Home

Operating Instructions IMSS500+__Simple Servo 500 600

1. SimpleServo 500 600 i1000 User Manual Rev 3 4 5 8 2 Autophasing Autophasing is the feature of the SimpleServo drives that helps determine some important motor parameters when using a motor which is not in the MotionView database Autophasing will determine Hall order sequence Hall sensor polarity and encoder channel relationship B leads A or A leads B for CW rotation To perform autophasing 1 Complete steps in Section 5 8 1 Setting custom motor parameters above If the motor file you are trying to autophase already exists on your hard drive simply load it per Selecting custom motor section above 2 Make sure that the motor s shaft is not connected to any mechanical load and can freely rotate 3 Make sure that the drive is disabled 4 Do not edit field Hall order and check boxes inverted B leads A for CW because their values are ignored for autophasing 5 Click OK to dismiss motor selection dialog MotionView responds with the question Do you want to perform autophasing 6 Click OK Safety reminder dialog appears Click Proceed and wait until autophasing is completed 7 If there was a problem with motor connection and or hall sensor connection MotionView will respond with an error message Correct wiring problem s and repeat steps 1 6 8 If autophasing is completed with no error then MotionView will return to motor dialog box and parameter fields Hall order and check
2. 2 6 SSi1000 drives features Indexing Index resolution Index position range Index generation control Indexing Motion Queue Acceleration deceleration Move profiles Gearing mode Velocity mode Events Scanned events Scanned events period Registration User Program 64 bit from 2 to 29 User Units Language statements or Host Interface commands Incremental absolute registered and segmented moves 32 levels deep Linear or S curved Trapezoidal Triangular S curved Dedicated inputs for quadrature master encoder reference Programmable on the fly Gear Ratio and Master Encoder PPR via interface or User Program Velocity reference Accel Decel programmable on the fly via interface or User Program event on any valid logic expression Expression can include any internal System and User variables I O states Flags arithmetic and logical expression results 256 uS 2uS reaction time Current position capture User programming language O Statements based Program control Types supported All major construction DO WHILE WHILE IF THEN ELSE GOTO GOSUB Subroutines supported Typeless All operands are 64 bit 32 32 format Operands representation Floating point Translation Program Object Execution Tools for program Development Host Interface support Multipass compiler Bytecode Java like virtual bytecode machine Full featured IDE integrated in MotionView software Single
3. 7 7 Security This option will protect source code of the User Program with password If password was set then SSi will ask for password before displaying User Program text Password can be any alphanumeric string 7 8 Faults Group Faults Group loads fault history from the drive New faults replace oldest faults in circular manner In any case fault 0 is the most recent fault To clear fault history from the drive s memory click on Reset Fault history button Each fault has its code and explanation of the fault 7 9 Tools 7 9 1 Drive monitor Drive monitor shows you motor hall sensors states and actual motor encoder counts This tool is useful when troubleshooting motor encoder s connections 7 9 2 Oscilloscope tool Oscilloscope tool gives real time representation of different signals inside SSi drive and is helpful when debugging and tuning drives Operation of oscilloscope tool described in MotionView software s User s Manual Below given the list of the signals you can observe with oscilloscope tool Phase Current RMS Motor phase current Phase Current Peak Motor peak current Iq Current Measures the motor Iq torque producing current Motor Velocity Actual motor speed in RPM Commanded Velocity Desired motor speed in RPM velocity mode only Velocity Error Difference in RPM between actual and commanded motor velocities Position Error Difference between actual and commanded position Step amp Dir
4. Select motor you are using according to the Section 5 7 After SSi connected click on the left tree to expand its Parameters folders Click on lt Drive Mode gt and select appropriate mode Click on lt Current limit gt parameter and enter current limit in Amp RMS per phase appropriate for your motor Click on lt Peak current limit gt parameter and enter peak current limit in Amp RMS per phase appropriate for your motor Set up additional parameters See section for list of available parameters Refer to Section 6 6 for details on compensation setup Optional Select lt I O gt group from node tree Set up drive s I O according to your system requirements Refer to Section 6 3 for details on I O After you configure the drive proceed to tuning procedure covered in Section 9 7 or 9 8 Tuning in position P V mode depending on operating mode selected Set up motor SSi parameters and gains On the left tree click on the folder lt Indexer program gt If SSi has a valid program in its memory it will be loaded to the right window where it can be viewed modified compiled or exported to the file Type your program then choose lt Compile and load gt from lt Indexer gt menu From lt Indexer gt menu choose lt Run gt to start program execution AC Tech S MPLEServo 61 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 9 4 Enabling the SS500 600 drives Regardless of
5. Step execution capability Breakpoints status and variable WATCH on the fly debug window Host Interface transports RS232 485 addressable 32 devices on network 10 100 Ethernet Host Interface commands Unified Set for all interface transports Could be executed SIMPLEServo concurrently with User Program statements AC Tech 10 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 Variables Internal format Number of User Variables Variables resolution System variables resolution 64 bit 64 64 bit 64 bit Arithmetic and logic functions Arithmetic functions Logic and bitwise functions Addition Subtraction Multiplication Division AND OR XOR NOT 2 7 Connections and I O All models RS232 serial interface Encoder Feedback Encoder buffered repeat Power SS500 600 drives Digital Inputs Digital Outputs Analog Inputs Analog Outputs I O Controller SSi10XX drives Digital Inputs Digital Outputs Analog Inputs Analog Outputs I O Connections Interfaces RS 485 Ethernet 10 100 Standard 9 pin D shell DCE Standard 15 pin D shell in 25 pin D shell 8 pin removable terminal block 9 pin for 3 P models 1 dedicated ENABLE 1 programmable 1 dedicated READY 1 programmable 1 differential analog input Full range 10V single ended and 5V differential Analog input is used for Torque or Velocity reference 1 single ended analog output 10 V full sc
6. Note e 1 Position loop filter settings only active if drive operates in Step amp Direction PIVFF mode It has no effect in Velocity or Current mode s P gain Proportional Proportional gain adjusts the system s overall response to position error Position error is the difference between the commanded position of the motor shaft and the actual shaft position By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal e gain Integral The output of the I term portion of the integral gain compensator is proportional to accumulative error over cycle time with I term controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is ona system running at low speed or in a steady state without rapid or frequent changes in position s D gain Differential The output of the D term portion of the filter proportional to difference between current position error and position error measured in previous servo cycle D term decreases bandwidth and increases overall system stability It responsible for removing oscillation caused by load inertia and acts similar to shock absorber in a car AC Tech SIMPLEServo 51 SimpleServo 500 600 i1000 User Manual Rev 3 4 e Vff Velocity feed forward The
