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HPD N “high power”

1. EMG main iter 25N 35N 45N 67N Control electronics dissipation w W Dissipation from W components Power stage switching frequency kHz 8 amp 8 Protection categor 22080074 Digital inputs 24V Digital outputs 24V 100mANPN NO 6 Voltage free digital outputs Encoder emulation RS 422 Frequency Sign OR encoder input k Auxiliary analogue input Auxiliary analogue output Tacho generator emulation output OM HOV 24V 2A The Overload Time for HPD25N is 4 Seconds Analogue reference 10 diff 15 bit V S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 1 6 Software features The following capabilities are implemented in the basic software supplied with the HPD N drive e Speed control Advanced torque limit manager Speed windows management Positioning with trapezoidal speed profile Digital locking functions with variable transmission ratio and phase shifting Spindle orientation Stepper motor emulation Torque control with overlaid speed control Acceleration ramp control with overlaid speed control Simplified maintenance and start up mode Internal PLC for advanced input output programming functions 1 7 Compliance with EMC standards Immunity EN50082 2 Basic immunity specifications IEC1000 4 2 ex IEC 801 2 level 3 Electrostatic discharge immunity IEC1000 4 3
2. 82 C Hardware characteristics 83 D DC bus voltage 5 84 E Standard Hee eec terere eee RET HAE ES 84 F Software oam pP ENS 84 G Pico PLC default program 85 H Elash information ie Selene er Dev 86 I Remote communications interface 87 L Application description form eere 88 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 1 INTRODUCTION 1 1 General information This manual describes operations required for the installation and commissioning of the high power family HPD N High Performance Drive New series with extended maximum voltage range drive for brushless motors Read all chapters of the manual carefully before using the drive Changes Upgraded to N standard New resolver s cable specification 1 2 Product description The HPD N drive is a digital frequency converter for driving AC brushless motors The adoption of a Parametric Operator Interface makes drive configuration procedures faster and easier to repeat The large number of configuration possibilities makes the drive suitable for numerous applications A high power 16 bit micro controller allows speed control with the characteristics required of a servo controller plus a range of auxiliary functions that ca
3. High Power Manual ACCELERATION CONTROL OPERATING MODE reserved reference main ref MAINTENANCE amp COMMISSIONING OPERATING MODE reserved reference wiring test selector pos b70 0 error code motor poles resolver phase b70 start stop reference input aux analog input digital input status 1 err std dev test speed test stroke starting point delay xl olol wi lo digital input status 2 encoder in counter ko o bus voltage offset compensation U o offset compensation V 48 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual TRAPEZOIDAL POSITIONER OPERATING MODE in progress profile generator feed forward servo error window Servo error reserved reference T proportional gain Pr 61 Pr60 steady time speed ramps target position Pr 63 Pr62 reset 1 rofile on reverse forward Pierre motor position target position motor position 0 pulses gt target position motor position shaft position Pr 65 Pr 64 incremental position steps for pulse target position motor position reset 3 incremental position Pr 65 Pr 64 0 reset 4 DIGITAL LOCK OPERATING MODE master speed encoder master feed forward proportional gain reserved reference max regulator speed moto
4. Pr2 Analogue reference full scale speed value in rpm corresponding to 10 V reference signal Pr8 Acceleration deceleration ramp values in seconds per 1000 rpm Prl6 Integral gain of speed control loop Pr17 Speed control loop damping Pr19 Peak current delivered to drive expressed as a percentage of the peak rated value of the drive 29 Number of motor poles Pr32 Rated speed rpm Pr33 Rated current that can be delivered by the drive can be maintained indefinitely expressed in percent of the peak rated current of the drive Pr35 Instantaneous current requested by the motor expressed as a percentage of drive peak rated current b99 6 Enable extended menu Default 0 Set to 1 to obtain the extended menu b99 7 Security Default 0 Set to 1 to protect parameters from modification b99 10 Alarm reset command b99 13 PLC status Default 1 At 1 the PLC program is executed at 0 the program is not executed b99 15 Parameter storage command Using extended menu you can manage all parameters and pico PLC instructions Restoring default parameters If you need to restore the factory set default parameter values disable the drive via hardware open terminal 11 on board X3 power up the system the display will show IdLE after approximately 3 seconds Set b99 7 and b99 13 to zero enter command b99 12 save your changes with b99 14 and b99 15 26 S B C Elettronica S p A Engineering Division HPDxxN H
5. Pr29 Pr30 Pr31 Pr32 Pr33 Pr34 Pr35 Pr36 Pr37 Pr38 Pr39 29 Code describing installed software version Read only parameter Serial line baud rate code Default 8 This is the code for programming transmission speed For more information consult the section on the serial interface Serial line address code Default 0 possible settings 0 31 For more information consult the relative section of the manual Motor shaft position Unit steps range 0 4095 Read only parameter that shows the absolute position of the resolver Number of motor poles Possible settings 2 64 default 8 Resolver position offset Default 0 use Pr30 for electronic correction of the mechanical resolver position Operating mode Default 0 Use Pr31 to select the active operating mode 0 indicates no operating mode Rated speed Unit rpm range 0 9000 default 3200 Nominal motor speed Should be programmed with the motor speed at which rated voltage corresponds to drive power feeding voltage reduced by 13 Consult the formula in section Commissioning the HPD N drive Motor rated current Unit of peak current range 10 0 50 0 resolution 0 1 default 5096 for HPD25N 67 for 35N 45N 67N Enter motor rated current Tacho generator emulation output gain Default 127 Use parameter 34 to alter analogue output gain in proportion to speed terminal 9 on board X2 Torque monitor Unit of peak torque resolution 0 1 This par
6. ELETTRONICA S p A HPD N high power HPD25N HPD35N HPD45N HPD67N User s Manual rev 8 February 2001 software rel 35 and later S B C Elettronica S p A Engineering Division HPD HIGH PERFORMANCE DRIVE SOFTWARE amp HARDWARE EXPANSION RS 485 or RS 422 SERIAL LINK c 5 5 Stand ELETTRONICA Via Gounod 1 Cinisello B MI Italy tel 39 02 66012459 fax 39 02 66012808 http www sbcelettronica com HPDxxN High Power Manual EXTENDED VOLTAGE RANGE DIGITAL LOCK VARIABLE RATIO POSITIONER STEP MOTOR SIMULATION EASY MAINTENANCE TORQUE CONTROL ACCELERATION CONTROL SPINDLE ORIENTATION FOR TOOL CHANGING BUILT IN P L C HPD everywhere for any application S B C Elettronica S p A Engineering Division HPDxxN High Power Manual WARNING HIGH VOLTAGE Certain circuits in the HPD N drive carry dangerously high voltages that could cause serious personal injury or death Do not attempt to service any parts of the drive when it is connected to the power supply If you need to access internal parts before working on the drive allow at least 15 minutes after power down to allow the DC bus capacitors to discharge It is the User s responsibility to make sure that the installation is executed in accordance with established industrial health and safety standards In relation to the interpretat
7. recte eed tenere ee RR ee 2 3 4 Basic etie teer teet 31 3 5 Calibrating speed 32 3 60 Operating modes iei iS 38 3 6 1 vv 38 3 6 2 Acceleration control suse teret ettet ee Dee a ERR 38 3 6 3 Maintenance and 39 3 074 Positioner Det De neue 40 3 6 5 Digital JOCKIN Give tele 41 3 6 6 Stepper motor emulation ss ieee eene 43 3 6 7 Spindle orientati nzi iso Dee eet opes 44 3 7 IBIOCK CIA STAINS cave Eee HERR 44 3 8 Digital input and output programming eese 51 ERU E eam 51 3 8 2 Examples and 56 3 9 Programming with Pcbrush T3 HPDxxN High Power User s Manual S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 4 SERIAL INTERFACE 5 eee test teet et sve 74 4 1 Communication protocol essere nennen nene nnne enne 74 4 2 Serial addresses and parameter lengths 79 APPENDIXES A HPD N drive mechanical dimensions eee 81 B MB series motor connectors
8. 1 ea ae MODEL J HPD 25N HPD 35 HPD 45 HPD67N SERIAL NUMBER MOTOR MOTOR SERIAL NUMBER OPERATING VOLTAGE __ ME FIRST HPD APPLICATION yes NO L MACHINE x d aided ta Oed ia re e Cer TASK PERFORMED BY AMPLIFIER eene FUNCTIONS USED EXTERNAL BRAKING MAINS FILTERS ENCODER IN BACK UP LOW VOLTAGE FUNCTION ENCODER OUT PARALLEL BUS INTERNAL PLC MOTOR COILS SERIAL LINE AMPLIFIER CONTROLLED BY MAKE MODEL INUMERCALCONTROL MASTER SLAVE CARD a 2 22 88 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual pr IF YOU USE AN INTERNAL PLC PROGRAM OTHER THAN THE DEFAULT PROGRAM PLEASE ENCLOSE THE LISTING ni in Ting n2 8 4 50 n3 h i9 5 7 n4 lh20 6 ns n5 of meat 37 vy I53 7 n6 hn22 H388 4 7 n7 83 Hm39 5 7 n8 4 4 0 6 n9 5 4 7 7 6 42 ns init In27 7 43 9 7 mes _ _ Pints of mag nt Tmt Pinta 9 nto mk pints 7 7 68 7 89
9. Speed control loop damping Range 0 32767 default 2000 If Pr16 is set to zero Pr17 sets the value for proportional gain of the speed control loop Bandwidth limiter Unit 512us range 0 1000 default 1 Use 18 to set the time constant of a first order filter located on the digital torque demand signal The filter cut off frequency will be 310 Pr18 Hertz Peak current Unit range 0 100 0 resolution 0 1 default 100 0 Maximum current that the drive can deliver to the motor expressed as a percentage of drive peak current It is good practice to maintain this value to within 3 times the rated motor current DC bus voltage Unit volt read only parameter Shows the value of DC bus voltage Torque limiter read only parameter Unit Can be used by operating modes to restrict motor torque Auxiliary analogue reference Unit The displayed value will be Pr22 Vin 100 9 76 Resolution is 0 2 Alarm code This code shows the currently active alarm zero means that no alarms are active Consult the table of alarm codes for more details Last alarm This parameter stores the last alarm Pr24 is reset when the alarm reset command is entered b99 10 pO 00000 21 fovervoltage 5 6 tive overheating 8 9 digital output overcurrent alarm 28 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual Pr25 Pr26 Pr27 Pr28
10. With this bit you can lock 1 or release 0 the axis from the input encoder reference b70 9 Reserved b70 10 Reset type 1 Resets motor and reference position Implemented only with b70 8 0 b70 15 Reserved 42 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 6 6 Stepper motor emulation This mode emulates the operation of a stepper motor each pulse received on the frequency input terminal board X6 channel A frequency channel B direction is multiplied by Pr51 and the result is added to the reference position The frequency input must be programmed as a direction sign signal by setting b42 5 0 Just as in all other operating modes it is possible to enable feed forward limit the action of the proportional part obtain servo error indication and select the most suitable type of reset Note that the frequency count occurs on the negative front of the signal and changes of the direction signal must be made at least 1 uS before the negative frequency front Unlike stepper motors in this case there is no risk of step loss Refer to Frequency input connection chapter for the connection diagrams PARAMETERS FOR OPERATING MODE 11 Pr50 Maximum speed Unit rpm default 3000 range 0 9000 This parameter makes it possible to limit maximum motor speed Pr51 Reference multiplication factor Default 1 0 4096 This parameter allows you to set the required multiplication ratio for input re
11. much current to supply to the motor TORQUE current flowing through the motor windings is converted into torque which allows the motor to accelerate and decelerate GAIN in consideration of the typical applications of the HPD N drive the expression gain in this section of the manual refers to stiffness To understand the concept of stiffness imagine a motor controlled by a drive with speed demand of Zero rpm The motor shaft will appear immobile but if we apply torque to the shaft it will rotate through an angle that depends on the amount of torque applied We can then apply the rated torque of the motor and then measure the stiffness angle in degrees The resulting value provides an indication of the fidelity of the drive thus parametrised although it is clearly not the only fidelity indicator WHAT S NEEDED To calibrate an HPD N drive correctly we recommend using an oscilloscope with memory Obviously the technician in charge must be well versed in the use of the instrument If it is impossible to use an oscilloscope we illustrate at the end of this section of the manual an alternative although less accurate method BEFORE STARTING Before starting observe figure 1 Tek Run 500 S s Hi Res Trig 08 40 26 Fig 1 The graph shows system response to a square wave speed reference Channel 1 Ch1 is speed and channel 2 Ch2 is motor current The channel 1 oscilloscope probe is connected to terminal 9 33 S B
12. 0 and b99 1 are refreshed only after the first pico PLC program scan The maximum number of instructions is 64 including the END instruction Note that mathematical operations occupy the space of two logical operations so when they are used the maximum number of instructions available is decreased accordingly The PLC program must always be terminated with an END instruction The pico PLC program can be edited on a PC see Programming with Pcbrush or directly from the keypad In this latter case to facilitate procedures when you need to delete an instruction select it and then press M to display the type of instruction now keep M pressed and simultaneously press when both keys are released the instruction will be deleted On the contrary in order to add an instruction after In06 for example select the next instruction 1107 press M to display the type of instruction now keep M pressed and press simultaneously when both keys are released an FIN instruction will be inserted In this latter procedure make sure that the instructions in the program are no more than the maximum number or you will lose the last one s The pico PLC program be edited or altered only when the PLC is in stop status 699 13 0 55 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual 3 8 2 Examples and applications The following examples illustrate possible functionalities obtained by suitable programming of
13. 4 SERIAL INTERFACE The drive communication protocol is master slave half duplex type on an asynchronous RS 485 RS 422 line The drives assume control of the line only following interrogation by the master Up to 32 drives can be connected on the same serial line allocating each a different serial address in parameter Pr27 It is also possible to set transmission speed in parameter Pr26 as specified in the table Pr26 decimal base time out ms 0 600 1200 2400 4800 9600 9600 19200 38400 57600 125000 57600 1 2 3 4 5 6 7 8 9 The version with code Pr26 4 differs from Pr26 5 because of the 25 ms response delay This version was developed to interface with PLCs that require this characteristic The version with code Pr26 10 was developed to allow data communication between two HPD N drives Refer to the heading Serial line connection for connection diagrams 4 1 Communication protocol The right hand column in the table shows the time out value in milliseconds for each communication speed this is the time starting from the beginning of each message STX within which the transmission of the message must terminate Therefore if the message is interrupted after the time out the drive will ignore the information already received and stand by to receive a new message Messages are made up of several consecutive data in the following format 1 start bit 8 data bits fol
