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User Manual DIS-2

1. No Name Meaning Scaling 0026 srvc_soft_prod_step Firmware main revision and subrevision Upper 16 bits Main revision number Lower 16 bits Subrevision 0030 seqc_opmode Parameterization of operating mode and none ramp 0031 jstat_conf2_1 Configuration words of the drive none 0032 rs232_stat_sum Status word of the status window none 0033 seqc_brake_unlock_time Delay for unlocking the holding brake Basic unit time 0034 seqc_brake_lock_time Delay for locking the holding brake Basic unit time 0035 seqc_auto_brake_time Minimum waiting time until the brake Basic unit time responds Not supported at present 0036 commh_ctrlenab_log Parameter describes the component 0 Only DIN9 enabling the controller 1 DIN9 and RS232 2 DIN9 and CAN 0040 _ commh_null Auxiliary object that always returns zero none 0050 _ rs232_baudrate Baud rate for the RS232 communication RS232 baud rate 0051 rs232_para_conf Configuration word for parameterization none software 0052 rs232_unit_x_var_i Physical units position none 0053 rs232_unit_x_conv_i Physical units position none 0054 rs232_unit_x_numerator Factor group position numerator none 0055 rs232_unit_x_divisor Factor group position denominator none 0056 rs232_unit_x_ decimals Distance decimals none 0057 rs232_unit_n_var_i Physical units Speed none 0058 rs232_unit_n_conv_i Physical units Speed none 0059 rs232_unit_n_numerator Factor group speed numer
2. 3 3 V 3 3 V 2 s V 5 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Continuation of the table B Pin assignment of connector X8 Pin no Name Value Specification 12 ag aio a7 ls Jas as Jas Jaa Jai J a2 All signals with 3 3 V CMOS logic level All signals with 3 3 V CMOS logic level 16 bit parallel interface data bus 16 bit parallel interface address bus Page 175 Ds Ao RD wr IRQB SYNC IROA Mos SCLK miso ss All signals with 3 3 V CMOS logic level Bus control signals for access to technology modules via the data and address bus and synchronous serial interface for access to technology modules with an SSIO interface GND Reference potential Reference potential User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 176 11 19 Electrical installation of the DIS 2 48 10 11 19 1 Connection to Power Supply and control in system The following illustration shows a typical application with two or more DIS 2 servo positioning controllers with a connection to
3. 11 9 Course program Examples This chapter includes several example to demonstrate the flexible solutions possible with the course program O il The input of course programs is described in chapter 7 1 Creating a course program 11 9 1 Example 1 Linear linking of positions The drive shall approach the positions 1 2 3 18 It shall stop for 1 second in every position Then the course program shall stop C Pos tC Pos2 Poss gt Pos 18 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 142 Realization oD f stor neei Pommet Nexte Posma bouti Doute ignore automatic ignore Off Off ignore automatic 2 ignore Off Off ignore automatic 3 ignore Off Off ignore automatic ignore accept accept accept accept Modus i Course program active NEXT1 DOUTI X Exit Course program stop NEXT2 gt DOUT2 Implementation The start delay for positions 1 2 3 and 18 has to be parameterized when the destinations are programmed 11 9 2 Example 2 Linear linking of positions and setting of a digital output The drive shall approach the positions 1 2 3 18 It shall stop for 1 second in every position Then the course program shall stop When the drive reaches position 3 the digital output DOUT1 shall be set to HIGH for one second C Post gt gt Pos2 gt gt Poss gt Pos 18 Realization
4. O y uojouny J kel JWU0D 9A lt NVO 1 JUOD JUBLIND SAY d i f uo Juana IP Id yes cecsy NIY ONIV Q TITR 019Z p XI 19 01 U09 JUBLIND 10 09 9S 0 Julod jes P ZNIG wij nb10 10 8 aS uo9 sod NVO OH OH Nei zeeSy LNIV O a O _ ONIV O _IINN 3S3 qulod jas uno 1109 10 99 9S ouks 4jU09 sod tod jes u NYO cezsy julod jas N N 101 U09 90 A d snia OH OH OH O7_ INIV O _ ONIV O 018Z paxy 418 01JU0D 90 A 10 09 8S Version 1 1 Figure 2 Speed controller User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 49 5 2 Speed controlled mode To activate the speed controlled mode the Commands windows has to be configured as follows J Controller enable nee C Torque control C Positioning J Couse program O For information on how to configure the setpoints in this operating mode see chapter 5 4 il Setpoint assignment through setpoint selectors 5 2 1 Optimizing the speed controller To optimize the speed controller for your application you can open the menu for configuring the controller parameters under Parameters
5. Error CAN Meaning Possible causes measures Release Reaction no error time c JE Iw code Angle encoder connected lt 5ms X Angle encoder cable defective Angle encoder defective Error Hall Check the configuration of the angle 17 7385 encoder encoder interface Angle encoder number of pairs of poles lt 100ms X X X and direction adjusted correctly Automatic motor identification performed Motor blocked I t error motor l t Check the power rating of the drive 19 2312 at 100 package I t error controller See error 19 lt 100ms X X X 20 2311 I t at 100 Motor blocked lt 100ms X X X Check the power rating of the drive package 26 2380 I t at 80 Motor Check the power rating of the drive lt 100ms X X X temperature 5 C package 27 4380 below maximum Check the power rating of the drive lt 100ms X X X package DIS 2 heated up by the motor Decouple Output stage the DIS 2 thermally if necessary temperature 5 C Check improve the installation and the 28 4280 below maximum cooling conditions Motor blocked lt 5ms X X xX Controller adjusted optimally particularly the internal control circuits for current and speed Acceleration parameterization too high Following error Error window too small Increase the 29 8611 control window Limit switch correctly wired lt 1ms xX X xX Limit switch defective Check the configuration of the limit 31 8612 Error limit switch switche
6. User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 58 DANGER Do not activate the positioning mode unless you have adjusted the motor parameters and the current and speed controller Incorrect basic settings may destroy the servo positioning controller the motor and the mechanical drive 6 3 Configuring and optimizing the position controller In positioning mode a superordinated position controller is active in addition to the speed control This position controller processes the deviation of the actual position from the set position and converts it into the corresponding setpoints for the speed controller The position controller generates a correction speed on the basis of the difference between the set position and the actual position and transfers this speed value as a setpoint to the speed controller The position controller is used in conjunction with the positioning control system It is a P controller with parameterizable input and output limitations You can open the window for parameterizing the position controller under Parameters Controller parameters Position controller Position controller Position controller Gain 0 20 0 20 EE 060Ct lt Following error max correction speed 500 000 r min Message 4 Dead range Dead range Enter the following values Gain Max correction speed In this field y
7. eecceecseeeeeeeeeeeeeennneeeeeeeeeeeeeeaee 29 4 3 Basic parameterization Of NOW MOTOMS ccccceeeseeeeeceeeeeeeeeeseeseeeeeeeeeeeeeeeeeeeees 30 4 3 1 ANQIO ONCOCGIS ero rnr E E ET A EE EEE 30 4 3 2 MO Or Bo FE te PE E E E A 33 4 3 3 POWGM SLAQG cornia o a e e E E Sake 35 4 3 4 Gurrent COmirolle tics 03 sce aae sek Pees E A aE EEEE S Aa Danses ent se eet 36 4 3 5 DC DUS MONILOLING eee eeeee cence eee eeeaeeeeeeeeecaaeeeeaeeseeeeeseaeeesaaeeseeeesaeestaaeeeeees 37 4 3 6 Motor temperature MONitOFing cee eeeeeece eee eeeee ences eani Ran akaa eneu R EEn eseina 38 4 4 Configuring application parameters ccccceceeeeeeseeeeeeeeeeeeeeeeeeeeeeeseaeeeeeeesaaeeees 39 4 4 1 General configuration 2 2 ee eee ce ceteeeeeeee cee eeeaaeeeeneeeeaeeeeaaesteeeeeeaeeetsaeeseaaeeseneeeaas 39 4 4 2 Configuring the display units ccececeeeeeeeeeeeeeeeeeeeeeeeeaeeeseaeeseaeeeseaeeeeaaeeeeeeeeaas 39 4 5 Definingin p t iMiss tanniner neering Mh Reatard 41 4 6 Selecting safety parameters ccccceescceeeeseeeceeeeeeseeeeeeeeeeeeeeeeseeaeeeeeneaeeneeesaaaeees 42 4 7 Configuring the controller enable logic ccccceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeneeeeeeeeeneees 43 4 8 Configuring the limit switch polarity sssssseesessneessnnrrsserrnnrernnressrrrnnerrnnnnssrernseet 44 4 9 Setting the direction of rotation sseseeessnnesoserneeeeneerssrtrnstrrnnnrrtnntnserernnerennneenne 44 User M
8. ccceeeeeeeceeeeeeeeeaeeeeeeeceeeecaaeeeeaaeseeeeeeesaeeeeaaeseeeeeseaeeeas 173 Table 37 Pin assignment to set up an RS232 adapter cable for connection to a PC notebook 173 Table 38 A Pin assignment of connector X8 cceeccceecceceseeeeeeeeseeeeeeeceeeeeeeseeeaeesseeseaeeeseeeaeeesensaees 174 Table 39 Description of the requirements to be met for the categories in accordance with EN 954 1178 Table 40 EMERGENCY OFF and EMERGENCY STOP according to EN 60204 1 Table 41 Stop categories User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 13 1 General 1 1 Symbols used in this manual il Information Important information and notes gt A Caution Non observance may result in severe property damage DANGER Non observance may result in property damage and personal injuries IV Caution Dangerous voltage The safety note indicates the possibility of a highly dangerous voltage 1 2 Features and area of application of the DIS 2 1 2 1 Basic information DIS 2 servo positioning controllers Decentralized Intelligent Servo 2 Generation are intelligent servo converters with extensive parameterization options Due to this flexibility they can be adapted to numerous areas of application Type key DIS 2 48 10 IC L Configuration connector RMS output current in ampere DC bus voltage 24 generation Type denomination User Manua
9. Internal operating voltages All operating voltages generated internally such as the 3 3 V supply of the processor are monitored 10 1 4 Heat sink temperature monitoring i Temperature derating The permissible maximum current will be reduced at high temperature levels to ensure a long service life of the servo positioning controller Shut down at overtemperature The heat sink temperature of the power stage is measured using a linear temperature sensor When the temperature limit described in the appendix in chapter 1111 14 1 Ambient conditions and qualification is reached an error message will be issued In addition a temperature warning will be issued when the temperature is about 5 C below the limit value 10 1 5 Motor monitoring Rotary encoder monitoring An error in the rotary encoder shuts down the power output stage In the case of resolvers the track signal is measured for example In the case of incremental encoders the commutation signals are checked Other intelligent encoders have other means of error detection Motor temperature measurement and monitoring The DIS 2 servo positioning controller has an analog input for detecting and monitoring the motor temperature Due to the analog signal detection also non linear sensors are supported The shut down temperature can be parameterized Alternatively the motor temperature can also be monitored with the help of a normally closed contact or a
10. Reference potential for the serial interface internally connected with the common 4 GND 5 GND reference potential for the intermediate circuit and the logic system i Shield f Shield E the cable shield on both sides of the connector housing User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 174 11 18 6 Connection Extension port X8 Configuration on the device 2x 26 RM 1 27 mm Buchsenreihe Mating connector X8 2 x 26 RM 1 27 mm Pinreihe eo eo r eo o oe o nnn Figure 42 Position and connection technology module Table 38 A Pin assignment of connector X8 Pin no Name Value Specification All signals with 3 3 V CMOS Not used logic level 24V Withdrawal of the protected logic supply of 24 V for max 100 mA future applications device variants Ding lov 24v Digital 24 V input for limit switches parallel to X1 DIN7 lov 24v Digital 24 V input for limit switches parallel to X1 GND o V l Reference potential ano lov Reference potential RxD 10V Serial interface signal RxD TxD 10V Serial interface signal TxD CANHI_NDR OV 5V Field bus signal CAN_H before filter CANLO_NDR o V 5V Field bus signal CAN_L before filter Technology module power supply 100 mA max together with 5 V Technology module power supply 100 mA max together with 3 3 V
11. 5V electronic system supply error Resolver track signal error carrier failure SINCOS track signal error SINCOS RS485 communication error SINCOS supply error Electronic power system under overtemperature Motor overtemperature User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 138 Error word high errh_err_field_1 Initialization error 30 Checksum error 29 Stack overflow 27 Pos precomputation error 25 3 operira mode error 24 _ Position data set error EEE data set error RS232 communication error 22 CAN communication error eses aeses i sr User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 139 11 8 Extended options in the Display units menu 11 8 1 Configuration of user defined display units If you click the User defined button in the Display mode field you can adapt the display units to your application Display units Display units Decimal places Direct input Jf OK Display mode r Translatory application Standard values Feed constant X Concet_ fi 0000000000 hea User defined User defined per revolution Direct input q Time base Torque in Nm Factor Time base speed in s
12. Freely selectable communication object Phase current Offset 5 00 Rotor position 5 Following error C DC bus voltage C Fixed voltage value C Freely selectable communication object I Numeric overflow limitation Ja cm Here a range of values is available Select the quantity you want to output through the analog monitor Configure the scaling in the Scaling field If you change the quantity to be displayed the units will be adapted automatically In the Offset field you can enter an offset voltage e g to display positive and negative values User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 94 If the check box Numeric overflow limitation is selected mathematical values above 10 V and below 0 V will be restricted to these limits If the check box is not selected values exceeding 10 V will be represented as voltages as of OV and vice versa m The option Freely selectable communication object is reserved for special 1 applications It is also possible to output and check other internal quantities of the controller to analyze them User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 95 9 Communication interfaces 9 1 Control through the CAN bus 9 1 1 Function overview The DIS 2 servo positioning controller uses the CANopen protocol in accordance with DS301 DS402 The followin
13. encoder q EE Automatic offset detection Y Torque controller recirculation P component controller via Encoder Motor EMK l component controller via Encoder Motor EMK Z x xX cma Depending on the angle encoder used the actual menu may differ from the menu shown below as different setting options are used The motor and the angle encoder can be identified automatically or manually If the motor is not installed in system and the shaft can move freely we recommend using the automatic identification The function can be called up in the following menus Parameters Device parameters Motor data Auto detect button Parameters Device parameters Angle encoder adjustments Automatic offset detection button User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 31 During the automatic angle encoder identification the controller is automatically activated for several seconds and the motor is driven with a controlled rotating field The automatic identification process determines the following parameters Number of pairs of poles of the motor not in the case of Six Step Hall encoders Angle encoder offset i e the offset between the index mark of the encoder and the magnetic axis of symmetry of the winding of phase 1 Phase sequence of the angle encoder left right Line count only in the case of SinCos encoders and incremental
14. 4 3 6 Motor temperature monitoring If your motor is equipped with a temperature sensor the sensor can be adjusted in the menu Parameters Device parameters Temperature monitoring Temperature monitoring Motor temperature C no motor temperature sensor digital motor temperature sensor analog motor temperature sensor Type ktY 81 82 210 220 250 gt Temperature threshold j x cmos In the Motor temperature field you can select whether you are using no motor temperature sensor at all an analog sensor or a digital sensor Select the digital motor temperature sensor option if the motor used is equipped with a normally closed contact or with a temperature sensor with PTC characteristics The controller supplies the sensor with a measuring current The system detects a voltage drop at the sensor and triggers the overtemperature error In the case of partly linear analog temperature sensors the temperature threshold has to be set If the analog motor temperature sensor option is selected you can do this in the analog motor temperature sensor field In addition you can choose one of the following standard temperature sensor in the scroll box KTY 81 82 210 220 250 KTY 81 82 110 120 150 KTY 83 110 120 150 KTY 84 130 150 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 39 4 4 Configuring application parameters 4 4 1 General configuration The
15. Course program mf om sre momi Posmen next roves 2 pouri vour ignore automatic ignore Off Off Posi ignore automatic 2 ignore Off Off Posi ignore automatic 3 ignore Target Off Posi ignore automatic ignore Target Off accept accept accept accept z p Modus File gt gt Program Debug C Edit Course program active NEXTI DOUTI Line 4 X Exit Course program stop NEXT2 gt DOUT2 Position 18 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 143 Implementation 7 Positions 1 2 3 and 18 are parameterized with a start delay of 1 second 7 The target reached setting for DOUT1 must be listed in line 3 and 4 as the setting ON and OFF will be taken over immediately and the signal would not be applied for one second When the drive moves to position 18 DOUT1 will be cleared 11 9 3 Example 3 Setting and inquiring digital inputs and outputs infinite loops First DOUT1 shall be set to HIGH for one second Then the system shall wait until NEXT1 is active Once this is the case the drive will move infinitely to position 16 start delay 3 seconds inquiry Next 1 Realization Course program o Posi ignore automatic 0 ignore On Off 1 Jump ignore automatic 2 ignore On Off 2 Posi ignore complete pos 16 ignore Off Off 3 Posi ignore automatic ignor
16. If the documentation in the language at hand is not understood accurately please contact and inform your supplier Sound and safe operation of the servo drive controller requires proper and professional transportation storage assembly and installation as well as proper operation and maintenance Only trained and qualified personnel may handle electrical devices In the sense of this product manual or the safety notes on the product itself are persons who are sufficiently familiar with the setup assembly commissioning and operation of the product as well as all warnings and precautions as per the instructions in this manual and who are sufficiently qualified in their field of expertise Education and instruction or authorisation to switch devices systems on and off and to ground them as per the standards of safety engineering and to efficiently label them as per the job demands Education and instruction as per the standards of safety engineering regarding the maintenance and use of adequate safety equipment First aid training The following notes must be read prior to the initial operation of the system to prevent personal injuries and or property damages o l These safety notes must be complied with at all times ji Do not try to install or commission the servo drive controller before carefully reading all safety notes for electrical drives and controllers contained in this document These safety instructions and a
17. eee eee eeeete eee e eects eeeeaeeeeaeeeeeeesaeestaeeesaees 158 11 14 14 Digital inputs and outputs X1 occ cece eee ee eeeeaeeeeeeaaeeeeeeaaeeeeeeeaaeeeeseaas 159 11 14 15 Incremental encoder output X1 eeeceeeeeeeeeeeeeeeceeeeeceaeeeseaeeseeeeeseaeeesaeeeenees 159 T1135 Mechanical MSTA AU OM ves ccs cstedsckaiecadieheaucceenennns ties ie seth eedeteaacnetmenetanale 160 T1151 IMpOrtant Notes iets bce Riba e Sheed EA cing aed eed 160 11 15 2 Position and connection of the pin and socket Connectors 161 11 15 3 HOUSING GIMENSIONS 0000 cece e cette ee eae aaan aanraai EK wak ENEE Paa Ewa ENKET eaS 162 TWA A Ae Installato merri reniras airetan aaia aana ba dings aia at havdtataladetiyanditesetands 163 11 16 Connectors at the DIS 2 48 10 ssssssessesnnnenesnnnsennresserrnnrernnnrssrnrnsserrnnnrrnnnneenne 164 11 16 1 Connection Power supply and I O X1 0 ccccecesceceeeeecceeeeeeeeeeeeeseaeeesaeenenees 164 11 16 2 Connection Angle encoder X2 c ccccccceeeeeeeeeeeeeeeeseaeeeeaeeseeeeesaaeeseneeeeaees 165 11 16 3 Connection Motor X301 X303 ee cece ceeeeeeeeeceeneeeceaeeeeaeeseeeeeseaeeeseaeeeeaees 166 11 16 4 Connection Holding brake X3 cccccccceeeeceeeeeeeeeeeeecaeeeeeeeseeeeesaeeeseeeenaees 166 11 16 5 Connection Extension port X8 cc cccccceeseeeeeeeeeeeeeeeaeeeeeeeseeeeeseaaeeseneeeeaees 167 11 17 Connectors at the DIS 2 48 10 IC eeccceeeecceeeeeeteeeeeeeesaaeeesessneeeeeeeeaa
18. COOPER PowerTools User Manual Copyright 2004 Metronix Mefigerate und Elektronik GmbH COOPER Power Tools DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Metronix MeBgerate und Elektronik GmbH Telefon 49 0 531 8668 0 KocherstraBe 3 Telefax 49 0 531 8668 555 gi D 38120 Braunschweig E mail vertrieb metronix de metronix Germany http www metronix de Seite 2 Copyrights 2006 Metronix MeBgerate und Elektronik GmbH All rights reserved The information and data in this document have been composed to the best of our knowledge However deviations between the document and the product cannot be excluded entirely For the devices and the corresponding software in the version handed out to the customer Metronix guarantees the contractual use in accordance with the user documentation In the case of serious deviations from the user documentation Metronix has the right and the obligation to repair unless it would involve an unreasonable effort A possible liability does not include deficiencies caused by deviations from the operating conditions intended for the device and described in the user documentation Metronix does not guarantee that the products meet the buyer s demands and purposes or that they work together with other products selected by the buyer Metronix does not assume any liability for damages resulting from the combined use of its products with other products or resulting from improper handling of machin
19. DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 81 8 Function of the inputs and outputs O Information concerning the pin assignment of the inputs and outputs can be found in Il chapter 11 16 Connectors at the DIS 2 48 10 8 1 Digital inputs DINO to DIN9 The DIS 2 servo positioning controller has ten digital inputs DINO to DIN9 Due to the limited number of connectors at the pin and socket connector some of the digital inputs are not active in all configurations The following table provides an overview of the configuration in which the digital inputs cannot be used X not available Table 11 DIS 2 48 10 digital inputs possible combinations Analog inputs active CAN active Incremental encoder emulation active Analog monitor active Digital outputs 1 amp 2 active Analog inputs active CAN active Incremental encoder emulation active Analog monitor active Digital outputs 1 amp 2 active Analog inputs active CAN active Incremental encoder emulation active Analog monitor active Digital outputs 1 amp 2 active User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 82 An overview of the available digital inputs and their current assignment can be found in the menu D
20. If there is a certain distance between the actual homing position i e the calculated zero point for the subsequent positioning runs and the home position of the homing run this distance can be entered into the Offset start position field If the option Go to zero position after homing run is selected the drive will move to the zero position at running speed after the homing run has been performed m If you select this option make sure that the zero position is not located behind the il destination of the homing run as this would cause a homing run error You can define a maximum search path If the DIS 2 servo positioning controller cannot detect a limit switch signal within this search distance it will issue an error message The search path is based on the maximum position limits The Max position limits button will lead you to the menu for parameterizing the general positioning settings e g positioning limits See chapter 6 4 Global positioning settings If the option Homing run at controller enable is selected the homing run will be started automatically once the controller is enabled Tab Driving profile Here you can enter Speed and Acceleration values for the following processes i Search Movement of the drive until it reaches the destination limit switch stop Crawl Reversal of movement at low speed to determine the contact threshold Running Optional movement to the zer
21. Maximum stop delay If the drive could not be brought to standstill in a controlled manner after the controller was disabled e g due to an incorrect parameterization the output stage will be switched off after this delay and the motor will coast down if it had not already been decelerated to zero Speed limitation The speed setpoint will be limited to the value set in this field Torque limitation The Settings button opens the Motor data menu see chapter 4 3 2 Motor data There you can define a torque limitation in Amperes by setting the limit Maximum current in A rms value User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 43 Absolute positioning range The Settings button opens the Settings position sets Course program menu see chapter 6 4 Global positioning settings There you can define a maximum positioning range SW limit switch functionality o Depending on the settings of the control circuits for current speed and position the Il parameters set may be temporarily exceeded due to overshoots in the control system This has to be taken into consideration when setting the system up It might be necessary to optimize the controller under real operating conditions 4 7 Configuring the controller enable logic To enable the power stage with a control system in the DIS 2 servo positioning controller the controller enable logic has to be configured The control
22. Cable ae a Supply and IO cable shielded x1 Figure 46 Connection of the DIS 2 to the power supply unit shield connection via cable The device variants DIS 2 48 10 IC and DIS 2 48 10 FB use Pluscon Variocon connectors made by Phoenix for X1 If the recommended metal connector housings see also chapter 11 17 1 and 71 18 17 are used a good PE connection is ensured by the design of the housing It is sufficient to connect the shield to the connector housing of the mating connector User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 186 A good PE connection has only a low impedance even in the case of very high interference frequencies Mounting the DIS 2 controller and the power supply unit to the same metal part of the machine is sufficient for most cases If not use a flexible copper strip width approx 10 mm or a connecting cable with a Cu cross section of at least 6 mm to set up a PE connection o DANGER For reasons of safety all PE ground connectors must be connected prior to start up The regulations of EN 50178 concerning protective grounding must be complied with during installation User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 INDEX A Actual speed value filter cccceesseees 49 Actual values Actual value WINdOW 0 ccceeseeeeeeees 112 ORSCIVO orre pre ra ER A EA 112 AMEE A a a a e as 113 Analo
23. Comment1 Comment 1 Comment2 Comment 20 Motor data Motor_data S OK X Cancel The fields Order Comment1 2 and Motor data will be taken over unchanged into the plain text output Enter the information as follows Field Content Order ID of the order project for which the parameter set was created Comment1 Comment2 Special features of the parameter set Motor data ID of the motor data set from the file motor ini For formatting reasons the entries should not be longer than half a line about 40 characters The current data is the default date for the plain text output The date field can be edited if you select the Change function The date will be taken over into the plain text output Page preview Press this button in the Print menu to create the plain text output and display it as a page preview It is a preview of the print output Save as text file If you click the Save as text file button you can save the print output as a txt file on the hard disk and process it further e g you can send it to another location by e mail O il The text files are saved in the TXT subdirectory of the parameterization program O il Parameter sets can be printed in the online mode and in the offline mode User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 151 11 12 Offline parameterization The tool bar underneath the menu bar indicates whether offline or
24. DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 50 speed setpoint This setting applies to most motors which can be operated using the servo positioning controller If a harder control response is required the gain of the speed controller can be increased further The gain limit is due to the fact that the drive tends to oscillate at high speed levels or when the shaft is excited The gain that can be reached in the speed control circuit depends on the load conditions at the motor shaft This is why you have to check the speed controller setting again when the drive is installed m If you parameterize the speed controller while the motor shaft runs at no load you have il to increase the speed controller gain after you have installed the drive 5 2 2 Optimization strategies The behaviour of the speed controller can be observed best by recording its response to a speed step Activate the speed control mode and deactivate any ramp functionality active in the setpoint selector menu You can realize a speed step for example by assigning setpoint steps through the RS232 interface Or you can use the setpoint assignment via an analog input which you have to short circuit in order to realize a step The reaction of the speed controller can be observed using the oscilloscope function see chapter 11 5 Using the oscilloscope function You can display the step response of the speed controller by setting the oscilloscope cha
25. Figure 33 Figure 34 Figure 35 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Numbered pins of X1 DIS 2 48 10 cece eeceeeeeeeeeeeeeeeeeaeeeeeeeeeeeeeeaaeeseaeeseeeeeseaeeesaeeneeeessas 164 Angle encoder Connector cceesceceeeeeeeeeeeeeneeceeeeeeeaeeeeaaesseneeecsaeseeaaesseceeceaeeesaaeeeeaaeesnees 165 Motor cable connection icn stan then a a a a a denial 166 Holding brake CONMECTION erru aeeaiei e a ae EE EE REENE E EE EAEE E E 166 Technology module connection 2 cece cee eeeeeeee cece cece eee eaaeeeeeeeeesecaaaaeceeeeeeeeseeenceaeeeeeeeeetaas 167 Numbered pins of X1 DIS 2 48 10 IC 0 cecceeeceeeeeeeceeeeeeaeeeeeeeeeeaeeeeaaeeeeeeeseaeeesaeeseaeeeeeas 168 Numbered pins of X1 DIS 2 48 10 FB 000 cceeeceeeeecceeeeeeeeeseeeeeeeaeeesaaeeeeeeeeseaeeesaeeeeeeesaas 169 Brake reSiStamCe COMMECTION cccceecccceseeeceeeseeeceeeteeececesneeceeesneeeeeeesseceeeesneeaeeetnneaeeneeaaes 171 Position and numbered pins X401 X402 and X5 at DIS 2 48 10 FB eee 172 Position and connection technology module eeeeeceeeeeneeeeeenteeeeeeeaeeeseeaaeeeeeenaeeeeeeaaes 174 Connection to power supply control and MOTO eeeececeseesceeeseeeeeceseeeseeeeseeseesesesaeens 176 Wiring example for the power supply and EMERGENCY OFF EMERGENCY STOP 181 Connection of the DIS 2 to the power supply unit shield connection on th
26. X303 are the connectors for the three motor phases U V and W X8 is an extension port for future technology modules X303 X302 ee X301 X3 Figure 30 Arrangement of DIS 2 pin and socket connectors top view of electronics module User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 162 imensions 11 15 3 Housing d yyBneup on Ly Ayo we4 I JU Z gt IZZID GR 5 s3IVAYNS ASSHL 40 9NINIH YW ON ny U nnn Ini IUU RED I WU UUU YUL SN GLE v v pappe suaisuawip g U Housing dimensions Figure 31 Version 1 1 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 163 11 15 4 Installation The servo positioning controller can be mounted directly on the motor using a seal The mounting surface on the motor should be plain and smooth with a circumferential groove
27. _ _ _ I g Figure 16 Homing to the negative stop Method 18 Homing to the positive stop If this method is used the drive moves in the positive direction until it reaches the stop The DIS 2 servo positioning controller needs at least 1 second to recognize the stop The mechanical design of the stop must be such that it cannot be damaged at the parameterized maximum current The zero position refers directly to the stop User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 69 Figure 17 Homing to the positive stop Do not use homing methods 16 and 17 unless the mechanical system of the positioning axis is configured accordingly Set the running speed as low as possible in order to limit the kinetic energy when the drive hits the stop Method 35 Homing to the current position no movement In the case of method 35 the zero position refers to the current position when the homing run is started 6 8 2 Parameterizing the homing run The homing run can be parameterized in the Homing position menu You can open this menu under Parameters Positioning Homing position or by clicking the REF button in the tool bar The following window will appear Homing position Settings Driving profile Mode m max search path Destination Limit switch z ie Max position limits Home position Limit switch Direction negative z 65536 000 R Mode 17 Offset start po
28. can be also displayed and modify here User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 62 The information 0 15 after the field name Positioning indicates that the selection relative applies to all positions in the 0 to 15 position group Some of the other parameters in this menu apply to all 64 positions In this case the field name is followed by 0 63 If no information is given after the field name the parameter applies only to this position The Positioning field can be used to state whether the specified destination should be interpreted as an absolute value referring to the reference point or as a relative value Relative refers to the current position setpoint e g during a positioning run being performed The option relative to last destination calculates the new position on the basis of the destination reached or currently being approached The relative option leads to different results depending on the setting in the field Start during positioning see below If the combination relative Wait for end of positioning run is selected the new position refers to the destination In the case of the combination relative Interrupt actual positioning the new destination will be calculated starting from the current positioning setpoint The field Start during positioning defines the behaviour of the servo positioning controller when a positioning run is still running and the controller re
29. 0141 can_node_id_offset Node number offset through digital inputs 0 63 0142 can_node_id_base Basic node number for CAN 0 127 0143 can_baudrate Sets the baud rate for the CAN bus to kBaud 125 250 500 kBaud 0144 can_comm_active Activates the CANopen protocol 1 CANopen 0145 _ can_options Sets various options none 0146 can_pdo_tx0_ mapped Identifier of mapped SDO object 0 transmit none 0147 can_pdo_tx1_mapped Identifier of mapped SDO object 1 transmit none option 0148 can_pdo_rx0_mapped Identifier of mapped SDO object 0 receive none 0149 can_pdo_rx1_mapped Identifier of mapped SDO object 1 receive none option 014A can_sync_time_slot Nominal interval between two SYNC frames inone on the CAN bus required for interpolated position mode 014B can_pos_fact_num Numerator of the factor for position none representation 014C lcan_pos_fact_div Denominator of the factor for position none representation 014D __ can_val_fact_num Numerator of the factor for speed none User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 133 No Name Meaning Scaling representation 014E can_vel_fact_div Denominator of the factor for speed none representation 014F can_acc_fact_num Numerator of the factor for acceleration none representation 0150 ca
30. 3 Speed controller too soft Remedy Increase the gain factor by 2 to 3 tenths Then decrease the time constant by 1 to 2 ms Case 2 Speed controller too hard Figure 4 Speed controller too hard Remedy Decrease the gain factor by 2 to 3 tenths Increase the time constant by 1 to 2 ms Case 3 Speed controller set correctly Figure 5 Speed controller set correctly User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 52 5 3 Torque controlled mode To activate the torque controlled mode the Commands windows has to be configured accordingly J Controller enable ree C Speed control Positioning ja Course program The torque setpoint can be specified in A or Nm This can be done with the help of the menu item Options Display units The associated menus will then automatically adopt the selected unit If you want to use the unit Nm for the torque you have to make the torque constant known i e the conversion factor between the current and the torque The torque constant has to be entered into the menu Parameters Device parameters Motor data and can be calculated using the information stated on the type plate of the motor Divide the rated torque by the rated current O il A torque constant of 0 Nm A is not permissible if torques in Nm has been selected 5 4 Setpoint assignment through setpoint selectors The DIS 2 servo positioning con
31. 78 7 1 5 Coves IS nesiaces erate ree r E A E EA ETT 79 7 2 Debugging a course program sssssssseseiiitttteeerittrittttttttkttinttnsssnsttttnnnnnsnatennen nn 80 8 Function of the inputs and OUtPUS ccseeeeeeeeeeeeeeeeeeeeneeeeeeeeeeeeeneees 81 8 1 Digital inputs DINO to DING sedis ees crzcasgsdeusadeedenes ex saat bontetenteascasy nerasteieecacaanee 81 8 1 1 Configuring the digital inputs cc cceeeeeeeeeeeeeeeceeeeeeeaeeeeeaeeseeeeesaeeeeaeeeeeeeeaas 83 8 2 Extended function of the digital inputs Tipp amp Teach ssec 83 8 2 1 Teaching positon S reira eera en e E ERT ETE AAEE 84 8 3 Digital outputs DOUTO to DOUTS os cars icensteccedanattendade restates secepdecesdecanescacnteasec 86 8 3 1 Configuring the digital outputs ccceeeeeeeeeeeeeeeeeeeeeeceaeeeeeaeeeeneeseaeeesaeeeeeneeee 86 8 3 2 Configuring the messages for the digital outputs ceeeeeeeeeeeeeeeeteeeeeeeeees 87 8 4 Incremental encoder emulation through DOUT1 and DOUT2 eee 89 8 5 Holding brake DOUTI naa detest aed tes ewer tunis a e a ad 90 8 5 1 Brake MUNCUONS e srn AE AEA E A AT caubeeataccod dag esesdith awicetacesasie 90 8 6 Analog inputs AINO and AINA sssciccicnisadeatceediveieteetln seis itt eiaeeeeuhaieneeee 92 8 7 Analog output AMON ses a jtecetie Cate tatst ce oe ihetctces Cidetejdecernecegeudens aera teecetaate eetedueuae 93 9 Communication INterfACeS cccccceeseeeeeeeeeeeeeeeeeeeeeeseeeeeeeee