7. to MotionView User s Manual for details how to make a connection to the drive Select motor you are using according to the Section 5 7 13 14 15 16 Subgroup Refer to Section 6 6 for details on compensation setup 18 19 Double click on the drive s icon to expand parameter group s folders Expand folder Parameters and choose operating mode for the drive Refer for details to Section 6 2 1 for details on operating modes Click on Current limit parameter and enter current limit in Amp RMS per phase appropriate for your motor Click on Peak current limit parameter and enter peak current limit in Amp RMS per phase appropriate for your motor Set up additional parameters suitable for operating mode selected in step 8 Refer to the section to determine parameters suitable for current operating mode Optional Select Limits group from node tree Select Velocity limits or Position limits Optional Select lt I O gt group from node tree Set up drive s I O according to your system requirements Refer to Section 6 3 for details on I O After you configure the drive proceed to tuning procedure if operating in Velocity or Step amp Direction mode Torque Mode doesn t require additional tuning or calibration Refer to Section 9 6 for details on tuning 9 3 Configure SSi1000 SimpleServo drives Before you can write programs and or control SimpleServo SSi drives via Host Interface you must first config
8. 12 oT ot ot o 1 23 T STEP 10 9722 o 1 fom o 21 ISTEP o OPTO OR OPEN 20 o COLLECTOR 7 O INDEXER WITH od 19 OUTPUTS DIFFERENTIAL ot OUTPUTS 01775 m 5 DIRECTION o9 T SE DIRECTION 16 e 3 OT p 2 Gant 9 1 Q4 M __ 5 24VDC TBSO TL 5 24 Return 13 25 12 24 11 23 P 10 22 9 21 dech 8 OPTO OR OPEN 20 COLLECTOR OUTPUTS Si gt ol 3l D ei ofefelelelefefefefe e jl AC Tech SIMPLESetvo 79 SimpleServo 500 600 i1000 User Manual Rev 3 4 12 Troubleshooting WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed Before troubleshooting Perform the following steps before starting any procedure in this section e Disconnect AC or DC voltage input from the SimpleServo Wait 30 seconds for power to discharge Check the SimpleServo closely for damaged components Check that no foreign material has become lodged on or fallen into the SimpleServo Verify that every connection is correct and in good condition Verify that there are no short circuits or grounded connections Check that the drive s rated pha
9. all cartons for damage which may have occurred during shipping Carefully unpack equipment and inspect thoroughly for damage or shortage Report any damage to carrier and or shortages to supplier All major components and connections should be examined for damage and tightness with special attention given to PC boards plugs knobs and switches D Customer Modification AC Technology Corporation its sales representatives and distributors welcome the opportunity to assist our customers in applying our products Many customizing options are available to aid in this function AC Technology Corporation cannot assume responsibility for any modifications not authorized by its engineering department AC Tech SIMPLESetvo 82 SimpleServo 500 600 i1000 User Manual Rev 3 4 AC Technology Corporation member of the Lenze Group 630 Douglas Street Uxbridge MA 01569 Telephone 508 278 9100 Facsimile 508 278 7873 Visit us on the web www SimpleServo com 12 00 USA 15 00 Outside USA AC Tech SIMPLEServo 5s Drive for Global Excellence
10. and parameters are accessible via universal software called MotionView Please Refer to MotionView User s Manual for details on how to make a connection to the drive and change parameter values This chapter covers programmable features and parameters specific to SimpleServo drives in the order they appear in the left tree of the MotionView Programmable parameters are divided into groups Each group holds one or more user s adjustable parameters 6 1 Motor Group Motor group shows currently selected motor You can click CLICK HERE TO CHANGE to view selected motor parameters or select new motor Please refer to Section 5 7 for details on how to select motor 6 2 Parameters Group 6 2 1 Drive operating modes The SimpleServo has 3 operating modes Torque Velocity or Step amp Direction Depending on what servo system you want to build you will choose on of these modes For Torque and Velocity modes drive will accept an analog input voltage on the IN and IN pins of TB502 or TB506 This voltage is used to provide torque or speed reference For Step and direction mode drive will accept step and direction logic signals or quadrature pulse trains Depending on the selected mode some parameters are active while others are disabled Refer to Table 14 to determine active parameters for mode selected e Velocity mode In velocity mode the servo control regulates motor shaft speed velocity proportional to analog input voltage Targ
11. boxes inverted B leads A for CW will be filled with correct values 9 Click Save File to save motor file to disk you can use the same filename as you use to save initial data in step 1 and click OK to send motor data to the drive 5 8 3 Custom Motor Data Entry Motor Parameters dialog has three sections frames dividing motor parameters on groups Electrical constants Mechanical constants and Feedback When creating custom motor entry you must supply all parameters listed in these sections All entries are mandatory except inertia Jm parameter You may enter 0 if you are not sure of a value Electrical constants e Motor Torque Constant Kt Be careful with the units This must be set in Newton Meters per Amp RMS N m A The torque constant for many motors will be given in different English units such as pound inches per Amp Ib in A or ounce inches per Amp oz in A You will need to convert these English units to metric To convert Ib in A to N m A multiply by 0 1130 To convert oz in A to N m A multiply by 0 00706 Example Suppose we are given a Kt 0 69 Ib in A Multiplying by the appropriate conversion factor yields Kt 0 69 Ib in A 0 1130 0 0780 N m A therefore the entry for Kt would be 0 078 Note Round the calculated result to 3 significant places AC Tech SIMPLESertvVo 40 SimpleServo 500 600 i1000 User Manual Rev 3 4 Motor Voltage Constant Ke This must be set in Volt
12. circuit board components are sensitive to electrostatic fields Avoid contact with the printed circuit board directly Hold the SimpleServo by the case only Protect the control from dirt filings airborne particles moisture and accidental contact Provide sufficient room for access to the terminal block Mount the control away from other heat sources Operate within the specified ambient operating temperature range Additional cooling with an external fan may be recommended in certain applications Avoid excessive vibration to prevent intermittent connections DO NOT connect incoming power to the output motor terminals U V W Severe damage to the SimpleServo will result Do not disconnect any of the motor leads from the SimpleServo unless power is removed or the control is disabled Opening any one motor lead may cause failure The DIN rail mounting tab is designed to bear only the weight of the SimpleServo and heat sink Make sure enough slack exists in the wire routing to ensure that the cables do not tug or pull downward against the DIN rail mounting tab AC Tech SIMPLEServo Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 4 1 Start Up Step By Step StartUp instructions are covered in Section 9 Operation 4 2 Mounting Note It may be necessary to add shock absorbing bumpers to the back of the SS500 1 2 Mount the SimpleServo vertically in the panel as s