14. 91 1 91 10 70 8 94 0 86 62 84 85 15 55 72 05 40 2 70 8 94 0 88 62 84 94 0 84 55 83 91 12 91 12 94 0 88 62 84 94 0 84 83 84 72 84 05 41 2 72 72 60 94 0 62 88 62 91 12 91 1 94 5 91 10 91 12 40 2 90 2 91 10 40 2 90 3 91 10 70 10 91 10 94 5 91 10 94 5 HPDxxN High Power Manual Fast input for digital lock trigger if the axis is locked fast input disabled and output enabled cycle in progress if homing has been carried out the bit is enabled Force double word operation comparison comparison for release test release test Pr86 lt Pr62 copy master speed into internal speed reference and enable it release axis force double word operation Pr84 remaining space force double word operation Pr83 time to reach zero rpm ramp stopped flag ramp down management Force double word operation Pr84 remaining space force double word operation calculate ramp speed and write in internal reference if speed is zero reset position reference modulus close force double word operation subtract modulus from motor dimension deactivate ramp in progress flag deactivate cycle in progress output enable fast output test if reference must be Pr6 test whether to execute homing execute homing Zero proximity sensor input honing end test position reset homing flag enable fast input if homing not executed disable fast input program e
15. BUS VOLTAGE N Pr 39 PHASE ADVANCE Y Pr 34 GAIN FOR TACHO B42 0 B42 1 ENCODER OUT RESOL Y B42 2 B42 5 QUADRATURE FD 41 14 EXTERNAL 41 15 FLAGS B41 6 PRE ALARM N B40 1 VIBRATION STOP Y B40 10 LOW VOLTAGE OP Y L2 b40 12 187 b40 2 b40 3 HPDxxN High Power User s Manual left sw Dp HIGH PERFORMANCE DRIVE right sw MAIN BLOCK DIAGRAM i torque demand ramps values S H band width i speed control limitator 1 5 Pr 16 Pr 17 user current limit torque Beale demand 0 b40 11 analog out motor speed rated current over reserved current limit Vout aux over speed high gt low aux reference trip code present drive enabled Pr 15 zero speed 5 over voltage under voltage over current resolver break hardware enable motor over temp power stage over temp external trip aux trip output short circuit PLC check sum PAR check sum software enable 46 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual REFERENCE SELECTION full scale main ref ref 1 ramps values full scale gt max fq ref internal reference b40 13 reserved reference TORQUE CONTROL OPERATING MODE main ref reserved current limit 47 S B C Elettronica S p A Engineering Division HPDxxN
16. C Elettronica S p A Engineering Division HPDxxN High Power Manual of X2 and channel 2 to terminal 7 of X2 The V div scale and the timebase are not mentioned as they may vary considerably CALCULATING Pr16 The value of Pr16 should be calculated before enabling the drive Pr16 defines system gain To convert Pr16 into degrees for rated torque use the formula T Pr33 28 where ac 15 the stiffness Pr16 angle Obviously before the formula can be used Pr33 must be set to motor rated current To evaluate ac correctly we shall consider that if the driven machine transmission is rigid not flexible and there is no transmission backlash the optimal stiffness angle could be around 4 degrees If the transmission is not sufficiently rigid it may be necessary to reduce gain If motor torque has been selected to achieve steep acceleration ramps while dynamic torque changes in normal operation are minimal stiffness angles of 20 30 or 40 degrees are acceptable without negatively affecting performance If you encounter difficulty in choosing the most appropriate stiffness angle start from 10 degrees which is the default value when using a motor with the same rated current as the drive Now enter the calculated value for Pr16 and start the motor with a square wave reference signal pay attention when setting the reference amplitude and frequency to avoid problems in the case of limited stroke axes On the oscilloscope note that the respons
17. Division HPDxxN High Power User s Manual In certain cases a more precise axis zero reference is required this is achieved using in addition to the proximity sensor on the machine also the motor position transducer In this setup the proximity sensor signal is correlated with the first zero on the motor position transducer The following example provides this functionality using operating mode 9 trapezoidal profile After setting default values set up operating mode 9 Pr31 9 b99 11 1 b40 2 0 b40 12 1 and any other settings required and then enter the zero proximity sensor homing speed in Pr5 Terminal 13 on X3 homing pulse command Terminal 14 on X3 PNP type axis zero proximity sensor Terminal 11 on X2 digital output Switches to 1 when the homing phase is terminated The following bits are utilised b91 8 b91 9 b91 11 The program is as follows LD 90 2 If homing command is given runs at speed set in Pr5 40 2 ANDN 91 9 and not yet executed disables RST 40 2 operating mode the motor 90 3 91 0 91 9 LD 90 3 we SET ANDN 91 0 when proximity sensor insi SET 91 9 operates alignment is enabled SET 40 2 on the resolver zero position 91 9 41 2 91 8 79 28 64 LD 91 9 n AND 41 2 proximity Sensor trip ANDN 91 8 followed by trapezoidal profile SUB 79 28 64 t align with resolver zero SET 708 positon SET 91 8 91 8 70 8 91 0 91 0 ser LD 91 8 INN SET ANDN 70 8 if alignment with resolver zero aid diia m AN
18. a FIN instruction is included from address 6h forward or anyway after any other instruction it will be ignored NOP The instructions must be one after the other starting from address Oh without any free bytes There is just one program and it terminates with the END instruction Serial line application examples For a better understanding of how to implement the serial line communication protocol we have provided a few examples for each type of message The values are entered simply by way of example Case 1 reading a 1 byte parameter Assume you want to read the value of parameter Pr 31 operating mode and that the value of this parameter is 9 assume the drive serial address is 0 The message to transmit is 7E 80 01 54 D5 The drive answers with the message 7E 20 01 54 09 7E 00 76 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Case 2 reading a 2 byte parameter Assume you wish to read the reference speed Pr 7 and that the relative value is 2000 assume also that the drive serial address is 1 The message to transmit is 7E 81 02 42 C5 The drive answers with 7E 21 02 42 D0 07 3C Case 3 writing a 1 byte parameter Assume you want to select operating mode 1 Pr 31 assume also that the drive serial address is 3 The message to transmit is 7E A3 01 54 01 F9 The drive answers with 7E 23 Case 4 wri
19. changes the value Xx If you wish to acquire the required position by moving the carriage press F1 the display will show the message manual dimension xx F1 selects the xx dimension to be programmed while 66 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual and are used to move the carriage The key provides the motor start stop in the positive direction while provides the start stop in a negative direction the translation speed in this case must be set in parameter Pr4 Once the required position has been reached press C to confirm the dimension Press F2 to set automatic mode To store the parameters you have programmed press S After having set the default values set the following parameters on the HPD N drive Pr4 10 manual translation speed Pr5 5 homing speed Pr31 9 b99 11 1 b40 2 1 b40 12 1 Pr81 80 dimension 1 Pr83 82 dimension 2 Pr85 84 dimension 3 Pr87 86 dimension 4 Pr89 88 dimension 5 terminal 12 on X3 pulse command execute positioning terminal 13 on X3 pulse command execute homing terminal 14 on X3 PNP zero axis proximity sensor terminal 15 on X3 select position terminal 16 on X3 select position terminal 17 on X3 select position terminal 11 on X2 output high during homing terminal 12 on X2 output high during positioning terminal 13 on X2 output high during manual translation The following auxiliary bits are u
20. ex IEC 801 3 level 3 Electromagnetic field immunity IEC1000 4 4 ex IEC 801 4 level 4 Fast transient burst conducted immunity Compatibility EN50081 2 Basic radio interference specifications EN55011 group 1 class Measurement limits for radio interference 1 8 Safety Safety standard EN60065 Low voltage Directive 73 23 CEE amended by 93 68 CEE Applied standard EN60204 1 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 INSTALLATION e The HPD N drive must be installed in a vertical position power terminal block X4 at the top Leave at least 190 mm clearance above and below the drive 2 1 Safety instructions Make sure the drive is correctly sized for the motor you intend to connect Compare rated voltage and current e Wire up electrical panel drive motor in accordance with the instructions in this section of the manual taking into consideration EMC requirements and established safety legislation e The User is responsible for installing fuses on the drive A C power supply Power conductors and control circuits must be kept apart at least 20 cm and when they must cross intersections must be at a right angle Motor lines and mains power lines must never be parallel e All power conductors must be sufficiently sized refer to table in heading 2 7 in all cases compliance with IEC227 2 must be guaranteed e Conductors connected to the system by means of the terminal strip mus
21. filtered digital input at 60 msec 727592 LD ADD ANDN ADD 99 0 RES RST 727592 ADD LDN 99 0 AND ADD RST RES 90 10 LD O n LD SET AND SET 90 11 LDN RST AND RES 90 1 90 10 72 75 92 99 0 90 1 90 10 72 75 92 99 0 90 1 90 10 90 1 99 0 90 11 90 1 99 0 90 11 if digital input 1 is low load 60 msec on counter if digital input 1 is high for 60 msec b99 0 will be set to 1 and b90 11 1 if digital input 1 is high load 60 msec on counter if digital input 1 is low for 60 msec b99 0 1 and b90 11 0 b90 11 is the status of filtered digital input 1 Example 5 correlation between parameter values 99 13 00 80 72 LD SUB LD OUT LD OUT LDN OUT LDN ANDN OUT LDN OUT LD OR OUT 57 99 13 0 80 72 99 3 81 0 99 2 81 1 99 3 81 2 99 2 99 3 81 3 99 2 81 4 99 3 99 2 81 5 calculate difference between PrO and Pr80 to set b99 2 and b99 3 if PrO Pr80 then b81 0 1 if PrO Pr80 then 681 1 1 if PrO lt gt Pr80 then b81 2 1 if PrO gt Pr80 then b81 3 1 if PrO gt Pr80 then b81 4 1 if PrO lt Pr80 then b81 5 1 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 6 filter 600 msec for reading the value of a parameter 99 13 35 60 60 um LD 99 13 Add Pr35 and Pr60 ADD 35 60 60 99 0 60 76 81 LD 99 0 if timer 1 expired calculate filtered Pr35 DIV 60 76 81 setting result in Pr81 SUB 60 60 60 zero set Pr60
22. rpm takes Pr52 thousandths of a second this function is useful during catch on fly cycles Pr53 Reference division factor Default 1 range 32000 32000 This parameter together with Pr51 makes it possible to set the required ratio for the input reference frequency Pr54 Reserved Pr55 Required speed Unit rpm Read only parameter Shows the input reference frequency converted into rpm Pr56 Servo error window Unit steps default 100 If the absolute value of the position error exceeds the value set in Pr56 b70 5 is set to 1 If utilised b70 5 must be reset by the user e g by the PLC program following servo errors Pr57 Position controller proportional gain Default 100 range 0 32000 58 Slip speed Pr59 Reserved Pr60 61 Position controller reference Unit steps Pr62 63 Motor position Unit steps 4096 steps per revolution Pr64 65 Reserved Pr66 67 Reserved Pr68 69 Reserved b70 2 Digital locking engaged During locking with ramp Pr52 other than zero this bit indicates the termination of the transitional phase b70 3 Enable position Default 0 During unlocking b70 3 1 enable position with Pr61 60 b70 5 Servo error b70 5 is set to 1 if the absolute value of the position error exceeds the value set in If utilised b70 5 must be reset by the user e g by the PLC program following servo errors b70 6 Feed forward Default 1 If set to 1 feed forward is enabled on the position controller b70 8 Axis lock release
23. the HPD N pico PLC The suggested solutions offer the possibility of reducing the components required to build the machine or part of the machine while in many cases also cutting the overall cost of the application Note that the pico PLC scanning time is 6 144 msec and the maximum number of instructions is 64 moreover the PLC is designed principally to manage the drive s digital inputs and outputs In addition to a concise description of the application the examples show the settings required for HPD parameters and the pico PLC program The program is shown in ladder diagrams and instruction listings Example 1 two inputs for on off functions 90 1 90 2 912 LD 90 1 digital input 1 sets bit b91 2 to on OR 912 digital input 2 sets bit b91 2 to off 912 ANDN 90 2 OUT 91 2 Example 2 changing a parameter value with the up down keys 90 1 99 0 05 73 05 LD 09 1 digital input 1 in high status increases AND 99 0 parameter Pr5 by one unit every 614 ADD 05 73 05 msec ADD 92 76 92 902 digital input 2 in high status decreases AND 99 0 parameter Pr5 by one unit every 614 ADD 05 71 05 msec ADD 92 76 92 Example 3 command on positive front of a digital input 901 90 10 708 LD 90 1 digital input 1 sets bit b70 8 just once ANDN 90 10 when the signal changes from low to SET 70 8 high 90 1 90 10 LD 90 1 OUT 90 10 56 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 4
24. to calculate the presence of an amount of spurious energy that depends on the size of the system drives motor lines motor Spurious energy generates EM radiation that can interfere with the operation of nearby systems Existing standards do not set down limits for this type of radiation Preventive measures Basic methods for preventing interference are decoupling of drive from its surroundings high quality and properly sized conductors to neutralise voltages earthing and adequate shielding Shields filters and drives must have a large contact area to achieve the maximum possible decoupling and hence optimal noise suppression Attention must be paid however to the entire installation as this is one of the most important precautions in assuring efficient noise suppression High frequency interference takes the form of radiation especially from the motor lines This effect can be reduced with the use of shielding Another essential counter measure for noise suppression is the use of filters The use of filters is aimed at reducing conducted interference on wiring and the return of conducted interference to source drive through routes offering the lowest impedance This method provides effective protection for other systems connected to the same electrical line also protecting the drive from interference originating from other systems When installing filters consider the mains input and motor feeding output the motor feeding output can b
25. used to limit motor torque Software enable Default 1 If set to zero the drive cannot be started Low voltage operation enable Default 0 If at 1 the inrush current circuit will be connected each time the drive is disabled thus permitting rapid increases in power supply voltage When the drive is started the inrush current circuit will be connected before the effective start up of the power stage This procedure causes a drive start up delay of 120mS Analogue output selector Default 0 If set to 0 the analogue output will carry a signal proportional to motor torque If set to 1 it carries a value proportional to Pr38 Digital analogue reference selector Default 0 If set to 0 the analogue input is selected as the main reference If set to 1 the reference will be digital and by means of 40 13 it can be set for internal or external If set for an external input using b42 5 this can be set for quadrature or frequency direction Internal or frequency reference selector Default 0 If b40 12 1 b40 13 can be set to 0 to select internal reference or to 1 to select the frequency input encoder in which in turn can be configured as frequency direction or quadrature signal using b42 5 Serial communication enable Default 0 Set this parameter to 1 to enable serial comms Reserved Must remain on zero Overspeed When the absolute motor speed value exceeds the value set in Pr13 b41 0 is on 1 otherwise it is on 0 30 S B C Elettronica S p