32. Connection to resolver signal R1 max 50 mMArms Others Connection to incremental encoder track N DATA 14 EIN 12 V 100 mA 12 V power supply for Stegmann Hiperface encoder Resolver Connection to resolver signal R2 Others Connection to incremental encoder track N DATA REF 3 Vams ditt N max 50 mArmus User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 166 11 16 3 Connection Motor X301 X303 Configuration on the device 6 3 mm FAST ON male Mating connector X301 X303 6 3 mm FAST ON female insulated externally 7 Gi Figure 35 Motor cable connection Table 29 Pin assignment of connector X301 X303 11 16 4 Connection Holding brake X3 Configuration on the device JST No BO2B XASK 1 Mating connector X3 JST No XAP 02V 1 contacts JST No SXA 001T P0 6 eeeeoeeeed e s Figure 36 Holding brake connection Table 30 Pin assignment of connector X3 Pane pame ae Specification 0V 24V Digital output high active for the holding brake max 700 mA internal supply via the 24 V logic supply OV Reference potential for the holding brake User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 167 11 16 5 Connection Extension port X8 Configuration on the device 2 x8 RM 2 54 mm female Mating connector X8 2 x 8 RM 2 54 m
33. EMERGENCY STOP switching device A safety chain is connected to this device PLC An SPC or an industrial PC that is used to control the system Under normal operating conditions the switching contacts in the ECS are closed The SPC actuates the power contactor K1 through a digital output Every DIS 2 unit signals to the SPC that it is ready for operation via DOUTO Thus every DIS 2 unit requires one digital input at the SPC The SPC uses a second digital output to control the controller enabling signal DIN9 of all the connected DIS 2 units This common enabling signal is also fed through the ECS In the event of an error EMERGENCY OFF EMERGENCY STOP the intermediate circuit supply and the controller enabling signal will be disconnected The selection of a suitable ECS depends on the actual application In the simplest case no ECS is used Instead multipolar switching contacts are used in the safety chain User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 181 S04 ureyo Ayayes adINep Bulyoyms Ly UM Seues ul eC pomo TO SEIUOO ueu Aous6iewe AO pug jeuondo x Lnod j lt Lnoa B A NIG x NIG 49 O1JUOD D1d Japoougz JaAjosey a b a a aseude OV A 00t Od A 8b Ajadns 13MOd Bulpjoy i l HI seyd OoOo OV A 0 2 Ld aulyoew snouoiyouss Wd ld OL 8b 2 SIa 90 A vz Aiddns 91607 l 2 SId 210 Figure 4
34. PTC In this case however the shut down threshold cannot be parameterized It current monitoring with motor warning The DIS 2 servo positioning controller also has an l monitoring system to limit the average power loss in the motor Since the power loss in the electronic power system and in the motor increases in a square manner with the current in the worst case the squared current value is taken as the measure for the power loss When 80 of the maximum integrated value are reached a warning parameterizable will be issued When 100 is reached the maximum current will be limited to the rated current Automatic motor identification process monitoring The system monitors whether the automatic identification of the phase sequence the number of pairs of poles and the angle encoder offset has been performed successfully User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 103 10 1 6 Motion sequence monitoring Following error The deviation between the position setpoint and the actual position is monitored Positioning range A running positioning run is monitored to see whether the positions are within the adjustable positioning range Limit switches If both limit switches are simultaneously active an error will be issued Course program The course program is monitored to detect invalid commands 10 1 7 Additional internal monitoring functions Memory test check sums
35. TANG oko 1 eee 34 Manual configuration s es 34 Motor data irede annat e Ache 33 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB N Numerical input fields c eeeeeeeee 110 o Offline parameterization 150 OKni e a aeia i 110 Optimisation Speed controller sseeeeseeeeeeeneeee en 50 Optimization Current controller cccceccecceseeeereeee 36 Position controller 59 Oscilloscope Channels vravzedit ccs ccavtarzedctasirdeatiieascaviaaes 118 SENG ssi ee Ga a ah Niais 118 Time DASC 0 eeeceesceeeeeeeeceeeeaeeeeeeeeeaes 118 Trigger cceccceeeeeceeseeeeeeeeeseeeeseaeeneeeeeees 118 OSCIIOSCOPEC eeceeeeeeeeceeeeeeeteaeeteeeeeeeees 118 P Position controller Manual configuration ccceseeeees 58 Position controlled mode 0 eeeeeeees 57 POSITIONING ss sisk teense ea abe tee 57 Approaching positions eseese 64 Destination parameters c0ccceeeeeeeees 61 SEMINGS E EE ieee 61 Speeds Acceleration Times 06608 62 Power stage ceecceceeeceeeeeeeeeeeeseeeeeenaeeneneees 35 Printing Parameter S t 148 150 Printing a parameter set 0 eeeeeeeee 148 Q Quitting the program ssssssseseesneeeeneeene 113 R REF DUON na ae a eats 69 RS232 interface cccceeeeeeeeceeeeeeteeeeeeees 98 Run Celay ceeceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeeees 91 S Safety parameters n eenen 42 Saving a DCO file Offl
36. The internal FLASH memory program and data flash memory is monitored with the help of a check sum test and the processor stack is also monitored Operating mode Depending on the operating mode specific monitoring functions are activated Communication The communication through the serial interface and through the field bus CANopen is monitored 10 1 8 Operating hour meter The DIS 2 servo positioning controller has an operating hour meter In the DIS 2 ServoCommander parameterization software it is displayed on the Times tab in the Info Info menu The count of the operating hour meter is saved in the internal flash once in a minute As a result there may be deviations of up to 60 seconds after a reset or a power on 10 2 Error overview The following table provides an overview of all possible errors In the Reaction column the reactions you can parameterize are marked with an X O The parameterization of the possible errors is described in chapter 10 4 Error il management The abbreviations C E and W have the following meaning Critical error The controlled operation of the motor cannot be guaranteed The power stage will be switched off immediately The motor will coast down Error The motor will be decelerated with the safety ramp Then the power stage will be switched off Warning The motor can still be used though perhaps only for a limited amount of time The user can para
37. When the controller is enabled in the operating mode speed control and position control or positioning the speed setpoint will be set to zero during this delay As a result the motor will be supplied with power but the drive remains in standstill with a holding torque until the brake is completely unlocked When the controller is disabled the speed setpoint will be set to zero When the actual speed is about zero the holding brake is activated The stop delay takes effect as of this point of time During this time the drive will be kept in its current position until the holding brake has developed its full holding torque When the delay period is over the controller is disabled In both cases the mechanical wear of the holding brake is reduced controller enable output state active holding brake unlock t lte run delay ta stop delay i speed setpoint speed actual value Figure 26 Holding brake time response User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 92 O After the controller has been enabled speed setpoints or positioning start commands do il not become effective until at the end of the run delay In torque control mode the torque setpoints become active or inactive when the controller is enabled internally 8 6 Analog inputs AINO and AIN1 The servo positioning controller has
38. a a E E 13 1 1 Symbols used in this manual ecg telaste tacheiien eaaided daca tecletind a heated enemas 13 1 2 Features and area of application of the DIS 2 eececeeeeeeeeeeeeneeeeeeteeeeeeeaes 13 1 2 1 Basic informalo seii aE aa E EKE i Er RE NEEE S 13 1 2 2 Area of application and intended USC cccsceceeeeeeeneeeeeeeeeeeeeseeeesaeeeeeeeeeneess 14 1 2 3 DIS 2 leah es aieia a a a A dian tina SES 14 1 3 DIS 2 ServoCommander features ccccscsecccssessesesssesescssssssesessacsescseensseseseees 16 1 3 1 Basic INTOFMALION isriiceeeriecctvieaitec e seeds sade 2c tale neeiiee Ld tea deal ac coadiideda tures 16 1 3 2 DIS 2 ServoCommander TOAtUROS 32 c5sist crics cei as sacri naisauneh dzlspoatardinaneiss ens 16 1 3 3 Hardware and software requirements cceeccceeeeeceeeeeeeceeeeeeeeseeeesaeeseneeenaees 16 1 4 Documentations nA EEEE Ek EEEE AEE NEEE EERE E SEKE 17 1 5 Supply state and scope of supply cecceeeeeececeeeeeeeeeeeeeeeaeeeeeeeeaaeeeeeenaeeeeeees 17 2 Safety notes for electrical drives and cControllers ccccccscseseeeeees 19 2 1 GSMS EOI e pera A cece aeatind pais tacts tases casiticeeye coed ee dededcnnadles nd eater AST 19 2 2 Danger resulting from MISUSE ss cis cence bees ea aaah eee 20 2 35 SAICTY Nole S E cede nela glace deren EE 21 2 3 1 General Safety notes 0 2 cececcceeeeeeeeceecee cence eeeaaeseeeeeseeeeeseaeeeeaaesdeneeceaeeesaeeeeeneeee 21 2 3 2 Safety notes for assem
39. and DIS 2 FB Content 1x 18 pin Phoenix mating connector comprising VARICON mating connector sleeve frame and sleeve housing 16 pin mating connector for angle encoder incl crimp contacts 2 pin mating connector for holding brake incl crimp contacts Metronix part number 9019 0300 00 Metronix part number 9019 0210 00 DIS 2 IC control panel with Phoenix pin and socket Metronix part number 9019 031 0 00 connector DIS 2 FB control panel with Phoenix pin and socket connector Metronix part number 9019 0320 00 RS232 connecting cable for DIS 2 48 10 FB Assembled connecting cable for the controller parameter configuration length approx 150 cm M8 circular connector for connection to the controller DSUB9 connector for connection to the COM port of the PC Metronix part number 9019 0221 00 Braking resistor for DIS 2 48 10 FB Plate resistor Metallux PLR 250 5 Q 10 100 W dimensions 55 mm x 43 mm height 1 5 mm height in the area of the connecting cable 4 mm with strands 100 mm User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Metronix part number 9519 0001 00 Version 1 1 Page 19 2 Safety notes for electrical drives and controllers 2 1 General notes o Il In the case of damage resulting from non compliance of the safety notes in this manual Metronix MeBgerate und Elektronik GmbH will assume any liability
40. and put to the surface 2 The error will be stated in red writing on the lower bar of the main window Error messages Error text Errors are handled in three steps 1 Error analysis In the example given here the error is caused by a broken unconnected connection to the angle encoder 2 Error elimination Eliminate the cause of the error In this example the correct connection to the angle encoder has to be provided 3 Error acknowledgement Click on the Clear button in the error window If the error was successfully eliminated the window will be minimized If the error still exists it will be maximized again You can minimize the window by clicking the Cancel button Any existing error message will remain in the error window on the status bar O il The Cancel button does not eliminate any error User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 109 10 4 Error management The error management window and the error window are used for error messages and warnings You can open the error management window under Error Error management Error management 1 16 17 32 33 48 49 64 Eror Controlled Stop x a lo c Cc E No 1 Unknown error om n A No 2 Unknown error C C C QE No 3 Motor overtemperature C C C E No 4 Over undertemperature power stage 6 C C C mm No5 Er
41. assessment following the machinery directive 98 37 EC EN ISO 12100 EN 954 1 and EN 1050 the machine manufacturer has to plan the safety system for the entire machine whilst taking into account all the integrated components Among these are also electric drives The standstill of the machine has to be initiated and ensured by the control system of the machine This applies particularly to vertical axes without a self locking mechanism or weight compensation The standard EN 954 1 subdivides the requirements placed on control systems into five categories graduated according to the level of risk see Table 10 Table 39 Description of the requirements to be met for the categories in accordance with EN 954 1 Category Summary of requirements System behavior Principles to achieve safet Safety related parts of control systems and or their protective equipments as well as their components shall be designed constructed selected assembled and combined in accordance with relevant standards to that they can withstand the expected influence The occurrence of a fault can lead to the loss of the safety function Mainly characterized by selection of components The requirements of category B shall apply Well tried components and well tried safety principles shall be used The requirements of category B and the use of well tried safety principles shall apply The safety function must be checked at suitable intervals by
42. been selected as the quantity to be displayed you can display any desired communication object on the oscilloscope This requires the following additional information The object number of the communication object Information as to whether the object returns a value with a sign In this case please check the signed check box The physical unit of the object A mask This mask is used to single out and display individual bits of a communication object In the case of analog values this mask should be set to FFFFFFFF hex The main purpose of this mask is to display individual bits of a status word O 1 The representation of freely selectable communication objects makes sense only in special cases The time resolution and the recording delay can be configured on the Time base tab 2 The upper Time slide is used to define the time resolution A value of 10 msec div for example means that the width of one square on the oscilloscope display corresponds to a time of 10 milliseconds The Delay slide is used to determine the position of the trigger event on the oscilloscope screen A value of 0 means that the trigger event will be plotted at the left edge of the oscilloscope screen A negative delay value means that the events before the occurrence of the trigger conditions will also be recorded Pretrigger The trigger source can be selected from the list in the Trigger source field on the Trigger ta
43. chapter 11 7 1 Basic units Table 24 List of all communication objects No Name Meaning Scaling 0000 currc_cyc_time_currc Current controller cycle time Basic unit time 0001 _ currc_cyc_time_spdc Speed controller cycle time Basic unit time 0002 currc_cyc_time_posc Position controller cycle time Basic unit time 0003 main_abtast_ablauf Communication handler cycle time Basic unit time 0004 fioh_uzk_nenn Rated DC bus voltage of the controller Basic unit voltage 0005 _ currc_i_nom_dev Rated device current peak value Basic unit current 0006 currc_i_max_dev Maximum device current peak value Basic unit current 0007 pfc_uzk_min Minimum DC bus voltage of the controller _ Basic unit voltage 0010 __ srvc_device_type Device ID none 0011 main_cpu_time_remaining Control interrupt utilization Basic unit per cent 0012 __ srvc_operation_time Operating hour meter in seconds 0013 _ srvc_commiss_state Commissioning state none 0014 __ srvc_device_serial_num Serial number of the device none 0015 srvc_device_revision Hardware revision Upper 16 bits Main revision Lower 16 bits Subrevision 0016 srvc_encoder_type Selected angle encoder variant Upper 16 bits Main revision Lower 16 bits Subrevision 0017 srvc_soft_main Firmware main revision and subrevision Upper 16 bits Main revision number of the version management s
44. during the teaching process 1 Activate the Tipp amp Teach mode in the commands window with DIN 0 Approach the desired target position with DIN 4 DIN 5 2 Activate the teaching function step 1 by setting DIN 3 to high This deactivates the function Homing Start of the digital input DIN 6 and activates the teaching function 3 Activate the teaching function step 2 by setting DIN 6 to high User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 85 4 Use the digital inputs DIN 0 to DIN 5 to select the position set into which the current actual position is to be saved 5 With the falling edge at DIN 6 the current actual position is taken over into the selected position set 6 The digital inputs will now be ignored for a preset time before they are available again This time has to be set in the Destination parameters window in the Tipp amp Teach position set A Attention The position s that is are written into the position set s with the help of the teaching function is are not automatically permanently saved in this these set s They can be saved permanently using the Save Parameter button The following chronological diagram shows the teaching process of a target position t 5 set pos g beach thoa X J k Setup min tignor ignore p ier TEE DING Ref Teach DINS Hi KD Tipp
45. enabled in the positioning mode The __ button leads to the course program menu see chapter 7 Course program In addition you can define two start lines for the course program The option 16 64 position sets can be used to define the desired number of target positions destinations e fthe option 64 position sets is active you can parameterize 64 independent target positions All the other motion profile parameters accelerations start delays options however have to be set in groups There are four groups with the position numbers 0 15 16 31 32 47 and 48 63 e Ifthe option 16 position sets is active you can parameterize 16 independent target positions The motion profile parameters accelerations start delays options can be set individually for each position User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 61 In order to switch from the 64 positions mode to the 16 positions mode or vice versa the DIS 2 has to reorganize the internal data structures for the positioning process During this reorganization settings already made for the targets are lost The position data sets are reset to default values This means that you have to re parameterize all the targets after you have changed the operating mode 6 5 Parameterizing position sets In the DIS 2 servo positioning controller 16 or 64 positions sets can be parameterized The parameterizing accom
46. encoders The following conditions have to be fulfilled for an automatic identification The motor is completely wired The DC bus voltage intermediate circuit voltage is present The servo positioning controller is error free The shaft must move freely DANGER Prior to starting the motor identification you have to set the current limits menu Parameters Device parameters Motor data as otherwise the motor may be destroyed Click the Auto detect button in the angle encoder menu The following menu will appear For the identification the motor must be able to rotate freely Attention Motor is starting on its own x Cancel AN Caution During the adjustment the shaft automatically starts to move for several seconds A successful motor identification is indicated by the following message Motor identification User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 32 If an error has occurred the program displays the following message Motor identification If the automatic determination cannot be performed the angle encoder data has to be entered manually This problem may occur in the following cases o e f special motors with a very high numbers of pairs of poles are used e fthe motor shaft cannot move freely e fthe mass inertia of the motor is very high and if the motor does not settle in the impressed position within the meas
47. faulty drive movements must be taken into account their magnitude depends on the type of control and on the operating state DANGER Dangerous movements Danger to life risk of injury serious personal injuries or property damage For the reasons mentioned above personal protection must be ensured by means of monitoring or superordinated measures on the device These are installed in accordance with the specific data of the system and a danger and error analysis by the manufacturer The safety regulations applying to the system are also taken into consideration Random movements or other malfunctions may be caused by switching the safety installations off by bypassing them or by not activating them 2 3 6 Protection against contact with hot parts DANGER Housing surfaces may be hot Risk of injury Risk of burning Do not touch housing surfaces in the vicinity of heat sources Danger of burning NED Before accessing devices let them cool down for 10 minutes after switching them off NED Touching hot parts of the equipment such as the housing which contain heat sinks and NED resistors may cause burns 2 3 7 Protection during handling and assembly Handling and assembly of certain parts and components in an unsuitable manner may under adverse conditions cause injuries DANGER Risk of injury due to improper handling Personal injury due to pinching shearing cutting crushing The followin
48. floppy disk etc The parameter set is read by the DIS 2 servo positioning controller and saved to a file or it is read from a file and saved in the DIS 2 servo positioning controller The extension of the parameter files on the PC end is DCO The following menus of the parameterization program are used for reading and writing of the DCO files File Parameter set File gt gt Servo This command transfers a DCO file from the PC to the servo File Parameter set Servo gt gt File This command writes a DCO file to the PC Please note that when writing a parameter set to a file on the PC you can fill in the fields Motor type and Description You can also enter a comment of up to 100 lines if you select the Comments tab We highly recommend generating descriptions to prevent confusions of parameter sets The name of the parameter set should also be selected carefully to facilitate finding the right file o 1 Please use the comment fields to save information O 1 DCO files can be sent from one location to another on floppy disks CD ROMs and or by e mail User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 149 11 11 3 Printing parameter sets You can print parameter set in plain text display and save them by selecting the menu option File Parameter set Print The following menu will be displayed Print positions x Cancel C none All C from 0 to 63
49. frequencies An optimum PE connection can be obtained by mounting the DIS 2 controller directly on the motor If you want to mount the DIS 2 controller and the motor separately make sure to mount them on the same metal part of the machine In this case the surface of the machine part should be made of uncoated aluminium or galvanized sheet metal 11 20 5 Connection between the DIS 2 and the power supply unit Use cable with a sufficient cross section to reduce ground bouncing effects on the DC bus supply intermediate circuit supply 2 5 mm AWG13 should be sufficient for a cable length of up to 5 m between the power supply unit and the DIS 2 controller Use a star shaped cable layout see chapter 11 19 1 Connection to Power Supply and control in system if you want to connect several DIS 2 controllers to one power supply unit The star point of the reference potential should be as close as possible to the power supply unit The power supply unit should have a Y capacitor of at least 100 nF between the DC bus voltage intermediate circuit voltage and PE as well as between GND and PE Make sure to set up a good PE connection between the DIS 2 controller and the power supply unit It is important to ensure a good feedback of the high frequency leakage currents generated by the clocked power stage in the DIS 2 controller combined with the winding capacity between the motor phase and PE in the motor To make sure that the radiat
50. i e to 32 or 8 destinations depending on the operating mode Table 10 Available position sets if the course program is active and the Course Posi input 0 Configuration 64 positions 16 positions Explanation 4 groups with 8 positions each 8 complete positions Standard configuration Pos 0 7 16 23 32 39 48 65 Pos 0 7 Control signal Course Posi at DIN 3 4 groups with 8 positions each 8 complete positions New configuration Pos 0 2 4 6 60 62 Pos 0 2 4 6 8 10 12 14 16 Control signal Course Posi at DIN 0 7 1 Creating a course program The menu for managing and creating course programs with up to 32 program lines can be opened under Parameters Positioning Course program Foursome m cmo stop Nextt Por ine1 NExT2 Pos ine 2 Douni vourz 0 s ignore complete pos ignore Posi ignore ignore complete pos 1 Off Off Posi ignore complete pos 2 ignore Off Off Posi ignore ignore complete pos 3 Off Off Posi ignore complete pos 4 ignore Off Off Posi ignore ignore complete pos 5 Off Off Posi ignore complete pos 6 ignore Off Off Posi ignore ignore complete pos 7 Off Off Posi ignore complete pos 8 ignore Off Off na Modus C Debug Edit M X Exit The File gt gt Program can be used to load an already existing course program into the servo positioning controller while the Program gt gt File button can be used to save a
51. online parameterization is active Table 26 Online Offline activation Online Offline Online parameterization active Online oftine Offline parameterization active The active mode is highlighted in green The parameterization program allows access to parameter sets even if no serial communication with the DIS 2 servo positioning controller has been established This however requires the presence of a corresponding DCO file see chapter 11 11 2 Loading and saving parameter sets It is possible to read controller parameters from a DCO file change controller parameters save modified values in the same or in another DCO file print parameter sets see also chapter 11 11 3 Printing parameter sets In order to let the changes made become effective the modified parameter set has to be loaded into the DIS 2 servo positioning controller see chapter 11 11 2 Loading and saving parameter sets The illustration below shows the principle of the offline parameterization PC DCO file DIS 2 ServoCommander gt Figure 29 Offline parameterization To activate the offline parameterization click on the menu item Options Communication Offline parameterisation or on the offline icon in the tool bar You will be asked which DCO file to open Select a corresponding file DANGER If you use a DCO file for a different type of device make sure to check the config
52. position controller can refer This position is called home position and has to be re determined whenever the controller is switched on This is done during a so called homing run Several methods are available for this o Absolute value encoders e g SinCos encoders with multiturn functionality are an il exception These encoders do not need to be homed 6 8 1 Homing methods There are 4 possible targets for the homing run Homing run to the negative or positive limit switch with or without the index pulse of the angle encoder Homing run without additional signal to the negative or positive stop Homing run to the index pulse of the angle encoder No movement The homing run is started by enabling the controller or through the field bus When the homing run is completed successfully this is indicated by a set status bit in the device This status can be evaluated through a field bus or through a digital output The different homing methods are explained in the following sections The numbers in little circles in the pictures correspond to the home positions of the corresponding homing method The number do not correspond to the homing method numbers defined in CANopen DSP402 Chapter 6 8 2 Parameterizing the homing run describes how to active the homing methods and how to set the required parameters Method 1 Negative limit switch with index pulse evaluation User Manual DIS 2 DIS 2 48 10 DIS
53. possible options depend on the selected general configuration which can be set in the menu Parameters Application parameters General configuration The following menu in which you can select the drive configuration will be displayed General configuration Application Gearbox Gearbox physical units rotary motion C translatory motion Display units R r min t min s Settings S OK X Cancel In the Application section you can define whether your application is a rotary or a translatory application If you want to use the unit of the outgoing shaft for the configuration of your application click the button in the Gearbox field or click the Settings button This will lead you to the Display units menu described in chapter 4 4 2 Configuring the display units Application examples e Rotary with gearbox Opening closing a barrier e Translatory with feed constant Positioning a carriage to transport goods for further treatment 4 4 2 Configuring the display units The menu Options Display units can be used to configure the display units for positions speeds and accelerations These unit will be used only for the display in the parameterization program The parameterization program uses so called communication objects to communicate with the controller These communication objects have a fixed physical basic unit These basic units are used for every access via t
54. program just created In the Modus field you can select either the input mode Edit or the monitoring mode Debug The monitoring mode is described in detail in chapter 7 2 Debugging a course program If you click the Edit line button or a line in the table another window opens in which you can define commands for the selected course program line The program offers the following basic course program commands Position branch and linear position sequence Branch Line User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 75 i Level test and unconditional program jump gt End of program Chapter 11 9 Course program Examples includes three small example applications for a course program The various course programs are explained in detail in chapter 7 1 2 End of program to 7 1 5 Level test 7 1 1 Course program options In the Options field you can define the evaluation of the digital inputs NEXT1 and NEXT2 If you have selected Evaluate NEXT1 or Evaluate NEXT2 the lower section of the window will show an additional field with the input options for the corresponding signal Ignore if target not reached If the signal comes in while a positioning run is running it will be ignored If no positioning run is currently being performed the new following position following line X will be approached Go to position line immediately The new following po
55. realized by the control by setting the setpoint to zero In order comply with the requirements of stricter safety categories additional external monitoring devices have to be used Table 41 Stop categories Stop category 0 Uncontrolled stop Stopping by immediate EMERGENCY OFF or EMERGENCY STOP disconnection from power Stop category 1 Controlled stop Power is disconnected when the EMERGENCY STOP machine has come to a standstill Stop category 2 Controlled stop Power is not disconnected when Not suitable for EMERGENCY OFF or the machine is at a standstill EMERGENCY STOP User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 180 11 19 3 EMERGENCY OFF EMERGENCY STOP wiring examples Figure 8 on the next page shows a realization example for a system that comprises one or several DIS 2 units power supply units with a mains power connection a control system and switching elements to realize the EMERGENCY STOP function in accordance with EN 60204 1 stop category 1 The system comprises the following components S1 Mains power switch F1 Fuse for the 24 V logic supply The logic supply is supplied with 230 V AC on the primary side through L1 and N Q1 3 phase circuit breaker The rating depends on the number of DIS 2 units and on the requirements of the power supply unit K1 Power contactor F2 Fuse in the 48 V power stage supply system Every DIS 2 needs a separate fuse ECS
56. s arising from faults is acceptable User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 179 The standard EN 60204 1 describes possible actions for emergency situations and defines the terms EMERGENCY OFF and EMERGENCY STOP see Table 11 Table 40 EMERGENCY OFF and EMERGENCY STOP according to EN 60204 1 Definition EN 60204 1 Emergency situation EMERGENCY This intervention is used to achieve electrical An EMERGENCY OFF has to be used if there is a OFF safety in an emergency situation by risk of electric shock or another risk caused by disconnecting the electrical power to a complete electricity system or installation or part of it EMERGENCY This intervention is used to achieve functional An EMERGENCY STOP is used to stop a process STOP safety in an emergency situation by stopping a or a movement which has become hazardous machine or moving parts As a consequence an EMERGENCY OFF device requires the disconnection of the power supply through at least one power contactor whereas an EMERGENCY STOP can be performed without disconnecting the power supply For stopping the drives EN 60204 1 describes three stop categories that can be used depending ona risk analysis see Table 12 The next section includes a connection suggestion that allows to realize the stop categories 0 and 1 Stop category 2 is not suitable for an EMERGENCY OFF or an EMERGENCY STOP Stop category 2 is often
57. set to error the falling edge is used to acknowledge any pending errors If this is successful the controller will be set to ready for operation mode and the power stage can be then enabled together with the power stage In the case of a falling edge the motor will be decelerated to zero speed and then the power Clear limit switch If the motor has hit the limit switch the falling edge is used to allow the motor to continue to move in the same direction The digital inputs DINO DIN3 can be used in all operating modes for an offset for the CAN node number See chapter 8 1 1 Configuring the digital inputs User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 83 8 1 1 Configuring the digital inputs The menu Parameters lOs Digital inputs can be used to configure the functionality of the digital inputs DINO DINS Digital inputs Digital inputs 0 3 I Offset node numbers V AIN s used as DIN s DINO Positioning selection DINI Positioning selection DIN2 Positioning selection DIN3 Positioning selection DIN4 Positioning selection DIN5 Positioning selection DING Positioning Start x Cancel Functional overview In the positioning mode a 6 bits wide position selector DINO DIN5 can be configured for addressing a destination on the basis of the 64 freely programmable targets In addition the Start input DIN6 is of impor
58. speed control In the positioning mode a specified position is set The motor has to move to this position automatically i e without any interaction with an external control system In this operating mode the controller cascade in the DIS 2 controller will be extended as shown in Figure 6 e The position controller is a proportional controller short P controller The current position is determined using the information of the internal encoder evaluation The position deviation is processed in the position controller and passed on to the speed controller as a speed setpoint e A trajectory generator computes the motion profile needed to reach the target based on the current position and on the current speed It provides the position setpoint for the position controller and a pilot speed for the speed controller to improve the control dynamics in the event of rapid positioning processes e The positioning control provides numerous messages required for the external control system e g a target reached messages and a following error message following error monitoring LL m following error trajectory generator correction speed position t dat t f controller Position Parameter of Emp oaase position set speed set positioning unit position point gt NY e point filedbus CAN parameter Q FN homing D cours
59. the manufacturer of the machine or system The technical data and the connection and installation conditions for the servo drive controller are to be found in this product manual and must be met DANGER The general setup and safety regulations for work on power installations e g DIN VDE EN IEC or other national and international regulations must be complied with Non compliance may result in death personal injury or serious property damages User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 22 Jo Without claiming completeness the following regulations and others apply VDE 0100 Regulations for the installation of high voltage up to 1000 V devices EN 60204 Electrical equipment of machines EN 50178 Electronic equipment for use in power installations 2 3 2 Safety notes for assembly and maintenance The appropriate DIN VDE EN and IEC regulations as well as all national and local safety regulations and rules for the prevention of accidents apply for the assembly and maintenance of the system The plant engineer or the operator is responsible for compliance with these regulations NED The servo drive controller must only be operated maintained and or repaired by personnel trained and qualified for working on or with electrical devices Prevention of accidents injuries and or damages NED NI N NI N o Additionally secure vertical axes against falling down or low
60. the DIS 2 48 10 FB the digital inputs and outputs are led out separately There are two alternative start points for starting the course program The start points can be parameterized as desired and are started with the help of digital inputs As a result you can either create a course program with two start points or as an alternative two smaller course programs with up to 32 steps which can be called up completely independently A course program can be created and monitored in a comfortable manner in the parameterization interface The application thus created can be saved in the parameter set or as an alternative in a course program file It can be transferred to other DIS 2 servo positioning controllers The program lines of the course program are processed every 1 6 ms This ensures that an output set by the course programs remains set for at least 1 6 ms The course program mode can be activated through the corresponding button in the commands window see chapter 6 2 Activating the operating mode The setting can be saved permanently in the servo positioning controller The course program is controlled through the digital inputs Digital inputs which are subject to level evaluation high low have to be pending stably for at least 1 6 ms course program processing time so that the level can be detected safely Edge sensitive inputs have to be pending for at least 100us Digital inputs which are normally used f