13. een 54 AC Tech SIMPLEServo rember ofthe rns croup 4 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 b SCOMPONS ATION sre layan tm iret eR mE Hm 55 7 5 1 Velocity LOOp filter eee RE REPE 55 7 5 2 Position Loop filter once nter mime tte eri 55 7 0 Indexer Progra neien nce memet Hte ee Rede 56 17 Ud etu EE 56 T8 Faults Group EEUU 56 59 T R 56 79 1 Drivemonitor een 56 7 9 2 Oscilloscopetool erener 56 8 DIAGNOSTICS Luse 57 8 1 Diagnostic LED RS 57 8 141 Front panel LEDS eek e aaa EE 57 8 12 Bottom side LEDS ua 57 8 2 Faults NN 58 8 2 1 Fav Event NET 58 022 Fault RESET soot RSOUUER AUN LIUM ILE LEE 58 9 OPERATION Sikini ss rcr exa tx ena bel sn EXX AA B le sa AA X RR RSEN ab XR s le a RSEN VN R RE B ke EX RN RE EX 59 9 1 Minimum Connections eee 59 9 2 Configure the S5500 600 SimpleServo drives eee eee eee 59 9 3 ConfigureSSi1000SimpleServodrives enne enne 60 9 4 EnablingtheSS500 600drives ea 62 9 5 EnablingSsSi1000drives enne enne enter enne nnne entente 63 9 6 Tuninginvelociiymode eee 64 9 7 TuninginposittonPVFFmode e 65 9 8 Tuning in position P V mode ee
14. inputs See application note in Section 12 of this manual for the connection guidelines The function of these inputs Master Encoder or Step and Direction is software selectable Use MotionView set up program to choose desirable function 5 2 2 Digital outputs There are two digital outputs READY and OUT AUX available in different output configurations On TB506 READY TB506 15 16 AUX C and AUX E TB506 19 20 Outputs are fully isolated from the rest of the drive circuits dry contact See figure below for its electrical diagram AUX C vk KV AUX_E AC Tech SIMPLESetvo 29 SimpleServo 500 600 i1000 User Manual Rev 3 4 On TB502 OUT RDY TB502 13 OUT AUX TB502 14 Functions the same as READY and AUX have open collector sinking outputs sinking only referenced to drive logic common See figure below for the electrical diagram OUT RDY OUT AUX Both versions of these outputs On TB506 and TB502 have the same logic READY output Activated when the drive is ready and enabled It is reset to an inactive state when the drive is disabled not operational or any fault is detected AUX output Programmable output Activated when any of the selected conditions are true These conditions are software selectable Use MotionView to select the condition assigned to this programmable output Only one condition at a time can be selected for output Possible cho
15. or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed Under no circumstances should power and control wiring be bundled together Induced voltage can cause unpredictable behavior in any electronic device including motor controls Use 18 28 AWG wire for reference and analog signal wiring Use 12 16 AWG wire for AC line L1 and L2 and motor Phase U V and W wiring AC Tech SIMPLEServo 17 SECH SimpleServo 500 600 i1000 User Manual Rev 3 4 4 4 Shielding and grounding 4 4 1 General guidelines AC Technology Corporation recommends the use of single point grounding SPG for panel mounted controls Serial grounding a daisy chain is not recommended The SPG for all enclosures must be tied to earth ground at the same point The system ground and eguipment grounds for all panel mounted enclosures must be individually connected to the SPG for that panel using 14 AWG 5 5 mm or larger wire Refer to Figure 6 for wiring guidelines In order to minimize EMI the chassis must be grounded to the mounting panel Figure 6 Use 14 AWG 1 6 mm or larger wire to join the enclosure to earth ground A lockwasher must be installed between the enclosure and ground terminal To ensure maximum contact between the terminal and enclosure remove paint in a minimum radius of 0 25 in 6 mm around the screw
16. output of the Vff term portion of the filter proportional to demanded motor speed when drive shaft travels from position to position Vff term is an open loop term It is responsible for removing velocity error while positioning thus increasing system response and precision e IL integral gain limit in of torque The output of the I term portion of the integral gain compensator could be limited to some level set by IL limiter In other words the influence of I term on motor shaft torque could be controlled by IL limiter This helps to decrease overshoot caused by gain especially when position error is integrated over a long time period 6 7 Faults Group Faults Group loads fault history from the drive New faults replace oldest faults in a circular manner In any case fault 0 is the most recent fault To clear faults history from the drive s memory click on Reset Fault history button Each fault has its code and explanation of the fault 6 8 Tools Group 6 8 1 Run Panel Run Panel is active in velocity mode only It replicates an analog potentiometer as if it would be connected to analog reference input Velocity Scale parameter in Parameter Group set the scale of this potentiometer just the same way it sets it for analog input There is a check box Enable Reference sweep which makes reference invert with period set by parameter on run panel Sweep Time This feature of the run panel allows you to create Square
17. phases that correspond to the Vrs Vst Vtr voltages are Hall B then Hall C then Hall A or halls number 2 then 3 then 1 Looking at Table 13 we find that 2 3 1 sequence is Halls Order number 3 We would enter 3 for the Halls Order field in motor dialog TABLE 13 HALL ORDER NUMBERS FOR DIFFERENT HALL S SEQUENSES Halls Order Hall Sequence 0 1 2 3 1 1 3 2 2 2 1 3 3 2 3 1 4 3 1 2 5 3 2 1 AC Tech SIMPLESENO 43 SimpleServo 500 600 i1000 User Manual Rev 3 4 Note e 1 Each Hall Voltage will be in phase with one and only one Output Voltage B leads A for CW This is encoder phase relationship for CW CCW shaft rotation When you obtain the diagram for your motor phasing similar to shown above it s assumed by software that motor shaft rotating CW when looking at the mounting face of the motor For that rotation Encoder phase A must lead phase B If it does leave check box unchecked Otherwise if B leads A check B leads A for CW box e Note 1 Some manufacturers timing diagrams are CW when viewed from the rear of the motor not from shaft AC Tech SIMPLEServo di Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 6 SS500 600 Programmable Features and Parameters All SimpleServo drives are SetUp through serial or Ethernet SSi drives only interface Drives have many programmable and configurable features and parameters These features
18. port to SimpleServo drive If you also wish to rotate a motor you must perform minimum system connections See Section 11 for various system connections examples Below is given minimum connection list WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed Connect serial cable between SimpleServo s TB505 and your PC serial port Connect a Power Cable between an external 120 240 VAC 50 60 Hz power source and L1 TB501 7 L2 TB501 8 and GND TB501 6 terminals Connect motor encoder cable to SmpleServo feedback connector TB504 Section 5 1 3 Connect motor windings U V W sometimes called R S T according to Section 5 1 1 If wiring SS500 600 drives you need to provide Enable switch according to Section 9 4 Perform drive configuration see below Note You must configure the drive before it can operate Proceed to Section 9 2 for SS500 600 or to Section 9 3 for SSi1000 drives 9 2 Configure the SS500 600 SimpleServo drives Regardless of the mode in which you wish to operate you must first configure the SimpleServo for your particular motor mode of operation and additional features if used Drive configuration consists
19. require fine tuning To optimize settings you will need to experiment with combinations of all gains P D and and IL limit settings AC Tech S MPLEServo 66 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 10Sample Motor Responses for Various Gain Settings 10 1 Motor response to gain settings Velocity mode 10 1 1 Low P gain P gain 100 I gain 0 Current didn t reach maximum possible value Channel Signal name Phase current RMS sl Scale jo Amps div Offset poo Amps Channel Signal name Motervelocty Scale 30000 RPM div Offset noo RPM Time base en ms div v Trigger Auto EI Options Level 2 00 EE Always ontop di AC Tech SIMPLESetvo 67 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 1 2 Right P gain P gain 500 I gain 0 Current reaches maximum value rTChannell Signal name Phase current RMS sl Scale jo Amps div Offset poo Amps Channel Signal name Motorvelocity lt Scale 300 00 RPM div Offset noo RPM Time base po ms div v Trigger Auto E Options Level 2 00 Close Always ontop Single 1 AC Tech SIMPLESENO 68 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 1 3 l gain too high P gain 500 gain 300 Notice big velocity overshoot Channel Signal name Commanded velocity v Scal