26. 1 the encoder signal is counted on all A and B signal switching fronts The motor position counter increases by 4096 steps each revolution The ratio between 41 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual master and slave can be entered using parameters Pr51 and Pr53 You can also select the ramp to utilise during catch or release cycles Pr52 add slip speed Pr58 and limit speed demands of the proportional part of the loop Pr50 Further information available master and slave locked and servo error Using Pr52 the main ramps and the internal PLC makes it possible to program various different catch and release modes with or without phase recuperation Refer to Frequency input connection chapter for connection diagrams PARAMETERS FOR OPERATING MODE 10 Pr50 Maximum speed Unit rpm default 200 range 0 9000 This parameter makes it possible to limit maximum speed of the motor it can be used to limit speed during a catch on fly cycle or during sudden speed changes see Pr58 Pr51 Reference multiplication factor Default 1 range 32000 32000 This parameter together with Pr53 makes it possible to set the required ratio for the input reference frequency Pr52 Acceleration deceleration ramp Unit s krpm default 500 0 30000 resolution 1 thousandth of a second The acceleration deceleration demanded of the motor can be restricted so that a speed decrease or increase of 1000
27. 13 0 b99 14 Save pico PLC instructions Saves the pico PLC program If an error occurs while saving retry is shown on display in this case transmit the command again b99 15 Save parameters Stores all parameters This command is not possible in the presence of a checksum error in this case set default parameters reset the alarm and then save the new parameterisation settings If an error occurs while saving retry is shown on display in this case transmit the command again 3 5 Calibrating speed loop IMPORTANT CONCEPTS SPEED LOOP the main task of any drive is to control motor speed so that it follows as faithfully as possible the required speed which is generally referred to as the REFERENCE High fidelity reproduction of the reference implies that motor speed is identical to reference speed in static conditions and also that it follows speed requirements closely also in the case of sudden changes in the speed reference dynamic conditions To perform this task the drive must be informed of various characteristics of the motor and the mechanical system to which the motor is coupled this type of information is set in the CALIBRATION PARAMETERS ERROR the error refers to the difference between reference speed and motor speed 32 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual The error value is utilised by the speed control loop to calculate using calibration parameters how
28. 4 b70 15 Reset incremental position Resets Pr64 65 This command is useful when the incremental value is programmed on the frequency input Forward Reverse When the start profile command is transmitted b70 8 if b70 4 0 the motor will execute Pr64 65 steps in the positive speed direction If b70 4 1 it will execute the same number of steps in the negative speed direction Servo error b70 5 is set to 1 if the absolute value of the position error is greater than the value set in Pr56 If utilised b70 5 must be reset by the user e g using the PLC program following servo errors Feed forward enable Default 0 If set to 1 feed forward is enabled on the position controller Profile in execution B70 7 1 indicates that the drive is executing a positioning profile Start profile To start positioning Enable frequency input Default 0 If set to 1 Pr64 65 can be set on the frequency input Reset type 1 Resets motor and reference position This command is only accepted when no profile is in execution Reset type 2 Command to set motor and reference position to equal the absolute position of the shaft Accepted only when no profile is in execution Reset type 3 Command to set the reference equal to the motor position Accepted only when no profile is in execution Reserved Reserved 3 6 5 Digital locking Operating mode 10 is a tracking function referred to a frequency input signal connector X6 set as an encoder signal with b42 5
29. 50 and the result is added to Pr64 65 The frequency input direction signal must be forced to a fixed level logical 0 Refer to the chapter Frequency input connection for the connection diagrams Pr51 Acceleration Unit s krpm range 0 002 30 000 resolution 0 001 default 0 002 S Acceleration ramp for positioning profile 40 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual Pr52 Pr53 Pr54 Pr55 Pr56 Pr57 Pr58 Pr59 Rpm at speed Unit rpm default 1000 Steady state speed used during generation of the positioning profile Reserved Reserved Reserved Servo error window Unit steps default 100 If the position error as an absolute value exceeds the value set in Pr56 b70 5 is set to 1 If b70 5 is utilised it must be reset by the user following servo errors This can be achieved for example by the PLC program Position controller proportional gain Default 100 range 0 32000 Reserved Reserved Pr60 61 Position controller reference Unit steps Pr62 63 Motor position Unit steps 4096 steps per revolution Pr64 65 Incremental position Unit steps On receipt of the profile request b70 8 the motor will execute Pr64 65 steps in the direction set in b70 4 Pr66 67 Reserved Cannot be used during profile generation Pr68 69 Reserved Cannot be used during profile generation b70 2 b70 4 b70 5 b70 6 b70 7 b70 8 b70 9 b70 10 b70 11 b70 12 b70 1
30. 6 144mS If used FIN instructions must be the first PLC instructions The first FIN instruction copies digital input 1 into bit y of parameter Pb40 second operand 0 or Pb70 second operand 1 The second FIN instruction copies digital input 2 into bit y of parameter Pb40 second operand 0 or Pb70 second operand 1 The third FIN instruction 54 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual copies digital input 3 into bit y of parameter Pb40 second operand 0 or Pb70 second operand 1 If the second operand is added to value 2 before the input is copied it will be inverted If a FIN instruction is included at any other position in the program it will have no effect FIN instructions can be enabled disabled for each FIN Ist FIN enabled if b94 5 0 2nd FIN enabled if b94 6 0 3rd FIN enabled if b94 7 0 A FIN instruction in the PLC program after the first three instructions or after any other type of instruction will always be ignored There are two timers Pr92 and Pr93 at the disposal of the user To use the first timer simply load the time in terms of number of samplings 6 144 mS in parameter Pr92 for example Pr92 100 is equivalent to 614 milliseconds Pr92 automatically decreases through time bit b99 0 remains on zero until the timer interval has elapsed when Pr92 0 then b99 0 1 The same functionality applies to the second timer regarding parameter Pr93 and bit b99 1 Ensure that Pr92 Pr93 b99
31. 70 8 41 2 91 12 31 0 31 31 31 72 82 51 72 84 53 72 72 58 72 72 70 70 6 72 75 31 91 1 return start management with trapezoidal profile if homing exec ref pr6 locking start request locking cycle output on no ramp pr52 0 homing request stand by for proximity reset dimensions homing exec flag if OPM 10 if homing is done and locked forces double word release dimension reached set release ramp and release axis if speed is zero disable OPM reset all b70 trapezoidal profile ramp trapezoidal profile speed copy position in incremental dimension and reverse for return set OPM 9 preset start profile at next scan if no profile in exec Motor stopped no profile preset and OPM is 9 disable OPM reset ratio reset ratio Zero set slip Zero set all bits enable feed forward set OPM 10 Zero set current cycle program end S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 10 Inter Drive Communication IDC Inter Drive Communication refers to a specific configuration of the serial port of the HPD N drive that makes it possible to interchange parameters between two or more units With IDC enabled Pr26 10 if bit b99 5 is set to 1 the HPD N activates a broadcast command by sending the value of Pr81 to the address of Pr80 HPD Ns that receive broadcast commands with Pr26 10 automatically set b99 5 to 1 causing automatic transmission of Pr81 t
32. 88 Free parameter Parameter with save facility at user s disposal word Pr89 parameter Parameter with save facility at user s disposal word b90 X Digital input X status If X is greater than 7 parameter with save facility at user s disposal b90 0 drive enable 51 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual b91 Y Pr92 Pr93 b94 0 b94 5 b94 6 b94 7 b99 0 b99 1 b99 2 b99 3 b99 13 Digital input Y status If Y is greater than 7 parameter with save facility at user s disposal Parameter Pb91 is not saved at power up and is definitely at zero First PLC timer Every 6 144 mS if Pr92 is not at O the timer is decreased if set to zero b99 0 is set at 1 Second PLC timer Every 6 144 mS if Pr93 is not at the timer is decreased if set to zero b99 1 is set to 1 Forces a double word formatted operation When the drive is powered up this parameter is on zero If it is on one the first mathematical operation of the pico PLC is executed setting the three operands as double word type after the operation is executed b94 0 is automatically set to zero If Pr60 Pr68 are utilised double word formatting is automatic see text Disables the first fast input b94 5 0 Set to zero at power up Disables the second fast input b94 6 0 Set to zero at power up Disables the third fast input b94 7 0 Set to zero at power up First timer status At 1 if Pr92 0 Seco
33. 9 0 Pr30 must be zero enable the drive via hardware and set b70 3 1 The drive will now execute the test routine When terminated b70 3 0 the error code in Pr56 can be displayed after setting Pr57 0 Error codes 0 no error 1 test not executed 2 motor phase sequence and resolver direction incompatible 3 number of motor poles and Pr29 incompatible 4 resolver phase error 5 Pr30 value not zero 99 procedure aborted By setting the various values in Pr57 you can get other useful information for installation and maintenance see table in block diagrams PARAMETERS FOR OPERATING MODE 8 Pr50 Manual speed Unit rpm default 100 This speed value is used for manual movements executed using b70 1 b70 2 with b70 0 0 and b40 2 1 Pr51 Profile execution speed Unit rpm default 1000 This is the speed at which the trapezoidal profile is executed Pr52 Distance Unit revolutions default 30 This is the number of revolutions of the motor shaft that must be performed during generation of the profile Pr53 Starting point Default 1 If set to 1 at start profile b70 0 the motor will start rotating and execute Pr52 revolutions with positive speed If set to 2 the motor will start rotating and execute Pr52 2 revolutions with positive speed If you set 3 the motor will start and execute Pr52 revolutions at negative speed Pr54 Pause Unit tenths of a second default 1 During execution of the profile the drive stops between positive speed movemen
34. 92 76 92 ADD 92 76 92 reset time m 1 to 600 milliseconds 81 15 817181 MUL LD 81 15 if Pr81 is negative its sign changes MUL 81 71 81 Example 7 homing If you are using an operating mode with spatial control 9 10 or 11 and you need to align the motor with a zero position defined by a proximity sensor when the system is powered up You can use two digital inputs one for the homing command and one to acquire the proximity sensor signal The commands are pulse type and the homing command is executed once only After setting the default values set up the required operating mode 31 b99 11 1 b40 2 1 and any other settings required and then set the homing speed for the zero proximity sensor in Pr5 and set b40 12 1 to enable Pr5 when b40 2 reaches zero Terminal 13 on X3 pulse command execute homing Terminal 14 on X3 PNP axis zero proximity sensor Bit b91 10 is utilised to signal that the operation is terminated Note that bits from b91 8 to b91 15 are at the disposal of the PLC and cannot be stored in the memory The program is as follows 90 2 91 10 40 2 LD 90 2 If homing command not ANDN 91 10 executed disables operating RST 402 mode 91 10 40 2 SET LD 91 10 If homing command executed So 5149 Saas SET 40 2 re enables operating mode SET LD 90 3 if proximity switch operated 91 10 ANDN 91 10 resets operating mode counters SET 70 10 sets homing executed flag SET 91 10 58 S B C Elettronica S p A Engineering
35. A Engineering Division HPDxxN High Power Manual b41 1 b41 2 b41 3 b41 4 b41 5 b41 6 b41 7 b41 8 b41 9 b41 10 b41 11 b41 12 b41 13 b41 14 b41 15 b42 0 b42 1 b42 2 At speed With b40 7 0 if the speed difference between motor and reference is lower than Pr14 and higher than Pr15 b41 1 will be 1 otherwise it will be 0 With b40 7 1 if motor speed is lower than Pr14 and higher than Pr15 b41 1 will be 1 otherwise it will be 0 Zero speed If motor speed Pr0 is zero rpm b41 2 1 otherwise b41 2 0 Forward If motor speed Pr0 is positive b41 3 1 otherwise b41 3 0 Drive Healthy If 1 no alarms are present otherwise 0 Hardware enable status 1 when hardware enable is set Temperature pre alarm 10 degrees before reaching the maximum temperature of the power stage b41 6 is set to 1 External alarm Alarm for user s equipment Auxiliary alarm Second alarm for user s equipment Calibration failed b41 9 1 indicates that initial calibration of current offsets has terminated incorrectly Speed control saturation b41 10 1 when the speed control loop is delivering maximum current active Indicates that Pr36 has reached 100 0 and therefore the drive is restricting current to the rated value Drive enabled Keypad fault b41 12 1 if communication between keypad and drive has failed External operating mode If set to 1 an external operating mode is installed External operating mode
36. CE LIMIT SWITCH SPEED NY amp internal MANAGER REGULATOR STOP TORQUE LIMIT MANAGER OPERATING MODE MISCELLANEOUS SPEED TRIPS WINDOWS MANAGER DIGITAL STEPPER SPINDEE EXTERN POSITIO MODE LOCK MODE ORIENT MODE MODE MODE TORQUE MODE See chapter Block diagrams for a better description of how to use the drive especially for operating modes See chapter Pico PLC to understand how to connect peripheral systems inputs outputs to the parametric system of the HPD N drive Parameters are divided as follows The principal parameter units and resolutions are speed revolutions per minute seconds 1000 rpm 0 001 4096 steps revolution 1 4096 revolution 1 of the drive peak current 22 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 1 Using the keypad The keypad display module is designed to provide an intuitive operator interface It can be used to program operating data monitor system status and enter commands The module has only three keys located at the top of the front panel just below the display The keys are marked M and M is used to change the display mode and consequently also the function of and There are two display modes parameter mode and parameter value mode When the unit is powered up provided there are no active alarms the message IdLE drive disabled or drive enable
37. DN 91 0 is terminated sets axis zero SET 910 terminated output SET 91 11 LD 41 4 HOA ANDN 91 11 if drive is OK operating mode SET SET 40 2 is enabled SET 91 11 59 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 8 execution of modulus in digital locking FILE E001 HPD To obtain the following functionality with reference to the figure assume you have a conveyor transporting product and a blade roller driven by the HPD N drive At start up on an external command the blade roller is aligned with a zero reference proximity sensor On receipt of the next pulse command which is generated by a product detection sensor the blade roller drive locks onto the conveyor master so that the product is always cut at precisely the same length when the cut is terminated the blade roller reassumes the starting position awaiting the next cutting command In this case the program permits the homing procedure see chapter 1 and then on receipt of the command from the product sensor it assumes digital locked mode and covers a space equal to the value of Pr87 86 when it reaches this distance the drive unlocks and ramps down to the standby position defined by parameter Pr89 88 modulus Note that one motor shaft revolution corresponds to 4096 steps so the modulus value to set is equal to the number of steps required by the motor shaft to execute a full revolution of the blade roller The value of Pr87 86 mu