61. the servo positioning controller to the distributor lt 5ms 5210 Error offset current metering The error cannot be eliminated by the user Send the servo positioning controller to the distributor lt 5ms 2320 DC bus overcurrent output stage Motor defective e g winding overloaded and burnt short circuit between winding and housing Short circuit in the cable between two phases or between a phase and the shield Insulation of motor phase connections Defect inside DIS 2 output stage defective or insulation fault insulating foil lt 10us 3220 DC bus undervoltage DC bus intermediate circuit supply too low DC bus intermediate circuit supply cannot be loaded sufficiently e g during acceleration with full current Check the configuration of the DC bus intermediate circuit monitoring system If necessary set to 70 to 50 of the rated voltage lt 1ms 3210 DC bus overvoltage DC bus intermediate circuit voltage gt 70 V DC bus intermediate circuit supply too high during idling Check rating Brake energy too high when axes are decelerated Capacity in DC bus intermediate circuit too low Install an additional capacitor approx 10 000 uF per 10 A motor current lt ms User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 106
62. trigger modes Auto Triggering occurs and is displayed continuously regardless of whether the trigger condition has been fulfilled or not Normal Triggering occurs and is displayed when the trigger condition is fulfilled After the display and if the trigger condition reappears triggering occurs again Single Itis triggered only once when the trigger conditions has been fulfilled Then the status is set to inactive by deselecting the Run check box see below 11 5 2 Oscilloscope window _ ee es E E Ife SS CH1 Freely selectable communication object Scaling 1 R div Offset 0 00 div Free KO OxEO Type Position 32 bits s Mask OxFFFFFFFF Gf CH2 inactive Scaling 20 div Offset 0 00 div A Time base Time 2 ms div Delay 6 00 ms T Trigger inactive Level 1 00 Rising Mode Auto 2 ms div Cursor 7 ms mM CHI m CH X Ert Force r RUN STOP inactive User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 122 The oscilloscope has various buttons to start certain activities They are shown in the following section Icon OJ BS elo co NIN sens F Additional buttons and controls Icon Gaiam CH2 30 ms 451 r min M CHI M CH2 X a Force m RuN STOP patior L Meaning Calls up the Oscilloscope Settings window Uses thin lines on the oscilloscope display Uses thick lines on the oscilloscope display Maximiz
63. two analog inputs for the input voltage range of 10 V They have a resolution of 12 bits These inputs can be used flexibly to assign speed and torque setpoints If you select Parameters lOs Analog inputs or click the button in the setpoint selector menu when the analog input is activated the following menu will be displayed Analog inputs AINO AIN1 AIN 0 Scaling i An input voltage of 10 corresponds to __ x Cancel Torque setpoint 7 7 07 A Torque limitation gt Speed setpoint 3000 000 r min 3000 000 r min Correcting setpoint F z 0 00 Offset omy 4 Safe Zero 0 00 Vv 0 00 Here you can enter a conversion factor between the input voltage and the torque setpoint or the speed setpoint In the Offset field you can enter a voltage that will be automatically added to the voltage measured at the analog input This can be used for instance to compensate for the offset of the analog control voltage of a control system and for the offset of the analog input in the controller This solves the problem that a very small setpoint is generated when a voltage of 0 V is assigned externally Another area of application is the possibility to assign positive and negative setpoints at an input voltage of 0 10 V The Safe zero function limits the setpoint to zero if it lies within the voltage range defined in this field This makes sure that in the case of a setpoint of 0 V the dri
64. unit from 0 to 5 on the Decimal places tab in the menu Options Display units Display units Display units Decimal places Direct input Position f X Cancel Decimal places 3 r Speed Decimal places 3 Acceleration Decimal places w 11 8 3 Direct input of distance speed and acceleration units On the Direct input tab you can directly enter values for the factor groups Position Speed and Acceleration if you have previously selected the Direct input option in the Display mode field on the Display units tab A Caution For experienced users only The direct input of physical units allows drastic changes of the controller parameters of the DIS 2 servo positioning controller You can also select from the following units for the display of the parameterization program Increments Degree Radian Revolutions User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 141 Metre Millimetre Micrometre User defined No unit Here an example in millimetres and hexadecimal display Display units Display units Decimal places Direct input Z E Wite access oniy for mode hect ist OE Factor group position Numerator 1 Milimeter mm O y Factor group speed Numerator BC Millimeters per second mm s x 4 Factor group acceleration Numerator Bc Millimeters per square second mm s z
65. which will be used automatically neither NEXT1 nor NEXT2 line n line x line y Figure 20 Course program Branch Line In Figure 21 it is assumed that a positioning run was started in program step 10 When the positioning run is started 10 the course program switches to the next state Assuming that NEXT1 2 has been set to Go to line immediately the NEXT1 2 inputs will be inquired in the course of the currently active positioning process We also assume that the NEXT1 2 signal becomes active before the positioning run is completed The evaluation takes place and the corresponding course program line next line 1 or 2 depending on whether NEXT1 or NEXT2 has become active first will be accessed and processed User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 79 program step program step 10 program step 11 program step x y positioning go to postion program step 10 gt target reached edge NEXT1 2 recognized DOUT1 2 high low DOUT1 2 high low program step 10 DOUT1 2 high low program step 11 DOUT1 2 target reached target reached remaining distance positioning program step 10 remaining distance activities course program 7 1 5 Level test start new position NEXT1 2 evaluate calculate new branch destination Figure 21 Branch Line time diagram Course pr
66. why the adjustable maximum current limits are slightly lower The clock frequency has practically no influence on the control behaviour The default setting of the clock frequency of the power stage is 10 kHz Clock frequency 10 kHz Save amp Reset O The settings can only be changed if the power stage is switched off In addition you have to save the parameter set and reset the device to make the setting effective User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 36 4 3 4 Current controller The current controller can be configured under Parameters Controller parameters Current controller in the following menu Current controller Gain Time constant X Cancel It is essential to adjust the current controller correctly in order to be able to the adapt the speed controller to the motor used The parameters to be configured are the gain and the time constant Enter the correct parameters If you are unsure keep the uncritical values Caution Incorrect data for the current controller gain and the time constant may lead to oscillations and due to temporarily excessive currents also destroy the motor The overcurrent detection system of the servo positioning controller may be activated DANGER Make sure that the maximum currents and the rated currents of the motor have been adjusted correctly prior to optimizing the cu
67. 0 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 42 O The input limits can be changed later They affect only the input fields of the il parameterization program Speeds and accelerations will not be limited physically in the drive The quantities in the drives can be limited in the Safety parameters menu described in chapter 4 6 Selecting safety parameters 4 6 Selecting safety parameters To protect the mechanical system from overload the speed and acceleration values as well as the movement range have to be limited to safe values for many applications The setpoint values can be limited in the menu Parameters Safety parameters Safety parameters Decelerations Torque limitation 250000 r min z Quick stop umna Settings 4 Speed limitation EEO rna Speed limit 3000 000 r min I F Absolute positioning range 32768 000 R 32768 000 R Settings x Cancel Limit switch You can configure the following safety parameters in this window 2e Decelerations gt Quick stop deceleration This deceleration will be used when the controller is no longer enabled or in the event of an error if possible gt Limit switch deceleration This deceleration will be used when the drive hits a limit switch gt Decelerations STOP input This deceleration is used if the digital input DIN1 is set to low in the jogging amp teaching mode
68. 0 FB Version 1 1 Page 34 Basic parameters Advanced parameters Select new motor Limit values Maximum current in A rms value Rated current in A rms value Ft time motor 2000 ms a Power stage Number of poles 4 j 2 pairs Torque constant 0 24 Nm A f gt Auto detect Enter the data shown on the type plate You can calculate the torque constant as the quotient of rated torque rated current m Please note that the values to be entered for the maximum current and the rated current Il are effective values If the currents are too high the motor will be destroyed as the permanent magnets inside the motor will be demagnetised The current limits stated by the manufacturer must not be exceeded The maximum current limits may depend on the clock frequency of the output stage To parameterize the clock frequency click the Power stage button See also chapter 4 3 3 Power stage In addition you can enter the number of poles of your motor There is also an automatic identification function which determines the number of poles and the offset angle of the angle encoder automatically Simply click the Auto detect button If the motor is equipped with Six Step Hall sensors the number of poles of the motor has to be entered through the parameterization software DANGER Prior to starting the motor identification you have to set the current limits menu Parameters Device param
69. 0 IC digital inputs possible COMbINATIONS cccecceceeesseceeeseteeeeessteeeeessteeeeeeees 81 Table 13 DIS 2 48 10 FB digital inputs possible COMbINATIONS ccccccecsseeeceesteeeeessteeeeeesteeeeeeees 81 Table 14 Digital inputs assignment cccecceceeeeeeeeeceae ee eeeeeeeeeeaeaeeeeeeeeeeeeaaeaeeeeeeeeseseeaaaeseeeeeeeenaees 82 Table 15 Tipp amp Teach Configuration of the digital inputs ccccccecssecececseeeeeeesseeeeessaeeeeeesaeeeeeeaas 84 Table 16 Error Overview eoin is cele iniaa a eek dee debe Ni a iai a a 104 Table 17 Control elements 22 dccucvaicewel deine ait anr e ain viaa ee 111 Table 18 Directories tic 24 c0 a eae ti ee ee i ele 113 Table 19 Recovering problems with serial COMMUNICATION cceeeceeeeeeeeeceeeeeeeeeeeeeseaeeeeaeeeeneee 116 Table 20 Command syntax of communication objects ceeeceeeeeeeeeeeeeeeeeeeeaeeeeneeeeeeeetaeeetaeeeeneeee 124 Table 21 Meaning of letters in the command SYNtAX ceecceeeeeceeeeeeeenee teense eeaeeeeeaeeseeeeeseaeeeeaeeeeneeee 124 Table 22 RS232 COMMANA SYNtAX neir eiai aaa ea a iaaieo da iia alai Teaia iaoa eonia 125 Table 23 Meaning of letters in the command SYNtAX ceccceeeeeeeeeeeteeceeeee eae eesaaeeseeeeeseaeeeeaeeeeaeeees 125 Table 24 List of all communication objects 0 2 cece eeeteeceee cece eeeaeeceeeeeseaaeeeeaaeseeeeeseaeeesaeseeaeeseeeeseas 126 Table 25 List of basic units vc Acie Avs nev
70. 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 77 neither NEXT1 nor NEXT2 line n line n 1 Figure 18 Course program Position branch If the digital signal NEXT1 is set to HIGH rising edge position A will be approached If the digital signal NEXT2 is set to HIGH rising edge position B will be approached If the program cannot detect any rising edges the course program will remain in a waiting state If neither Evaluate NEXT1 nor Evaluate NEXT2 have been selected the drive will always approach the position set under NEXT1 Thus a linear positioning run e g POS1 gt POS2POS3 can be performed In Figure 19 it is assumed that a positioning run will be started in program step 10 When the positioning run is started 10 the course program switches to the next line program step 11 If we assume that NEXT1 2 has been set to Complete position then target the inquiry of the NEXT1 2 inputs takes place at the far end of the program step when the target reached message has been activated However the system also evaluates the edges that have been detected since the start of the positioning run If the target reached signal has been set but the system has not detected a rising edge of NEXT1 2 the program will remain in program step 11 until at least one edge of NEXT1 2 is detected program step program step 10 program step 11 positioning go to position program step 10 target re
71. 2 48 10 FB Version 1 1 Page 110 11 Appendix 11 1 DIS 2 ServoCommander operating instructions 11 1 1 Standard buttons If a program window is open while you are working this window will have a button bar which often looks like this The buttons have the following functions OK All changes will be accepted and the window will be closed Cancel All changes will be undone and even already transferred values will be restored and the window will be closed You can actuate a button in the following ways e Click it with the left mouse button e Press the TAB key to activate the button and then press the ENTER key to confirm e Use the keyboard and press the underline letter key together with the ALT key If the appearance of the buttons in some menus differs from the form described here you will find more detailed information in this manual 11 1 2 Numerical input fields In the windows of the parameterization program you will always find fields for numerical entries as shown below 100 000 r min Entries can be made in the following ways 1 Directly using the keyboard Enter the value directly into the entry line As long as the entry is not complete the text will be shown in thin print and will not be transferred to the parameterization program yet see the illustration 2001000 r min E EE User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 111 At the end of the e
72. 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 66 If this method is used the drive moves in the negative direction at search speed until it reaches the negative limit switch In Figure 9 this is represented by the rising edge movement from the right to the left Then the drives moves back at crawl speed and tries to find the exact position of the limit switch The zero position refers the first index pulse of the angle encoder in the positive direction from the limit Index Pulse Negative Limit Switch l Figure 9 Homing run to the negative limit switch with index pulse evaluation Method 2 Positive limit switch with index pulse evaluation If this method is used the drive moves in the positive direction at search speed until it reaches the positive limit switch In Figure 10 this is represented by the rising edge Then the drives moves back at crawl speed and tries to find the exact position of the limit switch The zero position refers the first index pulse of the angle encoder in the negative direction from the limit switch Index er E Positive Limit Switch ee E Figure 10 Homing run to the positive limit switch with index pulse evaluation In the case of homing methods 1 and 2 you have to make sure that the index mark or VA f the index pulse of the encoder does not coincide with the switching edge of the limit switch or that it is located near the switching edge as this may lead to a home position offset of one motor r
73. 2 unit is Pc pc bus 0 7 Ws In applications where this is not acceptable the intermediate circuit has to be quickly discharged with the help of an additional contact connected to K1 and a suitably rated discharging resistor EMERGENCY STOP stop category 1 An additional contact set in the ECS also disconnects the controller enabling signal from the DIS 2 The drives decelerate along the quick stop ramp to zero speed Then the DIS 2 switches the output stage off The connection example shown may differ from the actual connection depending on the required safety category The connection example shown in Figure 44 fulfils the requirements of EN 954 safety category 1 The connection example shown in Figure 44 as well as drives with a holding brake delayed disconnection of the 24 V logic supply of the DIS 2 through the ECS ECS in accordance with EN 954 safety category 3 fulfils the requirements of EN 954 safety category 3 DANGER The EMERGENCY OFF and EMERGENCY STOP wiring described herein is only one possible realization example Depending on the application broader or completely different regulations concerning the design of these functions may apply The machine manufacturer or the project manager has to gather all the necessary information concerning the actual safety requirements work out a safety concept for the system and then select the connection and the components accordingly User Manual DIS 2 DI
74. 4 Wiring example for the power supply and EMERGENCY OFF EMERGENCY STOP Version 1 1 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 182 EMERGENCY OFF stop category 0 In an EMERGENCY OFF situation the safety chain is activated Depending on the actual machine the safety chain comprises various elements e g EMERGENCY OFF buttons key operated switches start buttons etc The ECS also checks the safety chain for faults such as line breaks short circuits etc In the event of an error or if the chain is open it ensures that K1 is switched off safely The mains power supply for the 48 V power supply unit will be interrupted The connection example shown may differ from the actual connection depending on the required safety category The connection example shown in Figure 44 fulfils the requirements of EN 954 safety category 1 The connection example shown in Figure 44 may be extended by a second power contactor and an ECS unit in accordance with EN 954 safety category 3 fulfils the requirements of EN 954 safety category 3 Z After the disconnection of the mains power supply there is still some residual energy in l the intermediate circuit capacitors of the 48 V power supply unit and of the DIS 2 The elimination of this energy by internal discharging resistors in the DIS 2 and in the power supply unit takes some time duration gt 5 minutes With Upc bus 50 V the electrical energy per DIS
75. 4 13 Analog inputs and outputs X1 High resolution analog inputs 10V input range 12 bits differential lt 250us delay input protection circuit up to 30V Analog input Analog input can be used to assign current or speed setpoints AINO AINO multiple use with DINO and DIN1 Analog input Analog input can be used to assign current or speed setpoints AINI AIN1 multiple use with DIN2 DOUTI and DIN3 DOUT2 Analog output 0 10V output range 8 bit resolution fimi kHz AMONO User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 159 11 14 14 Digital inputs and outputs X1 Parameter Signal level 24V 8V 30V active high compliant with EN 1131 2 Logic inputs in general DINO BitO DINI Bit 1 Destination selection for positioning DIN2 Bit2 16 destinations can be selected from destination table DIN3 Bit3 DIN4 Bit4 DINS Destination group selection for positioning 4 groups with separate positioning parameters Bit5 e g speed accelerations positioning mode can be selected Control signal for positioning start Limit switch input 0 Limit switch input 1 Power stage enabling in the case of a rising edge Error acknowledgement in the case of a falling edge Logic outputs in general 24V 8V 30V active high short circuit proof against GND DOUTO Ready for operation 24 V 20 mA max DOUT1 Ca
76. C DIS 2 48 10 FB Version 1 1 In addition to the commands for accessing the communication objects there are also some commands for controlling the servo positioning controller The following table shows the command set used Table 22 RS232 command syntax Command Response Description Page 125 BAUDbbbb OK Set baud rate BOOT SERVICE APPLICATION Status inquiry Bootloader active xxxx BUS nn bbbb mmmm CAN bus status Turn on message Load default parameter set Turn on message Cause HW reset xxxx CQT Clear error memory DONE Save parameter set in FLASH DONE Load parameter set from FLASH TYP dddd Type inquiry xxxx VERSION dddd Version inquiry iiiiss dd Simulation SDO write access iiiiss dd Simulation SDO read access Meaning hexadecimal status message Data bytes Node number Baud rate Mode Index of CANopen SDObject Subindex of CANopen SDObject User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 126 11 7 List of communication objects This chapter describes the communication objects used by the DIS 2 ServoCommander parameterization interface to exchange data with the DIS 2 servo positioning controller A list of the basic units used for the communication objects can be found in
77. Controller parameters Speed controller Speed controller Gain 0 70 0 70 Time constant 8 00 ms 8 00 ms a aa Actual speed filter 1 6 ms 1 6 ms In this menu you can configure the Gain and the Time constant for the PI controller To optimize the control response the measured actual speed value has to be smoothed This is done using an Actual speed filter The effective filter time constant can be parameterized m If the time constant of the actual speed value filter is too high the dynamic response il deteriorates as disturbances are detected with a delay In certain unfavourable cases a too high time constant can have a negative effect on the stability of the speed control circuit The additional run time may lead to oscillations If the time constant is too low and gain factors are high you will hear current noise in the speed controller and notice a slight unsteadiness of the shaft In addition the motor will heat up more strongly Set the time constant as low as possible for reasons of stability The downward limit is the noise Typical values for the actual speed filter are 0 6 ms to 2 0 ms The speed controller has to be adjusted such that there is only one overshoot of the actual speed value The overshoot should be about 15 higher than the set speed The falling edge of the overshoot however should not be below the speed setpoint or just slightly below it and then reach the User Manual DIS 2
78. IS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 60 6 4 Global positioning settings Via Parameters Positioning Settings position sets Course program you can open the Settings position sets course program menu where you can define the positioning range as a global setting for all positioning runs Settings position sets course program Positioning range Maximum value 32768 000 R Minimum value 32768 000 R Driving profiles C 16 Positions 16 driving profiles Course program I Course program active START1 Course program line START 2 Course program line ik iREF Destination parameters E In the case of absolute positioning runs the new destination is checked to see whether it lies between the limits for the absolute positioning range The minimum and maximum parameters in the field Positioning range indicate the absolute position limits for the position setpoint and the actual position value The positioning range always refers to the zero position of the drive The Homing run button leads you to the homing menu see chapter 6 8 Homing The Destination parameters button leads you to the menu for parameterizing the destinations see chapter 6 5 Parameterizing position sets In the lower section of the window some settings for the course program can be made In case the Course program active is select the check box from the course program will be
79. O Basic unit position Revolutions per volt Position setpoint scaling AIN1 Revolutions per volt 012D__ ssel_ain1_x_per_volt Basic unit position 012E seqc_home_sw_zero_dist Distance between index pulse and Basic unit position reference limit switch home switch not Supported 012F seqc_home_sw_zero_min Minimum distance between index pulse and Basic unit position reference limit switch home switch not Supported 0130 pos _x_ref Current position setpoint Basic unit position 0131 pos_control_n_korr Position controller output Basic unit speed 0132 __ posi_rev_dist Reversing distance not supported Basic unit position 0133 pos_sel_x_switch Position controller selector for position none setpoint 0134 pos_sel_n_switch Setpoint selector for speed feedforward none 0135 pos_can_x_ip Position setpoint in selected position set Basic unit position 0136 pos_busO_delay Start delay after start of a positioning run Basic unit time applies to all position targets 0137 posc_x_diff_32b Current position difference between the Basic unit position current position setpoint and the actual position 0138 pos_sel2_x_switch Position controller selector for position none setpoint 0139 _ pos_sel2_n_switch Setpoint selector for speed feedforward none 0140 can_node_id Node number resulting from basis and 1 127 offset
80. O Analog input 0 Differential analog input with AINO DINO a Digital input Positioning destination selector bit 0 AIN1 10 V 10 V RxD Reception signal RS232 specification eno Shared ground potential for the DC bus voltage and the 24V logic supply ZK Intermediate circuit supply DC bus DOUTO READY Ready for operation DINg Digital input Limit switch 1 blocks n lt 0 CANLO CAN low DIN5 un Digital input Positioning group selector bit 1 Negative analog input 1 Differential analog input with AIN1 10 V 10 V AIN1 DIN3 0 V 24 V Digital input Positioning destination selector bit 3 DOUT2 0 V 24 V Digital output Freely programmable encoder output track B Negative analog input 0 Differential analog input with 10 V 10 V AINO Digital input Positioning destination selector bit 1 TxD 10 V Transmission signal RS232 specification RE f V 10 V 2 mA Analog monitor 0 AINO DIN1 DIN6 0 V 24 V Digital input Positioning start 424V Logik 24 V lLogik 24 V power supply for the internal logic and the IOs 9 200 mA 1000 mA___ Shared ground with the intermediate circuit DC bus User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 165 11 16 2 Connection Angle encoder X2 Configuration on the device JST No B16B PHDSS Mating c
81. Page preview Print Save as text file In the Print positions field you have to select the positions to be printed at the end of the parameter list The selection affects the length of the plain text output You can expect 2 none The parameter list output will not include any position sets Length about 5 pages 7 all The output will include all 64 position sets Length about 7 pages 2 from to The position range can be defined explicitly The buttons of the Print menu have the following meaning Additional information Calls up the corresponding submenu Page preview Creates the plain text output and displays it on the screen Print Creates the plain text output and prints it on the printer Save as text file Creates the plain text output and saves it under a name defined by the user The default directory of the plain text output is the txt sub directory When the plain text output is created for the page preview and for printing the file txt will be written into the txt sub directory User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 150 Additional information The user can enter additional information concerning the parameter set into this menu The information will be taken over into the plain text output This applies particularly to the date which may differ from the current date Additional information xi Order Project
82. S 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 183 11 20 Notes concerning safe and EMC compliant installation 11 20 1 Definitions and terminology Electromagnetic compatibility EMC or electromagnetic interference EMI includes the following requirements Sufficient immunity of an electrical installation or an electrical device against external electrical magnetic or electromagnetic interferences via cables or the environment Sufficiently small unwanted emission of electrical magnetic or electromagnetic interference of an electrical installation or an electrical device to other devices in the vicinity via cables or through the environment 11 20 2 General information concerning EMC The interference emission and interference immunity of a servo positioning controller always depend on the overall drive concept consisting of the following components Power supply Servo positioning controller Motor Electromechanical system Configuration and type of wiring Superimposed control system i Ww S ko e ko e te i Ww DIS 2 servo positioning controllers are certified in accordance with product standard EN 61800 3 for electrical drives In most cases no external filter measures are required see below The declaration of conformity for the EMC directive 89 336 EEC is available from the manufacturer 11 20 3 EMC ranges First and second environment Proper installation and wiring of al
83. S 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 171 11 18 3 Brake resistance connection X304 X305 Configuration on the device 2 8 mm FAST ON female Mating connector X304 X305 2 8 mm FAST ON male insulated externally Configuration brake resistance Rer 2 4 7 Q Prom 100 W z B metallux PLR 250 5R Rgr connect between X304 und X305 co co ereeeee 92229222 Figure 40 Brake resistance connection Table 34 Pin assignment of connector X304 X305 X30x__ Name Value Specification ZK 48 V 15 A nom Intermediate circuit supply DC bus BR CHOP 0V 48V Connection to brake resistance transistor User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 172 11 18 4 Connection CAN bus X401 and X402 e Configuration on the device X401 M12 flush type plug 5 pin type A coded X402 M12 flush type socket 5 pin type A coded Position X401 front centre X402 front left Mating connector X401 Assembled M12 bus cable e g made by Phoenix one end male connector one end female connector prefabricated lengths order name SAC 5P MS xxx 920 FS SCO xxx defines the length in m The following lengths are available xxx 0 3 0 5 1 0 2 0 5 0 10 0 15 0 X402 X401 X5 Figure 41 Position and numbered pins X401 X402 and X5 at DIS 2 48 10 FB Table 35 Pin assignment of connector X401 and X402 Pin no N
84. The DIS 2 servo positioning controller has an extensive sensor system monitoring the operation of the controller power output stage motor and communication with the outside world Any occurring errors are stored in an internal error memory The main monitoring functions are described in the following chapters I The reaction to the errors can configured with the help of a comfortable error management system see chapter 10 4 Error management 10 1 1 i 10 1 2 i We i AO Overcurrent and short circuit monitoring Overcurrent and short circuit monitoring The overcurrent and short circuit monitoring system responds as soon as the current in the intermediate circuit DC bus exceeds two times the maximum current of the controller It detects short circuits between two motor phases and short circuits at the motor output terminals against the positive reference potential of the intermediate circuit DC bus If the error monitoring system detects an overcurrent the power output stage will be shut down immediately to guarantee resistance against short circuits lt current monitoring with controller warning The DIS 2 servo positioning controller has an lt monitoring system to limit the average power loss in the power output stage Since the power loss in the electronic power system and in the motor increases in a square manner with the current in the worst case the squared current value is taken as the measure for
85. X303 Data for use with 48V Thousing max 50 C Output power 500 VA Max output power for 2 s 1500 VA Output current 15 Acre Tpowerstage lt 50 C 10 Aeff TpowerStage lt 70 C Max output current for 2 s 40 Astr Tpowerstage lt 50 C 32 Aeff TpowerStage lt 70 C Clock frequency 10 kHz 20 kHz 11 14 6 Resolver X2 Suitable resolver Industrial standard Transformation ratio 0 5 Carrier frequency 10 kHz Resolution gt 12 bits typ 15 bits Speed resolution approx 4 rpm Absolute angle sensing lt 10 accuracy Max speed 16 000 rpm User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 157 11 14 7 Analog Hall encoder evaluation X2 Parameter Suitable Hall sensors HAL400 Micronas SS495A Honeywell and others Type differential analog output Vom 2 0 V 3 0 V Signal amplitude 4 8 V differential max Resolution gt 12 bits typ 15 bits Signal detection delay lt 200 us Speed resolution approx 10 rpm Absolute angle sensing accuracy Max speed 16 000 rpm Other signal levels as customized versions upon request Please contact your local distributor 11 14 8 Hiperface encoder evaluation X2 Parameter Suitable encoder Stegmann Hiperface SCS SCM60 SRS SRM50 SKS36 For other types please contact your local distri
86. _can Parameterizable torque limitation CAN Basic unit current OOCD _ currc_i_lim_ftd Parameterizable torque limitation FTD Basic unit current OOCE currc_i_lim_profi Parameterizable torque limitation Profi Basic unit current OOCF currc_ctrl Currc Control Configword 00DO __ currc_ctrl_gain_q Active current controller P gain Basic unit gain 00D1 __ currc_ctrl_time_q Active current controller time constant I part Basic unit time 00D2 _ currc_ctrl_gain_d Reactive current controller P gain Basic unit gain 00D3 _ currc_ctrl_time_d Reactive current controller time constant l Basic unit time part 00D4 __ currc_sel_i_switch Torque setpoint selector none 00D5 __ currc_sel_i_lim_switch Torque limitation selector none o0oD6 _ ssel_ainO_i_per_volt Torque setpoint scaling AINO Basic unit current Amperes per volt 00D7 _ ssel_ain1_i_per_volt Torque setpoint scaling AIN1 Basic unit current Amperes per volt User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 130 machine model No Name Meaning Scaling 00D8 __ currc_i_ref_jog1 Jogging setpoint 1 not supported Basic unit current 00D9 lcurrc_i ref _jog2 Jogging setpoint 2 not supported Basic unit current 00E0 ssel_n_ref Speed setpoint input variable of the speed Basic unit speed control
87. _pos Ramp generator gradient at Positive Basic unit acceleration speed falling edge OOF5 ssel_n_acc_neg Ramp generator gradient at Negative Basic unit acceleration speed rising edge OOF6 ssel_n_dec_neg Ramp generator gradient at Negative Basic unit acceleration speed falling edge OOF7 _ ssel_lim_sw_ramp_dec Deceleration for limit switch ramp Basic unit acceleration OOF8 _ ssel_enab_off_ramp_dec Deceleration for quick stop ramp Basic unit acceleration 00F9 spdc_n_target_speed Declared speed for message When n_mel Basic unit speed n_mel_hyst is reached one bit will be set in the status word OOFA spdc_n_target_win_speed Hysteresis for speed messages Basic unit speed n_ist n_mel and n_ist n_soll OOFB spdc_ramp_brake_max_time Maximum time at quick stop Basic unit time OOFC n_ramp_brake_min Speed at which quick stop was successfully Basic unit speed completed OOFD spdc_n_ref_jog1 Jogging setpoint 1 not supported Basic unit speed OOFE spdc_n_ref_jog2 Jogging setpoint 2 not supported Basic unit speed OOFF ssel_n_act_ixr Actual speed value calculated through Basic unit speed User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 131 No Name Meaning Scaling 0100 _ ssel_n_act_filter Actual speed value filtered with actual Basic unit
88. a 48 V intermediate circuit DC bus supply to a 24 V logic supply and to a control or to a PLC The mains power supply with the master contactor fuses and an EMERGENCY OFF device is not shown The connection is described in chapter 11 19 2 EMERGENCY OFF EMERGENCY STOP terminology and standards Power Supply Fane bisaan use 2 C characteristic CIC PM synchronous machine 4 U_ZK aavDC pT eo gt 20A 15A C characteristic AMONO RxD TxD ine eee yF L lt holdi Power Supply Fae a ar E a E CA a Ly brake 120R E pes CANHI A 24VDC E pme gt 2A P central GND point Controller PLC I connected internal DIS 2 48 10 FB U_ZK 24V GND AMONO AINO AINO RxD TxD GND CANHI DINx holding brake Resolver Encoder rX X2 12 X2 2 X304 X304 Rerake other DIS 2 48 10 Figure 43 Connection to power supply control and motor User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 177 The servo positioning controller is connected to the 48 V intermediate circuit DC bus supply and to the 24 V logic supply A shared reference potential GND is used A central star point near the power supply units for all GND connections reduces the ground bouncing effects between the controllers The motor has to be connected through the FASTONs X301 to X303
89. a correspondingly advanced firmware version If the DIS 2 servo positioning controller has no firmware or if its firmware is complete the following window will be displayed IN Servo has no firmware Boot now If the correct firmware is already installed in the DIS 2 servo positioning controller the error message will not be displayed In this case you can skip the following chapter o To read out the firmware version installed in the controller open the Firmware Hardware tab in the Info Info menu User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 153 11 13 1 Loading the firmware You can load a new firmware under File Firmware download When a new firmware is loaded the parameter set stored in the servo positioning controller will be overwritten This is why the following message is displayed The firmware download overwrites the current parameter set Do you want to save the current parameter set before the download mo Here you can decide whether you want to save your parameter set on the PC If you click the Yes button the menu for saving the parameter set will be opened The following selection menu is displayed Suchen in E Firmware z Sl gl c a FW _DIS2_1p1 s Dateityp Firmware code gt Abbrechen ZA 1 Select the firmware to loaded and click the Open button 2 Then a window for selecting the data transfer rate baud ra
90. a total of 18 contacts Mating connector X1 Phoenix PLUSCON VARIOCON kit comprising 1x VC TFS2 2x VC TFS8 1x VC TR2 3M 1x VC MEMV T2 Z 1x VC EMV KV PG21 11 5 15 5 13 5 Dimensions approx L x W x H 86 mm x 80 mm x 32 mm L763 see Bl ee 4 81716 518 7 6 5 Figure 39 Numbered pins of X1 DIS 2 48 10 FB User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 170 Table 33 Pin assignment of connector X1 Pinno Name Vale Specification o Ready for operation DINs o v 24 V Digital input Limit switch 1 blocks n lt 0 DINS o v 24 V Digital input Positioning group selector bit 1 AIN1 DIN3 10 V 10 V 0 V 24 V Inv analog input 1 Differential analog input with AIN1 or Digital input Positioning destination selector bit 3 DINg o v 24 V Digital input Power stage activation DIN7 Digital input Limit switch 0 blocks n gt 0 DIN4 ov 24V ov 24Vv Digital input Positioning group selector bit 0 AINI DIN2 10 V 10 V 0 V 24 V Analog input 1 Differential analog input with AIN1 or Digital input Positioning destination selector bit 2 AINO DIN1 10 V 10 V Inv analog input 0 Differential analog input with AINO Digital input Positioning destination selector bit 1 DouT2 o v 24 V D