20. selected operating mode the SimpleServo must be enabled before it can operate Refer to drawings below for various enabling options 1 1 2 2 3 3 4 4 5 18502 e TB502 3 15 PIN 7 15 PIN TERMINAL g TERMINAL 5 BLOCK g BLOCK 9 OPTO ISOLATOR TB502 15 PIN TERMINAL BLOCK 5V TTL CMOS logic gate Active LOW LOGIC COMMON Enabling options via TB502 connector 5 24VDC TTL CMOS output i Enabling options via TB506 connector AC Tech SIMPLEServo T Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 JB505 Enabling options via TB506 connector Using drive s internal power supply 9 5 Enabling SSi1000 drives SimpleServo SSi must be enabled before it can index SSi drive s can be enabled by executing ENABLE statement You can set hardware enable input A2 see table 7 to active state Enable input configured as active System will get enabled only if this input active ON If you execute ENABLE statement but input A2 not active system will be placed in fault state If during the operation input A2 will be deactivated system will be placed in fault state as well FN Untitled Motion View Project Node Tools Yiew Help SimpleServo 551008 unt Parameter name Value Units E Motor Output 0 function Not assigned ei Parameters Output 1 function Not assigned a 10 Output 2 function Not assigned L
21. switches action Inputs AO and A1 serve as Hard Limit switches inputs If lt Not assigned gt option is selected then inputs have no effect on SSi operation as can be used as general purpose inputs Available actions are e Not assigned s Fault Drive disabled immediately and generate fault e Stop and Fault Drive stops first then disabled and generate fault Refer to Programmer Manual for additional information on each action item 7 4 Limits 7 4 1 Position Limits e Position error This parameter sets maximum allowable position error before Position Excess Error fault will be generated This parameter works in conjunction with Max Error Time Position Error is set in primary motor encoder quadrature counts e Position error time This parameter sets time how long position error allowed to be bigger then limit set by Position error parameter until Position Excess Error fault will be generated AC Tech SIMPLEServo 54 SimpleServo 500 600 i1000 User Manual Rev 3 4 7 5 Compensation 7 5 1 Velocity Loop filter e Note 1 These parameters have an effect on velocity regulator behavior when the SSi is in V P mode It has no effect in PIVFF mode e P gain Proportional Proportional gain adjusts the system s overall response to velocity error Velocity error is the difference between the commanded velocity of a motor shaft and the actual shaft velocity By adjusting the proportional gain the bandwidt
22. wave reference with adjustable period Sweep Time and magnitude Reference Slider for easy tuning 6 8 2 Drive monitor Drive monitor shows you motor hall sensors states and actual motor encoder counts This tool is useful when troubleshooting motor encoder s connections 6 8 3 Oscilloscope tool Oscilloscope tool gives real time representation of different signals inside the SimpleServo drive and is helpful when debugging and tuning drives Operation of oscilloscope tool described in MotionView software s User s Manual Below given the list of the signals you can observe with oscilloscope tool Phase Current RMS Motor phase current Phase Current Peak Motor peak current Iq Current Measures the motor Iq torque producing current Motor Velocity Actual motor speed in RPM Commanded Velocity Desired motor speed in RPM velocity mode only Velocity Error Difference in RPM between actual and commanded motor speed Position Error Difference between actual and commanded position Step amp Direction mode only AC Tech SIMPLESetvo 52 SimpleServo 500 600 i1000 User Manual Rev 3 4 7 SSi10XX Programmable Features and Parameters In this chapter we will cover programmable features and parameters specific for SSi drives in order they appear in left tree of the MotionView 7 1 Motor folder This folder contains action button to choose particular motor The rest of the fields contain information about selected moto
23. 0 i1000 User Manual Rev 3 4 3 2 SS604 SS608 SSi1004 SSi1008 Series Dimensions pe DIM A F 80 os Tm Chee ee 7 80 198 DIMENSION A MODEL DIMENSION SS604 ssi1004 2 60 66 SS608 ssi1008 3 54 94 ALL DIMENSIONS IN INCHES MILLIMETERS AC Tech SIMPLESetvo 13 SimpleServo 500 600 i1000 User Manual Rev 3 4 3 3 SS610 SS612 3P SSi1010 SSi1012 3P Dimensions with Heat Sink Fan Kit Installed 4 45 113 PF 6 80 MER y v I ALL DIMENSIONS IN INCHES MILLIMETERS AC Tech SIMPLEServo 14 SimpleServo 500 600 i1000 User Manual Rev 3 4 3 4 Suggested Clearance for Cooling Air Circulation All Models NOTE 0 5 INCH SIDE CLEARANCE IS FOR SS504 AND SS604 SERIES ONLY ALL OTHER SS SERIES DRIVES HAVE NO MINIMUM CLEARANCE 2 00 51 0 50 ns 1 00 25 AC Tech SIMPLESetvo 15 SimpleServo 500 600 i1000 User Manual Rev 3 4 4 Installation WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed The SimpleServo must be mounted vertically for safe operation at the maximum current rating Printed
24. 20 5 12 TB502 Analo Digital OTerminalBlock 21 5 13 Encoder feedback eee 23 5 14 TB504 MotorFeedbackiInput eee 23 5 15 TB505 SeralCommunicationsPort 25 5 1 6 TB506 Controller Interface SS500 600 drives sse 26 5 1 7 TB506 Encoder repeat and analog input connections SSi1000 drives 27 5 1 8 ConnectorsandWiringNotes nennen 28 5 2 Digital UO details 8S500 600 drives nn 29 5 2 1 Step and Direction Master Encoder Inputs esse eee 29 5 2 2 Digital outputs eee 29 5 2 3 Digital inputs een 30 5 3 Digital Odetails SSi1000drives en 32 53 1 Digital inputs RM 32 5 3 2 Digital outputs eee 32 5 4 Analog UO details 35 5 4 1 Analog reference Input eee eee ee 35 5 42 Analogoutfput eee 35 5 5 Communication interfaces SS500 600 drives sse 35 5 6 Communication interfaces SSi1000 drives 35 5 6 1 RS5232 Tn e eee 35 5 6 2 RS485 TT Te eee 36 5 6 3 Ethernet interface Ze a all alada kn ela saa sallamak senle 37 AC Tech SIMPLEServo 3 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 7 5 8 6 6 1 6 2 6 3 6 4 6 6 6 7 7 7 1 7 2 7 4 leie Le 1 roino iE iE EAEE EEE EEA AE 38 5 1 Setting Up MOTOT m al er aye e i alar l aa li
25. 38 Using custom motor reet ERR DER Se den sama il 39 5 8 1 Setting custom motor Darameiers een 39 5 8 2 Autophasing eee 40 5 8 3 Custom Motor Data Entry ssersst sages sZo zet 22 na ayaz 2 ire Tsa onion gah iot RRR ener entere 40 SS500 600 PROGRAMMABLE FEATURES AND PARAMETERS 0 45 MoorGop uDCuIES E E 45 Parameters Group EE 45 6 21 Drive operating modes erede een 45 622 Current B Ee 47 0 2 3 21 2 c Huns Ta ege geet 47 6 24 Analog input scale Current scale sees ee eee eee eee 47 6 2 5 Analoginputscale Velocityscale 48 6 2 6 ACCEL DECEL Limits Velocity mode only sse 48 6 2 Reference Velocity mode only maya serere tr Fere seb zen course 48 6 28 Reset 9 lele aes ero re OH EAE E FOR EVE eases REEL coe li Neo ae heat 48 6 2 9 Steps per Revolution Step and Direction mode only sss 48 6 2 10 Step input type Step and Direction mode only sse 48 exempt M M 49 6 3 1 Programmabledigitalinput enne enne 49 6 3 2 Programmabledigitaloutput entente 49 0 3 3 Analog output anama mes gale HERR REIR alimli EAS 49 6 3 4 Analog output current scale Volt amps sese eee eee eee eee eee eee eee 49 6 3 5 Analogoutputvelocityscale m
