» mode. Key F9 allows to define the triggering mode: - on positive level, - on negative level, - on up edge, - on down edge, - on an amplifier error. 32 Chapter 6 Commissioning