91. aaeeeeeeeeceaeeeeaaeeseeeeseaeeesaeeseaaeseaeeesaas 79 Figure 22 Level test course program 00 0 ee eeeeceeeeeeteceeeetee ee ee eae ee ee taae eset eaaeeeeeeaaeeeeeeeaaeeeeetaaeeeeneaeeeeniaeeeeee 79 Figure 23 Level test time Cia grain sissie ceirnin eaei r ERARA ne E EEEIEE E R E EE AKARA ACi 80 Figure 24 Teaching process of a target position ceccceeeecececeeeeeeeeeeeeeeceaeeeeeaeeeeneeseaeeesaeeeeeneeeseeeaas 85 Figure 25 Coupled incremental encoder emulation cccccccececeeeeeeeeeeeeeeeeeeeaeeeeaaeseeeeeseeeeseaeeeeaeeeees 89 Figure 26 Holding brake time response sieran i a a a R EE E 91 e ERTEN EL weil thie ee ee ae A a ae ea hd 93 Figure 28 Online parameterization ccccccccececeeeceeeneeceeeeeceaeeeeaaeeeeneeseeeeesaaeeesaaesdeeeeseeeeeesaaeeseneeeneees 147 Figure 29 Offline parameterization cccccceecceceeeceeeeeeeeeeeceaeeeeaaeeeeaeeceaeeeceaeeesaaesseneeseeeessaeeseneeeenees 151 Figure 30 Arrangement of DIS 2 pin and socket connectors top view of electronics module 161 Figure 31 Housing CIMENSIONS ceeeceeeeeceeeee cee eeeeeeeeeeeeeceaeeecaaeeeeaeeseeeeesaaeeesaaeseeneeeseaeeesaeesineeenees 162 Figure 32 DIS 2 application example Synchronous servo motor in the power range of 500 W with a DIS 2 servo positioning controller and a gearbox for a steering application 00 163 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 10
92. ached edge NEXT1 2 rill recognized DOUT1 2 high low program step 10 DOUT1 2 z target reached remaining distance target reached positioning program step 10 remaining distance activities course program we f evaluate start J new position _ NEXT1 2 ie calculate new branch destination new positioning DOUT1 2 high low DOUT1 2 high low program step11 Figure 19 Position branch time diagram User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 78 7 1 4 Branch Line Befehlsart Optionen C Position branch IV Evaluate NEXT1 V Evaluate NEXT2 Branch Line I Evaluate Stop signal C Level test pouT1 Off C End of Program DOUT2 Off NEXT1 NEXT2 Next line 1 Ja a Next line 2 fa a Ignore if target not reached Ignore if target not reached C Go to line immediately C Go to line immediately Complete position then line Complete position then line X Exit Depending on NEXT1 and NEXT2 the program continues in different lines If the digital signal NEXT1 is set to HIGH rising edge the program will continue in line X If the digital signal NEXT2 is set to HIGH rising edge the program will continue in line Y If the program cannot detect any rising edges the course program will remain in a waiting state If neither Evaluate NEXT1 nor Evaluate NEXT2 have been selected you can state a next line
93. activated in the setpoint selector menu using the icon or under Operating mode Ramps The following window will be displayed User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 55 Ramps Speed r Connections r B P r4 12 P R B r4 r Positive direction of movement 125000 r minis gt 12 n_ref gt 0 125000 riminis gt ri 0 gt n_ref Negative direction of movement r3 0 gt n_ref 14 n_ref gt 0 1125000 rimin s dl The ramps can be configured separately for right handed and left handed rotation as well as for rising and falling speeds If the ramp accelerations are partly identical you can reduce your input workload by selecting the check boxes r3 r1 r4 r2 or r2 r3 r4 r1 il The ramp generator should be used if the controller is in soeed controlled mode and no position control is active also not in an external control Configure the ramps such that the drive will not be controlled into the current limitation during acceleration under realistic load conditions When the setpoint ramp is configured correctly overshoots of the speed controller when running into the speed setpoint can be reduced considerably compared to the operation without a setpoint ramp The setpoint ramp must not be activated in the case of application with a position control system either internal or t
94. all values e g to half of the rated current as this prevents strain on all components including the mechanical system if other drive parameters are improperly configured To let the motor rotate in a speed controlled manner you have to configure the following points 1 Activate the speed control mode see chapter 5 2 Speed controlled mode 2 Set the controller enable logic to via digital input see chapter 4 7 Configuring the controller enable logic User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 46 3 Activate the speed control via the analog input 0 see chapter 5 4 Setpoint assignment through setpoint selectors and parameterize the desired analog speed range chapter 8 6 Analog inputs AINO and AIN71 If you cannot use the analog input you can also assign the setpoints via the serial interface see chapter 5 4 Setpoint assignment through setpoint selectors 4 Before you test the controller enabling process you should save the parameters in the drive To do so click the button shown here You can ieee find the button on the upper menu bar of the main window 5 Now briefly activate the controller enabling system After the control system has been enabled the shaft has to start rotating If the motor does not show this behaviour there is either an error or the DIS 2 servo positioning controller has been parameterized incorrectly The following table shows typical errors and how you can elimi
95. ame Value Specification Contact for cable shield in the DIS 2 connected with 1 shiglg PE the housing N Not used Reference potential for the CAN bus internally 3 CAN_GND OV connected with the common reference potential for the intermediate circuit and the logic system 4 CANHI o V5V Signal CAN_H according to CAN bus specification 5 cANLO o V5V Sionai CAN_L according to CAN bus specification User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 173 11 18 5 Connection Serial parameterization interface X5 Configuration on the device M8 flush type socket 3 pin type Position front right see Mating connector M8 mating connector for free configuration e g Phoenix SACC M8MS 3CON M SH Table 36 Pin assignment of connector X5 Pues ene Le _ Set __ _ _ Reception signal RS232 specification Transmission signal RS232 specification Reference potential for the serial interface internally 4 GND OV connected with the common reference potential for the intermediate circuit and the logic system Table 37 Pin assignment to set up an RS232 adapter cable for connection to a PC notebook X5 pin at Dsub 9 connector econ i y Specification aa 2 48 10 FB econ connection to a PC 1 RxD 3 TxD_PC Reception signal RS232 specification TxD_PC Transmission signal RS232 specification
96. ameterization program If you select Search baud rates the parameterization program will try out all kinds of baud rates to set up a communication Use the Offline parameterisation option only if you want to work on parameter set files without a servo positioning controller See also chapter 11 12 Offline parameterization If the servo positioning controller has no valid firmware or if you want to download the firmware you can initiate this by selecting the Firmware download option User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 116 Clicking the radio button Exit program immediately terminates the parameterization program The following table describes possible error causes the error elimination strategies Table 19 Recovering problems with serial communication Communication error Click on Retry with old parameters Wrong COM port selected Click on Change COM port and follow the instructions The baud rate of the parameterization program Click on Search baud rates does not match the baud rate of the servo positioning controller The communication of the servo positioning RESET the servo positioning controller i e switch it off and controller is disturbed on again Then click on Retry with old parameters Hardware error Servo positioning controller not switched on Eliminate the error and then click on Retry with old arameters Connecting cable disco
97. ance 0 20 mH Maximum current rms value 32 004 Current controller Gain 1 71 Maximum speed 4000 r min Current controller time const 1 80 ms Torque constant 0 12Nm A Speed controller Gain 0 70 Sense of rotation tight Speed controller time const 16 00 ms S Accept values and close dialog x Quit without changes Select your motor if you can find it on the list and confirm your selection by clicking the Accept values and close dialog button Otherwise click the Quit without changes button User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 30 4 3 Basic parameterization of new motors 4 3 1 Angle encoders The DIS 2 servo positioning controller supports four angle encoder types Resolvers analog Hall sensors with SIN COS signals upon request Stegman SinCos encoders with Hiperface interface Hall encoders Six Step Incremental encoders with Hall sensor only DIS 2 48 10 FB The menu for adjusting the angle encoder parameters can be called up via Parameters Device parameters Angle encoder adjustments Depending on the angle encoder used the actual menu displayed may differ from the menu shown below as different adjustment options are used Angle encoder adjustments Angle encoder Resolver C Analogue Hall encoders C SinCos C Hall encoder Six Step Commutation Phase sequence gt C block commutation C right Sine commutation left Offset of angle 45 0
98. anual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 5 4 10 Making the system ready for operation enabling the power stage 45 5 Current and Speed control cccccccceeseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 47 5 1 Function OVEIVICW aix tr cies has hc ot cceece sales adem aeaach auch canhaatnnaesmenepnnntsnacteaee toa haete 47 5 2 Speed controlled NOME as ctee cst senerertns huss dnececsyieneenslnetty deeayeianadas gedeeendsvaeteta teamed 49 5 2 1 Optimizing the speed controller occ eeeeeceteceeneeeeeeeeeeaeeeeaeeseeeeesaeeeeaeeeeneeeaas 49 5 2 2 Optimization strategies ee ceeseeeeeeee cece eeeeaeeeeeeeeeeeeeseaaeseeeeeseeeeesaeeseaaeeseneeeaas 50 5 3 Torgue controlled Mode see css nec acini tee eed a eet ie 52 5 4 Setpoint assignment through setpoint selectors cceeeeeeeeeeeeeeeeeteeeeeeeteeeaes 52 5 4 1 Speed controlled MOG cecceesceceeeeeeeeeeeeeaaeeeeneeceeeeeesaeseeaeesseeeessaeeseeaaeeneneeees 53 5 4 2 Torque controlled MOG ersen eiia a a a n 53 5 4 3 Setpoint assignment through RS232 cccccceeeseeceeeeeeeeaeeeeaeeseeeeeseaeesenaeeeeneeeaas 54 5 4 4 Setpoint rampes adh ele Oe a a line iets ai lhe 54 5 4 5 Torque limitation esasa i ceeded cairns 55 6 Positioning MOGC veciciesscieesee cide enniecineteneeninnnenienintenenieniendenwns 56 6 1 FUNCTION OVEIVICW inai oieee nans a nae tha oc EAER EEE ai 56 6 2 Activating the operating Mode
99. arameter set save parameter set reset controller Figure 28 Online parameterization The current parameter set of the DIS 2 servo positioning controller is stored in the RAM RAM Random Access Memory The RAM looses its contents when the power supply is switched off In order to permanently save a parameter set it can be copied into the controller memory using the command File Parameter set Save parameter set The memory keeps its contents even if the power supply is switched off User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 148 When the servo positioning controller is reset the contents of the FLASH memory are copied into the RAM A reset can be initiated as follows Deactivation and reactivation of the power supply Activation of the menu item File Reset Servo Activation of the RESET button in the toolbar of the parameterization program The DIS 2 also has default parameter set This parameter set is fixed in the firmware and cannot be overwritten If a parameterization is not successful for some reason the default parameter set can be loaded to continue with default values The default parameter set is activated by selecting File Parameter set Load default parameter set The default parameter will then be copied into the FLASH memory and into the RAM 11 11 2 Loading and saving parameter sets Parameters can also be stored and managed externally i e on a hard disk or
100. ator none o05a _ rs232_unit_n_divisor Factor group speed denominator none 005B rs232_unit_n_decimals Speed decimals none 005C frs232_unit_a var_i Physical units Acceleration none 005D rs232_unit_a conv_i Physical units Acceleration none 005E rs232_unit_a_numerator Factor group acceleration numerator none 005F rs232_unit_a divisor Factor group acceleration denominator none 0060 rs232_unit_a decimals Acceleration decimals none 0061 rs232_kommando Command word none 0062 rs232_osc_screen_time Total time Basic unit time 0063 lrs232_display_free_adr Free CO address CO number free CO 0070 Jerrh_err_field_0 Bit field of main error numbers 1 to 32 Bit 0 Error not active Bit 1 Error active 0071 Jerrh_err_field_1 Bit field of main error numbers 33 to 64 Bit 0 Error not active Bit 1 Error active 0072 lerrh_prio_field_0 Bit field of main error numbers 1 to 32 Error Bit 0 Brake motor power stage off 0073 Jerrh_prio_field_1 Bit field of main error numbers 33 to 64 Bit 1 Power stage off 0074 jerrh_warn_field_O Bit field of main error numbers 1 to 32 Warning Bit 0 Do not display warning 0075 Jerrh_warn_field_1 Bit field of main error numbers 33 to 64 Bit 1 Display warning User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 128 No Name Meaning Scaling 0080 currc_i_
101. b Just like CH1 and CH2 the trigger event can be selected from a list of predefined standard events Alternatively you can also select Freely selectable communication object and use any communication object for triggering A distinction is made between digital and analog trigger sources Digital trigger sources can only have the status yes or no active or inactive An example is Din7 limit switch 0 Analog trigger sources on the other hand can take on any numerical value e g actual speed value User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 121 In the case of analog trigger sources a scroll box for the trigger level will be displayed The trigger process starts when the analog value has exceeded or fallen below the level The trigger edge can be used to define when the system should react to an event Rising edge Digital trigger Event occurs Analog trigger Level exceeded Falling edge Digital trigger Event disappears Analog trigger Below level o The trigger mode and the therefore the oscilloscope are only active if the Run Stop 1 check box in the oscilloscope window is selected When you open the Transfer window or save the parameter set the oscilloscope will be deactivated This is why the check box has to be deselected and reselected afterwards to reactivate the oscilloscope The Mode field is used to select when triggering should occur There are three different
102. bly and maintenance ccccceeeeeseeteeeeeeeeeeeneeeeeeeeeees 22 2 3 3 Protection against contact with electrical parts c cccseeeeeeseteeestteeeteneeesees 23 2 3 4 Protection against electrical shock by means of protective extra low voltage PPE a Piet dot has bali nash tahini ni tt oan dere ance ta wed a admoam yt Mot aia 24 2 3 5 Protection against dangerous MOVEMENTS cceceeeeeeeeeeeeeeeeeeeeaeeeeeeaeeeeneaas 24 2 3 6 Protection against contact with Not Parts eee ee eeeeeeeeeetaeeeeeetaeeeeeeaeeeeneaae 25 2 3 7 Protection during handling and assembly eee cece ee eeeeeeeeeeenaeeeeeeenaeeeeeeaas 25 3 Preparation for COMMISSIONING ccccccceseeeeeeeeeeeeeeeeeeeeeeeeeneeeeeeeeeeneees 27 3 1 System OVOIVICW ieee eetietecrn arco ea E ea mere ees ieee eto eis Oa ee ee ares 27 3 2 Connecting the DIS 2 to the Control system ceeeeeeceeeeeteeeeeeeeeeesneeeeeeeeeees 27 3 3 Installation and start of the DIS 2 ServoCommander cccceccsescseeseeeseeeeeees 27 4 Initial parameterization of the controller eeeeeeeeeeeeeeeeeeeeeeeeees 28 4 1 COMM SS ONINg 24 cccttaus atetcy Sececnn daa se conte 6 cane tene edetastiaaattenss tecepeaaattemexchane tapes cence 28 4 1 1 Parameter set in the delivery State 0 ccccccesesceeceeeeeeeeeeeeneeseeeeeseaeeesaeeeeneeenaees 28 4 1 2 Manual commissioning i43 scant ete teeta ited iat eet 28 4 2 Parameterization using the motor database
103. butor Resolution Up to 16 bits depending on line count Signal detection delay lt 200 us Speed resolution approx 4 rpm Absolute angle sensing lt 5 accuracy Max speed 6 000 rpm generell 3 000 rpm with an encoder with 1024 lines 11 14 9 Incremental encoder evaluation X2 only DIS 2 48 10 FB Parameter Line count 32 1024 lines per revolution can be prarametriezed Connection level 5 V differentiell RS422 standard Supply feedback system 5 V 100 mA max Input impedance R 1600 Q Limit frequency fiimit gt 100 kHz lines sec User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 158 11 14 10 Six Step Hall sensor and block commutation X2 Suitable Hall sensors Hall sensor with 5V supply 120 phase offset open collector or push pull output ipy gt 5 mA Resolution 6 steps per electrical revolution Signal detection delay lt 200 us Speed resolution Depending on the number of pairs of poles of the motor Max speed 3 000 rpm in the case of a motor with two pairs of poles 11 14 11 RS232 X1 RS232 In accordance with RS232 specification 9600 bits s to 115 2 k bits s 11 14 12 CAN Bus X1 Parameter CANopen controller TJA 1050 Full CAN Controller 1M bit s maximum adjustable value 500 kbit s CANopen protocol In accordance with DS301 and DSP402 11 1
104. cceeeceeeeeeeeeceeeeeeeeteeeeeseaeeesaeeeenees 111 11 1 5 Standardi Window eeecceecceceseceesceeeeeceseaeeeenaeessaeeesaaeeeeaaeseeaesseeeesaeeeeneaeenaees 112 WAG SDIFECLOMOS srn e pete beak aE AAAA A 113 11 1 7 Communication via communication objects ccccceeeeseeeeeeeeeeeteeeeeeeeeenees 113 11 1 8 Quitting the PrOQraWn oe ee cece ee eneeeeee eect eeeeaeeeeeeeeeaeeesaaeeeceeeeseaeeesaeeneneeeeaees 114 Setting up the serial COMMUNICATION eeeeeeeeeeeteeeeeeeeeeeeeeeeeeeeeeeettaeeeeeneaes 115 VAG WI OW i aa aa Eaa aa a doadedoust RAER 117 Fast access via the tool bar srsiscicinch eta ee sae aoe ee 118 Using the oscilloscope function ssesssssrisseerrrrrrrrrerssrrrrrrrrrnrrnsrrrnseerrnnnnrrnnnnnene 119 11 5 1 Oscilloscope SettingS eeeccee cece eeeee cece eeeeaeeeeaeeeeaeeeeaaeseeaeeseeeetaeseeaaeeenaees 119 11 5 2 Oscilloscope WINGOW eeeeececeeeeeeceeee cent eeeeaeeeeeeeecaeeesaaeseeeeeeeeeesaeeeeaeeennees 121 Serial COMMUNICATION PROLOCO lisse cicecctcesstcce iaiadd teleda ie tect veie nee teaches encase ek 124 List of communication OD CCIS ai 2eidacctnntetnctina een Gon cdl cane tetas 126 ae ley ea ree oilenlalitcemeercen cece nereerereer rc treet rerterncr erect aire cere career T cree 134 11 7 2 Bit configuration for command word status word error Word 135 Extended options in the Display units MENU cece ee eeeeenteeeeeeeeeeeeeeeee 139 11 8 1 Configuration of user define
105. ceives a start command for a new destination It has the following options i Wait for end of positioning run The current positioning run will be completed before the new positioning process is started The next positioning run can be selected prior to the running positioning run The new positioning run will be started automatically when the current positioning run is completed Interrupt actual positioning The current positioning run will be interrupted and the new position will be approached immediately Ignore start command The positioning command for the new position cannot be selected or started before the current positioning run is completed m Please note that a bouncing switch at the digital start input may lead to problems if wait Il for end of positioning run or interrupt actual positioning is allowed in the case of a relative positioning run As a result the drive may move just a little too far The Messages field can be used to parameterize trigger signals which can be issued via the field bus or a digital output These trigger signals indicate the remaining distance up to the end of a positioning run The parameterized remaining distance applies to all 64 destinations Information on how to feed this message to the digital outputs can be found in chapter 8 3 Digital outputs DOUTO to DOUT3 The Start delay field can be used to define a certain delay period After a start command the servo positio
106. cidental contact by means of a housing e g a switch cabinet The regulations VGB4 must be complied with NED Always connect the ground conductor of the electrical equipment and devices securely to the mains supply NED Comply with the minimum copper cross section for the ground conductor over its entire length as per EN60617 NED Prior to the initial operation even for short measuring or testing purposes always connect the ground conductor of all electrical devices as per the terminal diagram or connect it to the ground wire Otherwise the housing may carry high voltages which can cause electrical shock NED User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 24 NED Do not touch electrical connections of the components when switched on Prior to accessing electrical parts carrying voltages exceeding 50 Volts disconnect the device from the mains or power supply Protect it from being switched on again NED lan For the installation the amount of DC bus voltage must be considered particularly Wa regarding insulation and protective measures Ensure proper grounding wire dimensioning and corresponding short circuit protection 2 3 4 Protection against electrical shock by means of protective extra low voltage PELV All connections and terminals with voltages between 5 and 50 Volts at the servo drive controller are protective extra low voltage which are designed safe from contact in c
107. ctors Torque control Speed control 0 000 r min Setpoint ramp Selector Speed setpoint p KX RS232 4 E f Selector Correcting setpoint l Speed setpoint Analog input 0 hd foi r Selector Torque limitation Torque limitation Analog input 1 Eo 0 219 A In the speed setpoint selector menu shown above you can also activate the torque limitation This is symmetrically possible and the limitation source can be selected as desired 5 4 2 Torque controlled mode If you select the Torque control tab you can select any of the above mentioned setpoint sources under Selector Torque setpoint However the ramp generator and the correcting setpoint are not available in torque controlled mode You can also activate the torque limitation Torque control Speed control vw OK Selector Torque setpoint Torque setpoint Analog input 0 x ee X Cancel i 0 000 A eae Selector Torque limitation Torque limitation RS232 bd rl 0 495 A If an analog input is activated as the setpoint source but the menu does not show a line towards the setpoint the digital inputs may be activated See chapter 8 1 1 Configuring the digital inputs o User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 54 5 4 3 Setpoint assignment through RS232 If you have configured one of the setpoint sources such that
108. d Basic node number 1 C 250 kBaud Offset inactive 0 EA C 500 kBaud Effective node number 1 x Cancel You can define the following communication parameters Baud rate This parameter determines the baud rate used on the CANopen bus Basic node number This parameter includes the basic node number of the device This number is used to calculate the effective node number It is possible to include the digital inputs into the calculation of the effective node number see below User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 97 The identifiers of the messages are based on the node number A node number may be assigned only once on a CANopen network Addition of DINO DIN3 to node number The value of the digital inputs DINO DIN3 will be added to the basic node number The input combination will be read out only when the CANopen interface is activated or directly after a RESET of the DIS 2 servo positioning controller Thus up to 16 different device addresses can be assigned by using simple jumpers connected to 24V at the digital inputs If you want to use this function you must parameterize the digital inputs accordingly see chapter 8 1 1 Configuring the digital inputs Clicking the button opens the menu for configuring the digital inputs The Effective node number field shows the node number resulting from the basic node number and the offse
109. d display units cccecceeeeeseeeeeeeeeeeeeeesseeeenees 139 11 8 2 Decimal places eo eraa ann Ee E AT NAET sient Aci thei 140 11 8 3 Direct input of distance speed and acceleration units 140 Course program Examples s csienccieecacnss tile cect ea tee cdetilens eeedetelandbbcuececateaceencundaees 141 11 9 1 Example 1 Linear linking Of positions 0 2 0 0 cece eeeeeeeeeteeeeeeeceeeeetaeeeeeeeeeenees 141 11 9 2 Example 2 Linear linking of positions and setting of a digital output 142 11 9 3 Example 3 Setting and inquiring digital inputs and outputs infinite loops 143 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 7 11 10 Timing GIA PAINS sesioen ina kE aaea EEEE ENAKE KAKE AE ia 143 11 10 1 Switch on sequence oo eee cee e cence cece eee aeeeeaaeeeaeeeceaeeeeaaeseaeeseaeeessaeeeenaeeenaees 144 11 10 2 Positioning Destination reached eeeceeeeeeeeeeeeneeeeeenaeeeeeeaeeeeeeaeeeeeeaaes 145 11 103 Speed Signal it urren tolea ernn tedeebime rahe neiaa ea aa a et eeann 145 TETO Quit rrOlinn e a bid eaa e aE a aaaea 146 OR EAO EE E E E E A AAEE 146 11 11 Parameter set management ccccnadcneniinneaioseoniasie anaes 147 apes ba ea ees Generalne ema e a A a a aeaa A a creer rer rece 147 11 11 2 Loading and saving parameter sets 0 ec eeceeeeeeeeenneeeeeeaeeeseeaeeeeeeeaeeeeneaaes 148 11 11 3 Printing parameter Sets eee eeeeeeeeeeeeeaeeeeeeeaaeeeeeeaae
110. d set the gain to 0 5 2 Open the menu for parameterizing the position data sets see chapter 6 5 Parameterizing position sets and enter the following values for destination 0 and destination 1 Destination 0 10 R Destination1 10 R gt Speed half rated speed gt Acceleration maximum value gt Deceleration maximum value 3 Start the oscilloscope see the appendix chapter 11 5 Using the oscilloscope function by activating the menu item Display Oscilloscope and set the following values Channel 1 Actual speed value scaling 1000 rpm div 2 div s Channel 2 Rotor position scaling 50 div offset 1 div Time base 100 ms div delay 200 ms Trigger Source actual speed value level half running speed mode normal falling edge 4 Enable the power stage Start the positioning run alternately with destination 0 and destination 1 with the help of the Go to destination menu see chapter 6 6 Approaching destinations The motor now reverses within the specified limits Ke ae ae ate e K Optimization Evaluate the speed and the rotor position during stopping If the transient process of the position takes too long increase the gain If the speed starts to oscillate during stopping the gain has to be decreased Figure 7 Speed controller optimization Please note that the overshoots are due to missing acceleration and deceleration time values User Manual D
111. d time t5 gt 1 6 ms 11 10 3 Speed signal speed setpoint D 3 j gt speed actual DOUT speed setpoint reached ti lt 1 6 ms t2 lt 1 6 ms Version 1 1 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 146 11 10 4 Quit error ca 10ms controller enable DOUT READY DOUT error 11 10 5 Limit switch limit switch active velocitiy actual value velocitiy actual value t1 lt 0 2ms t2 Nx0 2ms Depends on the quick stop ramp t8 lt 0 2ms t4 Nx0 2 ms Depends on the speed ramp Actual speed Direction of rotation permanently blocked by the limit switch Actual speed Direction of rotation not permanently blocked by the limit switch User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 147 11 11 Parameter set management 11 11 1 General In order for the DIS 2 servo positioning controller to control the motor properly the properties of the DIS 2 servo positioning controller must be set correctly In the following the individual properties are called parameters The total of all parameters for a servo positioning controller motor combination is called a parameter set The following illustrations shows how the parameter sets are managed DCO file DIS 2 ServoCommander Reading from servo and save in file serial communication Servocontroller Default parameter set load default p
112. desired sign of the speed and current torque to a direction of movement User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 45 J Controller enable ae C Torque control Speed control C Positioning f Selection 64 positions Course program DINS Ea M New 1 70 assignment High Course program Low Selection 32 positions Tipp amp Teach DINO High Tipp amp Teach Low Selection 32 positions pn DANGER A If this option is activated the drive moves in the opposite direction with the same settings 4 10 Making the system ready for operation enabling the power stage The aim of this chapter is to let the motor rotate at a constant speed Then the other control functions such as the speed controller and the position controller can be optimized The setpoints are assigned via the analog inputs The controller has to be enabled via the digital controller enable input DANGER Do not work through this chapter until you have completely followed the instructions given in the other parts of chapter 4 and particularly the instructions concerning the configuration of the current limits the current controller and the safety parameters Incorrect basic settings may destroy the servo positioning controller motor and the mechanical drive It has turned out to be useful to set the current limits and particularly the maximum current of the controller to sm
113. dex pulse evaluation eeeeteeeeeeeeeees 66 Figure 10 Homing run to the positive limit switch with index pulse evaluation s 66 Figure 11 Homing to the negative limit SWItCN 0 cece ee ente ee ee ene ee eet ae eee e ea ae seer taaeeeeeetaeeeeeeaeeeee 67 Figure 12 Homing to the positive limit switch 0 0 0 cece eeeeeeeneeeeeeeeeeaee cents ceaeeeeaaeseeneeseaeeesaaeeseaaeseeeeeeaas 67 Figure 13 Homing run referred only to the index PUISC cececeeeeeeeeeeeeeeeee eee eeeeaeseeeeeeeaeeeseaeeeeeetee 67 Figure 14 Homing run to the negative stop with index pulse evalUatiONn ceceeeeseeeeeeenteeeeeeeteeeeees 68 Figure 15 Homing run to the positive stop with index pulse evaluation eecceeeeeeeeeeeeeteeeeeetteeeeeees 68 Figure 16 Homing to the negative Stop c ce ceeeccceeeenneeeeeeecneeeeeeaeeeeeeaaeeeeeeaaeeeeesaaeeeeeeeaeeeeetaeeeeeeeeeeeee 68 Figure 17 Homing to the positive StOD eee eeeeeeee scence ee ene ee eet ae ee eee ae ee eet ae eset taaeeeeeetaaeeeeetaeeesnaaeeeeee 69 Figure 18 Course program Position branch cccccsceeeeeeeeeeeeeeeeeeeeeeeeeeeeceaeeeeaaeeeeeeeseaeeeseaeeeeaeeeseesaas 77 Figure 19 Position branch time Cara sesasi entirar si Ee ERE EREE E RE EERE EE OES 77 Figure 20 Course program Branch Line 0 cecceceeeeeeeeeeeeeeeeeeaeeeeaeeceeeeeseaeeesaaeeeeeeeseaeeesaeeeseneeseeeeeas 78 Figure 21 Branch Line time GiaQram cccccceeeeceeeeeeeeeeceeeeeeeaeeee
114. directive Not applicable CE conformity EN 61 800 3 Other certifications UL under preparation 11 14 2 Dimensions and weight Dimensions H W D 65 x 90 x 100 mm without mating connector Weight approx 500 g 11 14 3 Performance data Intermediate circuit voltage 0 V 60 V DC 48 V DC rated 15 A rated DC bus voltage 24V supply 24 V DC 420 200mA A U Ripple gt 1 5 Vss 1008 700 mA 100 mA Internally protected through a poly switch switches at about 1 A Braking resistor connection Rer 2 4 7 Q Prom 20 W 200 W only present in DIS 2 48 10 FB Brake chopper DIS 2 FB Switching threshold ON Uchop on 60 V 5 Switching threshold OFF Ucnop off 55 V 5 1 An external 15A fuse is required 2 Current consumption of the DIS 2 48 10 without additional wiring 3 Maximum admissible current consumption of an optional holding brake Maximum current consumption when DOUTO to DOUT2 and the CAN bus are loaded User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 156 11 14 4 Motor temperature monitoring Parameter Values Digital sensor Normally closed contact Regia lt 500 Q Ranot gt 100 KQ Analog sensor Silicon temperature sensor KTY series KTY81 2x0 KT Y82 2x0 R25 2000 Q KTY81 1x0 KTY81 2x0 R25 1000 Q KTY83 1xx R25 1000 Q KTY84 1xx Rioo 1000 Q 11 14 5 Motor connection data X301
115. distance Basic unit position trigger applies to all position targets 0120 posc_x_target_win_pos Target reached tolerance window Basic unit position 0121 posc_x_target_time Target reached time constant Basic unit time 0122 psel_home_offs Offset for homing run Basic unit position 0123 posi_bus0O_ctrl Control word for the characteristics and the none process of the current positioning run 0124 posi_busO_x_end_h Target position in selected position set Basic unit position 0125 posi_busO_v_max Running speed during positioning run Basic unit speed Positioning group parameter 0126 posi_busO_v_end Final speed during positioning run Basic unit speed At present 0 Positioning group parameter 0127 posi_busO_a_acc Acceleration in the motor range of the drive Basic unit acceleration Positioning group parameter 0128 posi_busO_a_dec Acceleration in the generator range of the Basic unit acceleration drive deceleration Positioning group parameter 0129 posi_busO_a_acc_jerkfree Jerk free parts during acceleration Basic unit time Positioning group parameter 012A posi_busO_a_dec_jerkfree Jerk free parts during deceleration Basic unit time Positioning group parameter 012B _ seqc_homing_method Homing method In accordance with CANopen DSP 402 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 132 No Name Meaning Scaling 012C ssel_ainO_x_per_volt Position setpoint scaling AIN
116. e 7 o we moma Se ao 5 End accept 5 End accept End accept re End accept E Course program active NEXT1 DOUTI Line 4 X Exit Course program stop NEXT2 DOUT2 Position 16 Implementation A trick is used to realize the defined setting of DOUT1 Position 0 is set to 0 revolutions relatively with a start delay of 1 second At first the drives approaches position 0 and DOUT1 is set to HIGH Then the program jumps to line 2 To obtain an infinite loop line 4 contains a program line jump to line 3 11 10 Timing diagrams The following diagrams show some typical applications of the DIS 2 servo positioning controller and the corresponding timing of the digital inputs and outputs Since some times depend on the operating status of the controller only approximate values can be given in some cases In these cases the control system has to inquire additional status messages of the DIS 2 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 144 The times stated in the diagrams have a tolerance of 100 us This tolerance has to be taken into consideration in addition to the times given in the timing diagrams o The DIS 2 position controller has a sequential control with a time base of 1 6 ms The Il statuses of the digital inputs and outputs are checked and updated cyclically The cycle time of the SPC or of the control must be
117. e 69 Index 0 0 eee 67 Negative limit switch 0 cceeeeeeeees 66 Negative limit switch with index pulse evaluation 0 eee eeeeteceeeeeeeeteeeeeeeteeeeeees 65 Negative Stop ceceeesseeeseeeseteeeeneeeseeees 68 Negative stop with index pulse evaluation67 Positive limit SWitCh 0 cceeeceeeeeeeeees 67 Positive limit switch with index pulse evaluation 0 eee ee ceteeeeeeeeteteeeetaeeteneeeeees 66 Positive StOP eeeeeeeceteeeeneeeceteeeetaeeteneeee 68 Positive stop with index pulse evaluation 68 Homing method 0 ccceescceeeeeesseeeeeneeeeees 65 Homing run Destination c eeeececeeeeeeeeeeeeeetetaeeeeeeees 70 Go to zero position after homing run 70 Offset start position cceeceeeeeeeteeeees 70 SONGS aiaa ai a delve Tee 69 Homing run at controller enable 70 j Incremental encoder emulation 89 Information siara ineine 116 Input limits rinane is 41 Installation from CD ROM 27 L Limit switch Decelerations ccceeeeeceeeeeeeeeeeeeeeeees 42 Loading a DCO file Offline parameterization 0cceeee 150 Online parameterization 0 ceee 147 Loading a parameter set cceceeseeeeees 147 Loading the firmware ccceeeeeees 151 M Manual input of angle encoder data 32 Messages Digital outputs eceeeeeeeeeeeeeeeeeeeeeee 87 Following error 58 Remaining distance s 62 Motor data
118. e chassis 185 Connection of the DIS 2 to the power supply unit shield connection via cable 185 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 11 List of Tables Tablet Scope Of Supply tacizee sig iia caida Gite i eae ail eee 17 Table 2 Additional parameterization program eececeeeeeeneeeeeeneeeeeeeaeeeeeeaaeeeeeeaaeeeeeeaeeeeeeeaeeeeeeaeeeenaes 17 Table 3 DIS 2 48 10 ACCESSOSICS 00 eree ia aeaieie a aaea aiaa aaaea iaaa aaa aaa ie a aaan ad ieai 18 Table 4 DIS 2 48 10 IC and DIS 2 48 10 FB accessories ceccceeeseeceeeee cee eeeaaeeeeneeseeeeesaeeeeeneeeeaes 18 Table 5 Angle encoder parameters ececeeeeeteeeeeenneeeceenaeeeeeesaaeeeeeeaaeeeeeeaaeeeseeaaeeeeeeaaeeeseeaaeeeeeeeaeeeeeaas 32 Table 6 Display MOOG a aer E EEE EE EOE EE EEE E NT 40 Table 7 Error elimination Speed control cecececeeeeeeeeeeeeeeee eee eeeeaeeeeaeeseeeeesaaeeseaeeseeeeseaeeesaeeseaeeeeaees 46 Table 8 Course program Assignment of the digital inputs ceeceeeeeeeeeeeeeeeeeeceeeeesaeeesaeeteneeteaees 73 Table 9 Course program Configuration of the digital inputs new I O configuration 0 cee 73 Table 10 Available position sets if the course program is active and the Course Posi input 0 74 Table 11 DIS 2 48 10 digital inputs possible combinations cccccccecceeceeeteeeeeesteeeeessteeeeeeseeeeeeees 81 Table 12 DIS 2 48 1
119. e deceleration ramp When the stop signal reaches the HIGH level again the positioning run will be continued The position branch will not be performed The program will remain in the current program line The edge evaluation of the signals NEXT1 and NEXT2 will be continued even if the stop signal is active The outputs DOUT1 and DOUT2 will not be affected by the stop signal 7 1 2 End of program r Befehlsart Optionen Position branch C Branch Line fanch Uinn V Evaluate Stop signal C Level test End of Program A running positioning run will be completed Then the program will be stopped at this point No digital outputs will be set reset No other positioning run will be started If the check box Evaluate stop signal is selected the running positioning run can be interrupted 7 1 3 Position branch Course program line 0 Befehlsart Optionen V Evaluate NEXT1 M Evaluate NEXT2 I Evaluate Stop signal Position branch C Branch Line C Level test DOUTI Off S C End of Program DOUT2 Off NEXT1 M NEXT2 Following position 1 fo a Following position 2 fo z b Ignore if target not reached Ignore if target not reached C Go to position immediately Complete position then target Different positions are approached depending on NEXT1 and NEXT2 The course program continues in the following command line User Manual DIS
120. e program 5 speed feed POS forward A A dead range target reached y remaining distance message e x actua start positioning Figure 6 Positioning control block diagram User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 57 In contrast to many competition products the DIS 2 controller recalculates the entire movement process in every control cycle This means that positioning processes can be changed or aborted at any time even during the movement This concept is supported by the high level of performance of the Motion Control DSP inside the DIS 2 controller il The high performance positioning control system in the DIS 2 controller has numerous parameters and position data sets Up to 64 position sets can be stored in a non volatile manner in the DIS 2 and approached with the help of the trajectory generator Each of the 64 position sets includes a separate target position destination The other parameters of the 64 position sets are divided into 4 groups The following parameters can be set for each of the 4 position groups Pe Accelerations Running speed Selection of the type of acceleration Jerk limited speed profile or time optimal constant acceleration Relative or absolute positioning Wait for end of running positioning run or reject Start delay As an alternative the DIS 2 also allows to save all the parameter of a position set individually for each posit