38. Engineering Division HPDxxN High Power User s Manual Appendix 1 remote communications interface If the application calls for a simple operator interface use console 048 049 064 The console is connected to the drive by means of the serial line it does not provide I O capabilities and it does not have buffered memory The connection cable is not part of the standard supply and the software must be generated by S B C to client specifications 90 Power supply type 064 128 5 Rear panel view H P D connector P2 pins 4 ho 4 11 11 3 11 11 5 X5 IMP i i 2 Hu 3 x x N se for burden resistors refer to Serial line connection 87 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Appendix L application description form In order to develop our products in co ordination with user s needs we are most interested to learn about your HPD N application Please fill in this form and return it to us This will also enable us to tailor our technical support to your individual requirements Fill in these forms in full and keep them with the machine technical documentation to facilitate maintenance to S B C Elettronica S p A ITALY R amp D department fax 39 02 66012808 CUSTOMER 3 Contact name 11111113 3 3 dei tesbeteitasumitiudttuton _ B c
39. Pr50 Pr51 Pr52 Pr53 Pr54 Pr55 Pr56 Pr57 Pr58 Pr59 Pr60 Pr61 Pr62 Pr63 Pr64 Pr65 Pr66 Pr67 Pr68 Pr69 Pb70 80 Pr81 Pr82 Pr83 Pr84 Pr85 Pr86 Pr87 Pr88 Pr89 Pb90 Pb91 Pr92 Pr93 Pb94 Pb99 05Ch 056h 060h 064h 066h 068h 06Ah 06Ch O6Eh 070h 072h 074h 076h 078 07Ah 07Ch 07 080h 082h 084h 086h 088h 08Ah 062h OCEh ODOh 0D2h O0D4h OD6h OD8h ODAh ODCh ODEh OEOh OE2h 08Ch O8Eh 090h 032h 092h R2 NY WY HPDxxN High Power Manual flags used by main block flags used by main block flags used by main block flags used by operating mode inputs outputs timer 1 timer 2 flags used by PLC flags used for PLC and commands PLC area length 128 bytes addresses 00h to 7Fh 79 HPDxxN High Power User s Manual S B C Elettronica S p A Engineering Division Appendix A Mechanical Dimensions EDO D Dimensions can be changed of discrection of the manufacturer 26 5 80 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual Appendix B MB series motor connectors CONNECTIONS FOR MBmax BRUSHLESS MOTORS resolver A white red Bz white yellow EXCT FAN MOTOR CONNECTOR FOR MBmax 105 C blue D ye
40. RN operations follow the same logic except they use the inverted value of the specified bit There are 8 bits with save facility from b90 8 to b90 15 reserved for the PLC a further 8 bits from b91 8 to b91 15 are available for the PLC these are not stored and are always at zero at drive power up Also 10 word parameters are reserved specifically from Pr80 to Pr89 with save facility and option for use as 5 double word parameters For mathematical operations the pico PLC has 9 constants available from Pr71 to Pr79 selected from those that are most frequently utilised in standard applications When using mathematical instructions ADD SUB MUL DIV note that operators are assumed as words with their relative signs If a double word operation is necessary parameter b94 0 must be set to 1 before the operation after the operation the PLC will automatically set the bit to zero Parameters Pr60 Pr69 are considered as double words so an operation like ADD 71 72 64 will write the result 1 in the double word Pr64 65 without having to set b94 0 1 before the operation If 80 1 and Pr81 0 the operation ADD 80 72 64 will have the result Pr64 65 1 while the same operation performed with b94 0 1 will assume Pr81 as the high part of the double word Pr80 81 so the result will be Pr64 65 65535 In the first case therefore operands other than Pr60 Pr69 will be treated as words while in the second case they will be treated as double words Note
41. VOLTAGE 40 in rush control included Appendix E Standard settings Reference Shaft moving motor shaft view clockwise Torque monitor Positive R D Counter UP Encoder out A ee G B tacho signal torque esin torque e sin IN AUX positive P122 positive Pr38 positive OUT AUX Positive um B 83 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Appendix F Software timers 2 048 mS Slow operating mode Speed reference manager Digtaliput PLCimsmeonscan po Digital output O 84 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Appendix G pico PLC default program 90 1 90 10 90 2 90 10 90 10 40 4 UD 40 5 UD 40 6 6 400 oO 90 11 85 057105 050505 40 12 LD ORN OUTN LD ORN OUTN LD ORN OUTN LD OUT LD SUB LD OUT OUT LD OUT LD OUT LD OUT LD OUT LD AND ADD MUL LD OR OUT END 90 1 90 10 40 4 90 2 90 10 40 5 90 3 90 10 40 6 90 4 40 0 90 5 05 05 05 41 0 91 0 41 1 91 1 41 2 91 2 41 3 91 3 41 4 91 6 41 11 91 4 90 11 99 0 92 78 92 05 71 05 90 5 90 11 40 12 digital input 1 for left hand limit switch enabled only if b90 10 1 digital input 2 for right hand limit switch enabled only if b90 10 1 digital input 3 for emergency stop en
42. a thermal magnetic circuit breaker must be installed between resistor and drive The minimum wire size for the connection is 4 mm the connection cables should be as short as possible and in any event no longer than 3 metres 20 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 14 Backup When you need to keep the drive electronics powered up during mains losses for example to maintain the simulated encoder function certain precautions are necessary A Use an external 24Vdc 2 A regulated power supply with protected output Connect the positive pole to 8 X3 Vbackup and negative pole to 9 X3 Vbackup B Set b99 8 to programme the automatic undervoltage alarm reset when the mains voltage is restored Furthermore is not required to write in the pico PLC the programme described in the example 11 Examples and applications chapter 21 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 PARAMETERS AND PROGRAMMING The features torque speed acceleration and position control are the task of a dedicated electronic circuits In this chapter you can see how to set up and the meaning of any parameter functional block diagrams and advanced functions description too In the figure below it is described the general block diagram of the drive s functions that you can configure by parameters analogue TORQUE DEMAND digital REFEREN
43. abled only if b90 10 1 digital input 4 for clockwise or counter clockwise rotation digital input 5 for start stop reset parameter Pr5 digital output 0 indicates speed greater than Pr13 digital output 1 indicates motor speed reference digital output 2 indicates motor speed 0 digital output 3 indicates clockwise or counter clockwise motor shaft rotation digital output 6 indicates drive healthy digital output 4 indicates active motor thermal image if b90 11 1 the drive performs a direction inversion at 6 second intervals at the speed in Pr5 digital input 5 for start stop disabled if b90 11 1 program end S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Appendix H flash information e USE b99 15 TO SAVE PARAMETERS e USE b99 14 TO SAVE PLC PROGRAM TO CHANGE PLC INSTRUCTIONS b99 13 MUST e WHEN CHANGING OPERATING MODE USE 5699 11 TO LOAD DEFAULT PARAMETERS b40 2 0 WARNING BEFORE CHANGING Pr31 MAKE SURE b40 2 0 e SPEED REFERENCE IS LIMITED TO THE VALUE IN Pr32 IN TORQUE CONTROL Pr2 AND Pr3 MUST BE SET TO 1000 TO USE THE ACTIVE OPERATING MODE b40 2 MUST BE SET TO 1 e TO USE Pr32 TO CHANGE FEEDBACK RESOLUTION ON THE FLY DISABLE TORQUE COMPENSATION b42 6 0 e IF YOU CANNOT UPDATE READ WRITE PARAMETERS FROM THE KEYPAD MAKE SURE b99 7 0 IF b99 7 0 THE PARAMETERS ARE PROBABLY MANAGED BY THE PLC PROGRAM 86 S B C Elettronica S p A
44. ameter indicates the percentage of torque or current that the motor is delivering Thermal image of motor winding Unit of reference temperature This read only parameter indicates an estimation of the heat on the innermost windings of the motor If the value reaches 100 0 which is equal to the nominal value b41 11 switches to 1 so that current can be limited to the rated value Thermal image of braking resistor Unit of nominal temperature This read only parameter indicates an estimation of the heat on the braking resistor If the value reaches 100 0 96 or more consider using an external braking resistor Auxiliary analogue output Unit of 9 76V default 0 range 100 0 resolution 8 bit If b40 11 is equal to 1 the auxiliary analogue output will be equal to 976 Pr38 100 volts Phase correction This parameter may be used in certain applications with special motors that are to run also at constant power Range 32000 default 0 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual BINARY PARAMETERS Binary parameter Pb40 can be read written and saved Binary parameter Pb41 provides information regarding system status Parameters Pb42 and Pb99 are read write parameters with save facility b40 0 b40 1 b40 2 b40 3 b40 4 b40 5 b40 6 b40 7 b40 8 b40 9 b40 10 b40 11 b40 12 b40 13 b40 14 b40 15 b41 0 Selecting the first or second speed reference full scale va
45. ation control the first requirement is a stable speed loop When this is present set Pr2 ACC 3 2 where ACC is acceleration in rad s2 required with a 10V reference signal b40 0 0 b40 12 0 b40 2 1 and Pr31 2 Maximum speed must be programmed in Pr50 PARAMETERS FOR OPERATING MODE 2 Pr50 Maximum speed Unit rpm default 3000 range 0 9000 This parameter makes it possible to limit maximum absolute motor speed during operation with acceleration reference Pr55 Acceleration deceleration ramp read only parameter Unit s krpm range 2 30000 resolution 1 thousandth of a second Pr60 61 Reserved Pr62 63 Reserved Pr66 67 Reserved 38 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual 3 6 3 Maintenance and commissioning This operating mode is designed to assist technical personnel during commissioning Mode 8 provides various tests to check drive wiring It s also possible to move the move the shaft manually by means of Pr50 b70 1 and b70 2 or using the internal profile generator which simplifies speed control loop set up and ensures that there is no overrun on the programmed movement Programming parameters for generating internal profiles are speed motor revolutions starting position and interval in seconds between forward and reverse movement To perform the wiring test the motor must be disconnected from all loads including inertia loads disable the drive via software b40
46. auxiliary bits are utilised b91 10 b91 11 Program LD 91 10 If homing already ar SET 40 2 executed enable operating mode 22 Pro 202 90 2 If digital input 2 RST ANDN 91 10 execute homing if not 90 3 91 10 70 10 SET 40 2 yet done SET LD 90 3 or ANDN 91 10 If digital input 3 and SET SET 70 10 homing not executed EN SET 91 10 reset counters homing exec flag 70 8 digital output 0 at zero 72 72 64 90 4 If profile terminated 90 5 select dimension 94 0 according to the three 80 72 64 digital inputs 90 6 94 0 88 72 64 70 8 90 5 90 6 94 0 82 72 64 90 4 94 0 84 72 64 70 8 90 4 90 5 90 6 94 0 86 72 64 If profile terminated 70 8 and input 1 1 execute 91 10 profile resetting 90 1 direction bit and 70 8 calculating distance 70 4 with respect to current 64 60 64 motor position 99 2 if negative sign set 70 4 b70 4 1 70 8 digital output 2 91 1 indicates profile on program end S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 14 reading 4 digit preselector BCD Thumbwheels FILE E005 HPD To change the value of parameter Pr82 by means of a 4 digit preselector This procedure involves the use of four digital outputs and four digital inputs terminal 12 on X2 output for selection of first preselector digit least significant terminal 13 on X2 output for selection of second preselector digit terminal 14 on X2 output for selection of third preselector di
47. d is displayed this is also the position of parameter Pr0 Press or to scroll through the parameters If you want to check a parameter value press M when the value is shown it can be updated using and To return to parameter mode press M again The display can be shown in various forms depending on the parameter in question If you need to increase or decrease a parameter value quickly press M while the up key or down key is pressed HPD keypad 23 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual In addition to the parameter values and the pico PLC instructions the display may show the following messages XX IdLE run Er xx dcbuS Prxx Pb xx bxx yy In xx donE rESet tESt rEtrY At the time of power up this message indicates the software version installed 2 seconds approx At power up and in correspondence with PrO this message shows that no alarms are present and the system is disabled At the time of power up and in correspondence with PrO this message indicates that no alarms are present and the drive is enabled the motor shaft may be spinning In correspondence with PrO this message indicates that the drive has detected an alarm xx indicates the alarm code and has therefore been disabled When an alarm is detected the display automatically switches to parameter PrO and shows the alarm code In correspondence with PrO this me
48. des the drive with the necessary position reference during digital locking SLAVE MOTOR PROX SENSOR CARRIAGE SENSOR lt MASTER ENCODER After having set the default values program the following parameters Pr5 10 homing speed 31 10 b99 11 1 b40 2 1 b40 12 1 Pr80 trapezoidal profile ramp Pr81 trapezoidal profile speed Pr82 copy of P 51 in digital locking Pr83 digital locking release deceleration ramp Pr84 copy of Pr53 in digital locking Pr87 86 release dimension in steps terminal 13 on X3 pulse command for homing execution terminal 14 on X3 axis zero position PNP proximity sensor terminal 12 on X3 digital locking sensor pulse command terminal 12 on X2 output high during cycle execution digital locking commands received during cycle execution will be disregarded The digital locking delay interval can be up to 6 144 msec The following auxiliary bits are utilised b91 10 b91 12 Program see on next page 62 S B C Elettronica S p A Engineering Division 63 91 12 70 8 91 12 94 0 86 60 88 72 83 52 HPDxxN High Power Manual LD SET RST LD SET AND SET SET ADD RST END 91 12 70 8 91 12 91 10 40 2 90 1 70 8 91 1 72 72 52 90 2 91 10 40 2 90 3 91 10 70 10 91 10 31 1 91 10 91 1 94 0 86 60 88 89 15 72 83 52 70 8 41 2 31 31 31 72 72 70 72 80 51 72 81 52 72 60 64 70 4 71 75 31 91 12
49. e a speed window around zero rpm is defined within which speed is set to zero The value of the threshold is set in parameter Pr88 in rpm parameter Pr89 is used as an auxiliary memory area The required pico PLC program is as follows 9913 07 72 89 LD 99 13 Copy analogue reference value in Pr89 ADD ADD 07 72 89 89 15 89 71 89 m LD 89 15 if Pr89 lt 0 invert Pr89 to obtain the MUL 89 71 89 modulus 99 13 89 88 72 SUB LD 99 13 calculate difference between Pr89 and p AND 99 2 OUT 40 6 if negative set drive to stop 71 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 9 Programming with Pcbrush The HPD N serial kit is supplied to enable communication between a PC and the drive The kit includes an RS 422 RS 232 converter relative 230V power supply and serial connection cable The enclosed communication software supplied free of charge designated Pcbrush has the following HW SW requirements 486 microprocessor or higher Windows 3 1 or more recent version mouse and serial port for drive connections The main features of Pcbrush are serial connection of up to 32 drives reading and setting of basic parameters and drive commands reading and setting of commands and parameters of operating modes functional block diagrams pico PLC program displayed as ladder diagrams display of pico PLC program status during operation status file storage of parameterisation includin