26. I Limits Dutput 3 function Not assigned H Compensation Hard lity Enable inp switches action Not assigned Activated Enable input configured to be active G Indexer program CJ Security CC Tools 2g Faults gt For Help press F1 Ln 2000 Col 200 RS 485 RS 232 Online AC Tech SIMPLEServo 63 SimpleServo 500 600 i1000 User Manual Rev 3 4 9 6 Tuningin velocity mode Note In this mode the settings for Position compensation have no effect Note In this mode settings for Position compensation have no effect 1 2 3 10 11 12 13 14 15 16 Make sure that drive is online connected Make sure that the drive is disabled Select lt Parameters gt folder from the node tree Click on lt Reference gt parameter and change it to INTERNAL This will tell drive to use internally generated reference controlled by Run panel tool Select lt Parameters gt folder from node tree Make sure that Enable Accel Decel limits set to DISABLE Select lt Tools gt then lt Run Panel gt from node tree to bring run panel control Select lt Tools gt then lt Scope gt tool from node tree to engage oscilloscope Check checkbox Always on top so MotionView main window doesn t cover oscilloscope tool On the Scope tool select e Phase current RMS as source for Channel 1 Motor Velocity as source for Channel 2 Timebase 50mS Trigger Channel 2
27. Input B3 21 Output 4 E 9 Input B4 22 Output 5 C Ready C 10 Common for B 23 Output 5 E Ready E section 11 Common for C 24 Input C4 section 12 Input C2 ME B 25 Input C3 Registration 13 Input C1 MEA AC Tech SIMPLEServo 33 SimpleServo 500 600 i1000 User Manual Rev 3 4 Inputs A1 A4 COM 1 16 v SL At co 211 15 3 14 4 4 i 1 Az C I L 3 5 12 M YA XC A3 CI 7 10 YA SL OUT1 A4 CI 8 9 OUT1 Inputs B1 B4 COM OUT2 SSi drive s OUT2 circuitry OUT3 1 16 OUT3 K B1 co 2 Y 4 st 15 OUT4 3 14 OUT4 M 4 A st 13 B2 CI 5 12 READY YAS B3 co 6 11 READY 7 10 YAS B4 S Inputs C1 C4 COM e c3 c3 c3 C4 SSi drives I O arrangements AC Tech SIMPLESENO 34 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 4 Analog UO details 5 4 1 Analog reference input IN IN TB506 23 24 or TB502 2 3 Analog differential input This input will accept 10V single ended voltage on IN or IN input or 5V differential voltage between IN and IN Both connections must be referenced to Analog Common TB506 25 or TB502 5 of the drive This input is used to control speed or torque of the motor in velocity or torque mode SS500 600 only The total reference voltage as seen by the drive is the voltage difference between IN and IN If used in sin
28. ME specifies maximum allowable time in mS during which position error can exceed value set for POSITION ERROR parameter before Position Error Excess fault generated AC Tech SIMPLESENO 50 SimpleServo 500 600 i1000 User Manual Rev 3 4 6 6 Compensation group This group includes two subgroups Velocity Loop Filter and Position Loop Filter 6 6 1 Velocity Loop Filter Note e 1 Velocity loop filter settings are only active if the drive operates in Velocity mode or in Step amp Direction Position P V mode It has no effect in Step amp Direction Position PIVFF or Current mode H P gain Proportional Proportional gain adjusts the system s overall response to velocity error Velocity error is the difference between the commanded velocity of a motor shaft and the actual shaft velocity By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal e gain Integral The output of the I term portion of the integral gain compensator is proportional to accumulative error over cycle time with I term controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is ona system running at low speed or in a steady state without rapid or frequent changes in velocity 6 6 2 Position Loop Filter
29. MWRPM 50 6 3 6 Analog input offset parameter eee eee e 50 6 3 7 Analog input dead band e 50 6 3 8 Adjust analog voltage offset AA 50 Velocity Limits Group 50 Position limits een 50 Compensationgroup eee 51 6 6 1 Velocitylooprilter eee 51 6 6 2 Positionloopfilter eee 51 SUE e EE KR TOOS Go TN 52 0 8 1 Run Parnell iy rie E ERROR E EGER ER EISE ERE R EN DIEA 52 6 8 2 Drive monitor esse eee eee eee 52 6 8 3 Oscilloscopetool eee 52 SSI10XX PROGRAMMABLE FEATURES AND PARAMETERS eese 53 Motor folder da s tee tds dee ttem tee alya ba eds 53 Paramete Sio screen micum ee 53 TaI Mul 53 122 Qurrent LIME dende 53 1 23 Peak Current BI nere eee EE OE He EI HERR E EE anl 53 124 AUtODOOU is eee nee eR He ERE ERE EE ERE ERE ba la 53 1 25 Feedback loss d etectlon cec eee eee nere ne e rie an aaa 53 7 26 IRS485 configuration eee nme menn mad mel a ami lela 53 EC dE E re ie HIE EE 54 7 28 lPpropertes commandbutton eee 54 jo 54 7 3 1 Outputs 1 2 3 4 functions eee 54 7 3 2 Hard limit switches action see eee ee 54 in ME E ME SEMER YAY Yi e ME e A a EE EM YY EY e eee 54 741 Positionlimils
30. RAMETERS ACTIVE FOR SELECTED DRIVE OPERATION MODE Analog X input current scale Analog X input velocity scale Enable X accel dece limits Acelimt px Decellimit X Steps per X revolution Step input X type Reference X Fault reset 6 2 2 Current Limit The CURRENT LIMIT setting determines the nominal current in amps RMS per phase 6 2 3 Peak current limit Peak current sets Motor phase current in Amps RMS allowed for 2 Sec After 2 Sec expires current limit will be folded back to value set in Current Limit parameter When current demand drops below nominal current for 2 Sec drive will automatically enable peak current level again This technique allows you to get high peak torque for demanding fast moves and fast start stop operations with high regulation bandwidth 6 2 4 Analog input scale Current scale This parameter sets analog input sensitivity for current reference used when drive operates in Torque mode Units for this parameter are A Volt To calculate value use following formula Iscale Imax Vin max Imax maximum desired output current in A motor phase current RMS Vin max max voltage fed to analog input at Imax Example Imax 5A phase RMS Vin max 10V Iscale Imax Vin max SA 10V 0 5 A Volt gt value to enter AC Tech SIMPLESENO 47 SimpleServo 500 600 i1000 User Manual Rev 3 4 6 2 5 Analog input scale Velocity scale This parameter sets analog in
31. Resistor AOPE 08 Od A072 001 OW 1 a DN OND dwna gt dWNNA wn S A gt JISVN3 DM OND LOSEL Euiuue uid 6 XL c c SH XY cec su QNO y Japoous 18M0d Japoou3 y Japoouy V TIVH 8Jepoou3 gJepoou3 N 9 TIvH Z i9poou3 9 TIVH Z Jepoou3 8 TIVH jndino xny jndino Apeay ZJSATIp BUTT ve J3I8VN3 yndu xny 1ndno Bojeuy 7HIQ 8IN OND y Jepoou3 HIQ SWN y Jepoou3 Ono Apesy g J9poou3 370 Apeey g Jepoou3 318VNI z Japoouy HIG 8WN d3lS VA 31SVN3 Z J9poou3 gano xnv OND d3lS vlN ONS AOL d3H 43H AOL Tue uid GL gov BWOZ AG J8M0d jepoou3 OND ODIN 338 d3LS YW RES dalS vlN QNOV HIG 8WN YAALNANOD od member of the Lenze Grou Drive for Global Excellen 78 SIMPLEServo SimpleServo 500 600 i1000 User Manual Rev 3 4 11 4 Indexer connections options for position follower TB505 TB505 18 o 3 4 25 Bags
32. Rising Trigger level 0 Rpm Enable the drive Set the Reference slider in the Run panel to a motor test speed of either 250 RPM or 500 RPM If your motor s maximum speed is less than 5000 RPM set the slider to approximately 250 RPM f your motor s maximum speed is greater than 5000 RPM set the slider to approximately 500 RPM The default reference setting is zero After setting the slider to the appropriate test speed the motor should begin to run Make sure that Enable Reference Sweep check box is checked The sweep range is 10 1000 milliseconds msec The default setting is 1000 msec maximum Set reference sweep to 200 mS By enabling reference sweep you can generate a bi polar square wave DC signal which allows you to monitor your motor s behavior when changing direction Reference sweep is used in adjusting proportional gain and integral gain Select lt Compensation gt then lt Velocity Loop filter gt from node tree set P gain to 100 and gain to 20 Slowly increase P gain until current waveform grows to maximum value when velocity changes from negative to positive or visa versa See sample waveforms in Section 10 1 Slowly increase I gain and watch for overshoot on Motor Velocity waveform Leave it at a level where overshoot just starts to happening or is very narrow less then 5mS or less then 3 590 If fast acceleration deceleration in your servo system is not an objective but stiffness at low velocity or stall torque i