121. ed the setpoints remain unchanged Only the actual values will be different due to the different class of performance This prevents a step by step change of a parameter set resulting from the device s class of performance o 11 1 5 Standard window In the default configuration the commands window the status window and the actual value window are open during the online parameterization During the offline parameterization the status window and the actual value window are not open The Actual values window displays the current controller parameters such as currents speeds etc The Actual values window is configured under Display Actual values The check boxes of all values to be displayed must be checked With the options Enable all or Disable all the Actual values window can be quickly minimized or maximized User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 113 Speed Actual value 1963 000 1 min Act val Motor EMK 1979 000 r min Setpoint 1964 000 r min Torque Actual value 074A Motor current rms 0 78 A Rotor position 155 84 Temperatures Temp motor Temp in power unit 31 C Position 3272 203 R Pt motor 0 Pt servo 0 DC bus voltage 24V 11 1 6 Directories The installed version of the parameterization program has the following sub directories Table 18 Directories Directory Content FIRMWARE Firmware v
122. ed on the motor shaft is approximately proportional to the active current in the motor one can justifiably talk about torque control m The accuracy of the torque control depends mainly on the motor and the sensor system Il used to measure the rotor position With a good synchronous machine a high resolution rotary encoder SINCOS encoder and good controller adjustment the DIS 2 can reach a torque ripple in the range of 1 to 3 referred to the maximum current or the associated maximum torque of the motor In speed controlled mode a certain speed setpoint is assigned The DIS 2 servo positioning controller determines the current actual speed n_actual through the encoder evaluation To make sure that the speed setpoint is complied with the current setpoint i_set is determined User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 48 uns 39U919 1 i yor X Jay AWDOJOA peN IJUOD 9A OH O7_ NVO _zezsy O _INIV __ ONIY xew sea os Soo N uolyeyesdseyu JOSUAS B UBW9J9U sa JOSURS SO os uS N 10SU Quis Ar An A sal soo nN uolyeyesds9yu Josuas eH anboyeue sa usn 1 A0S H soi uls N mire gt Meseud a A2eseud Efe al 9 nepal neseud lt ________ Meseud N toseugn E Z at N seyd N
123. eeeeeaaeeeseeaeeeeneaaes 149 11 12 Offline PAaraMeteriZAtlONs cic sseocecissathensdeswesaseeishontendepenseleadesunkeandasdsdnens Gaaaedandesenderd 151 11 13 Loading firmware into the DIS 2 firmware Update eee eeeeeereeeeeeeee 152 TWAS Loading the firmware iren area aea aa aa aree hve lat tian ies 153 11 14 Technical Cate cnnan cide aniseed ees le es etait 155 11 14 1 Ambient conditions and qualification ccccceceeeeeeeeeeeeeeeeeeeeeeeseaeeeseeeeennees 155 11 14 2 Dimensions and weight cece cceeeeeeeeeeeeeeeeeeaeeeeeeaaeeeeeeaaeeeeneaaeeeseeaeeeeeseaas 155 11 14 3 Performance dat nd e e a ai aai a ai 155 11 14 4 Motor temperature monitoring esssssesssssessssrrrsssirrssinnsstinnsstinnnstinnnnntnnnnnenn 156 11 14 5 Motor connection data X301 X303 esssseseesenssssrnssssrnssrsrnssrinnssrennssrennns 156 T1146 Resolver A2 angaar a Raa AAE aA tte te Petter ae ANARA 156 11 14 7 Analog Hall encoder evaluation X2 esseesseeeseneneessenesnnssnnssnnssrnssnnssrnssrnsns 157 11 14 8 Hiperface encoder evaluation X2 eccceeceeeeeeeeeeeeeeeeeeaeeseeeeesaeeeenaeeeeaees 157 11 14 9 Incremental encoder evaluation X2 only DIS 2 48 10 FB nnes 157 11 14 10 Six Step Hall sensor and block commutation X2 ccccceeeseeeseeeeeteeeeeeees 158 VASAT RS232 KA E tie cetera i Ma et tei ee at ee a 158 Loa P a 2 CAN Busi X E AE AE EEE A E EEE E 158 11 14 13 Analog inputs and outputs X11
124. eeeeeeeeeeseneees 95 9 1 Control through the CAN BUS aris secon crate erecpesoudeperendaneenlustaa eure ect asarngeoeaesengeatats 95 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 6 9 2 9 3 10 10 1 10 2 10 3 10 4 11 11 2 11 3 11 4 11 5 11 6 11 7 11 9 9 1 1 FUNCION OVEIVIOW oana anaia ea raa AEE PANE EA AAA a a aA A Eaa AnA 95 9 1 2 Processing Of CAN Me SSQQEG cccccececeeeeeceeeeeeeaeeeeaaeeseneeseeeesaeeetaaeeseneeenaees 96 9 1 3 Configuring the CANopen communication parameters 96 Control through the serial interface ccccceceeeesseeeeeeeeeeeeeeeeeeeeeeeeeaaeeeeeesaeeeees 97 9 2 1 UNCON OVEIVIOW ie v tian wide aan ida aiken dan alee 97 9 2 2 Serial communication through DIS 2 ServoCommander csscessessesseeeeeee 98 9 2 3 Configuring the RS232 communication parameters cccceccecesssteeeeeesteeeeees 98 9 2 4 Transfer WING OW isisisi iiini cada aiden abe diese aay eesti anes 99 9 2 5 Communication window for RS232 tranSmMiSSiON ccccceeeeeeeteeeeeeeteeeeeeees 99 Control through the technology interface cccceececeeeeeeeeeeeeeeeeeeeeeeeeneeeeeenaes 100 Error messages Error table isisisiicnisisdsincsincsinardncstnartndventvancvenavdnduenarduane 101 Error monitoring in the DIS 2 2 ceshs bine toiciatanbiadenudetiet enh ease vteeravetitaeeeaeebe 101 10 1 1 Overcurrent and short circuit MONItOFING eeeeeceee
125. eeeeeeeeeeteeeeetaeeeeeeeeenees 101 10 1 2 DC bus voltage monitoring 0 cceeceeececeeeeeeeeeeeeeeceeeeeseaeeeeaeeseeeeeeeaeeseneeeeaees 101 105183 toge SUPPLY MONITOFING eesse ete Eae ERs a eA ES ERN KORE EAER 102 10 1 4 Heat sink temperature monitoring ssessssssssssssrssssrrsssirrnssirnsstinnnstnnnnnrennssrnnnns 102 TOLOS Motor MONK MO selire e e e sa e eesi 102 10 1 6 Motion sequence monitoring essesssssssssrrssssrrrssrirnssttrnsstinnsstinnnntnnnnatennnnnnen 103 10 1 7 Additional internal monitoring FUNCTIONS ccccecseeeeeeeeteeeeeeeaeeeeesaeeeeseaaes 103 10 1 8 Operating hour meter 2 cece eeeneeceeeeeeeaeeeeeeeceaeeeeeaeseeaeeseeeeesaeeeeaeeenaees 103 Error OVGIVIOW moseri tenha A aeei palain ARAE a SE a aN a editors 103 Error display in DIS 2 ServoCommander cccccsccscscsesesesesesesesesesesesesesesenees 108 Error management a Pct wcieen iyi ah east de pmedtrevase stark athah cancaatsnanteactuacenodmneneok oatauaties 109 PADD CICK E E T AA A A A E 110 DIS 2 ServoCommander operating instructions ccccccecccesssessssescseeeeeeeeees 110 VAT Standard buttons seve ceux seeded es Sees ee iN E ee es NNE Ea eds 110 11 1 2 Numerical input fields 20 00 cece cceseeeece cece eeceaeeeeaeeseeeeeeeeaeeseaeeseeeessaeeesaeeeeeees 110 11 1 3 Control elements 20 0 ceccce ccc ee cece eeeece cee eeeeaaeegeeeeeaeeeeaaeseeaeeseeeesaeeeeaaeesnees 111 11 1 4 Display of setpoints and actual values c
126. eeees 168 11 17 1 Connection Power supply and I O X1 ccceeesceeeeeeeseeeeeeeeseeeeeseaeeeseeeeeeees 168 11 17 2 Connection Motor encoder brake ExtENSiONS ccccccccccceceeceeeeeeeeeeeeeeenees 169 11 18 Connectors at the DIS 2 48 10 FB ceeeccceeeeeeneeeeeeeeeeeeeeeeaeeeeeeeneeeeeeeeeeeees 169 11 18 1 Connection Power supply and I O X1 0 ccceccseeeeeeeeeeeeeeeeeeseeeeeseaeeesaeenenees 169 11 18 2 Connection Motor encoder brake ExtENSiONS ccccccccccccceeeeeeeeeeeseneeenenees 170 11 18 3 Brake resistance connection X304 X305 ceesceceeeeeeeeeeeeeeeeteeeeseeeeeenees 171 11 18 4 Connection CAN bus X401 and X402 ceeeceeeeeeceeeeeeeeeseeeeeseaeeeseeenenees 172 11 18 5 Connection Serial parameterization interface X5 ccccceeecesseeeeseeeeeeees 173 11 18 6 Connection Extension port X8 c cccccceeeeeeeeeeeeceeeeeseaeeseaeeseeeeeseaeeneeeeeeaees 174 11 19 Electrical installation of the DIS 2 48 10 ecceceeeeceeeeeeeeeeeeeeeeeeeeeeeeeeeaeeees 176 11 19 1 Connection to Power Supply and control in SYSteM 0 cceeeeeeeeeeeeeeeteeeeeees 176 11 19 2 EMERGENCY OFF EMERGENCY STOP terminology and standards 178 11 19 83 EMERGENCY OFF EMERGENCY STOP wiring examples 0 ccee 180 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 8 11 20 Notes concerning safe and EMC compliant installation 11 20 1 Definitions and
127. encoder activated iit monitoring gt limitation to nominal current IIT motor servo Positioning run started activated for the duration of an IPO cycle Speed message n_actual n_soll n_mel_hyst 1 speed message n_actual n_mel n_mel_hyst Remaining distance of positioning run reached set to zero at the start of the follow up positioning Destination reached message n_actual x_setpoint x_mel_hyst Message positioning completed x_setpoint pos_x_actual set to zero at the start of the follow up positioning Positive limit switch reached DIN8 amp Negative limit switch reached DIN7 Home switch reached Homing active User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 137 Error word low errh_err_field_0 Error limit switch Following error monitoring Output stage temperature 5 C below maximum Motor temperature 5 C below maximum lT at 80 Controller I T error FT at 100 Motor I T error I T at 100 SINCOS track signal error Intermediate circuit overvoltage Intermediate circuit undervoltage Overcurrent intermediate circuit output stage Current measurement offset error 24V supply error out of range 12V electronic system supply error
128. er can only assume the role of the master The master transmits the position information in the form of incremental encoder track signals through the outputs DOUT1 track signal A and DOUT2 track signal B to the slave which receives the information through the corresponding incremental encoder input The illustration below shows the configuration X1 out input Master Slave Figure 25 Coupled incremental encoder emulation The master operates in one of the operating modes described earlier speed control positioning while the slave is in synchronized mode Among others the following applications are possible with this configuration Speed synchronous movement Position synchronous movement s Flying saw Classical servo applications such as speed control in the servo controller or position control in the control system also required a feedback of the actual position from the servo controller to the control system This is also handled using the incremental encoder emulation of the servo positioning controller In both cases the DIS 2 controller as the master emulates the track signals of the incremental encoder defined by the parameters in the menu Operating mode Incremental encoder emulation User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 90 Incremental encoder emulation Incremental encoder X Cancel Number of increments 1024 J Nu
129. er in special areas of application with particularly high normative requirements e g medical technology or avionics requiring particularly high levels of device safety the user has to check whether the DIS 2 fulfils the corresponding standards In case of doubt please contact your local distributor The DIS 2 may only be used if the operating conditions described and the technical data of the controller stated in the appendix in chapter 11 14 Technical data are complied with In addition all relevant regulations concerning installation start up dismounting and maintenance have to be complied with 1 2 3 DIS 2 features The DIS 2 has the following features Compact design The housing closed on five sides can be mounted on the motor either directly or using an adapter plate Highly precise control thanks to a high quality sensor system Full integration of all components for the controller and power section including an RS232 interface for PC communication and a CANopen interface for integration in automation systems Integrated universal rotary encoder evaluation for the following encoder types gt Resolvers User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 15 Analog Hall sensors with SIN COS signals upon request High resolution Stegmann incremental encoders absolute encoders with HIPERFACE Vv v WV Six step Hall encoders gt Incremental encoders with commutati
130. er reset hardware reset via commh Debug mode 0 off 1 on Load default parameters from program memory init Setpoint lockout activated internally by the controller Direction bit O left handed rotation 1 right handed rotation inverts the speed setpoints and the position setpoints in the torque control mode also the torque setpoints Error acknowledgement Positioning or homing start Rotation direction reversal inverted rotation direction with identical setpoints Activate synchronous positioning submode Activate homing Activate positioning Activate speed control Activate torque control Activate position control Controller enable User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 136 Status word rs232_stat_sum 31 30 2 28 27 MOTID mode 2 INTERNAL controller and output stage enabling 22 21 20 9 Automatic encoder adjustment active Homing run performed 1 Positive direction blocked 18 Negative direction blocked 17 Common error message 16 Warning message no common error and no shut down Ready for operation Output stage switched on Speed message n_actual 0 n_mel_hyst SinCos
131. ering after the motor has been switched off e g by means of gt Mechanical locking of the vertical axle gt External braking catching or clamping devices or gt Sufficient balancing of the axle The motor holding brake supplied by default or an external motor holding brake driven by the drive controller alone is not suitable for personal protection Render the electrical equipment voltage free using the main switch and protect it from being switched on again until the DC bus circuit is discharged in the case of gt Maintenance and repair work gt Cleaning gt long machine shutdowns Prior to carrying out maintenance work make sure that the power supply has been turned off locked and the DC bus circuit is discharged Be careful during the assembly During the assembly and also later during operation of the drive make sure to prevent drill chips metal dust or assembly parts Screws nuts cable sections from falling into the device Also make sure that the external power supply of the controller 24V is switched off User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 23 The DC bus circuit or the mains supply must always be switched off prior to switching off the 24V controller supply o Carry out work in the machine area only if AC and or DC supplies are switched off Switched off output stages or controller enablings are no suitable means of locking In the case of a malfunc
132. erization program transmits the value to the DIS 2 servo positioning controller The parameterization program immediately reads out the now valid parameter and displays it in the green field The scroll box itself remains unchanged Speed controller Time constant Actual speed filter 1 X Cancel User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 112 Definition of terms 7 Setpoint value The setpoint value value desired by the user transmitted to the DIS 2 servo positioning controller Actual value This value is currently active in the DIS 2 servo positioning controller Deviations from the setpoint value may have several reasons Examples gt Quantization effects rounding effects etc gt The changed parameter has to be saved and a RESET has to be performed in order to make the parameter effective gt Temporary value range overshoots e g rated current gt maximum current gt Incorrect value ranges e g when loading a parameter set of a servo positioning controller of a higher class of performance rated current gt rated device current The idea behind the concept of different setpoints and actual values is the following A parameter set can be loaded from a servo positioning controller of one class of performance to a servo positioning controller of another class of performance and vice versa As long as no other parameterization has been perform
133. ersions Default directory for plain text output of parameter data Default directory for the parameter files 11 1 7 Communication via communication objects The parameterization program accesses the DIS 2 servo positioning controller by means of so called communication objects via a standardized internal software interface During the processing of the communication tasks an internal check for the following errors will be performed Write access to read only communication objects Read access to write only communication objects Overshooting or undershooting of the values range Erroneous data transfer The first two cases are fatal errors which normally should not occur in practice In the last case the parameterization program repeatedly tries to perform the read or write process without a bit error Overshooting and undershooting of the value range of a communication object are indicated by a warning If there is an internal value for this object the value will be saved as a desired value However the original value will be maintained internally Otherwise the value will be rejected User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 114 11 1 8 Quitting the program The program can be quit as follows Select the menu option File Exit Press the shortcut lt Alt gt F4 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Click the X button on
134. erty damage due to unintentional movements of the motors User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 21 2 3 Safety notes 2 3 1 General safety notes WS oo oo WD WD PY o NED The servo drive controller corresponds to IP54 class of protection as well as pollution level 1 Make sure that the environment corresponds to this class of protection and pollution level Only use replacements parts and accessories approved by the manufacturer The devices must be connected to the mains supply as per EN regulations so that they can be cut off the mains supply by means of corresponding separation devices e g main switch contactor power switch Gold contacts or contacts with a high contact pressure should be used to switch the control contacts Preventive interference rejection measures should be taken for control panels such as connecting contactors and relays using RC elements or diodes The safety rules and regulations of the country in which the device will be operated must be complied with The environment conditions defined in the product documentation must be kept Safety critical applications are not allowed unless specifically approved by the manufacturer For notes on installation corresponding to EMC please refer to chapter 11 20 Notes concerning safe and EMC compliant installation The compliance with the limits required by national regulations is the responsibility of
135. ervo positioning controller generates a message when the required operating conditions are violated or reached The menu item Parameters Messages opens a window for configuring these messages Here you can configure tolerance ranges for the messages declared speed achieved target reached and following error Tab Following error 7 Following error Tolerance range for the permissible following error 7 Message delay Delay during which the actual position must be outside the tolerance window before the following error message will be set Messages Motor speed message Destination Following error Following error ranges Following error 0 139 R gt Message delay 100 0 ms 100 0 ms 4 m The following error message should be activated in all positioning applications Il The recommendable range of the tolerance windows depends on numerous parameters such as the controller gain in the speed and position control circuit the resolution of the User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 88 position detection system etc The Message delay parameter can be used to increase the robustness of the system as it makes sure that not every brief position deviation triggers a following error message Tab Destination 7 Angle Distance Tolerance range in which the target reached message will be set 7 Me
136. es or systems Metronix MeBgerate und Elektronik GmbH reserves the right to modify amend or improve the document or the product without prior notification This document may neither entirely nor in part be reproduced translated into any other natural or machine readable language nor transferred to electronic mechanical optical or any other kind of data media without expressive authorisation by the author Trademarks Any product names in this document may be registered trademarks The sole purpose of any trademarks in this document is the identification of the corresponding products ServoCommander is a registered trademark of Metronix MeBgerate und Elektronik GmbH Microsoft and Windows are either registered trademarks or trademarks of Microsoft Corporation in the United States and or other countries User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 3 Revision Log Author Metronix MeBgerate und Elektronik GmbH Manual name User Manual DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB File name UserManual_DIS 2_1p1 doc Storage location of the file pets _ fans Date of change First authorized version 24 06 2005 Revision Extension to DIS 2 48 10 FB and to firmware 3 0 15 05 2006 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 4 TABLE OF CONTENTS 1 err a a
137. es the oscilloscope window Minimizes the oscilloscope window Prints the oscilloscope window Calls up Excel and creates a spreadsheet containing the measurement values of the last measurement Excel has to be installed on the PC Zoom function Help text Stops the zoom function Shifts the area shown in the horizontal direction nan Aa O Se we User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 123 These controls are used to control and visualize the cursor of the oscilloscope When the user opens the actual oscilloscope window the current value of the selected channel cursor position is displayed in a numerical form In this example channel CH2 has the value 451 r min at the time t 30 ms The Cursor button can be used to switch to another channel These check boxes are used to show and hide the channels in a selective manner A selected check box means This channel is shown This coloured area indicates the current status of the oscilloscope The following entries are possible inactive The oscilloscope is not active at present start The oscilloscope is started wait for trigger The system waits for the trigger event pretrigger The system has started to record data for the pretrigger trigger found A trigger event has been found but the system has not started to record data yet data read The channel data are transferred to the parameterization program The LED indicates the cur
138. eters Motor data as otherwise the motor may be destroyed If encoders with a poor resolution e g Six Step Hall encoders are used speed recirculation through the Motor EMK can have a positive effect on the running behaviour of the motor If the speed is determined with the help of the Motor EMK electromotive force of the motor the following formula N eux On L X R mor x N wem Nenn User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 35 is used to determine another actual speed value of the motor using the terminal voltage at the motor the impressed current and the motor parameters You can configure the parameters required for calculating the Motor EMK on the advanced parameters tab Motor data Basic parameters Advanced parameters Real voltage 48 V a Idling speed 3000 rimin 4 Ses gt Stator resistance 0 20 Ohm aa E Stator inductance 0 20 mH j 4 3 3 Power stage This menu Parameters Device parameters Power stage determines the behaviour of the power stage You can select a clock frequency of 10 kHz or 20 kHz If the clock frequency is low the motor emits a singing sound If you want the motor to run as quietly as possible choose the 20 kHz clock frequency In addition the losses in the motor are slightly reduced at a high clock frequency on the other hand the losses in the DIS 2 servo positioning controller will increase which is
139. f the angle 7 7390 SINCOS encoder encoder interface Resolver connected lt 5ms X Angle encoder cable defective track signals Check the configuration of the angle 8 7380 carrier failure encoder interface The error may be due to a defective angle lt 5ms X encoder due to defective Hall sensors or due to a wiring error of X2 Possible error on technology module X8 Electronic error in the DIS 2 device The error cannot be eliminated by the user Error 5V internal Send the servo positioning controller to the 9 5113 supply distributor User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Error no CAN error code Meaning Possible causes measures Release time Page 105 Reaction C JE W 5114 Error 12V internal supply The error may be due to a defective angle encoder due to defective SINCOS encoder or due to a wiring error of X2 Electronic error in the DIS 2 device The error cannot be eliminated by the user Send the servo positioning controller to the distributor lt 5ms X 5112 Error 24V supply out of range 24 V logic supply too high or too low 24 V logic supply cannot be loaded e g when the holding brake is actuated Error in the holding brake or in the wiring to X3 or overload of the brake output due to a brake with a too high current consumption Electronic error in the DIS 2 device The error cannot be eliminated by the user Send
140. f the controller to meet a wide range of customer requirements oO il The information stated in this manual refers to the following versions of the controller operating software and of the parameterization program DIS 2 servo positioning controller firmware Version 3 0 Parameterization software Version 2 1 1 5 Supply state and scope of supply The supply comprises Table 1 Scope of supply DIS 2 servo positioning controller Supply state Default parameter set for operating the resolver motor Table 2 Additional parameterization program DIS 2 ServoCommander Metronix part number 9019 0900 00 Windows parameterization program German English French Mating connectors for power control or rotary encoder connections are not part of the standard scope of supply They can be ordered as accessories User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 18 Table 3 DIS 2 48 10 accessories Connector set AMP pin and socket connector Content 1x crimp contacts 16 pin AMP mating connector incl 16 pin mating connector for angle encoder incl crimp contacts 2 pin mating connector for holding brake incl crimp contacts Metronix part number 9019 0200 00 DIS 2 control panel with AMP pin and socket connector Table 4 DIS 2 48 10 IC and DIS 2 48 10 FB accessories Connector set Phoenix pin and socket connector been suitable for DIS 2 IC
141. fi 000000 Time base acceleration in s fi 000000 Display units User defined m Il User defined units are marked by You can enter the scaling in User defined units per revolution into the Feed constant field in the Translatory application section Example You have a drive with 1 76 inch per revolution without a gearbox You would like to enter the position in inch You have to enter 1 76 into the Feed constant field In addition the input fields Time base speed and Time base acceleration are available Use the field Time base speed to define your own speed units Example rotary operation You have a drive with 20 mm per revolution without a gearbox You would like to enter the speed in mm minute Enter 20 into the Feed constant field and 60 into the Time base speed field 60 seconds 1 minute Use the field Time base acceleration to define your own acceleration units User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 140 Example You have a drive with 20 mm per revolution without a gearbox You would like to enter the acceleration in mm minute s Enter 20 into the Feed constant field and 60 into the Time base speed field 1 minute x 1s 60 x 1 s 60 s 11 8 2 Decimal places Another way of configuring the display units is the configuration of decimal places You can enter the number of decimal places for the position speed and acceleration
142. g MP tS iisa a ei 92 Analog monitor Numeric overflow limitation 008 94 Sealing eirinn aeaa an a aeta 93 Analog monitor ssseeeeieeeeeeeresreereen 93 Angle encoder Configuration seeen 30 Angle encoder identification 0 c ee 30 Automatic angle encoder identification 30 B Baud rate Actual data transfer rate 0 0 00 98 Preferred transfer rate cccccceesseeeeeees 98 Brake fUnCtions ccccscccccessseeceesseeeeessaes 91 Cc Camela e a NE 110 CANopen Addition of DINO DIN3 to node address 97 Basic node NUMbET cccceecceeeeenees 96 Baud fate ioiii rne tn tied 96 Configuring the communication 96 Commissioning Loading a parameter Set c cccceeseees 28 COMMISSIONING 0 cseeeeeeeeeeeeeeeeetaeeeeeeeees 28 Communication via communication objects113 Communication window for RS232 transmissi Moe etait ee ieuadae 99 Communication with R8232 98 Configuring the communication 5 98 Control Cle Ment cccecccceseestteeeseetees 111 Control interrupts 0 cccceeeeeeeeeeeeseeeeeeees 116 Controller cascade cceeeeeeeteeeeetteeeeeeeees 47 Controller enable lOGic ccccceeeeeeeeees 43 Course program Creating a program 74 Global settings cceseeeeeceeeeteeeeneeeeees 60 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 187 Course program ssseeseeseeeeeereerree
143. g controller comes supplied with the default parameter set During commissioning the default parameter set has to be adapted to the specific application Otherwise the DIS 2 servo positioning controller has the status not commissioned m The default parameter set includes a basic parameterization of the controller for use as a Il speed controller with setpoint assignment through analog input AINO The controller settings and the current limits are set so low that a connected motor of a typical type will not be overloaded or destroyed if the controller is released accidentally The manufacturer settings in the default parameter set can be restored with the help of the menu File Parameter set Load default parameter set m When the default parameter set is loaded the application specific parameters will be 1 overwritten and the controller status will be set to not commissioned This should be taken into consideration when using this function as it requires a new commissioning 4 1 2 Manual commissioning If you do not have a parameter set adapted to your motor or application you should parameterize the following menus in the order stated 1 Parameters Application parameters General configuration 2 Options Display units 3 Options Input limits 4 Parameters Device parameters Motor data Motor identification using the list or the motor data menu o Parameters Device parameters Angle encoder adjustmen
144. g general safety notes apply User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 U feb Q o gt N oO NED Comply with the general setup and safety regulations on handling and assembly NED Use suitable assembly and transportation devices Ng Prevent incarcerations and contusions by means of suitable protective measures NED Use suitable tools only If specified use special tools NED Use lifting devices and tools appropriately If necessary use suitable protective equipment e g goggles protective footwear protective gloves Ng Ng Do not stand underneath hanging loads NED Remove leaking liquids on the floor immediately to prevent slipping User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 27 3 Preparation for commissioning 3 1 System overview The DIS 2 servo positioning controller was designed such that it can be mounted directly on the motor As a result it forms a compact and harmonized unit together with the motor Simply connect the power supply and if applicable the inputs and outputs or field busses used for your application The DIS 2 ServoCommander parameterization program can be used to parameterize commission and analyze the DIS 2 servo positioning controller in a particularly comfortable way 3 2 Connecting the DIS 2 to the control system Prior to activating the power supply for the DIS 2 servo positi
145. g operating modes specified in CANopen are supported Torque controlled mode profile torque mode Speed controlled mode profile velocity mode Homing homing mode Positioning mode profile position mode Synchronous position assignment interpolated position mode The following access types are supported for the exchange of data SDO Service Data Object Used for the normal parameterization of the controller About 150 SDOs are supported PDO Process Data Rapid exchange of process data e g actual speed Object possible 2 PDOs are supported SYNC Synchronization Synchronization of several CAN nodes Message EMCY Emergency Transmission of error messages Message NMT Network Network service All CAN nodes can be influenced Management simultaneously for example HEARTBEAT Error Control The communication members are monitored through Protocol regular messages m More information concerning the communication and control of the DIS 2 servo Il positioning controller via the CANopen interface and information concerning the connection of the CAN bus can be found in the CANopen manual for the DIS 2 servo positioning controller User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 96 9 1 2 Processing of CAN messages The DIS 2 has a command interpreter for the CAN messages received This command interpreter is activated every 1 6 ms It can process an SDO or a special message such a
146. gh overvoltage gt 70 V the DIS 2 servo positioning controller will be shut down This is a safety function and cannot be parameterized Intermediate circuit voltages that are too low can cause an error if this is configured accordingly by the user The menu can be activated under Parameters Device parameters DC bus monitoring Rated DC bus voltage 48 0 V gt Siindeivaliogs action Response threshold C Eror Immediate Stop of output stage C Eror Controlled Stop Warning Show Warning C Warning Do not show Warning X Cancel The field Rated DC bus voltage shows the voltage for which the power stage is rated This value cannot be changed In the field Undervoltage detection you can define the response threshold below which the voltage has to fall so that the controller detects an undervoltage Depending on the power supply unit used a normal value would be 50 70 of the rated DC bus voltage User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 38 An undervoltage detection value lt 50 makes not sense as in this case the power Il supply unit cannot supply the voltage required by the controller in the application Use a stronger power supply unit instead In the error field you can define the response of the servo when it detects an undervoltage You can also make this setting in the error management menu see chapter 10 4 Error managemeni
147. he RS232 interface User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 40 The user can select display units for the following physical quantities Position Revolutions Speeds Accelerations Torques in Nm or A Display units Display units Decimal places Direct input Display mode r Gearbox gt Standard values I with gear X Cancel User defined Direct input Speed I Torque in Nm oT 3 Pai ts r Display units r Acceleration min s Revolutions R z C vs rotatory gt gt translatory Display units R r min tmin s m The display units are configured regardless of any setpoint assignment via field bus 1 Thus the configuration of the display units does not affect the factor group or the notation and dimension indices in field bus specific protocols such as the CANopen factor group Table 6 Display mode Selection Units Standard values For linear axles Positions in distance units speeds in distance units s accelerations in distance units s For rotary drives Positions in revolutions degree or radian different speed and acceleration units User defined Examples For linear axles and non metric distance speed and acceleration units e g inch inch min For rotary drives with special distance speed and acceleration units Direct input Free configura
148. he maximum permissible temperature of the housing is 70 C to guaranteed the specified service life of the electronic system te as Connect the connecting cable for X1 as closely as possible to the DIS 2 servo positioning controller to increase the reliability of the cabling t Installation spaces Keep a minimum distance of 100 mm underneath and above the device to other components to ensure sufficient ventilation Power supply DIS 2 Inputs Outputs Communication Motor Power Co DIS 2 feedback Inputs Outputs b DIS 2 mounting options a Mounted directly on the motor standard b Separated from the motor Please contact your local distributor to check whether this option is available User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 161 11 15 2 Position and connection of the pin and socket connectors The DIS 2 servo positioning controller has the following connections X1 is the only IO connector led to the outside It includes digital and analog inputs and outputs the power supply the CANopen interface and some debug signals X2 is used to connect the angle encoders This connector supports the following angle encoders gt Resolvers gt Analog Hall sensors upon request gt Stegmann HIPERFACE gt Digital Hall sensors Six Step encoders X3 is used to connect the holding brake X301 X302
149. hrough the external control as from a control point of view the ramp operates like a PT filter and decreases the stability in the control circuit 5 4 5 Torque limitation As mentioned before a torque limitation can be parameterized in the speed control operating mode In this case the selected setpoint source specifies a certain maximum torque This maximum torque then limits the setpoint symmetrically for the current controller or the torque controller Please keep in mind that the current setpoint is also limited by the values set in the motor data menu for the rated current and the maximum current The current setpoint is limited to the lowest torque limit z Application requiring torque control in a quadrant i e the adjustment of the torque from 1 zero to maximum in one direction of rotation can be realized well in most cases in the speed control mode with torque limitation e The torque setpoint is assigned through the torque limitation e The speed setpoint is assigned through a separate setpoint This prevents the drives from spinning under no load conditions and the speed will be limited to non dangerous values User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 56 6 Positioning mode You can skip this chapter if your drive is used only in speed or torque mode i 6 1 Function overview In the positioning mode a positioning control is superimposed on the
150. icencis cissisancsedaneeiede dusseie sbesnagestdaaboisasedandscauensenbanen 57 6 3 Configuring and optimizing the position controller cccceeeeeeeeeeeeeeeeteeeeeeeees 58 6 3 1 Position controller OPtiMiZation 0 eee eceeeeeeeeeene eee eeeaeeeeeeaeeeeeeaeeeeeeaeeeeseaas 59 6 4 Global positioning SSUINGS eietoccces een cect cee eys daca ce eee ea dadedceteetennie a teeaeite das 60 6 5 Parameterizing position SOUS iss ci2isccamecesndrered ecw edeenedustedonnsaceed tena nes aces 61 6 6 Approaching destinations iicsic ciccnciseisdaschiageedane opens ronceetatdeneadereda cledhctatassevenenatnonnens 64 6 7 Setting of digital outputs 25 A waccasiededesevads nase eat cau kcteh halve get necdpnaceseectncectaea toes 65 6 8 HOMINO eraa a anette tebe Ea Aaa Aa vanes EAE Sache une aa Eaa 65 6 8 1 Homing methods sesoses ae iniia E AE ANE ENA T 65 6 8 2 Parameterizing the homing FUN eee ee eeeeeeeeeeeee eee eeeaaeeeeeeaaeeeeeeaaeeeeeeaaeeeeeeaae 69 7 Cours prograM sssssssiiis anneanne aamiais aaa aawa eaaa Haaa Eaka iaaa Eanan 72 7 1 Creating a course program x 2 caeets snes a hcctee tei cindeee once itnao ae 74 7 1 1 Course program OPTIONS eeececeeeceeeeeeceeeeeeeaeeeeneeseeeeeceaeeeeeneeseeeesaeeeeaeeseneesaas 75 7 1 2 ENG Ol DhOOKAIN Aik eave See hee ahha ae na aN AC Ae ES ecg 76 7 1 3 Position DIAN sretan pneuri ener eiaeia eese aaa Ena dea neistainsanie winacbianbeieninag 76 TAA Branch Line orzer aaraa an ei AA A AAN Avia AA