50. e changes as 17 is altered Lowering Pr17 will allow you to approach system response as shown in figure 2 Tek Run 500 S s Hi Res be petet R 70 28 Mar 1996 08 42 16 Fig 2 For higher values of Pr17 system response will resemble the situation of figure 3 below 34 S B C Elettronica S p A Engineering Division Tek Run 500 S s Hi Res T HPDxxN High Power User s Manual 5 00 V 0V 28 Mar 1996 08 43 22 M 100ms Fig 3 The optimal value of Pr17 can be considered when system response is as shown in figure 4 Tek Run 500 S s Hi Res T 5 00 V We must therefore obtain approximately followed immediately by undershoot 0V 28 Mar 1996 08 44 37 M 100ms Fig 4 10 overshoot Make sure that the overshoot is not Once you have set the optimal value for Pr17 pay attention to the movement of the motor shaft if it moves smoothly without vibration and noise you can deduce that system calibration procedures are terminated Otherwise repeat all the previous steps using lower values for Pr16 35 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual In certain applications you can reduce system acoustic noise levels by raising parameter Pr18 by a few points Fig 5 shows that the optimal system response is accompanied by a current fluctuation that can generate acoustic noise and mechanical vibration increasing Pr18
51. e expected with most drives adopt one of the following measures additionally a Increase shield size to at least 10 mm b Install a detection system to monitor the shield and automatically disconnect the drive in the presence of faults Install a second conductor in parallel electrically with the shield using separate terminals 12 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual 2 4 Control cubicle layout example All conductors down line of the mains filter mustbe shielded and mounted to a copper bar with large contact area Also the copper bar must present an ample area of contact with the cubicle mounting plate Large surface area partition shield with generous contact area around perimeter Remove paint from contact points in the cubicle keep separate as far as possible mains cable control cable Cubicle interior or mounting plate POWER CONTROL 13 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 5 Terminal assignments LM 4 S B C Elettronica S p A Engineering Division 6 meherSinbw S resolver Costow jug e 5 Terminal board X2 reference high Aux reference high Aux analogue output lt lt N 7 9 24V OUT 200 mA TX oo 6 E CE 15 X6 DB9 female HPDxxN High Power User s Man
52. e protected with output filters that minimise interference levels generally torroidal ferrite core coils bearing several windings of all three motor wires 2 3 Installation instructions to ensure EMC To guarantee electromagnetic compatibility in compliance with the relevant standards the maximum priority must be awarded to EMC requirements when designing the control cubicle To obtain the best results from internal filters follow the instructions in this section carefully because even a complex and expensive filter is ineffective unless it is installed taking EMC aspects into consideration Avoid routing noise emitting cables parallel to clean cables parallel cables especially in the vicinity of the filter ensure physical separation cable loops keep cables as short as possible and close to the common potential 11 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Additional measures With the exception of mains cables to the filter all power and control wiring must be shielded and wherever possible kept segregated minimum distance 20 cm If control and power cables must cross the intersection must be at a right angle Shielded cables must be installed on a copper bar by means of a high conductivity wire clamp The area of contact must be as large as possible and the shield must be unbroken In general the shield should be connected at each extremity In certain circum
53. erence is internally limited so that deceleration of 1000 rpm takes Pr11 seconds S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Pr12 Pr13 14 15 16 17 18 19 20 21 22 23 24 Deceleration ramp for limit switch stop functions Unit s krpm range 0 002 65 535 resolution 0 001 s default 0 002 s Deceleration required of the motor by the limit switch and stop functions is internally limited so deceleration of 1000 rpm takes Pr12 seconds Overspeed threshold Unit rpm range 0 13000 default 3500 If the absolute value for motor speed exceeds the value entered in Pr13 b41 0 must be 1 otherwise it will bez 0 High speed threshold Unit rpm range 13000 default 20 When b40 7 0 if the speed difference between motor and reference is less than Pr14 and greater than Pr15 b41 1 will be 1 otherwise it will be 0 In the case of b40 7 1 if motor speed is less than Pr14 and higher than Pr15 b41 1 will be 1 otherwise it will be 0 Low speed threshold Unit rpm range 13000 default 20 When b40 7 0 if the speed difference between motor and reference is less than Pr14 and greater than Pr15 b41 1 will be 1 otherwise it will be 0 In the case of b40 7 1 if motor speed is less than Pr14 and higher than Pr15 b41 1 will be 1 otherwise it will be 0 Integral gain of speed control loop Range 0 32767 default 120
54. et in Pr54 at this point the position loop is closed PARAMETERS FOR OPERATING MODE 12 Pr50 Pr51 Pr52 Pr53 Pr54 Pr56 Pr57 Pr58 Pr59 b70 5 Maximum speed during spindle orientation Unit rpm default 200 range 0 500 This parameter makes it possible to limit maximum motor speed during spindle orientation Reserved Deceleration ramp Unit s krpm default 500 range 2 30000 resolution 1 thousandth of a second When the spindle orientation command is set b40 2 1 deceleration required of the motor can be limited by this parameter so that a change of 1000 rpm takes Pr52 thousandths of a second Reserved Motor shaft position for spindle orientation Unit steps default 0 range 0 4095 One revolution of the motor shaft corresponds to 4096 steps Servo error window Unit steps default 100 If the absolute position error is greater than the value set in Pr56 b70 5 is set to 1 Position control loop proportional gain Default 100 range 0 32000 Reserved Reserved Servo error b70 5 is set to 1 if the absolute position error is greater than the value in Pr56 otherwise it is set to zero 3 7 Block diagrams The main block diagram provides a graphic description of how to use the drive Each rectangular block represents one or more read write parameters each rhomboid shape represents read only parameters In the diagram there are other functional blocks such as greater than equal to the smallest among lo
55. eter lengths Parameter Address Length Meaning PrO 038h 2 motor speed in rpm 1 034h 2 analogue reference Pr2 03Ah 2 full scale 1 Pr3 03Ch 2 full scale 2 Pr4 036h 2 frequency full scale Pr5 03Eh 2 internal reference Pr6 040h 2 reserved reference Pr7 042h 2 chosen reference 8 OAEh 2 positive acceleration in seconds Pr9 OBOh 2 positive deceleration in seconds Pr10 0B2h 2 negative acceleration in seconds 11 OB4h 2 negative deceleration in seconds Pr12 OB6h 2 limit switch deceleration Pr13 OB8h 2 overspeed threshold 14 044h 2 top speed limit Pr15 046h 2 lower speed limit Pr16 048h 2 integral gain Pr17 OBAh 2 damping factor Pr18 OBCh 2 filter time constant Pr19 OBEh 2 user current limit Pr20 04Ah 2 DC bus voltage Pr21 04Ch 2 reserved torque limit Pr22 04Eh 2 auxiliary reference Pr23 051h 1 current alarm code Pr24 052h 1 previous alarm code Pr25 053h 1 software version code Pr26 05 1 baud rate Pr27 05 1 serial address Pr28 0COh 2 shaft position 0 4095 Pr29 061h 1 motor poles Pr30 OC2h 2 resolver offset Pr31 054h 1 operating mode Pr32 OC4h 2 rated motor speed Pr33 0C6h 2 rated current Pr34 055h 1 scale factor for tacho generator Pr35 OC8h 2 filtered torque request Pr36 058h 2 i t accumulation Pr37 05Ah 2 thermal image for braking Pr38 2 auxiliary analogue output Pr39 0CCh 2 K for phase advance 78 S B C Elettronica S p A Engineering Division Pb40 Pb41 Pb42
56. etween itself and inverted bit y of parameter Pa if stack bit is at 1 parameter sum operation is executed therefore Pc Pa Pb if stack bit is at 1 subtraction operation is executed on parameters therefore Pc Pa Pb if stack bit is at 1 multiplication operation is executed on parameters therefore Pc Pb if stack bit is at 1 division operation is executed on the parameters therefore Pc Pa Pb program end fast scanning input The pico PLC program is scanned every 6 144 msec at each sampling first the inputs are read then the two timers are updated Pr92 Pr93 b99 0 and b99 1 the user program is scanned and finally the outputs are updated Therefore reading of the inputs and output updates can deviate temporally by up to 6 144 mS with respect to the physical event All pico PLC instructions with the exception of mathematical instructions operate on single bits moreover available stack depth is a single bit Instruction LD LDN loads the bit defined as operand into the stack while all other logical instructions operate on the stack Mathematical operations are executed only if the stack bit is at 1 The following logic operations truth tables are provided for the user s convenience 3 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual logical AND operations logical OR operations 0 0 3 0 B 1 1 1 0 0 1 0 1 1 1 1 1 1 1 The relative inverted ANDN and O
57. ference frequency Pr54 Reserved Pr56 window Unit steps default 100 If the absolute position error is greater than the value in Pr56 b70 5 is set to 1 If utilised b70 5 must be reset by the user e g by the PLC program following servo errors Pr57 Position control loop proportional gain Default 100 range 0 32000 Pr60 61 Position control loop reference Unit steps Pr62 63 Motor position Unit steps 4096 steps per revolution Pr64 65 Reserved b70 5 Servo error b70 5 is set to 1 if the absolute position error is greater than the value in Pr56 If utilised b70 5 must be reset by the user e g by the PLC program following ServO errors b70 6 Feed forward enable Default 0 If set to 1 feed forward is enabled on the position controller b70 8 Axis lock release With this bit you can lock 1 or release 70 the axis from the input encoder reference b70 9 Reserved b70 10 Reset type 1 This command resets motor and reference position b70 11 Reset type 2 Sets motor and reference position equal to the absolute shaft position b70 12 Reset type 3 Sets the reference equal to the motor position 43 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 6 7 Spindle orientation When this mode 12 is selected it becomes operational when b40 2 1 The motor reaches the speed in Pr50 on the ramps in Pr52 It now spins at constant speed until it reaches the position s
58. g pico PLC program uploading of parameterisation including pico PLC program from a file that can be selected from among those previously stored speed regulator and position controller simulation PC HPD N connection layout HPD N serial kit CL 422 X5 HPD personal computer DB9 DB25 o 20 i307 5 0 707 refer to text for burden resistors To create line load burden resistances jumper pins 2 and 6 and pins 4 and 7 on connector X5 of the last drive on the serial line If the PC is a battery powered laptop i e not connected to ground use the following connection layout personal computer X5 HPD DB9 DB25 pannes To install Pcbrush open WINDOWS insert the diskette in drive A select the File menu in Program Manager and then Run option Now run Setup exe on by typing the following string on the Command line A setup exe or by selecting the file with the Browse button The following installation procedure automatically creates a new icon for Pcbrush Once the program is installed launch it by double clicking the relative icon or select the icon and then press ENTER Set the following parameters on the drive Pr26 6 Pr27 0 b40 14 1 b42 3 1 Windows and the Windows logo are registered trade marks or trade marks owned by Microsoft Corporation in the United States of America and or other countries 72 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual
59. gical and or we have used standard symbols for all these blocks Binary parameters are shown as switches and the position depicted is the default value 44 S B C Elettronica S p A A B D E F Pr X A B Pr X ES bx y 45 PrX Engineering Division HPDxxN High Power Manual Read write parameter PrX A value of PrX Read write parameter PrX B value according to values of A and PrX Read only parameter PrX is value of A can also be binary Read write bit parameter switch position shows bx y 0 Value of bit parameter bx y sets the switch If A is smaller than B C 1 true otherwise C 0 false The value of G is the lower value among A B C D E and F 1 only when 1 and B 1 otherwise C 0 If Aor Bare 1 1 otherwise C 0 values from hardware values to hardware Value of A is converted to B E g if the triangle symbol contains A D the analogue value of A is converted into the digital value B Maximum value of A is PrX S B C Elettronica S p A Engineering Division offset main ref 40 0 e full scale ref 1 full scale max fq ref reserved reference Q Param DESCRIPTION R W Pr 25 SOFTWARE RELEASE N Pr 26 BAUD RATE Y Pr27 SERIAL LINK ADDRESS Y Pr28 SHAFT POSITION N Pr 29 MOTOR POLES X Pr 30 RES PHASE SHIFT Y Pr 31 OPERATING MODE Y Pr 32 RATED SPEED Y Pr 36 2 ACCUMOLATOR N Pr 37 BRAKE RESISTOR USE N Pr 20 DC
60. git terminal 15 on X2 output for selection of fourth preselector digit terminals 12 15 on inputs for reading digit in BCD terminal 12 is least significant bit connection diagram shown on next page LD 90 1 Copy bit 0 BCD digit 800 OUT 80 0 LD 90 2 copy bit 1 BCD digit e OUT 80 1 am LD 90 3 copy bit 2 BCD digit OUT 80 2 803 LD 90 4 copy bit 3 BCD digit OUT 80 3 80 738 LD 91 1 if first digit MUL MUL 80 73 81 calculate units ZOL LD 91 2 if second digit MUL MUL 80 75 81 calculate first decimal place 80768 LD 91 3 if third digit MUL 80 76 81 calculate second decimal place 80778 LD 91 4 if fourth digit E MUL 80 77 81 calculate third decimal place 99 13 818282 ABD LD 99 13 add calculation result to auxiliary ADD 81 82 82 parameter Pr81 82 72 83 LD 91 4 if last digit most significant ADD 82 72 83 copy final value in Pr83 SUB 82 82 82 zero set parameter Pr82 LD 91 3 refresh outputs to enable reading of OUT 91 4 next digit LD 91 2 OUT 91 3 LD 91 1 OUT 912 LDN 91 2 if last digit already acquired start LDN 91 3 scanning digits starting from units LDN 91 4 OUT 91 1 END program end 70 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual CONNECTION OF 4 DIGIT PRESELECTOR Example 15 programmable zero speed window Assume you want the value of the main analogue reference to remain below a programmable threshold when it is cancelled In practic
61. igh Power Manual 3 3 Basic parameters To access all the following parameters open the extended menu by setting b99 6 to one For this procedure b99 7 must be set to zero DECIMAL PARAMETERS Pri Pr2 Pr3 Pr4 Pr10 Pr11 27 Motor speed this is a read only parameter expressed in rpm the message PrO never appears on the display In its place a message corresponding to drive status is shown Analogue reference offset This is expressed in input A D converter counts Programming limits are 10000 and 10000 while the range of the A D converter is from 16384 16383 over 10 V First full scale of analogue reference Unit rpm range 10000 default 3000 If b40 0 0 and b40 12 0 Pr7 will be equal to Pr2 9 76 where Vin is the voltage on the analogue input Second full scale of analogue reference Unit rpm range 10000 default 3000 If b40 0 1 and b40 12 0 Pr7 will be equal to Pr3 9 76 where Vin is the voltage on the analogue input Frequency reference full scale connector X6 Unit rpm range 32767 default 3000 If b40 12 1 and b40 13 1 Pr7 will have the following value ifb42 520 Pr7 Fin Pr4 500000 frequency direction signal if b42 5 1 7 Fin Pr4 125000 quadrature signal where Fin is the frequency on the encoder input Internal reference Unit rpm range 9000 default 0 If b40 12 1 and b40 13 0 Pr7 will be the same as Pr5 Reserved read only speed refere
62. ion of standards note that the drive is considered as a component and not as a machine Any tampering or unauthorised modification of the drive will invalidate the guarantee immediately Guarantee cover is otherwise provided for 1 one year This instruction manual is applicable to the standard version of the drive S B C Elettronica S p A declines all liability for any whatsoever form of damage caused by inappropriate use of the drive Installation and maintenance of the drive and connected equipment must be performed exclusively by qualified and trained personnel with basic skills in electronics Commissioning of the drive must performed exclusively by qualified and trained personnel with advanced skills in electronics and drive technology Training courses can be supplied by S B C Elettronica S p A on request The quoted performance of the HPD N drive is quaranteed only when used with series MB synchronous motors manufactured by S B C Elettronica S p A ISBNO0102091439 S B C Elettronica S p A Engineering Division CONTENTS 1 INTRODUCTION eti eite tette uas utes 6 1 1 General information ip ete EP Ete 6 1 22 Prod ct descriptions aie eR a E S 6 1 3 Direct mains 7 14 Jdentific tion oie ee eter tree dj 1 5 Main hardware 8 1 6 Soft