33. SIMPLESetVO USER S MANUAL MODELS SS504A SS508A SS604A SS608A SS604A 3P SS608A 3P SS610A SS612A 3P SSi1004A SSi1008A SSi1010A SSi1012A 3P SimpleServo 500 600 i1000 User Manual Rev 3 4 Copyright 2001 by AC Technology Corporation All rights reserved No part of this manual may be reproduced or transmitted in any form without written permission from AC Technology Corporation The information and technical data in this manual are subject to change without notice AC Technology Corporation and its Divisions make no warranty of any kind with respect to this material including but not limited to the implied warranties of its merchantability and fitness for a given purpose AC Technology Corporation and its Divisions assume no responsibility for any errors that may appear in this manual and make no commitment to update or to keep current the information in this manual MotionView SimpleServo and all related indicia are either registered trademarks or trademarks of AC Technology Corporation in the United States and other countries This document printed in the United States of America AC Tech SIMPLEServo 2 SimpleServo 500 600 i1000 User Manual Rev 3 4 TABLE OF CONTENTS 1 GENERAL INFORMATION rnaro DR Nu E RD ER Ra granada da sn 7 2 xldzeljswpelm 8 2 1 Electrical Characteristics cett ntt tite bete tete bene iie ied ete eie todo ten 8 23 EMVIFONMEN REM 8 2 3 Di
34. a not inertia in kilogram meters squared kg m The rotor moment of inertia for many motors will be given in English units such as pound inches sguared Ib in or ounce inches squared oz in These must be converted to metric as follows To convert Ib in to kg m multiply by 2 93x10 To convert oz in to kg m multiply by 1 83x10 To convert Ib in sec to kg m multiply by 0 113 To convert oz in sec to kg m multiply by 7 06x10 e Note 1 Round the calculated result to 3 significant places Maximum Motor Speed in RPM This is also listed as Speed V motor speed at the terminal voltage rating The maximum motor speed will typically be a round even value between 1000 and 6000 RPM Feedback tab e Number of Poles This is a positive integer number represents number of motor s poles which is normally 2 4 6 or 8 Encoder Line Count The Encoders for servomotors normally have Line Counts of 1000 1024 2000 or 2048 The Encoder Line Count must be a positive integer Z Position Enter 0 zero Zero marker pulse position This field is reserved for backward compatibility All SimpleServo drives determine actual marker pulse position automatically e Halls Order Each hall signal is in phase with one of the three phase phase voltages from motor winding Hall order number defines which hall sensor match to what phase phase voltage Motor phases are usually called R S T or U V W or A B C Phase Phase voltages a
35. age is present at the ENC pin the SimpleServo will switch its internal power 5 VDC supply to the encoder WARNING A Use only 5 VDC encoders Do not connect any other type of encoder to the SimpleServo reference voltage terminals When using a front end controller it is critical that the 5 VDC supply on the front end controller NOT be connected to the 5 VDC supply on the SimpleServo as this will result in damage to the SimpleServo Note i SimpleServo inputs are compatible with single ended or open collector type of hall sensors If you have these type of hall sensors just connect them to HA HB HC and leave HA HB HC inputs unconnected You don t need to supply pull up resistors in case the hall sensors are open collector Necessary pull up circuits are already provided inside SimpleServo amplifier Encoder connections must be full differential SimpleServo doesn t support single ended or open collector type outputs for encoder An encoder resolution of 2000 PPR or higher is recommended for optimum performance 5 1 4 TB504 Motor Feedback Input TB504 is a 15 pin DB connector that contains connections for Hall effect sensors and encoder feedback Refer to Table 5 for connector pin assignments Encoder inputs on TB504 have 26L S32 or compatible differential receivers for increased noise immunity Inputs have all necessary filtering and line balancing components so no external noise suppre
36. ale o0 Counts div Offset o Counts Time base 20 ms div v Trigger Auto z Options Level 0 00 EIE Iv Always ontop Single N AC Tech SIMPLEServo 71 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 2 20 PVFF mode P gain D gain relationship Optimal setting P gain 200 D gain 600 Vif 1 Note 1 Fixed problem in Section 10 2 Position error is small and only 20 mS long Position regulation bandwidth of the system is 1 20mS 50HZ x Channel Signal name Motor velocity v Scale 100000 RPM div Offset bn RPM Channel 2 Signal name Position Error v Scale o0 Counts div Offset poo Counts Time base 20 ms div v Trigger Auto E Options Level 0 00 e V Always on top Single 1 AC Tech SIMPLESetvo 72 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 2 3 VFF gain effect Vff gain 0 e Note 1 Notice position error at steady velocity Channel Signal name Motor velocity D Scale 100000 RPM div Offset bn RPM r channel e E Signal name Position Error v Scale o0 Counts div Offset poo Counts Time base 20 ms div v m Trigger Auto S Options Level 0 00 GENE IV Always on top AC Tech SIMPLEServo 73 SimpleServo 500 600 i1000 User Manual Rev 3 4 Vff gain 1 Note 1 Notice position error is very small at stea
37. ale range Analog output can be assigned to various drive s signals 15 pin removable terminal block or 25 pin D shell Standard 25 pin D shell 5 24V rated 12 digital optically isolated inputs separated into 4 groups Each group has common terminal for the group 2 of 12 inputs are suitable for connection of master encoder with up to 2 MHz signals rate 4 1 dedicated optically isolated digital outputs 20mA capability suitable for 24V system control voltages Both collector and emitter available for each output at the terminal Dedicated output assigned for READY function 1 differential analog input Full range 10V single ended and 5V differential Analog Input can be read via System Variable AIN 1 single ended analog output 10 V full scale range Analog output can be set by User Program System Variable AOUT or via Host Interface 25 pin D shell for digital I O and 15 pin removable terminal block for analog input output connections 4 pin removable terminal block RJ 45 modular jack if equipped Windows Software MotionViewTM Windows 95 98 NT 2000 SIMPLEServo AC Tech T Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 3 Dimensions 3 1 SS500 Series Dimensions 7 50 191 DIMENSION A MODEL DIMENSION SS504 2 60 66 NO HEATSINK NECESSARY SS508 3 80 97 ALL DIMENSIONS IN INCHES MILLIMETERS AC Tech SIMPLESetvo 12 SimpleServo 500 60
38. and inverted fields as they are You can execute autophasing see below to set them correctly Enter motor model text in Motor Model edit box Do not enter Motor ID For custom motors it is 0 and will be assigned automatically when you save motor data to file Click Save to File button and enter filename without extension Default extension cmt will be given when you click OK on file dialog box Note Saving the file is necessary even if you are going to use the autophasing feature and still don t know all of the final parameters After autophasing is completed you will have a chance to save the corrected motor file again before loading it to memory ap Click OK to dismiss Motor Parameters dialog MotionView will ask if you want autophase your custom motor If you answer No motor data will be loaded immediately to the drive s memory If you answer Yes motor dialog will be dismissed and drive will start autophasing seguence Refer to topic below for autophasing information If you answered Yes when prompted for autophasing after autophasing is completed you will be returned to the same motor selection dialog box At this time fields B leads A for CW Halls order and inverted fields will be assigned correct values Click Save File to save custom motor file and then OK to dismiss dialog and load data to drive memory AC Tech S MPLEServo 39 Drive for Global Excellence