151. igital Output Programmable encoder output track B AMONO 0 V 10 V 2 mA Analog monitor 0 GND lov Reference potential for the control signals AINO DINO 0 V 10 V Analog input 0 Differential analog input with AINO Digital input Positioning destination selector bit 0 DouT1 0 V 24 V Digital Output Programmable encoder output track A DING o v 24 V Digital input Positioning start 24V Logik 24 V 24 V power supply for the internal logic and the IOs GND OV Shared ground potential for the intermediate circuit voltage DC bus voltage and the 24V logic supply 48 V 15 A nom Intermediate circuit supply DC bus The X1 interface of the DIS 2 FB is to a large degree compatible with the one of the DIS 2 IC The double utilization of the inputs and outputs has been reduced to a large degree DOUT1 and DOUT2 as well as DIN4 and DIN5 are now available in all operating modes 11 18 2 Connection Motor encoder brake extensions The connectors for the motor phases X301 X303 the holding brake X3 the angle encoder X2 and the extension port X8 are compatible with the DIS 2 48 10 Information concerning the connection and the pin assignment of these connectors can be found in the corresponding sub sections 11 16 Connectors at the DIS 2 48 10 of the appendix User Manual DIS 2 DIS 2 48 10 DI
152. in the negative direction until is reaches the stop The DIS 2 servo positioning controller needs at least 1 second to recognize the stop The mechanical design of the stop must be such that it cannot be damaged at the parameterized maximum current The zero position refers the first index pulse of the angle encoder in the positive direction from the stop User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 68 Index Pulse Figure 14 Homing run to the negative stop with index pulse evaluation Method 2 Positive stop with index pulse evaluation If this method is used the drive moves in the positive direction until it reaches the stop The DIS 2 servo positioning controller needs at least 1 second to recognize the stop The mechanical design of the stop must be such that it cannot be damaged at the parameterized maximum current The zero position refers the first index pulse of the angle encoder in the negative direction from the stop Index Pulse Figure 15 Homing run to the positive stop with index pulse evaluation Method 17 Homing to the negative stop If this method is used the drive moves in the negative direction until it reaches the stop The DIS 2 servo positioning controller needs at least 1 second to recognize the stop The mechanical design of the stop must be such that it cannot be damaged at the parameterized maximum current The zero position refers directly to the stop _
153. ine parameterization 0 cceeee 150 Online parameterization 147 Saving a parameter S t 0 ee 146 147 Scope Of supply ceseeeeeeeeeceeeeeeeteeeeeeeeees 17 Serial communication Version 1 1 OPtiMIZAtiON iee e 98 Troubleshooting e cceeeeeeeeeeeeeeteteeeees 115 Serial interface Change COM port sessen 114 Firmware download ccccccseeseees 114 Offline parameterization 0 cceee 114 Retry with old parameterS 000 114 Serial interface Search baud rates 114 Setpoint ramp eee eeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 54 Setpoint SOUICES ccccccceeeecessseeeeessteeeeeees 52 Setpoint values 00 0 eeceeeeeeteeeeeeeteeeeeseeeees 112 SelpOIntS snc en R E A Ae 52 Setting of digital outputs 0 0 0 eeeeeeeeeees 65 Speed controller User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Page 189 Manual configuration ccceeeeeeees 49 Speed limitation c ee eeeccceesseeeeeeesneeeeseees 42 Speed controlled MOde cecceccsseeeeeees 49 T Temperature monitoring sessen 38 Tool bar FaSt accessi inaen 117 Offline online parameterisation 150 Online offline parameterization 150 Torque CONSTANL cceecceceseeecessteeeeesteeeeees 52 Torque controlled MOde 0ecceceeeeeeeees 52 Transfer WINdOW 00 cccccsscccecessteeeeesteeeeees 99 Version 1 1
154. ings Oscilloscope Settings CH1 cH2 Time base Trigger CHT Freely selectable communication object oe oe F Offset Freely selectable communication object Object number Eo hex signed IV physical unit Position 32 bits Mask FFFFFFFF hex xX Cancel The Oscilloscope Settings window includes four tabs for precise settings Chi Selection of the measuring quantity on channel 1 Ch2 Selection of the measuring quantity on channel 2 Time base Setting of the time base Trigger Configuration of the trigger The oscilloscope has two channels The following settings can be selected on the tabs CH1 and CH2 for the corresponding channels Quantity to be displayed Click on the scroll box of the channel and select the physical quantity or the event you would like to display graphically User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 120 Channel colour Click on the coloured screen area A dialog box for selecting a colour will be displayed Y Scaling Use the slide next to Scaling to adjust the scaling in vertical direction Offset Y Position Use the slide next to Offset to shift the vertical position of the curve Clicking the 0 button resets the offset to 0 The representation of the two channels can be cleared by clicking on the Clear button If Freely selectable communication object has
155. ion Then normal positioning mode with destination selection through DINO DIN1 DIN2 and position group selection through DIN4 and DINS STOP Low A running positioning run will be interrupted The program stops in the active low current course program line l NEXT2 Rising edge Continue with following position 2 START2 Rising edge Movement to a defined start position Start of the course program START has a higher priority than START2 if both are activated simultaneously Rising edge Continue with following position 1 NEXT has a higher priority than NEXT2 if both are activated simultaneously STARTI Rising edge Movement to a defined start position Start of the course program Start Rising edge positioning If DIN3 low Start positioning homing If DIN 3 high Start homing User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 74 The new IO configuration that is shown in table 9 ensures a better utilization of the functions in the course program in spite of the double utilization of the signals DIN2 DOUT1 and DIN 3 DOUT2 on the X1 connector It can be activated through the corresponding check box in the commands window If the digital input Course Posi is set to 0 V the course program is inactive Normal positioning runs can be called up through the digital inputs but as shown in table 10 the number of destinations is reduced by half
156. ion limits are complied with use a shielded cable User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 185 cage clamp presses cable shield to conductive chassis e g Phoenix SK 20 CAN BUS es oe S o AINO AIN1 DINO DIN9 DOUTO 2 Electrical 7 conductive Cable Shield connection Supply and IO cable shielded Electrical conductive connection Mounting chassis sheet metal Figure 45 Connection of the DIS 2 to the power supply unit shield connection on the chassis If possible connect the cable shield to the machine part on which the DIS 2 servo positioning controller is mounted as shown in Figure 45 Remove the cable sheath only in the area of the shield terminal Then press the open cable shield onto the machine part using a shield terminal The selection of the shield terminal depends on the mechanical design The suggested SK 20 D shield terminal made by Phoenix is rated for a maximum metal sheet thickness of 2 mm A conductive and flat connection between the motor and the machine part and between the machine and the cable shield has to be ensured If this type of shield connection is not possible for design reasons you can also connect the cable shield under the fastening screw of the DIS 2 using a suitable cable lug see Figure 46 Connection of cable shield to DIS 2 48 10 with FAST ON PE cable approx 40 mm length DINO DIN9 DOUTO 2 _
157. ion set This means a higher level of flexibility in the various motion profiles As a result the maximum number of available position sets is reduced to 16 e e e k9 e ko te The maximum number of available position sets i e 16 or 64 can be set through the DIS 2 ServoCommander see chapter 6 4 Global positioning settings In addition there are position data sets for positioning processes using the CAN bus DSP402 and position sets for homing The positioning control thus supports point to point movements with the final speed zero standstill at target point Positioning process can be aborted during the movement and the next position can be directly approached The groups and positions are selected through the digital inputs see chapter 6 6 Approaching destinations The RS232 interface can be used alternatively for the selection The position data sets for homing or for positioning processes through CAN DS402 are fed directly to the trajectory generator 6 2 Activating the operating mode F Gontrofler enable j To activate the homing or positioning mode the Commands windows has to be configured as follows C Torque control C Speed control Positioning Selection 64 positions C Course program DIN3 F New 1 0 assignment 0 High Course program 0 Low Selection 32 positions C Tipp amp Teach DINO High Tipp amp Teach _ Low Selection 32 positions
158. is Qin vied Aaa ie ne Rueda iy ieee aa i da 134 Table 26 Online Offline ACTIVATION 00 eect eeetce cece ee eeaaeeeeeeeceeeeeeeaeeeeaaeeeaeeeeaeeeeaaesseaeeeeaeeseaaeseeaseenaeeee 151 Table 27 Pin assignment of Connector X1 c cccceeeeeeeeeeeeeeeeeaeeeeeeeseeeeceaeeesaaeseeeeeeseaeeeeaaeseeeeeseaeeeas 164 Table 28 Pin assignment of Connector X2 c ccceeeeeeeceeeeeeeeeaeeeeeeeeeeeeeceaeeesaaeseeeeeseaaeeseaaeseeeeeesaeeas 165 Table 29 Pin assignment of connector X301 X803 0 c ccceceeeeeeeeeeeeeeeeeeeeaeeeeaeeseeeeeseaeeeteeeseeeee 166 Table 30 Pin assignment of Connector X3 ccceeceeeeeeeeeeeeeeaeeeeeeeeeeeeceaeeeeaaeseeeeeesaeeseaaeseeeeessaeeeas 166 Table 31 Pin assignment of Connector X8 cccceceeeeeeeeeeeeeeeaeeeeeeeceeeecaaeeeeaaeseeeeeeseaeeseaaeseeeeessaeeeas 167 Table 32 Pin assignment of Connector X1 ccccceeeceeeeceeeeeeeaeeeeeeeeeeeeeeaaeeesaaeseeeeeeseaeeseaaeseeeeeseaeenas 168 Table 33 Pin assignment of Connector X1 cccccceeeeeeeeteeeeeeeeaeeeeeeeseeeeeceaeeeeaaeseeeeeeeaeeseaaeseeeeeeeaeenas 170 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Seite 12 Table 34 Pin assignment of connector X304 X305 2 eee cece eeeeeeeeeeeeeaeeeeeee sense saeeeteeeeeeeeeee 171 Table 35 Pin assignment of connector X401 and X402 0 0 0 cecceeeeceeeeeeeeeeeeeeeee teense teaeeeeaeeeeeeeees 172 Table 36 Pin assignment of Connector X5
159. isplay Digital inputs DIN 0 inactive Analoginput C DIN 1 inactive Analoginput DIN 2 inactive Analoginput _ DIN 3 inactive Analoginput DIN 4 Positioning selection _ DIN 5 Positioning selection DIN 6 Positioning Start DIN 7 Din7 Limit switch 0 DIN8 Din8 Limit switch 1 DINS Error Clear Table 14 Digital inputs assignment Input Function Description DINO Selection of Positioning mode DINT positioning e DIN5 amp DIN4 Selection of the positioning parameter group parameter set accelerations times positioning speeds DIN2 e _DIN3 DINO Selection of the destination within a group DIN3 or course Course program mode DIN4 program contol e See chapter 7 Course program DIN5 DING Positioning start In the case of a rising edge the positioning run will be performed using the parameter set selected beforehand DIN7 Negative limit Positive DIN8 or negative DIN7 setpoints are enabled only if the switch limit switch inputs are passive 24V if normally closed contact OV if normally open contact DIN8 Positive limit If there is no signal the drive decelerates to zero speed at the current switch limit The power stage remains active DIN9 Controller enable In the case of a rising edge the control system will be initialized and stage will be deactivated re enabled with the next rising edge Clear error If the controller is
160. it and a superimposed speed control circuit These controllers are PI controllers The setpoint selectors are used to transfer setpoints from various different sources to the corresponding controllers see chapter 5 4 Setpoint assignment through setpoint selectors The basic structure is shown in the block diagram on the next page In the case of a rotor oriented control two phase currents and the rotor position are measured At first the currents are transformed into an imaginary part and a real part with the help of a Clark transformation Then they are transformed back into the rotor coordinates using a Park transformation This allows the rotor currents to be controlled to corresponding rotor voltages using Pl controllers and to transform them back into the stator system The driver signal generation uses a symmetrical pulse width modulation for the power stage in sine commutation with the third harmonic An integrator monitors the current time integral of the controller If a maximum value maximum current for 1s is exceeded a warning will be issued and the current will be limited to the rated current The main advantages of the rotor oriented current control have already been summarized in chapter 1 2 3 DIS 2 features In torque controlled mode a current setpoint i_set is predefined for the active current controller In this operating mode only the current controller in the servo positioning controller is active As the torque generat
161. its and standardizations than the communication objects User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 98 9 2 2 Serial communication through DIS 2 ServoCommander The parameterization program uses the serial interface to communicate with the DIS 2 servo positioning controller In the delivery state the parameterization program assumes the following data Interface COM1 9600 bauds data transfer rate factory setting of the servo positioning controllers 8 data bits 1 stop bit no parity check These settings are fixed It uses a certain protocol defining the individual commands You can find a list of these commands in chapter 11 6 Serial communication protocol When the program is started it tries to set up a communication with a servo positioning controller If it fails an error message will be displayed In this case you have to configure the data for the communication correctly To do so you need to know the serial interface COM port number and the data transfer rate used 9 2 3 Configuring the RS232 communication parameters You can increase the baud rate based on the actual data transfer rate in the menu under Options Communication Baud rate Actual data transfer rate 115200 Baud Preferred data transfer rate 115200 Baud 9600 Baud 19200 Baud 38400 Baud Jf OK X Cancel 57600 Baud 115200 Baud You have to select a prefe
162. ject NNNN DDDDDDDD Always 32 bits as the reply In the case of an OR NNNN or error the command and an error code will be OR FFFF FFFF transmitted Read internal value NNNN DDDDDDDD Always 32 bits as the reply In the case of an Ol NNNN or error the command and an error code will be Ol FFFF FFFF transmitted Read minimum value NNNN DDDDDDDD Always 32 bits as the reply In the case of an ON NNNN or error the command and an error code will be ON FFFF FFFF transmitted Read maximum value NNNN DDDDDDDD Always 32 bits as the reply In the case of an OX NNNN or error the command and an error code will be OX FFFF FFFF transmitted Table 21 Meaning of letters in the command syntax Meaning hexadecimal Communication object number l Data bytes Error code 0x00000002 Data value too low gt not written 0x00000003 Data value too high gt not written 0x00000004 Data value too low gt written but limited beforehand 0x00000005 Data value too high gt written but limited beforehand 0x00000008 Bit constant value not permissible 0x00000009 Bit data value not permissible at present in this operating mode 0x00000010 Read or write error in flash memory 0x00020000 Lower object limit does not exist 0x00030000 Upper object limit does not exist 0x00040000 No object present with this number object does not exist 0x00050000 Not allowed to write object User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 I
163. l DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 14 1 2 2 Area of application and intended use The DIS 2 servo positioning controller was designed for the decentralized control of three phase magneto electric synchronous machines Thanks to numerous options for feedback and to various different control methods such as block commutation and sine commutation the controller can be adapted optimally to the motor characteristics Normally it is mounted directly on the motor However it is also possible to detach the DIS 2 from the motor and to connect it to the motor using a short shielded cable Further information concerning the installation can be found in the appendix in chapter 11 15 Mechanical installation The DIS 2 servo positioning controller is supplied with power through a power supply unit or a battery with 24 V DC or 48 V DC protective low voltage At the motor connection it supplies the synchronous machine with a pulse width modulated symmetrical 3 phase rotating field with variable frequency current and voltage The DIS 2 was designed for a continuous torque speed and position control in typical industrial applications such as e Positioning and feeding drives in machines e Palletizing and packaging machines e Wood processing machines e Reeling drives wire drawing drives etc e Drives in tightening and press fitting applications e Conveying applications Prior to using the DIS 2 controll
164. l connecting cables provided the DIS 2 servo positioning controllers fulfil the requirements of product standard EN 61800 3 This standard no longer refers to classes but to so called environments The first environment includes mains supply networks supplying residential buildings The second environment includes mains supply networks exclusively supplying industrial buildings User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 184 11 20 4 Connection between the DIS 2 and the motor If the DIS 2 servo positioning controller is mounted directly on the motor the cables are located inside the housing They are only a few cm long In this case shielding is not necessary If you want to mount the motor and the DIS 2 separately please observe the following wiring instructions Use shielded cables only The encoder cables should have an internal and an external shield Use separate cables for the motor phases and the angle encoder Alternative Use a combined cable for the motor and the angle encoder but with separate shields Connect all external shields with the housing of the DIS 2 controller Connect the shield of the motor cable with the motor housing Connect the internal shield of the encoder cable to PIN 1 of X2 Make sure to set up a good PE connection between the motor and the DIS 2 controller A good PE connection has only a low impedance even in the case of very high interference
165. l outputs Digital outputs Functional overview Standard outputs 3 DOUT O Controller ready for operation CO DOUT1 Off DOUT2 Off DOUT 3 Holding brake unlock Sf OK 8 3 1 Configuring the digital outputs The digital outputs DOUT1 amp DOUT2 can be parameterized in the menu Parameters lOs Digital outputs Digital outputs Standard outputs Doutro Controller ready for operation pout1 Pt Motor sevo H Doutz ne pouT3 Holding brake unlock SS Ze x men User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 87 One of the following signals can be assigned independently to DOUT1 or DOUT2 OFF i e output inactive LOW level through integrated pull down resistor ON i e output active 24 V HIGH level through integrated high side switch Output stage active i e output stage switched on lt Motor Servo Warning Following error Remaining distance message Target reached Homing mode complete Declared speed achieved Course program e Se keo 2e as 2e as S S lt ko x keo te te keo 2e as Some of the scroll boxes are followed by a button with three dots Clicking this button opens another window where you can make additional settings 8 3 2 Configuring the messages for the digital outputs For many applications combined with a control system it is useful that the s
166. ler 00E1 _ ssel_n_act Actual speed value Basic unit speed 00E 2 ssel_n_act_disp Actual speed value filtered for display in Basic unit speed D2SC 00E3 spdc_n_ref_rs232 RS232 speed setpoint Basic unit speed 00E4 spdc_n_ref_can CAN speed setpoint Basic unit speed 00E5 __ spdc_n_ref_ftd FTD speed setpoint Basic unit speed 00E6 spdc_n_ref_profi Profi speed setpoint Basic unit speed 00E7 spdc_n_ref_hilf_rs232 Auxiliary RS232 speed setpoint Basic unit speed 00E8 spdc_n_ref_hilf_can Auxiliary CAN speed setpoint Basic unit speed 00E9 spdc_n_ref_hilf_ftd Auxiliary FTD speed setpoint Basic unit speed OOFA spdc_n_ref_hilf_profi Auxiliary Profi speed setpoint Basic unit speed OOEB _ ssel_ctrl_stat Speed control configuration none 0O0EC spdc_ctrl_gain Controller P gain Basic unit gain 0O0ED spdc_ctrl_time Controller time constant l part Basic unit time 00 spdc_sel_n_switch Speed controller selector for speed setpoint none 0O0EF spdc_sel_h_n_switch Auxiliary setpoint selector for speed setpointnone OOFO ssel_ainO_n_per_volt Speed setpoint scaling AINO Basic unit speed Number of revolutions per volt OOF1 ssel_aini_n_per_volt Speed setpoint scaling AIN1 Basic unit speed Number of revolutions per volt OOF2 ssel_time_c_n_act_filter Filter time constant of actual speed value _ Basic unit time filter 00F3 ssel_n_acc_pos Ramp generator gradient at Positive Basic unit acceleration speed rising edge OOF4 ssel_n_dec
167. ler enable logic defines the conditions to be fulfilled so that the controller can be enabled and the motor can be supplied with power You can find the menu for configuring the controller enable logic under Parameters Device parameters Controller enable logic This menu can also be called up via the Commands window To do so click the button in the Controller enable field Controller enable logic Controller enabled via Din9 and serial interface RS 232 via Din9 and CAN bus You can select the following options from a so called combo box Via digital input DIN9 The controller will be enabled exclusively via the digital input DIN9 e Via DINY and serial interface RS 232 To enable the controller DIN9 must be set and a corresponding serial command must be issued This can be ensured for example by selecting the Controller enable check box in the Commands window Via DIN9 and CAN bus To enable the controller DIN9 must be set and an enabling command must be issued via the CAN bus User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 44 4 8 Configuring the limit switch polarity The servo positioning controller supports limit switches with normally closed contacts and normally open contacts Adjust your drive such that no limit switch is active when the drive is located in the permissible positioning range Make sure that no LED is active in the menu shown be
168. ll other user notes must be read prior to any work with the servo drive controller In case you do not have any user notes for the servo drive controller please contact your sales representative Immediately demand these documents to be sent to the o User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 20 person responsible for the safe operation of the servo drive controller If you sell rent and or otherwise make this device available to others these safety notes must also be included o o The user must not open the servo drive controller for safety and warranty reasons Professional control process design is a prerequisite for sound functioning of the servo drive controller o DANGER Inappropriate handling of the servo drive controller and non compliance of the warnings as well as inappropriate intervention in the safety features may result in property damage personal injuries electric shock or in extreme cases even death 2 2 Danger resulting from misuse DANGER High electrical voltages and high load currents Danger to life or serious personal injury from electrical shock DANGER High electrical voltage caused by wrong connections Danger to life or serious personal injury from electrical shock DANGER Surfaces of device housing may be hot Risk of injury Risk of burning DANGER Dangerous movements Danger to life serious personal injury or prop
169. log monitor 1 Scaling Basic unit gain 008F fioh_aout1_offset Offset voltage for the analog monitor Basic unit voltage 0090 fioh_ainO_ offs Offset AINO Basic unit voltage 0091 fioh_ain1_offs Offset AIN1 Basic unit voltage 0092 fioh_ainO_safezero Safe zero Basic unit voltage 0093 _fioh_aini_safezero Safe zero Basic unit voltage 0094 loh control Configuration of analog monitors amp hone temperature sensor 0095 fioh_pins_used Optionally the values for DINO DIN3 can none lbe parameterized as AINO AINO AIN1 HEAIN1 00a0 leeval_enc_phi Returns the rotor position without angle Basic unit degree encoder offset 00a1 lenc_config Encoder configuration word none 00A2 Jemu_ctrl Setting of operating modes none 00A3 Jeeval_enc_phi_offs Offset angle of the angle encoder one Basic unit degree revolution OOA4 leeval_x2b_line_cnt Line count of an analog incremental Increments line count 4 x encoder line count User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 129 No Name Meaning Scaling 00Aa5 lemu_enc_line_cnt Number of output increments of the encoder Increments line count 4 x emulation line count 21 1024 OOA6 lemu_enc_offset Offset between the angle setpoint and the Basic unit degree output angle of the encoder emulation 00A7 _leeval_motid_w_status Status of M
170. low You can set this by selecting either the NC contact option DIN7 DIN8 24V gt setpoint enabled or the NO contact option DIN7 DIN8 24 V gt setpoint blocked Type of limit switches NC contact NO contact Options S Limit switch Limit switch 0 E0 Ej The little illustration in the middle shows a red arrow when the drive moves in the direction of one of the limit switches Thus you can directly see how the limit switches are assigned to the direction of movement and change the wiring of the limit switches if necessary a As long as a limit switch is active the setpoint in the corresponding direction of rotation is blocked In applications where the drive can overrun the limit switches or in applications with bouncing limit switches the option Limit switch inhibits direction permanently can be used If the option is activated the direction of rotation in which a limit switch has been set off remains blocked when the limit switch has been left In this case the drive can leave the limit switch but it is not possible to move in the direction of the limit switch again The blocked direction of rotation remains blocked until the controller is disabled 4 9 Setting the direction of rotation The option Reversal of rotation direction can be activated in the lower area of the Commands window This option can be used to assign a certain angle counting direction or the
171. m male xB 16 14 12 10 6 4 2 ss as anfo 7 s 3 fi Figure 37 Technology module connection Table 31 Pin assignment of connector X8 pin no Name _ Value EE Specification Reference potential Technology module power supply 100 mA max together with 5 V mos SPI Serial Master Output SCLKB SPI Serial Clock 20 MBit s max MISO SPI Serial Master Input 6 ss SPI Slave Select viROA 8 RaB All signals with RESET a V ae RESET Signal 3 3V RESET Controller ogic leve 10 cLK40 j System clock of the DSP ant 12 ans 2 1 4 3 3V IO interrupt signals of the DSP Optional analog inputs of the DSP 0 V 3 3 V RxD Optional asynchronous serial interface 14 1x0 3 3 V level 115 kBit s max GND Reference potential Technology module power supply 100 mA max together with 3 3 V User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 168 11 17 Connectors at the DIS 2 48 10 IC 11 17 1 Connection Power supply and I O X1 Configuration on the device Phoenix PLUSCON VARIOCON with a total of 18 contacts Mating connector X1 Phoenix PLUSCON VARIOCON kit comprising 1x VC TFS2 2x VC TFS8 1x VC TR2 3M 1x VC MEMV T2 Z 1x VC EMV KV PG21 11 5 15 5 13 5 Dime
172. mber of increments per pos tC S revolution V Suppress zero pulse I Reversal of rotation direction Offset angle 0 0 In addition you can deactivate the incremental encoder emulation in order to be able to use the digital inputs DIN2 and DINS or the digital outputs DOUT1 and DOUT2 for other functions You can make the following configurations in the Incremental encoder field Number of increments You can select 32 64 128 256 512 or 1024 as the number of increments for the emulation gt Suppress zero pulse If the check box is selected no index pulse will be issued Reversal of rotation direction If the check box is selected the direction of rotation of the incremental encoder emulation will be inverted Offset angle Here you can set an offset between the index position of the encoder of the DIS 2 servo positioning controller and the emulated index pulse m The outputs DOUT1 and DOUT2 supply signals with a 24 V level so called HTL signals il Older or low cost control systems in particular can directly process these signals In order to be able to transmit high speeds with a high resolution DOUT1 and DOUT2 should be equipped with a resistor of 1 KQ against 0 V Please contact your local distributor if your control system cannot process HTL signals but RS422 compatible track signals In many cases the DIS 2 controller can also be connected to these inputs provided they are equipped with additional resi
173. meter sets Printing of parameter sets Offline parameterization Oscilloscope function Languages German English French Windows conform operation Course program 1 3 3 Hardware and software requirements Requirements to be met for installing the parameterization program BM compatible PC AT Pentium Il processor or higher with at least 32 MB main memory and at least 10 MB free hard disk memory Operating system Windows 95 Windows 98 Windows NT Windows 2000 Windows XP CD ROM drive Free serial interface User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 17 1 4 Documentation This software manual is intended to ensure safe working with the DIS 2 ServoCommander parameterization program for the DIS 2 servo positioning controller Further information can be found in the following manuals of the DIS 2 product range CANopen manual CanOpen_Manual_DIS 2 Description of the implemented CANopen protocol in accordance with DSP402 Mounting instructions Mounting instructions_DIS 2 Instruction manual concerning the installation of the DIS 2 servo positioning controller The servo positioning controller has a FLASH program memory allowing the operating software of the controller to be updated even after it has be delivered and installed in a machine The manufacturer is continuously revising and extending the operating software o
174. meterize whether warning will be displayed or not User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 104 gt Display The error will be displayed but no other measures are taken gt No display The error will be ignored completely Table 16 Error overview Error CAN Meaning Possible causes measures Release Reaction no error time lc JE Iw code Check the configuration of the temperature lt 100ms X X X monitoring system Temperature sensor correctly wired Motor Movement of mechanical system impaired 3 4310 overtemperature motor too hot Temperature of the electronic power lt 100ms X X system lt 40 C or gt 85 C DIS 2 heated up by the motor Decouple Over the DIS 2 thermally if necessary undertemperatur Check improve the installation and the 4 4210 e power stage cooling conditions Angle encoder connected lt 5ms X Angle encoder cable defective Angle encoder defective Error SINCOS Check the configuration of the angle 5 7392 supply encoder interface Angle encoder connected lt 5ms X Angle encoder cable defective Angle encoder defective Error SINCOS Check the configuration of the angle RS485 encoder interface 6 7391 communication New or unknown SINCOS encoder Angle encoder connected lt 5ms X Angle encoder cable defective Error of track Angle encoder defective signals of Check the configuration o
175. n ramps in order to realize a jerk limited acceleration The following illustrations show the speed profile of a positioning run with and without a jerk limited acceleration Figure 8 Time optimal and jerk limited positioning The positioning range configured under Parameters Positioning Settings position sets Course program is displayed in the field Positioning range Input limits I The settings of the setpoint ramp have no effect on the motion profile during homing or in the positioning mode User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 64 6 6 Approaching destinations There are different ways to select destinations and to start positioning runs Through the digital inputs The destinations are selected through the digital inputs DINO DIN5 When there is a rising edge at digital input DIN6 the destination is adopted and the positioning run is started Information on how to configure the digital inputs for the positioning run can be found in chapter 8 1 Digital inputs DINO to DIN kS Through the serial interface The movement to the destination position and the homing run can be started via the parameterization program To do so activate the menu Parameters Positioning Go to destination You can move to the desired destination by clicking on the corresponding button You can also click the GO button to start a positioning run and to move to the destina
176. n be configured as desired Can be used as 24 V 20 mA max encoder output signal A pin is used multiple times with DIN2 and AIN1 Can be configured as desired Can be used as 24 V 20 mA max encoder output signal B pin is used multiple times with DIN3 and AIN1 DOUT3 X3 Holding brake 24 V 700 mA max 11 14 15 Incremental encoder output X1 Parameter Number of increments of the 32 64 128 256 512 1024 lines per revolution can be programmed output Connection level 24V 20 mA max Output impedance Ra 300 Q Limit frequency fiimit gt 100 kHz lines sec fiimit depends on the cable length data measured with Roag 1 KQ and Croaa 1 nF corresponds to a cable length of 5 m User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 160 11 15 Mechanical installation 11 15 1 Important notes t The DIS 2 servo positioning controller was designed for direct installation on the motor O Optionally it is also possible to use it separately from the motor In this case additional connecting cables between the motor and the DIS 2 servo positioning controller are required These cables should be as short as possible The maximum length is 1 m te as Optimum cooling can be ensured if the DIS 2 servo positioning controller is mounted in a vertical position This means that connector X1 is located on top or at the bottom t T
177. n_acc_fact_div Denominator of the factor for acceleration none representation 0160 Josc_control Oscilloscope control word operating modes none 0161 Josc_status Oscilloscope status word operating modes none 0162 losc_samples Number of sampling processes Number of sample values per channel 0163 losc_sample_time Minimum sampling time between two Basic unit time samples 0164 osc_triggermask Oscilloscope trigger mask for digital triggers Permissible are 01L 02L 04L etc FFL 0165 __ osc_triggerconfig Trigger configuration bit field none 0166 losc_triggerlevel Trigger level analog or level digital Depending on the quantity to be recorded 0167 osc_timebase Number of cycles until next storage Multiple of sampling time it sampl osc_timebase losc_sample_time 0168 Josc_delay Trigger delay Number of samples Value gt 0 Recording of events after trigger Value lt 0 Recording of events before trigger 0169 losc_datad Function number for channel recording none 016A losc KO_nrO Free CO address CO number free CO 016B losc_KO_mask0 Optimal mask to hide unnecessary bits or none value ranges in a communication object 016C _josc_datat Function number for channel recording none 016D josc_KO_nr1 Free CO address CO number free CO 016E losc_KO_mask1 Optimal mask to hide unnecessary bits or none value ranges in a communication object 016F losc_data2 Function number for channel recording none 0170 losc_KO_nr2 Free CO add
178. nals User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 169 AINO Analog input 0 Differential analog input with AINO BS DINO 10 Bed Digital input Positioning destination selector bit 0 B6 RxD 10 V Reception signal RS232 specification B7 DiN6 o v 24 V Digital input Positioning start a 24 V llogk 24 V power supply for the internal logic and the lOs B8 24V Logik 200 mA 1000 mA Shared ground with the intermediate circuit DC bus Shared ground potential for the intermediate ci GND OV circuit voltage DC bus voltage and the 24V logic supply C2 ZK 48 V 15A nom Intermediate circuit supply DC bus O The X1 interface of the DIS 2 IC is compatible with the interface of the DIS 2 The 1 signals AMONO and DIN6 were separated as there were still some free pins 11 17 2 Connection Motor encoder brake extensions The connectors for the motor phases X301 X303 the holding brake X3 the angle encoder X2 and the extension port X8 are compatible with the DIS 2 48 10 Information concerning the connection and the pin assignment of these connectors can be found in the corresponding sub sections 11 16 Connectors at the DIS 2 48 10 of the appendix 11 18 Connectors at the DIS 2 48 10 FB 11 18 1 Connection Power supply and I O X1 Configuration on the device Phoenix PLUSCON VARIOCON with
179. nate them Table 7 Error elimination Speed control Remedy The motor develops a holding The number of pairs of poles and or the phase sequence is incorrect Set torque It blocks in different the correct number of pairs of poles and or interchange the motor phases positions Perform another automatic identification See chapter 4 3 2 Motor data The motor shaft oscillates or runs The parameterization of the angle encoder offset see chapter 5 2 Speed unevenly controlled mode and or the controller parameters are incorrect Perform another automatic identification See chapter 4 3 1 Angle encoders The shaft does not rotate No intermediate circuit voltage DC bus voltage The limit switches are active The shaft does not rotate The The speed setpoint has not been configured correctly Further actual value window still shows a information can be found in chapter 5 4 Setpoint assignment through speed setpoint of 0 setpoint selectors oO When you are connecting the motor phases please have mind that the servo motor il manufacturers configure the phase sequences differently It might be necessary to interchange the phases U and W User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 47 5 Current and speed control 5 1 Function overview The current and speed control system is a cascade control structure with an internal current control circu