63. lettronica S p A Engineering Division HPDxxN High Power Manual Pr19 Pr33 3 The maximum value must be no higher than three times the value of Pr33 Pr29 calculation number of poles Use the following table for MB series motors Pr32 calculation rated speed If Pb 42 6 0 Pr32 Vmax 1 12 V If Pb 42 6 1 Pr32 83 where is nominal motor speed in rad sec Vmain is HPD N power supply in Vrms Vmot is motor rated voltage in Vrms Vmax is motor maximum used speed Evaluation of Pr16 and Pr17 speed regulator gain The default values of Pr16 and Pr17 have been chosen considering identical motor and drive rated currents if this is not the case correct the values of parameters Pr16 and Pr17 with the ratio of the motor rated current drive rated current Preventive execution of this compensation will eliminate the risk of motor vibration at the first start up 6 Set the analogue reference signal to O V terminals 1 2 of board X2 and enable the drive 24 V on terminal 11 of board X3 7 The motor shaft must be stopped when the analogue reference voltage is changed motor speed should change proportionally If this is not the case check your wiring 8 Save your changes with b99 15 The drive is preset with default values designed to meet the requirements of the majority of applications With the default values the pico PLC in the drive runs the program described in appendix G so the f
64. llow Cos E black Sin CONNECTOR Male CONNECTOR Female F red Sin G Gnd shield of cable H Gnd shield of cable K PTC motor Az B motor C 2 see on page 17 D Gnd E FAN MOTOR CONNECTOR FOR 145 and 205 G Brake 24 10 CONNECTOR Male CONNECTOR Female F G BRAKE C B A MOTOR see on page 17 81 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Appendix C hardware characteristics digital input input impedance VH VL digital output type PNP open collector VH using internal supply 20 26 V IO for single output 100 mA IT current for all outputs 177 using internal supply IT current for all outputs using mA ext supply 24 VIN VSW max voltage between 1 V out 6 A and out 6 B ISW max current trough out 6 ee mA and out 6 B analogue reference type differential impedance 20 Kohm range MEME OM NECS CMMR 260 dB resolution 15 bits aux analogue input type differential impedance 250 Kohm range Oo ee ee CMMR 240 dB resolution 10 bits analogue output ended resolution 82 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual Appendix D DC bus voltage thresholds 1024 870 OVER VOLTAGE 805 B high treshold 780 B low treshold normal operation 120 in rush control excluded 56 UNDER
65. lowing one byte between square brackets 1 parity bit even 1 stop bit The message structure is STX CMD ADDR LUN PAR D0 Dn CHK 73 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual where STX 7E transmission start indicator If a field other than STX should assume the value 7E in the message this field is followed by a 00 to ensure that it cannot be interpreted as an STX CMD ADDR command and address of peripheral device always different to zero This datum is composed as follows the first 5 bits from to 4 define the drive address from 0 to 31 the remaining 3 bits from 5 to 7 define the type of message as described in the following table bit7 bit5 message type 0 0 1 drive response 0 read PLC instruction 1 write PLC instruction 0 read parameter 1 write parameter 0 bit change 1 broadcast parameters to all drives 1 1 0 0 1 1 LUN total number of bytes transmitted parameter or PLC instruction can assume values from 1 to 4 This value must not hold zero characters 00 after values that coincide with the initial transmission character 7E PAR parameter or PLC instruction read write address D0 Dn 2 datum transmitted CHK 256 modulus sum of all fields except STX checksum Message types 1 drive response to data request format STX 001 ADDR LUN PAR D0 Dn CHK or co
66. lue Default 0 If set to 0 Pr2 is used to standardise the analogue reference If set to 1 parameter Pr3 is used Activation of algorithm for the suppression of vibration at 0 rpm Default 0 Set to 1 to activate the algorithm Selecting user reserved reference If set to 1 the reserved reference is used in accordance with the currently active operating mode If set to zero the reference selected by b40 0 b40 12 and b40 13 is employed Default is 0 Reference freeze Default 0 If set to 1 the reference will not be updated so that motor will not follow input reference modifications If set to zero the reference will follow variation in the input reference Left limit switch Default 0 If set to 1 and the selected reference requires negative speed the reference will be forced to zero in accordance with the ramp in Pr12 If set to zero no type of control is performed Right limit switch Default 0 If set to 1 and the selected reference requires positive speed the reference will be forced to zero in accordance with the ramp set in Pr12 If set to zero no control Is performed Stop function Default 0 If set to 1 the motor is stopped according to the ramp set in Pr12 Absolute relative speed window selection Default 0 If set to zero speed windows Pr14 15 b41 1 will operate in relative mode if set to 1 the speed windows will operate in absolute mode Analogue torque limit Default 0 If set to 1 Pr22 i e auxiliary analogue input will be
67. n help reduce the presence of control electronics in the application and thus permit considerable economic savings In addition to the positioner functions with Trapezoidal Profile Digital Lock Spindle Orientation Stepper Motor Emulation Torque Control and Acceleration Control the HPD N drive also has an internal pico PLC The pico PLC adopts the most diffused industrial programming standards and offers considerable freedom for use of inputs and outputs It also enables users to develop a range of additional functions that are not among the basic features of the drive The HPD N drive is complete with an RS 422 RS 485 Serial Interface which can be used for configuration monitoring or simultaneous transmission of commands to a multiple system comprising up to 32 HPD N drives In addition to the above functionality the HPD N drive is designed as an open system with the facility to accommodate hardware and software expansion cards For further information on currently available expansion cards contact S B C Elettronica directly or your Local Dealer S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual 1 3 Direct mains connection The HPD N series of drives is specifically designed for direct connection to a three phase mains power supply from 90 to 480V 50 60 Hz without interposing transformers It is the responsibility of the User to connect the system via protection fuses The HPD N require an auxilia
68. nce Unit rpm range 9000 If b40 2 1 Pr6 is only utilised as a speed reference for the control loop The active operating mode will enter its speed request in parameter Pr6 Main reference read only parameter Unit rpm range 9000 If b40 2 0 Pr7 is used as a reference for the speed control loop In certain operating modes Pr7 can be used as a reference for other factors torque acceleration In this case Pr7 is expressed in a suitable unit Acceleration ramp for positive speed values Unit s krpm range 0 002 65 535 resolution 0 001 s default 0 002 s Acceleration for positive speeds required of the motor by way of the speed reference is internally limited so that acceleration of 1000 rpm takes Pr8 seconds Deceleration ramp for positive speed values Unit s krpm range 0 002 65 535 resolution 0 001 s default 0 002 s Deceleration for positive speeds required of the motor by way of the speed reference is internally limited so that deceleration of 1000 rpm takes Pr9 seconds Acceleration ramp for negative speed values Unit s krpm range 0 002 65 535 resolution 0 001 s default 0 002 s Acceleration for negative speeds required of the motor by way of the speed reference is internally limited so that acceleration of 1000 rpm takes Pr10 seconds Deceleration ramp for negative speed values Unit s krpm range 0 002 65 535 resolution 0 001 s default 0 002 s Deceleration for negative speeds required of the motor by way of the speed ref
69. nd S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 9 movement with digital locking and return to origin FILE E002 HPD To obtain the following functionality with reference to the figure below assume there is a conveyor transporting product and a carriage running parallel to the conveyor and controlled by an HPD N drive On receipt of an external start command the carriage is aligned on a zero reference position proximity sensor With a second pulse command provided by a product detection sensor the drive locks on to the conveyor in order to perform an operation on the product at a precisely defined position when this operation is terminated the carriage returns to its starting position In this case the program makes it possible to execute homing see chapter 1 after which on receipt of the manual command from the sensor the carriage locks on and covers a distance equal to the value of Pr87 86 when this distance is reached the drive unlocks and stops according to the ramp programmed in parameter Pr83 The motor now automatically returns to the origin position executing a trapezoidal profile with the ramps set in Pr80 and the speed in Pr81 Note that one motor revolution corresponds to 4096 steps so the value to set in Pr87 86 should correspond to the number of steps of the motor shaft needed for the carriage to execute the required translation The master encoder on the conveyor shaft provi
70. nd timer status At if Pr93 2 0 At 1 if the result of the last PLC operation is negative At 1 if the result of the last PLC operation is zero PLC status Default 1 If set to 1 the PLC program is executed if on zero the program is not executed and modification of PLC instructions is enabled 52 S B C Elettronica S p A Engineering Division PLC INSTRUCTIONS Pa y H Pa y I M N Pa y Pa y OUT V OUTN SET RST RES Pa y AND iS 7 ANDN Pa y JH Pa y ORN ADD 2 SUB Pa Pb Pc MUL Edi DIV Pa y FIN END FIN OPERATIONAL DESCRIPTION Pa y Pa Pb Pc Pa Pb Pc Pa Pb Pc Pa Pb Pc y 0 1 HPDxxN High Power Manual load bit y of parameter Pa in the stack load inverted bit y of parameter Pa in the stack set bit y of parameter Pa to the value loaded in the stack set bit y of parameter Pa to the stack value and invert it if stack is at 1 set bit y of parameter Pa to 1 if stack is at 1 set bit y of parameter Pa to zero the bit loaded into the stack assumes the result of the logical AND operation between itself and bit y of parameter Pa the stack bit assumes the result of the logical AND between itself and inverted bit y of parameter Pa the bit loaded into the stack assumes the result of the OR between itself and bit y of parameter Pa the stack bit assumes the result of the OR b
71. ne with an interface such as Pcbrush Default parameterisation b99 12 provides a PLC program see appendix G designed to fill the requirements of the broadest possible range of applications therefore it is not necessary to reprogram the PLC in the majority of cases Main features of the PLC Program steps 64 scan time 6 144 mS timers 2 instructions 15 stack depth 1 mathematic operations 16 32 bits fast inputs fast copy 3 512 us PLC PARAMETERS Pr71 Constant value 1 Double word Pr72 Constant value 0 Double word Pr73 Constant value 1 Double word Pr74 Constant value 2 Double word Pr75 Constant value 10 Double word Pr76 Constant value 100 Double word Pr77 Constant value 1000 Double word Pr78 Constant value 1024 Double word Pr79 Constant value 4096 Double word Pr80 parameter Parameter with save facility at user s disposal word Pr81 Free parameter Parameter with save facility at user s disposal word Pr82 Free parameter Parameter with save facility at user s disposal word Pr83 Free parameter Parameter with save facility at user s disposal word Pr84 Free parameter Parameter with save facility at user s disposal word Pr85 Free parameter Parameter with save facility at user s disposal word Pr86 parameter Parameter with save facility at user s disposal word Pr87 Free parameter Parameter with save facility at user s disposal word Pr
72. nfirm message in response to data entry or update format STX 001 ADDR where ADDR identifies the answering drive CMD2 read message of PLC area instruction format STX 010 ADDR LUN PAR CHK CMD3 write message of PLC area instruction format STX 011 ADDR LUN PAR Dn CHK CMD4 parameter read message format STX 100 ADDR LUN PAR CHK CMDS parameter write message format STX 101 ADDR LUN PAR DO Dn CHK CMD6 byte parameter bit change message format STX 110 ADDR LUN PAR D1 CHK 74 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual In this case LUN 2 two bytes are transmitted for the data the first byte is the mask containing in the positions of the bits to change and 1 in the other positions the second byte contains 1 in bit positions to be set to 1 and 0 in the other positions The address PAR corresponds to the parameter byte in which one or more bits is to be modified If the parameter is a word and the bit to be modified is among the first 8 b0 b7 PAR parameter address otherwise if the bit to modify is one of the upper 8 b8 b15 PAR parameter address 1 CMD7 parameter write broadcast message to all drives connected to the serial line format STX 11100000 LUN PAR D0 Dn CHK The address of peripheral device ADDR must be zero Notes Parameter
73. o one to evaluate the vibration of the motor shaft incrementing parameter Pr64 in absolute terms by a value proportional to the vibration detected The user is responsible for evaluating Pr64 and bringing it to zero in relation to the appropriate time interval b70 6 Reserved b70 7 Reserved b70 8 Reserved 3 6 4 Positioner Operating mode 9 executes a simple trapezoidal profile For this profile the user must define acceleration with Pr51 steady time rpm with Pr52 and displacement using the pair of long format parameters Pr64 and Pr65 At each profile execution command b70 8 the motor executes Pr64 65 steps one motor revolution is equivalent to 4096 steps The parameters of a trapezoidal profile cannot be changed during execution b70 7 1 except Pr64 65 In the block diagram note the four different reset types the availability of servo error indication and the possibility of using space contro with or without feed forward The incremental position must be always positive and movement direction must be selected with parameter b70 1 Displacement can be defined using the drive frequency input Additional features are available using the internal PLC Note that the profile execution command is not generated on a constant time base profile calculation may require more than 2 milliseconds PARAMETERS FOR OPERATING MODE 9 Pr50 Pulse input multiplication factor K Default 1 If b70 9 1 frequency direction input pulses are multiplied by Pr
74. o the address of Pr80 in broadcast mode Using this potential it is extremely simple to connect two HPD N drives in a loop via the serial ports and a short program on the internal PLC will suffice to start transmission at power on and restore it in the event of communication errors The following example describes the PLC program required to copy Pr81 from the two drives in parameters Pr80 Connection function drive 1 drive 2 X5 X5 drive 1 drive 2 Pr81 80 80 Pr81 i 100 99 5 75 7492 LD 99 5 If broadcast is received DIV timer is set to 30mS DIV 75 74 92 99 0 99 5 if time out is present LD 99 0 SET 99 5 reset serial comms 75 74 92 DIV 75 74 92 and set timer These PLC instructions must be entered on only one of the drives both drives must have parameter Pr26 10 to enable the IDC function 64 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 11 automatic undervoltage alarm reset Not necessary This page is intentionally left blank 65 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 12 5 positioning with teach in FILE E003 HPD To obtain the following functionality with reference to the figure assume you need to acquire 5 different machine positions and then execute them automatically MOTOR PROX SENSOR CARRIAGE POSITIONS 0 1 2 3 4 5 Thi