39. anual Rev 3 4 DIP SWITCH DS501 has its first 5 switches for address assignment and switch 6 for baud rate selection Two speeds are possible 38 400 and 115 200 baud As mentioned previously up to 32 drives can be connected to a single network Each drive on the network has to have its own unigue address set via DIP SWITCH Pulling switch UP sets it ON and pulling switch DOWN sets it OFF The drive address will be a sum of all ON switch values For example if switches 1 2 and 5 are ON and the rest of the switches are OFF the resulting address will be 1 1 2 2 16 5 19 TABLE 12 DIP SWITCH DS501 Dip switch Value 1 1 2 2 3 4 4 8 5 16 6 OFF 115200 ON 38400 baud To assign an address of 10 the sum of the switch values must be equivalent to 10 In this case switches 2 and 4 would need to be set to ON 2 8 10 Diagnostic LED green There are two LEDs near RS485 connector Green LED lights up when data is sent to or from drive over the RS485 interface Refer to Section 9 1 2 for more information on the LEDs 5 6 3 Ethernet interface SSi drives support standard 10 100 Ethernet connection via modular RJ 45 jack and CAT 5 standard twisted pair network cable used in computer equipment The RJ 45 socket has two integrated LEDs showing network status Green LED lights up when physical connection is present and yellow LED lights up when SSi sends or receives data over the Ethernet SSi dri
40. de Step and Direction inputs are not wired correctly In MotionView program check lt Parameters gt lt Step input type gt is set for lt S D gt if you use a step and direction indexer output and lt Master Encoder gt if you use quadrature type output from a master motor encoder or indexer Position loop P gain set to 0 Set P gain to 100 and D gain to 200 If in PIVFF mode or if in P V mode P gain to 10 and D gain for 5 and Velocity P gain 50 and I gain 20 initially to get motion Tune them afterwards for best performance In velocity mode the motor runs away Hall sensors or encoder mis wired SimpleServo not programmed for motor connected Check Hall sensor and encoder connections Check that the proper motor is selected For more troubleshooting tips check our website www SimpleServo com SIMPLEServo AC Tech Se Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 13 Warranty and Other Info A Warranty AC Technology Corporation warrants the SimpleServo control to be free of defects in material and workmanship for a period of twelve months from the date of sale to the user or eighteen months from the date of shipment which ever occurs first If the amplifier under normal use becomes defective within the stated warranty time period contact AC Technology s Service Department for instructions on obtaining a warranty replacement unit AC Technology Corporation reserves the right to make the
41. dy velocity Channel Signal name Motor velocity D Scale 00000 RPM div Offset noo RPM m Channel Signal name Position Error v Scale o0 Counts div Offset o Counts Time base 20 ms div v Trigger Auto zl Options Level 0 00 EE Iv Always on top Single AC Tech SIMPLESENO 74 Rev 3 4 SimpleServo 500 600 i1000 User Manual 11 System Connection Examples 11 1 System with external motion controller 3epooue pue szosues Ten 40 Ohm 100W ASA Dump Resistor A0v E 08 OG A072 00T1 OW 1 a LT T XL ZEZ SU XH ZEZ SU ONS anna dWna wn S A AN JEpoouUJ DM Lose Jemod 1epoou3 euiuue uid e v Jepooug Y TIVH g Jepoou3 Y TVH g JEpo2uJ 9 TVH ONS jndino xny nd no pe y y Jepoou3 HIG 8IN 31SVN3 y Jepoou3 DANO Apesy nduj xny 91900702 3900 Apesy 1ndjno Gojeuy g Jepoou3 3 18VN3 glaraN Z 18p09UJ J18VN3 HIQ 8N Z J9poou3 DANO xnv d3 LS YW OND 3900 xny d3LSAVN PUS EWOZ AS GONDV Jemod jepoou3 AOL d3H 338 da3lS v ONE AOL SCH SISCH 1euluaj uid GL YYILNANOD Od WG IOHLNOO NOILON 2 75 SIMPLEServo Rev 3 4 SimpleServo 500 600 i1000 U
42. e 50000 RPM div Offset Kan 27 RPM m Channel Signal name Motorvelocity Scale 30000 RPM div Offset noo RPM Time base 50 ms div v Trigger Auto EI Options Level 2 00 EE Iv Always on top Single l AC Tech SIMPLEServo 69 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 1 4 Correct P gain and I gain P gain 500 I gain 100 Notice very low velocity overshoot and very close match of the waveforms Channel Signal name Commanded velocity v Scale 50000 RPM div Offset Kan 27 RPM m Channel Signal name Motorvelocity sl Scale 30000 RPM div Offset noo RPM Time base 50 ms div v Trigger Auto EI Options Level 2 00 EE Iv Always on top Single N AC Tech SIMPLESetvo 70 SimpleServo 500 600 i1000 User Manual Rev 3 4 10 2 Motor response to gain settings Position Mode 10 2 1 PVFF mode P gain D gain relationship Non optimal setting P gain 200 D gain 300 Vff 1 Problem Noticeable oscillation Channel 2 Insufficient D gain excess of P gain for this D gain setting Treatment Decrease P gain increase D gain Side effects Decreasing P gain increases position error Increasing D gain lowers bandwidth and increases hi frequency noise x Channel Signal name Motor velocity D Scale 100000 RPM div Offset noo RPM r Channel2 Signal name Position Error v Sc
43. e 0 9 1 1 Set I gain to 2 Hz and IL to 15 This is initial setting Click on lt Store gains in EEPROM gt to save gains values in drives non volatile memory Note Remember that these are only initial settings for your system Your application will likely require fine tuning To optimize settings you will need to experiment with combinations of all gains P D and and IL limit settings AC Tech S MPLEServo 65 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 9 8 Tuning in position P V mode Note In this mode both settings for Position and Velocity compensation have full effect ONOORWN gt 10 11 Run indexer and observe Motor Velocity 13 14 15 16 17 Make sure that drive is online connected Make sure that the drive is disabled Set up your indexer run program for SSi drives to perform following move Move forward N steps where N number of steps to perform full motor shaft revolution Move backward N steps where N number of steps to perform full motor shaft revolution Set acceleration deceleration to maximum your system allows Select lt Tools gt then lt Scope gt tool from node tree to engage oscilloscope On the Scope tool select e Motor Velocity as source for Channel 1 Motor Velocity error as source for Channel 2 Timebase 50mS Trigger Channel 1 Rising Trigger level 0 Rom Select lt Compensation gt then lt Velocity Loop filter g
44. e 66 10 SAMPLE MOTOR RESPONSES FOR VARIOUS GAIN SETT NGS ennenen 67 10 1 Motor response to gain settings Velocity model sese eee eee e 67 10 1 1 LOW P galn men la dal n al m alm GE 67 10 1 2 Right e LT D 68 10 1 3 I galm too 80 1 mere em mai il ila ekle a an yan Selen 69 10 1 4 Correct P gain andlLoaim en 70 10 2 Motor response to gain settings Position Mode 71 10 2 1 PVFF mode P gain D gain relationship Non optimalsettind 71 10 2 2 PVFF mode P gain D gain relationship Optimal setting sees eee ee 72 10 25 VFF gain efoti EE 73 11 SYSTEM CONNECTION EXAMPLES eser ennenen nenen nenen anan n 75 11 1 System with external motion controller sess ener 75 11 2 SimplelorgucandVelocitySystem nennen nn 76 11 3 Position ele 78 11 4 Indexer connections options for position Tollower sese eee eee ee eee ee 79 12 TROUBLESHOOGTING nese 80 13 WARRANTY AND OTHER INFO rnnnoverrrnnnverrrnnnnersrnnnnnrsrsnnnnrrrsnnnnrevnnnnnnnnnnnnnnnnnnnnnnnnnnnnnennnnnnnennnnnnnnr 82 AC Tech SIMPLEServo 5 SimpleServo 500 600 i1000 User Manual Rev 3 4 Safety Warnings manual carefully before performing any of the procedures contained herein Failure to follow The symbol shown at left indicates an important safety consideration Please read this A these