180. nd DIS 2 48 10 IC above right in the picture it may be necessary to connect two cables to one pin of connector X1 This is not necessary in the case of the DIS 2 48 10 FB below right since there are already two connectors X401 and X402 for the CAN bus The DIS 2 48 10 FB has a separate connector X5 for the serial service interface On all the other DIS 2 variants it is connected through X1 The signals for the digital IOs DINx and DOUTx do not need a shield to protect them against interferences but a shielded cable between the DIS 2 servo positioning controller and the control system improves the EMC behaviour through out the entire system and particularly in view of radiated interferences At least the control signals DIN9 controller enable and DOUTO ready for operation have to be connected between the SPC and the controller Make sure that the DIS 2 servo positioning controller is completely connected prior to switching on the power supply for the intermediate circuit DC bus and the logic system If the power supply connections are reversed if the power supply is too high or if the connections of the intermediate supply and the logic supply are mixed up the DIS 2 servo positioning controller may be permanently damaged User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 178 11 19 2 EMERGENCY OFF EMERGENCY STOP terminology and standards In accordance with a danger analysis risk
181. nded function is active Table 15 Tipp amp Teach Configuration of the digital inputs Function Explanation DIN 0 Spec Posi High activation of the extended configuration Low normal positioning mode with destination selection through DIN1 DIN2 DIN3 and position group selection through DIN4 and DINS Only even position numbers are possible DIN 1 STOP active Low a running positioning run will be interrupted low STOP has a higher priority than Tipp pos Tipp neg and Homing run Start The deceleration ramp that is used for this purpose has to be set in the Safety parameters window see chapter 4 6 Selecting safety parameters DIN 3 TEACH High activation of the teaching function see section 8 2 1 Teaching positions DIN 4 Tipp neg High positioning run in the negative direction with the Tipp amp Teach motion parameters see chapter 6 5 Parameterizing position Sets DIN 5 Tipp pos High positioning run in the positive direction with the Tipp amp Teach motion parameters see chapter 6 5 Parameterizing position Sets Rising edge positioning If DIN 0 low Start positioning homing If DIN 0 high Start homing 8 2 1 Teaching positions The procedure described below can be used to approach positions Tipp through the digital inputs and to save them Teach in the controller internal position sets up to 64 The controller must be enabled
182. nflict between acceleration and running lt 5ms X Error position speed 57 6191 data set Please contact the technical support team Error Operating Change of operating mode while the power lt 5ms XIXIX 58 6380 mode stage is switched on Error Pos Internal error lt 5ms X 60 6190 precomputation Please contact the technical support team Internal error lt 5ms X 62 6180 Stack overflow Please contact the technical support team Check sum error Internal error lt 5ms X 63 5581 Please contact the technical support team Internal error lt 5ms X 64 6187 Initialization error Please contact the technical support team o The servo positioning controller internally manages the error no 1 to no 64 If your device displays an error number which is not described in the error table and marked as an unknown error in chapter 10 4 Error management please contact your local distributor It is possible to assign these error numbers for firmware extensions or customized firmware versions with additional monitoring functions User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 108 10 3 Error display in DIS 2 ServoCommander The error window is a permanent window in the parameterization program If there is no error the window is minimized In the event of a controller error the user interface changes in two ways 1 The error window will be maximized
183. ng distance activities course program x calculate evaluate p new branch destination level NEXT1 2 new positioning Figure 23 Level test time diagram 7 2 Debugging a course program If you switch to Debug mode additional status information will be displayed in the course program window Course program active Indicates that the course program is running and being processed Course program stop Indicates that the course program has been stopped by the stop signal NEXT1 NEXT2 Shows the current status of the digital inputs for NEXT1 amp 2 DOUT1 DOUT2 Shows the current status of the digital outputs DOUT1 amp 2 Line Shows the current line of the course program In addition the current line is highlighted in blue in the table Position Indicates the position set approached last m cM STOP NEXIT Posfine1 NEXI2 Pos ine2 Douni Doutz 63 2 ignore ignore target ignore target Posi ignore automatic ignore Off Off Posi ignore automatic 62 ignore Off Off Posi ignore automatic 61 ignore Off Off Posi ignore automatic 50 ignore Off Off Target ignore automatic 10 ignore On Off Posi ignore automatic 11 ignore On Off Posi ignore automatic 12 ignore On Off Posi ignore automatic 40 ignore On Off z Modus Course program active NEXT1 gt DOUTI Line 4 x Exit Course program stop O NEXT2 DOUT2 C Position 50 User Manual DIS 2
184. ning controller has to wait until this delay is over before it can start the positioning run Tab Driving profile User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Destination parameters Destination Settings Driving profile Destination 0 12 000 R Position Positioning range Input limits 32768 000 R 32768 000 R r Speed 0 15 Running speed 1000 000 rimin T rAcceleration 0 15 Acceleration 10000 rimin s Ti Negative acceleration 10000 rimin s C Tipp amp Teach C CAN Bus X coe M Times 0 15 Acceleration time 100 0 ms Deceleration 100 0 ms M Time constant jerk free 0 15 Acceleration ms a F Positioning settings 2A Go Page 63 You can enter the destination into the Destination field The destination will be interpreted in different ways depending on whether the user has selected an absolute positioning run or a relative positioning run See the Settings tab The Speed field can be used to enter the Running speed used to approach the destination The final speed is always zero and cannot be parameterized The values for accelerating or decelerating the drive can be entered into the Acceleration field The Times field shows the times resulting from the running speed and the accelerations The field Time constant jerk free can be used to define a filter time used to smooth the acceleratio
185. nnected P Connecting cable broken Incorrect pin assignment for the serial connection Connecting cable too long Reduce the baud rate or use a shorter cable User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 117 11 3 Info window You can call up general information concerning the DIS 2 ServoCommander under Info Info The following window will appear Copyright Firmware Hardware Communication Times DIS 2 ServoCommander Version 2 0 Application 0 KM release 1 1 Copyright Metronix GmbH Kocherstrasse 3 D 38120 Braunschweig Germany Tel 49 0 531 7 8668 0 FAX 49 0 531 7 8668 555 Internet http www_metronix de Email Support Metronix CooperT ools com You can find the following information on the Copyright tab PS Program name version Sales partner Address and phone number gt Internet link Click on the button to activate it gt Email address Click on the button to create an e mail i ae ate You can find the following information on the Firmware Hardware tab 7 Main board Type serial number version Bootloader Version i K 2 Firmware Version You can find the following information on the Communication tab COM port and baud rate used online parameterization File used offline parameterization The Times tab gives you information concerning the cycle times of the f
186. nnels to the actual speed value rough and to the speed setpoint value m Make sure that you do not change the numbers for the gain factor and the time constant 1 in too large steps Use small changes You should start with a relatively long integration time in the range of 8 ms to 10 ms and then increase the gain progressively Only after you have felt your way towards the right setting by increasing the gain should you reduce the integration time step by step After the numbers have been changed there may be two different situations gt If the setting is too hard the speed controller will become unstable gt If the setting is too soft the drive will not be rigid enough which will lead to following errors m The speed controller parameters are not independent of each other A measurement Il curve which differs from trial to trial can have various reasons This is why you should change only one parameter at a time Either the gain factor or the time constant To adjust the speed controller increase the gain until oscillation starts and then decrease the gain in small steps until oscillation ceases Then decrease the time constant until oscillation starts and decrease it again in small steps until the controller is stable and rigid enough at a setpoint 0 User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 51 Case 1 Speed controller too soft Figure
187. nsions approx L x W x H 86 mm x 80 mm x 32 mm LB A accu 432 14 3 2 Figure 38 Numbered pins of X1 DIS 2 48 10 IC Table 32 Pin assignment of connector X1 Specification Name Value DOUTO READY 0OV 24V Ready for operation A2 DINS o v 24V Digital input Limit switch 1 blocks n lt 0 CANLO CAN low A3 DIN5 o meee Digital input Positioning group selector bit 1 i Inv analog input 1 Differential analog input with AIN1 PARA ee Digital input Positioning destination selector bit 3 A4 DIN3 OVa N Digital output Programmable encoder output track DOUT2 0 V 24 V B A5 DIN9 o V 24 V Digital input Power stage activation Ao DIN7 ov 24 V Digital input Limit switch 0 blocks n gt 0 CANHI CAN high AT DIN4 0 V 24 V Digital input Positioning group selector bit 0 f Analog input 1 Differential analog input with AIN1 AIN TO y Digital input Positioning destination selector bit 2 A8 DIN2 OSA Digital output Programmable encoder output track DOUT1 1 0 V 24 V A f AINO 10 V 10 V Inv analog input 0 Differential analog input with AINO B1 DIN1 A Digital input Positioning destination selector bit 1 B2 TxD 10 V Transmission signal RS232 specification B3 AMONO o V 10 V 2 mA Analog monitor 0 B4 GND OV Reference potential for the control sig
188. nsmit a command enter the command in the upper input line and press lt ENTER gt or click the Send button 9 2 5 Communication window for RS232 transmission Under Options Communication Display communication window RS232 you can open a window in which you can observe the communication through the serial interface This window is mainly used for debugging and not of interest for standard users User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 100 9 3 The DIS 2 servo positioning controller has a technology interface which is equipped with a synchronous serial interface RS232 gt or 0085 lt 0085 0000FC00 64512 gt or 0030 lt 0030 00000010 16 gt or 0082 lt 0082 0017C44E 1559214 gt or 0071 lt 0071 00000000 0 gt or 0070 lt 0070 00000000 0 gt or 0036 lt 0036 00000002 2 gt or 0070 lt 0070 00000000 0 gt or 0070 lt 0070 00000000 0 gt or 0032 lt 0032 01004200 16818688 gt or 0030 lt 0030 00000010 16 gt or 0082 lt 0082 0017C776 1558390 gt or 0071 Control through the technology interface As aresult customized extension modules communication interfaces can be implemented Please contact your local distributor if you are interested in this option User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 10 10 1 Page 101 Error messages Error table Error monitoring in the DIS 2
189. ntry press the ENTER key or switch to another input field using the TAB key The numerical value will then be shown in bold print 2 Clicking the arrow keys The value changes in small steps fine adjustment 3 Clicking the areas between the grey boxes and the arrow keys The value changes is large steps rough adjustment 4 Clicking the grey box and moving the mouse with the left mouse key pressed down The value can easily be preset over the entire value range 11 1 3 Control elements The user is guided preferably with the help of graphically oriented windows The following table shows and describes the control elements used in the windows Table 17 Control elements An option which the user can activate or deactivate by checking the once e Radio button With this button the user can choose one of several options m Check box corresponding check box It is possible to check several boxes at 3 button A button which opens another menu when clicked by the user Settings General button A button which opens another menu when clicked by the user 11 1 4 Display of setpoints and actual values The parameterization program creates the setpoints which correspond to a desired user input and the actual values used in the device in accordance with the following concept 1 The user changes the scroll box in the window by moving the scroll bar or by entering a new value The paramet
190. o point home position of the application User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 71 Homing position User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 72 7 Course program A course program allows several position sets to be linked together in one sequence These positions will be approached one after the other A course program has the following characteristics Up to 32 course program steps can be set Apart from linear sequences which are terminated sooner or later circular linking is also possible A special digital input can be used to approach a position out of turn within the course program This position can be selected using digital inputs Up to 2 following positions can be set for every course program step As a result a course program can include branching Branching occurs depending on the logic status of digital inputs The course program can control two digital outputs For this purpose every course program step offers 4 different options on off target reached remaining distance message Please note On the DIS 2 48 10 and on the DIS 2 48 10 IC the digital outputs DOUT1 and DOUT2 are connected to the same pins as the digital inputs DIN2 and DIN3 If you use the outputs the control of the course program is subject to certain restrictions Please use the DIS 2 48 10 FB in this case In
191. oder and of the encoder evaluation in the DIS 2 and improves the running behavior AN Caution During the adjustment the shaft automatically starts to move for approximately 60 seconds Recirculation through the Motor EMK electromotive force of the motor has a positive effect on the running behaviour of the motor if encoders with a poor resolution e g Six Step Hall encoders or a low level of accuracy are used In order to use the recirculation through the Motor EMK other electrical parameters of the motor have to be entered in the menu Options Device parameters Motor data see chapter 4 3 2 Motor data Be careful when activating the recirculation through the Motor EMK The actual speed of the motor may deviate significantly from the setpoint if the function and the motor data are not properly configured The tolerances of the magnets and the windings of the motors in the series also affect the result A good compromise between smooth running and a good stationary accuracy can be realized by setting only the P component of the speed controller to EMK 4 3 2 Motor data O 1 This menu must be used if the motor could not be identified with the help of the motor list This function can be accessed via Options Device parameters Motor data The following menu appears You can enter the maximum current and the rated current of the motor used User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 1
192. ogram line 8 Befehlsart Position branch C Branch Line Level test Optionen NV Evaluate NEXT1 Evaluate NEXT2 I Evaluate Stop signal DOUT1 Off y C End of Program DOUT2 Off M NEXT1 HIGH M NEXTI LOW Next line 1 E Z Next tine 2 E z Complete position then evaluate Evaluate immediately X Exit NEXT1 high NEXT1 low line n line x line y Depending on the level of NEXT1 the program will continue in different lines Figure 22 Level test course program User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 80 If the digital signal NEXT1 is HIGH the program will continue in line X If the digital signal NEXT1 is LOW the program will continue in line Y An unconditional program jump e g for infinite loops can be generated by stating the same branch destination for NEXT1 HIGH and NEXT1 LOW In Figure 23 the level test of NEXT 1 2 is performed immediately at the start of program step 11 The line of the next course program command is determined depending on the result of this level test program step program step 10 program step 11 program step 12 DOUT1 2 high low DOUT1 2 high low program step 10 DOUT1 2 high low program step 11 DOUT1 2 high low program step 12 DOUT1 2 target reached target reached remaining distance progra step 10 remaini
193. ollowing components 7 Current controller 7 Speed controller Position controller i i The current count of the operating hour meter gt gt User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 118 11 4 Fast access via the tool bar Some functions of the parameterization program can be accessed directly using the icons beneath the menu bar Offline cin Ns ls ts 0 parameter Peset Meaning Oscilloscope Offline parameterization Online parameterization Search for communication Set French language Set English language Set German language Reset servo positioning controller Save parameters Approach positions Set positions Homing Position controller Speed controller Current controller Motor data menu User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 119 11 5 Using the oscilloscope function The oscilloscope function integrated in the parameterization program allows signal courses and digital statuses to be represented and physical parameters to be optimized The graphs e g step responses can be printed saved as bitmaps or exported into Microsoft Excel Za Two windows will open the actual oscilloscope and the window for configuring the oscilloscope The oscilloscope can be started under Display Oscilloscope or with the help of the button 11 5 1 Oscilloscope sett
194. on signals Integrated driver stage for 24 V holding brakes Compliance with current CE and EN standards without any additional external filter measures EMC optimized metal housing for direct mounting on the motor The device has an IP54 degree of protection Depending on the mounting methods and the seals used a degree of protection up to IP67 can be reached Integration of all filters in the unit required for compliance with the EMC regulations industrial environment e g filters for the 24 V supply and the inputs and outputs Can be used as a torque controller speed controller or position controller Integrated positioning control with extensive functionality in accordance with CAN in Automation CiA DSP402 and numerous additional application specific functions Jerk free or time optimal positioning relative or absolute with regard to a reference point Point to point positioning with and without spot tracing Speed and angle synchronous operation with an electronic gearbox via field bus Numerous homing methods Changeable clock frequency for the output stage Integrated course program to create simple positioning sequences with or without dependence on digital inputs Programmable digital outputs High resolution 12 bit analog input User friendly parameterization using the DIS 2 ServoCommander PC program Automatic motor identification Easy c
195. on the circuit board of the DIS 2 The DIS 2 controls an optional holding brake through connector X3 The encoder and the temperature sensor have to be connected through the recessed connector X2 on the circuit board The DIS 2 48 10 FB has an additional integrated brake chopper It is therefore possible to connect the braking resistor through the FASTONs X304 and X305 on the circuit board as shown below right in Figure 43 Connection to power supply control and motor Normally the braking resistor is installed on the mounting plate for the electronics housing If the analog inputs are used to assign setpoints we recommend using shielded and twisted cables for AINx AINx even if the control does not provide any differential signal Connection of AINx to the OV reference potential at the control system prevents common mode interferences which are caused by high currents flowing through the power stage and the external cables The shield prevents the penetration of interferences and should be connected on both ends to the housing of the DIS 2 servo positioning controller and to the housing of the control system The CAN bus should be cabled in the same way as the analog inputs A terminating resistor of 120Q 1 has to be installed at both ends of the CAN bus network The individual nodes of the network are always connected in line so that the CAN cable is looped through from controller to controller In the case of the DIS 2 48 10 a
196. oning controller for the first time you should connect or completely wire the superordinated control inputs and outputs field busses and the power supply unit Please read chapter 11 16 Connectors at the DIS 2 48 10 in the appendix For the parameterization of the servo positioning controller the serial interface of the DIS 2 has to be connected to a free COM port on the notebook PC Please check the wiring and the level of the supply voltages carefully prior to activating the power supply for the first time Wiring errors are the most common reason for operating problems A wiring error or a too high operating voltage may also damage the device 3 3 Installation and start of the DIS 2 ServoCommander Proceed as follows for the installation from CD ROM 1 Put the CD ROM into the CD ROM drive of your computer 2 Start the Windows Explorer 3 Select the directory DEUTSCH or ENGLISH on the CD ROM 4 Double click the SETUP EXE program to start it 5 Follow the instructions of the installation program The installation program creates a new program group called Metronix In this program group you will find the entry DIS 2 ServoCommander through which you can start the parameterization program User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 28 4 Initial parameterization of the controller 4 1 Commissioning 4 1 1 Parameter set in the delivery state The DIS 2 servo positionin
197. onnection to a superordinated control system e g to a PLC on the I O level or via a field bus Technology slot for extensions e g field bus connections only DIS 2 48 10 FB l monitoring system to limit the average power loss in the power stage and in the motor Integrated brake chopper only DIS 2 48 10 FB Separate RS232 and field bus connection only DIS 2 48 10 FB User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 16 1 3 DIS 2 ServoCommander features 1 3 1 Basic information The parameterization program ensures the comfortable parameterization of the DIS 2 servo positioning controller You adapt the DIS 2 servo positioning controller optimally to your application using the parameterization software The firmware of the DIS 2 servo positioning controller must match the parameterization software This means that following an extension of functionality in a new firmware version you also require the corresponding new version of the parameterization program Ao You cannot parameterize any other Metronix devices using this parameterization software 1 3 2 DIS 2 ServoCommander features The parameterization program has the following features Parameterization of the DIS 2 servo positioning controller Configuration of all parameters using the PC Display of operating quantities Loading of new firmware versions Loading and saving of para
198. onnector X2 JST No PHDR 16VS contacts JST No SPHD 002T P0 5 X303 X302 ee X3 Figure 34 Angle encoder connector Table 28 Pin assignment of connector X2 Pinno Name___ Value___ Specification Reference potential for incremental encoder analog Hall sensors Stegmann Hiperface encoder Reference potential for Hall sensor and or motor temperature sensor 5 V 100 mA l 5 V supply for linear Hall sensors or incremental encoder 5V 100mA 5 V supply for Hall sensors 1 5 VRus aitt Resolver Connection to resolver signal S1 Ri gt 10 kQ Others Connection to incremental encoder track A OV 5V Phase U Hall sensor for commutation Input with 4 7 kQ pull up at 5 V 1 5 Vams itt Resolver Connection to resolver signal S3 Ri gt 10 kQ Others Connection to incremental encoder track A OV 5V Phase V Hall sensor for commutation Ri 5 kO Input with 4 7 kQ pull up at 5 V 1 5 Vams ait Resolver Connection to resolver signal S2 Ri gt 10 kQ Others Connection to incremental encoder track B OV 5V Phase W Hall sensor for commutation R 5 kO Input with 4 7 kQ pull up at 5 V 1 5 Vams itt Resolver Connection to resolver signal S4 R gt 10 kQ Others Connection to incremental encoder track B 0V 3 3V Motor temperature sensor normally closed contact PTC or R 2 kQ analog sensor of KTY series connected to GND MTEMP t 3 Vams ditt Resolver
199. or SINCOS supply C C C C E No 6 Eror SINCOS RS485 communication C C C WM No7 Eror of track signals of SINCOS encoder CCO COCO Qi No 8 Error of resolver track signals carrier failure C C COC COC QE No 3 Error 5 internal supply CCC C N No10 Eror 12V intemal supply com E MM No 11 Error 24V supply out of range C C C E No 12 Unknown error C C C E No 13 Eror offset current metering C C C QM No 14 DC bus overcurrent output stage C OC amp No 15 DC bus undervoltage C C C QM No 16 DC bus overvoltage You can use this window to define the way the servo positioning controller should respond to an error One of four reaction types is assigned to each of these 64 possible events 1 2 3 4 The power stage will be switched off the motor will coast down Controlled shut down the motor will be decelerated to standstill in a controlled manner A warning will be displayed the error window will be opened automatically A warning will not be displayed i e a warning messages will be entered into the error window but the error window will not be opened automatically Some of the events are so serious that the user cannot downgrade them to warning or that a certain reaction is inevitable In these cases the user can select the option button but the servo positioning controller will correct this entry during the online parameterization User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS
200. or starting and assigning a position set are used as follows when a course program is active User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 73 Table 8 Course program Assignment of the digital inputs Function Explanation DIN 0 NEXT2 Rising edge Continue with following position 2 DIN 1 NEXT1 Rising edge Continue with following position 1 NEXT has a higher priority than NEXT2 if both are switched simultaneously DIN 2 STOP Low A running positioning run will be interrupted The program stops in the current course program line DIN 3 Course Posi High Activation of the course program Low Complete movement to position Then normal positioning mode with destination selection through DINO DIN1 DIN2 and position group selection through DIN4 and DINS DIN 4 STARTI1 Rising edge Movement to a defined start position Start of the course program DIN 5 START2 Rising edge Movement to a defined start position Start of the course program START has a higher priority than START2 if both are switched simultaneously Rising edge positioning If DIN3 low Start positioning homing If DIN 3 high Start homing Table 9 Course program Configuration of the digital inputs new I O configuration DIN Function Explanation DIN 0 Course Posi High Activation of the course program Low Complete movement to posit
201. orrespondence with the following standards International IEC 60364 4 41 European countries within the EU EN 50178 1998 section 5 2 8 1 DANGER High electrical voltages due to wrong connections Danger to life risk of injury due to electrical shock Only devices and electrical components and wires with a protective extra low voltage PELV may be connected to connectors and terminals with voltages between 0 to 50 Volts Only connect voltages and circuits with protection against dangerous voltages Such protection may be achieved by means of isolation transformers safe optocouplers or battery operation 2 3 5 Protection against dangerous movements Dangerous movements can be caused by faulty control of connected motors for different reasons Improper or faulty wiring or cabling Error in handling of components Error in sensor or transducer Defective or non EMC compliant components Error in software in superordinated control system These errors can occur directly after switching on the device or after an indeterminate time of operation The monitors in the drive components for the most part rule out malfunctions in the connected drives In view of personal protection particularly the danger of personal injury and or property damage this User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 25 may not be relied on exclusively Until the built in monitors come into effect
202. otation Method 17 Homing to the negative limit switch If this method is used the drive moves in the negative direction at search speed until it reaches the negative limit switch In Figure 11 this is represented by the rising edge Then the drives moves back at crawl speed and tries to find the exact position of the limit switch The zero position refers the falling edge of the negative limit switch User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 67 Negative Limit Switch Figure 11 Homing to the negative limit switch Method 18 Homing to the positive limit switch If this method is used the drive moves in the positive direction at search speed until it reaches the positive limit switch In Figure 12 this is represented by the rising edge Then the drives moves back at crawl speed and tries to find the exact position of the limit switch The zero position refers the falling edge of the positive limit switch I Positive Limit Switch Figure 12 Homing to the positive limit switch Methods 33 and 34 Homing to the index pulse In the case of method 33 and method 34 the direction of the homing run is negative or positive The zero position refers to the first index pulse of the angle encoder in search direction IndexPulse Figure 13 Homing run referred only to the index pulse Method 1 Negative stop with index pulse evaluation If this method is used the drive moves
203. otid_w none 00A8 lenc_sync_num Numerator for the gear factor for the none synchronization O0A9 jenc_sync_div Denominator for the gear factor for the none synchronization 00aa lenc _encoder_ status Angle encoder status none 00AB _ enc_hiperface_line_cnt Line count of a SINCOS encoder none OOAC leeval_enc_phi_offs_2 Offset angle of the 2 track e g Hall Basic unit degree encoder in the case of an incremental encoder 00CO lcurrc_i q act Actual value of the active current in rotor Basic unit current coordinates 00C1 jcurrc_i_ d_act Actual value of the reactive current in rotor Basic unit current coordinates 00C2 lcurrc_i_q_ref Setpoint of the active current in rotor Basic unit current coordinates 00C3 lcurrc_i_d_ref Setpoint of the reactive current in rotor Basic unit current coordinates 00C4 lcurrc_iit_pwr_level Current status of the i2t integrator for the Basic unit per cent power stage 00C5 currc_iit_mot_level Current status of the i2t integrator for the Basic unit per cent motor 00C6 currc_i_lim_act Current torque limitation Basic unit current limited to 0 i_max 00C7 currc_i_ref_rs232 Torque setpoint RS232 Basic unit current ooc8 lcurrc_i ref can Torque setpoint CAN Basic unit current 00c9 lcurrc_i ref ftd Torque setpoint FTD Basic unit current OOCA lcurrc_i ref profi Torque setpoint Profi Basic unit current 00CB currc_i_lim_rs232 Parameterizable torque limitation RS232 _ Basic unit current 00CC _ currc_i_lim
204. ou can define the speed to be added to the running speed in the event of a deviation between the position setpoint and the actual position At the beginning it should be set to about 500 rpm Dead range Here you can state an admissible distance between the setpoint value and the actual value within which the position controller stays inactive The dead range can suppress oscillations which may occur when encoders with a low resolution are used e g in block commutated drives with position recirculation exclusively through the Hall sensor integrated in the motor The dead range should be set to zero to reach the highest possible position accuracy Following error Parameterization of a following error and a response delay When the deviation between the setpoint and the actual value is greater than the configured limit a message or an error will be issued The reaction has to be set accordingly in the fault management system User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 59 6 3 1 Position controller optimization o To optimize the position controller it is essential that the current controller and the speed 1 controller have been adjusted correctly See the preceding chapters m Please make sure that the motor shaft can rotate freely and that the drive cannot be Il damaged The following steps have to be performed for the optimization 1 Activate the position controller an
205. plished in the menu Parameters Positioning Destination parameters Click the GO to start a positioning run with the destination set currently displayed Click the Positioning settings button if you want to change general positioning settings e g position limits see chapter 6 4 Global positioning settings Tab Settings Destination Settings Driving profile Position 0 15 Positioning 0 15 Start during positioning C relative C Ignore start command relative to last destination wait for end of positioning run C absolute Interrupt actual positioning Messages 0 63 Start delay 0 15 Remaining 0 000 R distance C Tipp amp Teach C CAN Bus z OK i x Cancel oy Positioning settings JA Go X conceit 9t Positioning stings _ You can select the positioning set which is to be parameterized in the Destination section on the left In use of 64 positioning sets these sets are divided into 4 position groups 0 15 16 31 32 47 48 63 If the option 16 Positions 16 driving profiles is activated in the menu Settings position sets Course program only 16 position sets are available These position sets however can be parameterized completely independently As an alternative to the displayed motion profile from the standard position sets 0 15 or 0 63 the motion profile from the options CAN Bus which has been parameterized via the CAN Bus and Tipp amp Teach
206. pos DIN 4 i K Pb Tipp neg l DIN 3 Teach 7 I ona ae nl nee DIN 1 A iK D Aatop o 1 ono KO oe Figure 24 Teaching process of a target position tmn gt 1 6ms tsetup gt 1 6 ms tteach gt 1 6 ms User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 86 tset pos gt 5 ms thoa gt 1 6 ms tignore gt 200 ms parameterizable A Attention After the time tignore the digital inputs re assume their functionality as it was before the teaching mode As a result the drive may start to move 8 3 Digital outputs DOUTO to DOUT3 There are four digital outputs DOUTO DOUTS3 to display selected operating states of the DIS 2 servo positioning controller The DOUTO output is hard wired and indicates the readiness for operation of the servo positioning controller Readiness for operation will be indicated if the DIS 2 servo positioning controller has started after power ON and no error has been detected or if the user has acknowledge an error The digital outputs DOUT1 amp DOUTZ2 can have different functions assigned see chapter 8 3 1 Configuring the digital outputs The digital output DOUTS is permanently assigned to the holding brake see chapter 8 5 Holding brake DOUTS An overview of the available digital outputs and their current function assignment can be found in the menu Display Digita
207. rent operating status of the oscilloscope A green LED means The oscilloscope is active An inactive oscilloscope is indicated by a red LED The RUN STOP check box is used to activate or deactivate the oscilloscope Activate the oscilloscope if you want to use it This button can be used to trigger a trigger event manually The oscilloscope starts recording data straight away User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 124 11 6 Serial communication protocol A serial communication protocol in the ASCII format is used for the communication between the DIS 2 servo positioning controller and the DIS 2 ServoCommander parameterization program interface A command always has to be terminated by lt CR gt The technical data of the serial interface are described in chapter 9 2 2 Serial communication through DIS 2 ServoCommanderTM So called communication objects are used mainly for the communication You can access the actual values and parameters of the servo positioning controller using these communication objects Physical quantities are transferred in standardized basic units The following table shows the command syntax of the communication objects Table 20 Command syntax of communication objects Response Description OK In the error free case OK will be returned In OW NNNN DDDDDDDD or the case of an error the command and an error OW FFFF FFFF code will be transmitted Read ob
208. ress CO number free CO 0171 losc_KO_mask2 Optimal mask to hide unnecessary bits or none value ranges in a communication object 0190 _ ftd_pointer_course_prog Pointer at an entry in a course program none 0191 fftd_line_course_prog Pointer at a line in a course program none 0192 fftd_line_course_prog_akt Pointer at currently processed line in a none course program 0193 _ fftd_line_course_prog start Sets the start lines for 1 and 2 none User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 134 11 7 1 Basic units Table 25 List of basic units Quantity Representation Resolution Resulting value range Current 32 bits 1 2 A 21 A Acceleration 32 bits 1 2 rpm s 2 rom s Speed 32 bits 1 2 rpm 524 288 rpm Position 32 bits 1 28 R 2 5R Torque constant 32 bits 1 2 Nm A 524 288 Nm A 32 bits 1 2 Volt 2 Volt 32 bits 1 28 VA 2 VA 32 bits 172 32 Time constant 32 bits 0 1 us 107s 430 s Temperature 16 bits 1 24 C 4 2110 32 bit factor 32 bits 1228 pols 16 bit factor 16 bits 0 1 0 4100 Resistance 32 bits 0 16 7 MO Torque change 32 bits 1 22 Als User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 135 11 7 2 Bit configuration for command word status word error word Command word seqc_opmode Controll
209. rre eene 72 Current controller Manual configuration seese eee 36 Cycle times eeeceeeceeseeeeeeeeeeeaeeeeeeesenees 116 D DC bus monitoring eeeeeeeeeeeeereerrenresn 37 Default parameter set c ccccceeseeeeeeereees 28 Destination parameters POSITIONING at ce ee dared 61 Digital INPUtS miseire anaa aa eaa aaia 81 Configuration s eeren 83 Function OVEIVIEW seeeeeeeeeeeeseenees 82 Digital outputs ccceeeeeeeeeeeteeeeeeeteeeeees 86 Configuration s eeren 86 Function OVervieW seese 86 Dir CtOrieS 0 cccceccccessseeeessseeeeessteeeeeeaes 113 Display units Display mode Direct int eee anais 40 Standard values eenen 40 User defined ccccccccccsseeeessteeeeeeees 40 Display mode seseeeeeeeseeeireersesr rese nens 40 E Emergency stop Decelerations ccccccccsseceeessteeeessteeeeees 42 Error acknowledgement cesceeeeee 108 Err ranal siS aoea atana iienaa 108 Error CliMination cccccccessseeeeessteeeeeeaes 108 Error management sseesseeeseeeseeer renees 109 Error messages s 101 Error WINAOW sissies ainser 108 Factory seting wecane nanei 98 Following error 58 G General configuration cccecseseeeeeeees 39 H Hardware and software requirements 16 FOMINGs catenin ae 65 Speeds Acceleration Times 00608 70 SLALUS eave cette A A 65 Version 1 1 Page 188 Homing method Current position enee