75. ocking chapter in this manual 2 11 Encoder emulation On connector X7 there are signals of encoder emulation phase A phase B and phase C reference zero The signals are RS 422 type For the relative programming of pulses per revolution consult the Basic parameters chapter in this manual bit b42 0 b42 1 and b42 2 default 2 1024 pulses revolution 19 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 12 Serial line connection The HPD drive serial line can be configured as RS 422 or RS 485 depending on the connection In both cases termination resistors must be used 150 Q Where more than one HPD N drive is connected to the bus the final node must be terminated as shown below The two cases are illustrated in the following diagrams RS 485 NODE 1 NODE n LAST NODE MASTER X5 X5 X5 NODE 1 NODE n LAST NODE 2 13 Braking resistor HPD N drives are equipped with an integrated braking resistor The effective use of the braking resistor can be checked by monitoring the value of parameter Pr37 which is expressed as a percentage If you intend to dissipate more power use two external braking resistors To connect up the system which must be carried out in conditions of complete safety disconnect the jumper between terminals R1 C1 and R2 C2 of terminal board X4 connect one resistor between AB and C1 and the other between BB and C2 on X4 The external resistor value must be 40 ohm and
76. ode see chapter Basic parameters bit b42 5 In the former case follow this connection diagram In the case of parallel connections to more than one HPD N connections to pins 9 5 6 and 8 must be made only on the last drive in the group 18 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual If the frequency direction mode configuration is adopted channel A is dedicated to frequency while channel B handles direction Frequently a 24V interface is preferred to an RS 422 serial port The conversion can be implemented on the external connector by following this wiring diagram PULSES see text for burden resistors The example in the figure shows the connection between two HPD N drives in digital lock with a master but this configuration can be extended to several drives connected in series On the final drive in the series connect the burden resistors by jumpering pin 1 with pin 9 pin 2 with pin 5 pin 3 with pin 6 and pin 4 with pin 8 on connector X6 The master can be an externally fed encoder or the simulated encoder output on another drive The signal from the master encoder must be differential type 5V RS 422 it is therefore possible to connect a maximum of 10 slave HPDNs If the master is an HPD N drive then up to 32 units can be connected in digital lock mode using the same simulated encoder signal RS 422 standard For the relative programming of the HPD N consult the Digital l
77. ollowing functions will be present on the input and output terminal boards TERMINAL BOARD X2 TERMINAL BOARD X3 real speed Pr13 motor speed reference 20 rpm left limit switch n c 13 real speed 0 right limit switch n c 14 real speed gt 0 5 motor thermal image active i t 17 terminal A drive ready terminal B n c contact 25 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual The functions on terminals 12 13 and 14 must be enabled by setting bit b90 10 to one This requires access to the extended parameters menu The default PLC program controls parameter Pr5 in addition to timer 1 Pr92 and bits b40 0 b40 4 b40 5 b40 6 b40 12 so in this case the above binary parameters and switches cannot be utilised unless the pico PLC is disabled b99 13 0 or the basic program is modified Short and extended menu When the HPD N drive is in default status only a limited number of parameters are displayed These parameters are the only ones required for applications in which the HPD N is employed as a straightforward frequency converter i e you are not using the advanced functions of the drive e g using HPD N with a Numerical Control or an intelligent axis control card Switch between short and extended menu using b99 6 Short memory parameters are PrO Real speed of motor shaft in rpm Prl Analogue reference offset terminals 1 and 2 of terminal board X2
78. r position reset 1 servo error window SNO target position motor position 0 servo error 49 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual STEPPER LIKE OPERATING MODE feed forward Servo error window servo error k mul pulses input proportional gain Pr 61 Pr60 reserved reference target position max regulator Speed Pr 63 Pr62 motor position reset 1 b70 10 NUES target position motor position 0 b70 11 gt gt target position motor position shaft position reset 2 b70 12 target position motor position reset 3 SPINDLE ORIENTATION OPERATING MODE proportional gain oriented window not oriented target position reserved reference max regulator Speed shaft position motor Speed 50 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 8 Digital input and output programming 3 8 1 Pico PLC The internal pico PLC makes it possible to connect peripheral systems inputs outputs to the parametric system of the HPD N drive The PLC can be used to copy a digital input into a bit parameter copy a bit parameter into a digital output and perform mathematical and boolean calculations The PLC program must be entered as a list of instructions from the keypad alternatively the PLC can be programmed with the ladder diagram system using a PC on the serial li
79. r5 until the proximity switch provides a signal at digital input 3 At this point digital inputs 4 5 and 6 select the position to be reached while a pulse on digital input 1 makes it possible to perform positioning on a trapezoidal profile The following table shows the relationship between parameters Pr80 Pr89 and the encoding on the 3 digital inputs for example only input 4 on one selects position 1 and the distance in steps between the zero axis point and position 1 is set in steps bearing in mind that one revolution of the motor shaft corresponds to 4096 steps PO qe p po cb Lt ms qr owe p xc qr qo ono messi L0 0 4 P786 0 1 5 other combinations 0 axiszero After having set the default values set the following parameters on the HPD unit Pr5 5 homing speed 31 9 b99 11 1 b40 2 1 b40 12 1 Pr81 80 dimension 1 Pr83 82 dimension 2 Pr85 84 dimension 3 Pr87 86 dimension 4 68 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Pr89 88 dimension 5 terminal 12 on X3 execute positioning pulse command terminal 13 on X3 execute homing pulse command terminal 14 on X3 PNP axis zero proximity sensor terminal 15 on X3 position selection terminal 16 on X3 position selection terminal 17 on X3 position selection terminal 12 on X2 output high during positioning The following
80. ry voltage 220V single phase for the internal control circuits All protections required for safety such as overvoltage detection short circuit fault protection and inverter and motor overtemperature detection are integral with the drive To simplify the design of electrical cubicle the HPD N has inside a filter mains and motor to meet the EMC standards In order to qualify your machine for CE marking adhere scrupulously to specification on next chapters The presence of internal filter MAY generate undesired interventions of differential switches in these cases change the set point of differential switch or even eliminate it Chapter 2 provides a detailed view of problems related to EMC N B leave at least 60 sec after switching the drive off before switching it on again 1 4 Identification HPD N High Power Drives are available in four models HPD25N HPD35N HPD45N and HPD67N The number that follows HPD is the value of drive rated current in amperes LZ HPD N drives an identification plate on the right hand side showing all essential information for correct identification of the unit Make a note of the information on this plate before consulting S B C on technical matters model identification plate S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 1 5 Main hardware specifications Parameter um Vaue 220 209107 motor titer
81. s can be achieved using a smart keypad module see appendix L SBC1 program connected on the serial communications line with the drive and with the internal PLC When the machine is powered up the drive will stand by to receive the homing exec command and the keypad will show the message axis zero F4 By pressing F4 or sending a pulse command to digital input 2 of the drive the motor shaft will turn at the speed established by parameter Pr5 until the intervention of the proximity sensor at digital input 3 The keypad display will now present the message automatic dimension 1 digital inputs 4 5 and 6 select the position to be reached while a pulse supplied to digital input 1 provides a trapezoidal profile to reach the selected position The following table shows the relationship between parameters 80 89 and the encoding of the 3 digital inputs for example input 4 on one selects position 1 and the distance in steps between the zero axis point and position 1 is set in Pr81 80 bearing in mind that one revolution of the motor shaft is equivalent to 4096 steps position dimension Pr81 80 Pr83 82 4 Pr87 86 Pr89 88 axis Zero Pr85 84 other combinations If you want to set the dimension from the keypad press F3 and the display will show the message dimension xx where xx defines the dimension in question and yyyy determines the relative value The and keys are used to modify the value yyyy while F3
82. s shown on the display with decimals must be treated as integer values e g 978 5 will be read and written as 9785 All values preceded by the symbol are hexadecimal numbers The value in square brackets is the basic unit byte of the message To be considered valid all messages must be terminated within a clearly defined time interval time out which is a function of speed and they must have correct parity and checksum The drive responds to data requests or transmission only if the message is received correctly if the message contains an error no answer will be transmitted The only exception is message type 7 with which a datum is transmitted with a single message addressed to all drives connected to the serial line Serial line initialisation and management Drive serial communication can be enabled or disabled by means of bit b40 14 The drive is factory set with b40 14 0 i e serial line disabled default If you want to use the serial line first set the baud rate in Pr 26 now set the serial address in Pr 27 finally enable serial communication by setting b40 14 1 and initialise using b42 3 At this point you must save the configuration using command b99 15 For parameter addresses and lengths refer to the relative table In the case of PLC instructions each one occupies 2 or 4 bytes the format of which is described below 75 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Man
83. sion HPDxxN High Power Manual 3 6 Operating modes Operating modes are selected by means of parameter Pr31 whose default value is 0 Each operating mode commands a speed loop by means of parameter Pr6 and can limit motor torque with parameter Pr21 see block diagrams Speed control uses Pr7 or Pr6 as a reference depending on the value of b40 2 Before changing Pr31 b40 2 must be set to 0 to prevent undesired motor movement it is now possible to set Pr31 to the value of the chosen operating mode and load default parameters by means of parameter b99 11 The operating mode will be enabled by setting b40 2 to 1 3 6 1 Torque control This operating mode 1 does not perform classic torque control because the speed loop remains active to monitor limit speed the torque reference is the main reference Pr7 To set torque control first program the speed loop to create a stable system Now set Pr2 1000 10 V 100 0 torque b40 0 0 amp b40 12 0 b40 2 1 to program the reserved reference Pr31 1 to enable the operating mode and Pr50 for maximum speed PARAMETERS FOR OPERATING MODE 1 Pr50 Maximum speed Unit rpm default 3000 range 0 9000 This parameter makes it possible to limit maximum absolute motor speed during torque control operation 3 6 2 Acceleration control Instead of performing closed loop acceleration control this mode 2 uses main reference Pr7 for dynamic modulation of the ramps To program analogue acceler
84. ssage indicates that the drive is not operating at low voltage b40 10 0 and that DC bus voltage is still below the 120 V threshold the inrush current circuit is still connected so the drive is not yet ready b41 4 0 Indication of parameter xx value displayed by pressing M Indication of bit parameter xx Indication of bit yy of parameter xx press M to display bit status Indication of instruction xx of PLC program Displayed for approximately 1 second each time a command is entered Displayed for approximately 1 second each time an alarm reset command is entered b99 10 Displayed during wiring test b70 3 It s displayed when a writing error is detected storing the pico PLC instructions b99 14 or while saving parameters 699 15 3 2 Commissioning the HPD N drive The steps described in this section must be followed carefully when the drive is started up for the first time 1 Connect motor to the drive in compliance with the wiring diagrams in the manual 2 Make sure the drive is disabled terminal 11 of board X3 must be open 3 Power up the drive 4 After some seconds the display shows IdLE 5 Setting essential parameters Pr33 calculation rated current Pr33 M 49g InD 2 where InM is rated motor current at zero rpm in Ampere InD is rated drive current in Ampere The maximum value of Pr33 is 50 0 for the HPD25N and 67 0 for HPD35N 45N 67N Pr19 calculation peak current 24 S B C E
85. st be less than the value of the modulus Pr89 88 The master encoder mounted to the conveyor shaft provides the drive with a position reference during the digital locking phase PROX SENSOR SLAVE MOTOR SENSOR MASTER ENCODER When you have set the default values set the following parameters Pr5 10 homing speed 31 10 b99 11 1 b40 2 1 b40 12 1 52 0 b70 3 1 Pr87 86 modulus ramp Pr89 88 modulus in which the ramp is expressed in steps i e it is the space that the axis must cover during ramp down Pay attention when programming Pr89 88 and Pr87 86 because these parameters are utilised as double word format by the PLC but they must be set up as two pairs of single whole words from the keypad For example if the modulus is 40960 steps Pr89 must be set to 0 and Pr88 must be set to 24576 Terminal 13 on X3 homing pulse command Terminal 14 on X3 NPN type axis zero proximity sensor Terminal 12 on X3 pulse command digital locking engage sensor Terminal 12 on X2 exit high during modulus execution if a digital lock command is transmitted during execution of the modulus it will be ignored The delay before digital locking varies by up to 2 048 msec max The following auxiliary parameters are utilised Pr83 Pr84 Pr85 b91 10 b91 12 It is assumed that parameter Pr34 is not used The program is as follows 60 S B C Elettronica S p A Engineering Division 72 72 60 8 1 90 1 70 8 94 5
86. stances however control cable shields may be connected only at one end to eliminate mains hum that could interfere with the control signal Decide case by case as numerous factors must be considered Adopt the following general approach if the shield is solely for shielding connect at both ends If current flowing in the shield interferes with the shielded signals connect at one end only The incoming cable must be connected to an earth terminal by means of a screw to ensure proper contact between shield and earth RF interference suppression filters must be installed as close as possible to the drive and must have a large area of contact with the power panel or the baseplate Remove all paint The filter earth terminal must be connected to the earth bar along the shortest possible route As far as possible keep the power side drive and control side PLC or NC physically separated by separating the metal mounting plates Do not route any cables through the mounting plates Protective measures for drives with gt 3 5mA dispersion current per phase Interference currents dispersed through the earth system may be considerable in certain conditions Therefore make sure all suppression filters are properly earthed before they are connected Cable sizes must be in line with the requirements of safety standards If a suppression filter is permanently connected and current dispersion during normal operation is greater than 3 5mA which would b
87. t and negative speed movement for an interval of Pr54 at Zero rpm Pr55 Deviation factor During execution of the profile assuming the same value of Pr16 the optimal value of Pr17 can be achieved by minimising the value of Pr55 Pr56 Value Returns information requested with Pr57 Pr57 Information request This parameter serves to query the drive A table of queries is shown in the block diagram of operating mode 8 Pr58 Reserved Pr59 Reserved 39 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Pr60 61 Reserved Pr62 63 Reserved Pr64 65 Reserved Pr66 67 Reserved Pr68 69 Reserved b70 0 Start profile Set 1 to execute the programmed profile Remember to set b40 2 1 to effectively switch the speed reference to the control loop b70 1 Manual forward speed If at 1 with b70 0 0 and b40 2 1 the shaft will rotate at the speed programmed in Pr50 b70 2 Manual reverse speed If at 1 with b70 0 0 and b40 2 1 the shaft will rotate at the speed programmed in Pr50 but in the opposite direction b70 3 Wiring test When you set this command the drive performs a test procedure and returns the result as an error code that can be viewed using parameters Pr56 and Pr57 Before entering this command make sure the motor is disconnected from all loads even pure inertia loads Also ensure that b40 9 0 b70 4 Reserved b70 5 Vibration test If none of the above functions is active you can set this bit t
88. t not be soldered 60065 art 15 3 5 e Make sure drive and motor and properly earthed Make sure that the maximum voltage on terminals L1 L2 L3 does not exceed rated voltage by more than 1096 in the worst possible case see EN60204 1 section 4 3 1 Excessively high mains feeding voltage can damage the drive Do not detach electrical connections when the drive is connected to the power supply Follow all installation instructions in this manual step by step If you are in doubt contact S B C customer service e Dangerous voltages may remain for 60 seconds after mains disconnection and system power down do not touch power cables during this interval Do not open the drive casing This action is potentially dangerous and will automatically invalidate the guarantee Installation and wiring must be carried out with the entire electrical panel disconnected from the power supply Make sure that the drive enable command is disconnected from the emergency circuit Qualified technical personnel must preside when the power panel is powered up for the first time 10 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 2 Interference suppression hints Because of the high speed voltage wavefronts in PWM high levels of stray current may sometimes flow through capacitive couplings and earth systems Stray currents of this type can affect other functional units It is therefore prudent
89. th of individual conductors that must be connected to earth we recommend using an earth busbar located as near as possible to the drive The busbar must be made of copper to ensure low inductance It must also be Length m uo ita 2 table shows minimum dimensions according to L wu ength 4315 3h 0r 16 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 Power connection layout RESOLVER SERVOMOTOR HPD DRIVE 2 8 Signal cable connections A twisted and shielded pair must be employed for the analogue reference The cable for emulated encoder signals must comprise three twisted pairs with a common shield Normal cables could be used for digital inputs outputs Minimum size of all signal wires is 0 35mm2 17 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 9 Signal cable connection layout MOTION HPD CONTROLLER REF 0 1 Reference out LLL _ 2 X2 Reference YY A N 1 gt 2 B 3 Encoder in Bl 4 X7 Encoder ot cL 5 Ml gt 6 7 24M Output 11 13 2 Enable Inputs 1 11 20 TO EARTH BAR 2 10 Frequency input connection RS 422 type frequency input can be software configured in two modes the first default to accept quadrature signals from encoders the second is frequency direction m
90. that in mathematical operations on double words operands and results are defined as follows the operand parameter defines the least significant part while the most significant part is represented by the word with the next serial address see chapter Serial addresses and parameter lengths Parameters from Pr50 to Pr69 and from Pr80 to Pr89 are successive At the completion of each mathematical operation b99 2 is set to O if the result is positive and to 1 if the result is negative likewise b99 3 0 if the result is zero and b99 3 1 if it is different from zero These settings remain valid until the next mathematical operation is performed the operation is executed only if the stack bit is equal to one A mathematical operation can be performed setting the result in one of the constant parameters Pr71 Pr79 in order to set bits b99 2 and b99 3 In the case of the DIV operation if it is executed on a double word the most significant part of the result contains the rest of the division i e if you set b94 0 1 and perform DIV 79 77 80 the result will be Pr80 4 and 81 96 Note that parameters Pr23 Pr24 Pr25 Pr26 Pr27 Pr29 Pr31 and Pr34 are bytes like Pb42 and Pb94 therefore these parameters cannot be used for mathematical operations logical operations must be used to alter their values FIN instruction Three instructions are provided for high speed input acquisition in this case the scan is executed at 51248 normal scanning 15
91. the communication speed Pr26 has been modified In any event the serial line is initialised when the drive is started up b94 1 Reset main reference offset This command automatically sets parameter 1 in order to reset any voltage offset on the main analogue reference This procedure is only possible if the absolute offset value is less than 200 mV b99 9 Current offset calibration request The command is accepted only if the drive is disabled The calibration procedure is executed when the drive is started up b99 10 Alarm reset This command resets Pr23 and Pr24 if the alarm persists it is shown on the display The command is not accepted in the presence of checksum errors Pr23 10 11 in this case set default parameters b99 12 and then reset the alarm If the backup power supply is present terminals 8 and 9 on X3 when mains power is restored to the terminals on X4 you must wait 10 seconds before transmitting the undervoltage alarm reset command and enabling the drive b99 11 Operating mode parameter default values This command sets current operating parameters to default values The command is executed only if b40 2 0 b99 12 Default values This command sets all parameters to default values and cancels the values used by the operating modes it also sets the pico PLC program as described in appendix G If a checksum alarm is present Pr23 and Pr24 are set to zero so that the alarm can be reset The command is executed only if b99
92. tilised b91 10 b91 11 The program is as follows LD 90 2 If digital input 2 and homing not yet ANDN 91 10 executed executes homing RST 40 2 LD 90 3 If digital input 3 and homing not yet ANDN 91 10 executed SET 70 10 reset mode counters SET 91 10 set homing executed flag RST 91 0 set digital output 0 to zero LD 70 8 copy bit b70 8 to digital output 1 OUT 91 1 LD 41 4 if drive OK enable operating mode ANDN 91 11 at power up SET 40 2 SET 91 11 END program end Inputs and outputs can be read and written directly via the serial communications line so there is no need to use the pico PLC if you have an intelligent unit connected to the drive via the serial line For more information regarding the serial line refer to the HPD N user manual 67 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual Example 13 5 positioning FILE E004 HPD Referring to the figure below assume you need to move the carriage to 5 different positions selected by means of three digital signals MOTOR PROXIMITY SENSOR CARRIAGE POSITIONS 0 1 2 3 4 5 The positions are set in parameters Pr80 Pr89 in resolver steps taking the position of the proximity sensor as the zero value When the machine is powered up the drive remains in standby mode awaiting the homing execution command when a pulse command is supplied to digital input 2 of the HPD N drive the motor shaft will turn at the speed set in parameter P
93. time slot If set to 1 indicates that the external operating mode is controlled at 2 ms intervals otherwise at 51215 Selector to configure encoder emulation Selector to configure encoder emulation Selector to configure encoder emulation Pr32 up to 9000 rpm Pr32 up to 3500 rpm Pr32 upto 875 rpm ENCODER OUT 16384 8192 4096 2048 1024 512 256 128 the double line indicates encoder resolutions available in the various speed ranges Default value is 1024 b42 4 b42 5 b42 6 b99 6 b99 7 b99 13 3l 24V over current Digital output trip Frequency input board X6 If set to 1 the frequency input is programmed to receive two phases in quadrature This is the default If set to O it is enabled to receive a frequency direction type input Torque compensation Default 1 When set to 1 torque compensation is implemented to improve linearity of response Extended menu enable Default 0 Set to 1 to enable the extended menu Security Default 0 Set to 1 to prevent parameter modification pico PLC status Default 1 If on 1 the PLC program is run if on zero the program is not run and the PLC instructions can be modified if required S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 3 4 Basic commands To transmit the following commands b99 7 must be on zero For commands b42 3 and b94 1 b99 6 must be on one b42 3 Re initialise serial line Command to reinitialise the serial line when
94. ting a 2 byte parameter Assume you intend to set rated current at 25 396 Pr 33 assume also that the drive serial address is 3 The message to transmit 1s 7E A3 02 C6 FD 00 68 The drive answers with 7E 23 Case 5 setting a bit to 1 Assume you want to enter the command to save the PLC program b99 14 1 assume also that the drive serial address 1s 0 The message to transmit is 7E CO 02 93 SBF 40 54 The drive answers with 7E 20 Case 6 setting a bit to 0 Assume you want to disable the drive by software b40 9 0 assume that drive serial address is 0 The message to transmit is 7E CO 02 5D SFD 00 1C The drive answers with 7E 20 Case 7 writing a PLC instruction Assume you want to set the first PLC instruction as LD 90 4 assume the drive serial address is 0 The message to transmit is 7E 60 02 00 40 5A SFC The drive answers with 7E 20 Case 8 reading the first PLC instructions Assume you want to read the first instructions of the PLC default program assume the serial address of the drive is 0 The message to transmit is 7E 40 04 00 44 The drive answers with the message 7E 20 04 00 10 5A A7 5A 8F which corresponds to the acquisition of the following instructions LD 90 1 ORN 90 10 77 S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 4 2 Serial addresses and param
95. to the value 3 will improve this condition significantly fig 6 Tek Run 500 S s Sample Gi E T 08 46 27 Fig 5 Tek Run 500 S s Hi Res Trig 08 47 40 Fig 6 If the driven mechanical system is prone to oscillation we recommend using very low values for Pr16 in this configuration the HPD N drive will smooth out motor torque requests to prevent the creation of mechanical oscillation Figure 7 shows this type of configuration 36 S B C Elettronica S p A Engineering Division HPDxxN High Power User s Manual Tek Run 250 S s Hi Res T rig e M 500 c5 00V M 200ms Chi F OV 28 Mar 1996 08 50 13 Fig 7 CALIBRATION WITHOUT INSTRUMENTS If an oscilloscope is not available proceed as follows A Calculate the value of Pr16 as described earlier B Calculate Pr17 using the following formula PT NM peak where J is total inertia motor load NMpeak is available torque with peak current of the system C Enable the drive and moving the axis with an external control change Pr17 to seek the value at which the axis moves as required If the resulting calibration is unsatisfactory repeat the procedure with lower values for Pr16 or setting Pr18 as described earlier Note the theoretical value of Pr 18 is pris 0i Pr16 If the result is 1 you would set 1 34 S B C Elettronica S p A Engineering Divi
96. ual Instruction length bytes LD Pa y 2 LDN Pay OUT Pay OUTN Pa y AND Pa y ANDN Pa y OR Pa y ORN Pay ADD Pb SUB Pa Pb Pc MUL Pa Pb Pc DIV Pa Pb Pc SET Pay RES Pa y FIN Pb40 y Pb70 y END 0 1 2 3 4 5 6 7 8 poe ES gt NNNNA AA T 5 WN The memory area available for PLC instructions is 128 bytes with addresses from Oh to 7Fh As the minimum length for each instruction is 2 bytes the PLC program can hold a maximum of 64 instructions The first four bits of the first byte in each instruction b0 b3 contain the instruction code For the first 8 instructions in the table LD ORN and the SET and RES instructions the remaining 4 bits of the first byte b4 b7 contain the value y while the second byte contains the value Pa For instructions ADD SUB MUL and DIV the second byte contains the value Pa the third Pb and the fourth Pc The second byte is not utilised for the END instruction For the FIN instruction the fifth bit b4 of the first byte selects the parameter b4 0 refers to Pr 40 b4 1 refers to Pr 70 the sixth bit b5 of the first byte is used for negative logic if required b520 the bit is copied b5 1 the bit is inverted and then copied The second byte of the FIN instruction contains the value of y If FIN instructions are used they must be the first of the program and there must be no more than 3 so they will occupy addresses from Oh to 5h If
97. ual Terminal board X4 BB css Rm Ss BI E eooo 3 Terminal board X3 7 X7 DB9 male oo lel Rete ON BL WL NM oO S B C Elettronica S p A Engineering Division HPDxxN High Power Manual 2 6 Power connections For the motor cable consider Choice between cable for fixed or floating installation Cable must be shielded and suitably sized in terms of insulation and wire sections Reticulated polypropylene is the preferred insulation material Length max 100 m note that conductor conductor capacitance must not exceed 8 nF If cable length exceeds 50 m install a triple 1 mH inductance between drive and motor with rated current identical to HPD N rated current Minimum conductor size is 6 mm for l HPD25N 8 mm for HPD35N 12 mm 2 for HPD45N and 16 mm for HPD67N For the mains power cable Power cables must not be shielded Minimum conductor size is 6 mm2 for lHPD25N 8 mm for HPD35N 12 mm2 for HPD45N and 16 mm for HPD67N Input fuses must be rated as follows MODEL Slow blow fuses A HPD25N HPD35N HPD45N HPD67N 100 Resolver cable The cable must comprise 4 twisted pairs with individual insulated shields and one common shield Capacitance for the length of cable must not exceed 10 nF wire size must be no less than 0 35mm Maximum length is 100 m Earth connections To reduce the leng
98. ware features eee te ee rrr e HE Pe ERROR 9 1 7 Compliance with EMC eese 9 NAE ete ea 9 2 INSTALLA TION aite i EE Melt e Eu heraus 10 2 1 Safety instr ctiOns 10 2 2 Interference suppression 11 2 3 Installation instruction to ensure EMC ee eeeeeececececeeeeeeneaeeeceeeeeeeeneaes 11 2 4 Control cubicle layout example eese 13 2 3 l rmminal assignments ecce tete eg eene ete ER INE eMe rn rhe req 14 2 6 Power connections senise eie dee e eese ee eere e Re rens 16 2 7 Power connection nnne 17 2 8 Signal cable 17 2 9 Signal cable connection 18 2 10 Frequency input nnne eterne E S 18 2 11 Encoder emulation eese ia 19 2 12 Serial line connection eee er 20 2 13 Braking resistor RP Ee ue 20 21 3 PARAMETERS AND PROGRAMMINQG eee 22 3 L Usimg the keypad ee eet e eee 23 3 2 Commissioning the HPD N dirive eese eee 24 3 3 Basic parameters cscs

HPD N “high power”

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HPD N &ldquo;high power&rdquo;

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HPD N “high power”