210. rred data transfer rate The program tries to set up a communication using the baud rate defined The preferred transfer rate will either be accepted or set to a lower value The actual baud rate will be displayed in the field Actual data transfer rate This baud rate is used for the normal online communication with the servo positioning controller A special baud rate will be selected for downloading the firmware Under Options Communication Interface you can select the interface COM port to be used by the parameterization program for the communication with the servo positioning controller COM port active until COM1 now New COM port COMI User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 99 9 2 4 Transfer window The Transfer window can be used to send commands directly to the DIS 2 servo positioning controller and to observe its response Use the menu command File Transfer to activate the Transfer window m When the Transfer window is active all other open windows are not served e g actual values oscilloscope Close the Transfer window if you do not need it anymore In general the Transfer window is used to transmit commands which are not of interest for normal operation In addition it can be used to read and write storage locations or communication objects This is only necessary in special cases 0R 0012 Receive f gt 0R 0012 If you want to tra
211. rrent controller If the currents are too high the motor will be destroyed as the permanent magnets inside the motor will be demagnetised The current limits stated by the manufacturer must not be exceeded See chapter 4 3 2 Motor data The current controller can be optimized using the oscilloscope function see chapter 11 5 Using the oscilloscope function You can display the step response of the current controller by setting the oscilloscope channels to the actual value and to the setpoint value of the active current Select the Torque control option in the Commands menu and enter a current setpoint Then try to adjust the optimum step response by varying the parameters The following illustration shows a good step response The current should reach the setpoint value within 1 ms and not overshoot by more than 20 In the case of motors with a high stator inductance the current may need more time to reach the setpoint value In any case the transient process should subside in a well damped manner and without excessive overshoots User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 37 500 us 7 div Figure 1 Current controller step response 4 3 5 DC bus monitoring In special applications e g when shafts with a high mass are strongly accelerated or decelerated the intermediate circuit voltage DC bus voltage may break down or become too high If the intermediate circuit voltage becomes to hi
212. s Has an angle encoder error occurred lt 5ms X Motor identification not performed Timeout Quick Successfully 35 6199 stop Acceleration parameterization too high Homing run could not be completed lt 5ms xX X X successfully Check the configuration of the homing run Error during Parameterization of the controller including 36 8A80 homing run the angle encoder configuration OK User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 107 Error CAN Meaning Possible causes measures Release Reaction no error time C JE Iw code Angle encoder connected lt 5ms X Angle encoder cable defective Error Motor and Angle encoder defective resolver Check the configuration of the angle 40 6197 identification encoder interface Course program Please contact the technical support team lt 5ms XIX unknown 43 6193 command The digital inputs for START1 amp START2 lt 5ms XIX Course program are set simultaneously invalid branch An invalid branch destination an invalid 44 6192 destination target position will be addressed Communication disturbed Check the lt 5ms xX X X installation under EMC aspects CAN Check the baud rate setting communication Check the node number setting node 55 8100 error used more than once in the network RS232 Communication disturbed Check the lt 5ms X X X communication _ installation under EMC aspects 56 7510 J error Co
213. s a SYNC telegram or an emergency message every time it is activated The processing of PDOs may take two time slices of the command interpreter depending on the complexity This structure results in restrictions concerning the speed with which the DIS 2 can process the CAN objects e The control system must not transmit PDOs more often than every 4 ms as otherwise the DIS 2 may not be able to detect or evaluate a PDO This may cause jumps in the control system or jerking of the motor e Inthe worst case a PDO does not become effective until after 4 8 ms e g as a speed setpoint This happens when two time slices are required to process the PDO and when the PDO is transmitted immediately after the command interpreter is called up e Upto 8 ms may pass between the transmission of an SDO and the response of the controller since the response data have to be compiled in the controller first m More information concerning the communication and the control of the DIS 2 servo Il positioning controller via the CANopen interface as well as information concerning the connection of the CAN bus can be found in the CANopen manual for the DIS 2 servo positioning controller 9 1 3 Configuring the CANopen communication parameters You can adapt the CANopen communication parameters of the DIS 2 servo positioning controller to your CAN bus network under Parameters Fieldbus CANopen M CANopen active Baud rate Node number 125 kBau
214. set to values lt 1 6 ms 100 ps 1 5 ms so that the SPC can detect all messages from the DIS 2 On the other hand all the control signals from the SPC must be applied gt 1 6 ms 100 ps 1 7 ms in order to ensure that the DIS 2 can recognize the signals correctly Example SPC with teycie 1 ms gt setting of the SPC outputs for at least 2 xX toycle 2 MS 11 10 1 Switch on sequence Power On DOUTO READY controller enable powerstage active holding brake unlocked speed setpoint actual velocity value t1 500ms t2 gt 1 6ms t3 10ms t4 Nx1 6ms th lt 1 6ms t6 Nx0 2 ms t7 Nx1 6ms _ t2 t5 o E i t6 4 Boot program and start of the application Depends on the operating mode and on the status of the drive Can be parameterized run delay braking parameter Depends on the quick stop ramp Can be parameterized stop delay braking parameter User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 145 11 10 2 Positioning Destination reached ti start positioning SS RX DINO DINS positioning active DOUT target readched position setpoint position actual value Pulse length of the START signal ti gt 1 6 ms t2 lt 1 6 ms Delay until the drive starts Target window reached response delay t3 Nx 1 6 ms t4 gt 1 6 ms Position selection set up time Position selection hol
215. sition 0 000 R I Homing run at controller enable I Go to zero position after homing run Positioning settings pi Go X Cancel The Positioning settings button will lead you to the menu for parameterizing the general positioning settings e g positioning limits See chapter 6 4 Global positioning settings P a Click GO if you want to start a homing run Tab Settings User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 70 You can select one of the homing methods described in chapter 6 8 1 Homing methods in the Mode field During the homing run the motor will run until the Destination has been activated The No movement method is a special case In this case the current actual position is defined as the homing position In this case the drive will not move at all In all other cases the destination will be approached at search speed Then the drive moves back at crawl speed to determine the exact contact threshold The running speed is used to approach the home position zero point of the application This may differ from the destination The index pulse for instance is preferred as the home position as it has a higher level of accuracy You can find the settings for the search crawl and running speed or the corresponding acceleration on the Driving profile tab for the speed acceleration and time values This tab will be described in detail below
216. sition following line X will be approached immediately The positioning run currently being performed will be interrupted immediately Complete position then target line The current positioning run will be completed Then the following position following line X will be approached in accordance with the incoming signal The following applies always If both NEXT signals are not set to evaluate following position following line 1 will be approached If NEXT1 is set to evaluate but NEXT2 is parameterized differently NEXT1 will be used If NEXT2 is set to evaluate but NEXT1 is parameterized differently NEXT2 will be used In addition you can select the following statuses for the digital outputs DOUT1 DOUT2 in the Options field i kod ON OFF Target reached Remaining distance message e ko e ko i The following applies always The options ON and OFF will be adopted immediately The options target reached and remaining distance message will not be adopted until the positioning run of the course program line is started The response to the STOP signal can also be configured in the Options field If the digital stop signal is evaluated the following actions will be performed User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 76 A running positioning run will be interrupted The drive will slow down with th
217. speed speed value filter 0110 _ psel_x_act Actual position value Basic unit position 0111 fioh_pos_selector Value of target selector valid at present 0 63 position data sets 0112 posi_busO_pointer Pointer at current position parameter 0 63 position data sets through RS232 0113 posi_bus1_pointer Pointer at current position parameter 0 63 position data sets through CAN 0114 posi_bus2_pointer Pointer at current position parameter 0 63 position data sets through FTD 0115 posi_bus3_pointer Pointer at current position parameter 0 63 position data sets through Profi 0116 posc_ctrl_gain Position controller gain Basic unit gain 0117 posc_n_lim_pos symmetric limitation of the max output Basic unit speed velocity from the position controller 0118 pos _sel_parameter Position controller setpoint selector none 0119 posc_x_diff_time Time until following error is triggered Basic unit time 011A posc_x_diff_lim_pos Following error position difference Basic unit position set actual 011B _ posc_x_dead_rng_pos Position difference dead range Basic unit position 011C _ ipo_sw_lim_pos Positive position limit software limit switch Basic unit position 011D lipo _sw_lim_neg Negative position limit software limit switch Basic unit position 011E posi_busO_start_delay Start delay after start of a positioning run Basic unit time applies to all position targets 011F posi_busO_x_trig Remaining distance for remaining
218. ssage delay Delay during which the actual position must be inside the tolerance window before the target reached message will be set Messages Motor speed message Destination Following error Tolerance window for target reached Angle distance Message delay 100 0 ms 100 0 ms Tab Motor speed message Declared speed Speed at which the declared speed achieved message will be set 7 Message window Tolerance range within which the actual speed has to be in the range of the declared speed so that the declared speed achieved message is set Messages Motor speed message Destination Following error Motor speed message 120 000 r mii Declared speed 2 Habba Message window User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 89 8 4 Incremental encoder emulation through DOUT1 and DOUT2 An activated incremental encoder emulation requires the digital outputs DOUT1 and DOUT2 As these outputs are connected to the digital inputs DIN2 and DIN3 these inputs cannot be used if the incremental encoder emulation is active o Exception DIS 2 48 10 FB with DOUT1 and DOUT2 led out separately For complex servo control systems two servo positioning controllers can be synchronized by coupling them in a master slave configuration using incremental encoder signals At present the DIS 2 servo positioning controll
219. stors 8 5 Holding brake DOUTS3 If your motor has a holding brake this brake can be controlled by the DIS 2 servo positioning controller as required by the operation The DIS 2 servo positioning controller can only control holding brake having a rated voltage of 24 V DC It has to be connected via the digital output DOUTS3 at connector X3 A detailed description concerning the connection of the holding brake and the maximum permissible operating currents of the brake can be found in chapter 1111 16 4 Connection Holding brake X3 in the appendix 8 5 1 Brake functions The holding brake is enabled when the controller is enabled and the power stage of the servo positioning controller is activated Holding brakes have switching delays due to their mechanical inertia and the electrical time constant of the control coil This is taken into consideration by the servo positioning controller You can parameterize corresponding delays User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 91 If you want to edit the parameters for controlling the holding brake open the menu under Parameters Device parameters Brake functions The following window will appear Brake functions Run delay Delay to unlock brake asma Stop delay Delay until brake locked 40 00 ms xX Cancel The run delay is used to adapt the control of the holding brake to its mechanical inertia
220. t The CANopen active check box is used to activate or deactivate the field bus communication with the set parameters This setting will be adopted straight away i e no reset is required to activate or deactivate the CANopen interface 9 2 Control through the serial interface 9 2 1 Function overview The DIS 2 servo positioning controller has an asynchronous serial interface In most cases this interface is used for the parameterization of the servo positioning controller The interface can also be used to control the controller in the application if the response time of the drive is not of prime importance In this case so called communication objects are used for the communication There are communication objects used to read out certain quantities such as the current or the speed Other communication objects are used to read and write parameters A communication objects comprises the following values Permissible minimum setting value Permissible maximum setting value Value set for the parameter Controller internal value of the parameter o Information concerning the command syntax can be found in chapter 11 6 Serial Il communication protocol Chapter 11 7 List of communication objects contains a list of all communication objects supported by the system m The controller internal value of a parameter may differ slightly from the adjusted value as Il the servo positioning controller internally uses other un
221. tance for the positioning run The digital inputs DINO DIN3 can be used for an offset for the CAN node address O The functionalities of DINO DIN3 can only be used if the analog inputs AINO and AIN1 il are used as digital inputs If the incremental encoder emulation is active DIN2 and DIN3 are not available 8 2 Extended function of the digital inputs Tipp amp Teach If the Tipp amp Teach option is activated in the Commands window the extended function of the digital inputs can be used Commands Controller enable ei C Torque control C Speed control Positioning C Selection 64 positions Course program DIN3 EE M New 1 0 assignment High Course program Low Selection 32 positions 0 a Tipp each Low Selection 32 positions Reversal of rotation direction User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 84 The function is used to approach and program any desired target position through the digital inputs The programming procedure is described in section 8 2 1 Teaching positions In addition it is possible to start a homing run through a digital input or to interrupt a positioning run and to stop the drive through another digital input without switching off the output stage The digital inputs which are normally used for starting and assigning a position set are used as follows when the exte
222. te opens Baudrate Boot Baudrate Boot C 4800 C 9600 19200 C 38400 57600 115200 3 Try a baud rate of 115200 bauds If this leads to data transfer problems error messages you have to reduce the baud rate for the next trial User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 154 A successful firmware download is indicated by the message below Load firmware If the firmware download was not successful the message Error at firmware download will be displayed Information x i Error at firmware download Load firmware In most cases this is due to a communication error during the transfer to data into the DIS 2 servo positioning controller Repeat the process described above with a lower baud rate User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 155 11 14 Technical data 11 14 1 Ambient conditions and qualification Permissible temperature Storage temperature 25 C to 70 C ranges Operating temperature 0 C to 50 C 50 C to 70 C with power decrease of 2 K Temperature shut down at about 80 C Permissible altitude Up to 1000 m above msl 1000 to 4000 m above msl with power decrease Atmospheric humidity Rel humidity up to 90 non condensing Type of protection IP54 depending on method of installation up to IP67 Pollution class 1 Low voltage directive EMC
223. terminology 11 20 2 General information concerning EMC User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB 11 20 3 EMC ranges First and second environment 11 20 4 Connection between the DIS 2 and the motor 11 20 5 Connection between the DIS 2 and the power supply unit Version 1 1 Seite 9 List of Figures Figure 1 Current controller Step reSPONSC cceeeeeeeceeeeeeeeeeeeeeaaeeeeaeeceeeeseaeeeeaaeedeneeseaeeescaeeeeaaeeeeeeeaas 37 Figure 2 Speed Controlleticcsiccasctes ezsteenceocceusslsvaeteezagcmevtgtereanendsceoues terecqetadacewegt es evunth tyecnautes aa EASRA 48 Figure 3 Speed controller t00 SOP vvsscesteccbiteceviechaceedoddece suet aan aaa asiaa aa hana aa na aaa i aaa anana daria 51 Figure 4 Speed controller too Nard eeeeeeeceeeeeceneeeeeeeeeeeeeceeeeceaeeeeeaaeseeeeeseaeeesaaesseaeeseaeeessaeeseneseaeeeeeas 51 Figure 5 Speed controller set correctly ccccceeeeceeeeeeeeeeceeeeecaeeeeeaeeeeeeeeseaeeeeaaeseeeeeseeeeeaeseeaeeeneeesaas 51 Figure 6 Positioning control block diagram eee ceeeeeee eee eeeeeeee entree ee eae ee ee eaeee eee eaaeeeeetaeeeeetaeeeeeeaeeeeee 56 Figure 7 Speed controller OptimiZation ecccececeeeeeeeeenee cece eeeaaeeeeaeeceeeeeseaeeesaaeeeeeeeseaeeesaaeeseaeeeneeesaas 59 Figure 8 Time optimal and jerk limited POSItiIONING ee eeeeeeeeeeeeeee eset teense ee eaeeeeetaeeeeetaeeeentaeeeeee 63 Figure 9 Homing run to the negative limit switch with in
224. the control system of the machine The occurrence of a fault can lead to the loss of the safety function but the probability of occurrence is lower than for category B The occurrence of a fault can lead to the loss of the safety function between the checks The loss of a safety function is detected by the checks The requirements of category B and the use of well tried safety principles shall apply Safety relevant parts must fulfill the following requirements It must be ensured that a single fault in any of the parts does not lead to a loss of the safety function The single fault is detected whenever this is reasonably practical When a single fault occurs the safety function is always performed Some but not all faults will be detected Mainly characterized by structure Accumulation of undetected faults can lead to the loss of the safety function The requirements of category B and the use of well tried safety principles shall apply Safety relevant parts must have a redundant design permanent self checking complete fault detection When faults occur the safety function is always performed Faults will be detected in time to prevent the loss of the safety function 1 The categories are not intended to be used in any given order or in any given hierarchy in respect of safety requirements 2 The risk assessment will indicate whether the total or partial loss of the safety function
225. the power loss When 80 of the maximum integrated value are reached a warning parameterizable will be issued When 100 is reached the maximum current will be limited to the rated current Current measurement check and offset calibration when the power stage is turned on When the power stage is turned on an automatic offset calibration of the current measurement will be performed If the offset lies beyond the permissible tolerances an error will be issued DC bus voltage monitoring Overvoltage monitoring The overvoltage monitoring system of the DC bus intermediate circuit responds as soon as the DC bus voltage exceeds the operating voltage range As a result the power output stage will be shut down Undervoltage monitoring The system checks whether the intermediate circuit voltage DC bus voltage is above a certain minimum limit see chapter 4 3 5 DC bus monitoring For User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 102 applications requiring the intermediate circuit to be run empty or a set up mode with a reduced DC bus voltage intermediate circuit voltage the response to this error can be configured 10 1 3 Logic supply monitoring gt 24V overvoltage undervoltage monitoring The power supply of the logic component of the DIS 2 servo positioning controller is monitored If the power supply of the logic component is too high or too low a fault message will be issued
226. the setpoint is assigned through RS232 you can configure this under Operating mode Setpoint selection RS232 You can also open the menu by clicking the button next to the setpoint selector The following window will appear Setpoint selection RS232 Main Z K i Speed setpoint gt 100 000 mm s X Cancel 4 gt M Transmit immediately vis Toneior r Correcting setpoint 0 000 mm s a U EE M Transmit immediately a Isanster T Torque setpoint M Transmit immediately r Torque limitation M Transmit immediately Activated RS232 sources are marked by a green arrow Here you can enter numerical values for the setpoints and limitations Click the red STOP button if you want to cancel false inputs immediately The setpoint will be set to 0 and transmitted immediately If you do not want to transmit the setpoint immediately deselect the Transmit immediately check box Then you have to click the Transfer button to transmit new setpoints 5 4 4 Setpoint ramp The DIS 2 servo positioning controller can process speed steps in numerous different ways It can transfer the step directly to the speed controller without filtering it or it can calculate a function to smooth the setpoints of the Selector Speed setpoint using a ramp with an adjustable gradient The ramp generator can be activated and deactivated using this button The menu for configuring the ramp can be
227. the upper left hand side of the main window Version 1 1 Page 115 11 2 Setting up the serial communication You have to perform the following steps to configure the data for the communication 1 Connect the DIS 2 servo positioning controller completely 2 Connect a free port of the PC with the DIS 2 servo positioning controller using null modem cable 3 Switch the DIS 2 servo positioning controller on 4 Start the parameterization program If the Online button in the toolbar is displayed in green see illustration the communication parameters are already set correctly If the parameterization program cannot open the serial interface the following error window will be displayed when the program is started C Change COM port C Search Baud rates C Offline parameterisation C Firmware download Exit program J OK This error can be due either to a wrong interface setting mostly mouse driver setting or another Windows or MS DOS program accessing the serial interface To solve this access conflict close the other program in the case of MS DOS based programs also close the MS DOS shell and click the button Retry with old parameters To correct the interface configuration click on the radio button Change COM port and following the instructions see chapter 9 2 3 Configuring the RS232 communication parameters The servo positioning controller may use another baud rate than the one set in the par
228. tion currently being displayed see also chapter 6 5 Parameterizing position sets In the lower section of the window you can make settings for the course program If you select Course Program active the course program will be enabled in the positioning mode The button opens the course program menu see chapter 7 Course program In addition you can define two start lines for the course program Go to Seana 2 2 leo _ m i e le le l wo N _ _ leeki bekke belek mananan e 2 ll e Ls bl l le le eg 1 TTT w p wo a oa pat 2 leis le ele le n w le le a 2 le le e le 2 a aa apa E a J D S Start Homing User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 65 6 7 Setting of digital outputs In the positioning mode a superimposed control system can be informed through digital outputs of the fact that a positioning run has been is being completed The digital outputs can transfer the following information Target reached Remaining distance up to the end of a positioning run reached Homing run performed The configuration of the digital outputs is described in chapter 8 3 Digital outputs DOUTO to DOUTS3 6 8 Homing Most applications using the DIS 2 servo positioning controller in positioning mode require a zero position to which the
229. tion of the distance speed and acceleration units For experienced users only User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 41 The Decimal places tab can be used to adapt the resolution of the quantity to be represented to the actual conditions The Direct input tab can be used to configure the DIS 2 SerovCommander such that other display units than the ones offered can be used O 1 Further information can be found in chapter 11 8 Extended options in the Display units menu Caution For experienced users only On the Direct input tab you can directly write to the factor group if you have select the direct input option When you quit the menu the program displays the following question 2 Do you want to adapt the input limits O The input limits are automatically adapted to the selected physical units If you want to il you can check this Click the Yes button to do so 4 5 Defining input limits Options Input limits opens the following menu Torque values Maximum adjustable Js 00a v4 OK torque value X Cancel rS peed values Maximum adjustable 000 000 r min velocity Ha F Maximum adjustable acceleration re a i eT Enter the maximum speeds and accelerations you are expecting for your application The program uses this information to limit the input fields User Manual DIS 2 DIS 2 48 1
230. tion the drive may accidentally be put into action NED Initial operation must be carried out with idle motors to prevent mechanical damages e g due to the wrong direction of rotation NED Electronic devices are never fail safe It is the user s responsibility in the case an electrical device fails to make sure the system is transferred into a secure state NED The servo drive controller and in particular the brake resistor externally or internally can assume high temperatures which may cause serious burns NED 2 3 3 Protection against contact with electrical parts This section only concerns devices and drive components carrying voltages exceeding 50 V Contact with parts carrying voltages of more than 50 V can be dangerous for people and may cause electrical shock During operation of electrical devices some parts of these devices will inevitably carry dangerous voltages DANGER High electrical voltage Danger to life danger due to electrical shock or serious personal injury The appropriate DIN VDE EN and IEC regulations as well as all national and local safety regulations and rules for the prevention of accidents apply for the assembly and maintenance of the system The plant engineer or the operator is responsible for compliance with these regulations Before switching on the device install the appropriate covers and protections against accidental contact Rack mounted devices must be protected against ac
231. to protect the installation against splash water An IP67 class of protection is possible with a good mechanical design 1ml File nane Page na Description 1 2 itle Artirlp tode rev Dyos E onzo M Rey flips nv Changed Date Drawing ne Id A Figure 32 DIS 2 application example Synchronous servo motor in the power range of 500 W with a DIS 2 servo positioning controller and a gearbox for a steering application User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 164 11 16 Connectors at the DIS 2 48 10 11 16 1 Connection Power supply and I O X1 Configuration on the device AMP Junior Timer 1 963215 1 Mating connector X1 AMP 1 963217 1 contacts 929938 1 a Pag ee ee oe _16151413121110 9 Figure 33 Numbered pins of X1 DIS 2 48 10 Table 27 Pin assignment of connector X1 inne Same _ Value _ Speeoion _ _ _ ___ Digital input Power stage activation DIN7 ov 24 V Digital input Limit switch 0 blocks n gt 0 CAN high Digital input Positioning group selector bit 0 Analog input 1 Differential analog input with AIN1 Digital input Positioning destination selector bit 2 GOOT Ca Digital output Freely programmable encoder a output track A AIN
232. troller allows you to assign the setpoint through a setpoint management system in the torque control and speed control mode You can find the corresponding menu under Operating mode Setpoint Selection The following setpoint sources can be selected 2 analog inputs gt AINO and AIN 1 parameterization see chapter 8 6 Analog inputs AINO and AIN1 Fixed value RS232 Fixed value CAN Position controller in speed control mode Speed controller in torque control mode o il If no setpoint source is active the setpoint is zero The setpoint management system manages your settings separately for the individual operating modes This means that when you change the operating mode the setpoint selector will be automatically set to the values defined last by you in the respective operating mode User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 53 5 4 1 Speed controlled mode The setpoint management system includes a ramp generator Any of the above mentioned setpoint sources can be selected under Selector Speed setpoint and run through the ramp generator You can also select another addition setpoint source Selector Correcting setpoint This other setpoint source however will not be fed through the ramp generator The total setpoint is a summation of the two values The acceleration and deceleration time of the ramp can be parameterized depending on the direction Setpoint sele
233. ts 6 Parameters Safety parameters 7 Parameters Controller parameters Current controller User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 29 8 Parameters Controller parameters Speed controller 9 Parameters Controller parameters Position controller 10 Parameters Device parameters Temperature monitoring 11 File Parameter set Save parameter set Flash Permanent storage of the parameters in the internal flash memory of the servo 12 File Parameter set Servo gt gt File Storage of the parameter set as a file option 4 2 Parameterization using the motor database The DIS 2 DIS 2 ServoCommander parameterization program has a motor database in which the most important data for the different motor types can be stored m Normally your distributor creates this motor database which then contains data Il concerning all motors offered by this particular distributor Please contact your distributor to order this database if it is not included on your installation CD This function can be accessed through the menu Parameters Device parameters Motor data Select new motor The program displays a list on which you can find your motor Motor selection z Motor data Angle encoder Resolver Real voltage 30 Pole number 10 Idling speed 3000 r min Offset of angle encoder 95 0 Stator resistance 0 05 Ohm Rated current rms value 20 334 Stator induct
234. u_act Measured phase current of phase U Basic unit current 0081 currc_i v_act Measured phase current of phase V Basic unit current 0082 fioh_uzk volt DC bus voltage intermediate circuit voltage Basic unit voltage 0083 fioh_mot_temp Motor temperature Basic unit temperature 0084 fioh_power_stage_temp Power stage temperature Basic unit temperature 0085 fioh_din Pin status of the digital inputs none 0086 fioh_dout_data Current status of the digital outputs DOUTO ready for operation Bit field hard wired DOUT1 programmable DOUT2 programmable DOUT3 holding brake Hard wired 0087 jioh_aout_range Value range of the analog monitor Basic unit voltage maximum for both channels 0088 lioh_aout_resolution_volt Resolution of the analog monitor indication Basic unit voltage of a voltage for one bit referred to the value range 0089 jioh_dout2_1_func Defines which functionality will be connectedinone to which digital output 008A jioh_aoutO_ko_nr Analog monitor 0 Number of the Number of the communication object of the quantity to be communication object of the displayed quantity to be displayed 008B _ jioh_aoutO_scale Analog monitor 0 Scaling Basic unit gain 008C _ jioh_aoutO_offset Offset voltage for the analog monitor Basic unit voltage 008D jioh_aout1_ko_nr Analog monitor 1 Number of the Number of the communication object of the quantity to be communication object of the displayed quantity to be displayed 008E ioh_aout1_scale Ana
235. urations for rated current maximum current angle encoder offset phase sequence number of poles current controller and speed controller to prevent damages to the servo positioning controller motor During the offline parameterization the parameterization program shows a behaviour which may deviate from the online parameterization Certain menus e g firmware download are inaccessible User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 152 The menu File Parameter set has different submenus gt Open file gt Save file gt Save file as 2 When you quit the program you will be asked whether the currently open parameter file shall be saved To end the offline parameterization click on the menu item Options Communication Online parametersation or on the online icon in the tool bar 11 13 Loading firmware into the DIS 2 firmware update The firmware is the operating program of the DIS 2 servo positioning controller The controllers come supplied with a firmware loaded Under the following circumstances it might be necessary to load a new firmware Update to a new firmware version Loading of a special firmware with customized functions in order to be able to use additional functions Incomplete firmware e g due to an interrupted firmware download Due to continuous product developments the parameterization program may include options which require
236. urement time The manual determination of the angle encoder data requires good knowledge of synchronous machines and the encoder used We recommend contacting your local distributor in this case You have to set the following parameters Table 5 Angle encoder parameters Resolver Hall Incremental encoders encoder with Six Step Hall sensor Angle encoder offset Phase sequence Offset of second track Hall encoder Phase sequence of second track Line count number of increments Index pulse yes no AN Caution Incorrect angle encoder data may lead to uncontrolled movements of the drive This may damage the motor or the entire system User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 33 In addition to the angle encoder configuration this menu can also be used to perform basic configurations concerning the control system Commutation Block commutation or sine commutation Speed controller recirculation Encoder or Motor EMK separately for P component and I component If a motor with analog Hall sensors is used for the commutation the automatic adjustment of the encoder signals can be started by pressing the button Automatic encoder optimization The DIS 2 determines the optimum offset values and the amplitude values of the SIN and COS track signals and saves them This reduces the tolerances of the enc
237. ves remains at precisely at standstill for a long time without drifting away slowly User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 93 voltage safe zero Figure 27 Safe zero Do not activate the safe zero function in the case of applications with a position control 1 internally or through the external control as from a control point of view it acts like a dead range or a backlash in the control system see Figure 27 During operation this downgrades the stability in the control circuit This menu has separate tabs for the two analog inputs so that you can scale them independently from each other 8 7 Analog output AMON The DIS 2 servo positioning controller has an analog output for outputting and displaying internal control variables that can be visualized using an external oscilloscope The output voltage is in the range of 0 V to 10 V The resolution is 8 bits Select Parameters IOs Analog outputs to configure the analog monitor Channel 0 Analog monitor Scaling C Speed setpoints C Speed actual value raw C Speed actual value filtered C Speed actual value Motor EMK Position setpoint C Position actual value Active current setpoint Object number 80 hex Active current actual value C Reactive current setpoint C Reactive current actual value Phase current U Offset 10 Volt is equal to
238. ystem Lower 16 bits Subrevision 0018 srvc_custom_main Customer application number Upper 16 bits Main revision Subrevision number Lower 16 bits Subrevision 0019 main_bootloader_version Main revision and subrevision of the boot Upper 16 bits Main revision loader Lower 16 bits Subrevision 001A srvc_motid_ctrl Control word for angle encoder identification 0 Reset identification 1 Identify angle encoder 001B _ srvc_u_nenn_mot Rated motor voltage Basic unit voltage 001C currc_i_nom Rated current peak value of the motor Basic unit current 001D lcurrc_i max Maximum current peak value of the motor Basic unit current 001E _ currc_iit_mot_time l2t integration time for the motor Basic unit time 001F _ srvc_torque_const Torque constant Basic unit torque constant 0020 __ srvc_nenn_mot_speed Rated motor speed Basic unit speed 0021 _ spdc_n_ref_lim_pos Speed setpoint limitation Basic unit speed 0022 Jleeval_enc_polp_num Number of pairs of poles of the encoder Number of pairs of poles not system motor number of poles 0023 lioh_ mot Inductivity of the Ls winding of the motor Basic unit inductivity 0024 lioh_r mot Resistance of the Rs winding of the motor Basic unit resistance 0025 fioh_mot_temp_max Maximum motor temperature Basic unit temperature User Manual DIS 2 DIS 2 48 10 DIS 2 48 10 IC DIS 2 48 10 FB Version 1 1 Page 127

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