45. e a complex servo system with multiple drives connected to an external controller This makes troubleshooting easier since the fault will not be reset until the drive is re enabled Thus a technician can more easily determine which component of a complex servo system has caused the fault 6 2 9 Steps per Revolution Step and Direction mode only Steps per revolution defines how many pulses must be supplied to the step and direction input to make one full revolution of the motor shaft This number can be negative effectively reversing motor rotation Used also to set gear ratio if drive following a master motor 6 2 10 Step input type Step and Direction mode only Two types of inputs are possible Step and Direction select S D or master encoder If master encoder is selected drive expects full quadrature A amp B signals Refer to hardware manual for specifications on Master encoder pulse train input AC Tech SIMPLESetvo 48 SimpleServo 500 600 i1000 User Manual Rev 3 4 6 3 I O Group 6 3 1 Programmable digital input N A Input not assigned and has no effect on drive operation External Fault Input serves as external fault input Servo will stop and indicate fault if this input is activated Stop In velocity or current mode sets input reference to 0 regardless of voltage on analog input Reverse Sign of input reference voltage is reversed 6 3 2 6 3 3 Programmable digital output Not assigned No functi
46. e output of the D term portion of the filter proportional to difference between current position error and position error measured in previous servo cycle D term decreases bandwidth and increases overall system stability It responsible for removing oscillation caused by load inertia and acts similar to shock absorber in the car e Vff Velocity Feed Forward The output of the Vff term portion of the filter proportional to demanded motor speed when drive shaft travels from position to position Vff term is an open loop term It responsible for removing velocity error while positioning thus increasing system response and precision s IL integral gain limit in of torque The output of the I term portion of the integral gain compensator could be limited to some level set by IL limiter In other words influence of I term on motor shaft torque could be controlled by IL limiter This helps to decrease overshoot caused by gain especially when position error is integrated over a long time period AC Tech SIMPLESetvo 55 SimpleServo 500 600 i1000 User Manual Rev 3 4 7 6 Indexer Program This will select MotionView Studio section of the MotionView software Right panel is used to enter edit and debug User Programs Menu and toolbar will display additional features needed for program preparation compiling debugging and loading to the SSi s memory Motion View Studio tools and operations are described in details in Programmer s Manual
47. ection mode only Commanded position Target theoretical position SSi drives only Actual position Actual shaft position SSi drives only Note 1 If the drive filter is configured for PIVFF mode Commanded Velocity is not available since commanded velocity is not calculated directly in this mode If this signal is selected it will show O RPM and Velocity Error will show Motor Velocity if selected as source AC Tech SIMPLESENO 56 SimpleServo 500 600 i1000 User Manual Rev 3 4 8 Diagnostics 8 1 Diagnostic LED s The SimpleServo has five diagnostic LEDs mounted on the front panel and two LEDs located on the bottom side near RS485 connector These LEDs are designed to help you monitor system status and activity as well as troubleshoot any faults 8 1 1 Front panel LEDs READY Green Green LED lights when drive is enabled and there is no fault If drive is disabled by the ENABLE input or because any fault occurs this light will turn off Fault Red Red LED lights when drive detects fault The LED will flash once or multiple times according to Table 15 below than pause for about 1 5 Sec then start over again until fault is reset Note e 1 SSi drives have more then 9 faults If the fault LED turns on permanently then the fault code is higher then 9 In this case you need to use MotionView to retrieve the fault code Refer to Programmer s manual for details on fault codes for SSi drives OVER CURRENT O C Red LED l
48. end controller it is critical that the 5 VDC supply on the front end controller NOT be connected to the 5 VDC supply on the SimpleServo as this will result in damage to the SimpleServo The encoder needs to have power supplied to it A front end controller as well as the SimpleServo has a 5 VDC supply voltage that may be used to power the encoder The SimpleServo contains patent pending automated switching circuitry which will power the encoder from a front end controller if it is present through the ENC pin If no supply voltage is present at the ENC pin the SimpleServo will switch its internal power 5 VDC supply to the encoder AC Tech SIMPLESetvo 28 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 2 Digital I O details SS500 600 drives 5 2 1 Step and Direction Master Encoder Inputs TB506 11 12 13 14 and TB502 6 7 8 9 You can connect a master encoder with quadrature outputs or a step and direction pair of signals to control position in step direction operating mode These inputs are optically isolated from the rest of the drive circuits and from each other Both inputs can operate from any voltage source in the range of 5 to 24 VDC and do not require additional series resistors for normal operation See figure below MA STEP MB DIR Master encoder step and direction input circuit You can connect a single ended or differential signal to the inputs You can also connect sinking or sourcing outputs to these
49. et speed set speed is calculated using formula Set Velocity RPM Vinput Volt X Vscale RPM Volt where Vinput voltage at analog input Vscale velocity scale factor input sensitivity set by Analog input Velocity scale parameter e Torque mode In torque mode the SimpleServo control provides a current output proportional to the analog input signal up to the maximum current output rating of the drive Set Current current the drive will try to provide is calculated using formula Set Current A Vinput Volt X Iscale A Volt where Vinput voltage at analog input Vscale current scale factor input sensitivity set by Analog input Current Scale parameter AC Tech SIMPLESetvo 45 SimpleServo 500 600 i1000 User Manual Rev 3 4 e Step and Direction mode In this mode drive reference is step and direction digital inputs Drive position and distance moved can be calculated using formula DISTANCE MOVED Revolutions NUMBER OF PULSES SUPPLIED TO INPUT Steps per revolution Scaling is set in Steps per revolution parameter and input type is set by Step input type parameter See below in this topic e Gearing Gearing is accomplished by connecting Master encoder to Step and Direction Inputs If master encoder has outputs in quadrature parameter Step input Type should be set to Master Encoder If Master encoder has single output unidirectional encoder then Step input Type should be set to S
50. f T torque is expressed in units of pound inches Ib in then Kt must be expressed in pund inches per Amp Ib in A Likewise if T is expressed in units of Newton meters N m then units for Kt must be expressed in Newton meters per Amp N m A Example Suppose that the maximum continuous phase to phase winding current Imax is not given Instead we look up and obtain the following Continuous stall torque T 3 0 Ib in Motor torque constant Kt 0 69 Ib in A Dividing we obtain Imax 3 0 Ib in 0 69 Ib in A 4 35 A Our entry for Imax would be 4 35 Note that the pound inch Ib in units cancelled in the equation above leaving only Amps A We would have to use another conversion factor if the numerator and denominator had different force x distance units e Nominal Bus Voltage Veys If the motor nominal terminal voltage is 200 240VAC phase to phase enter 325 V If the motor nominal voltage is below 200VAC enter 165 V This value is initial seed voltage for drive and correct voltage will be calculated dynamically depending on the drive s incoming voltage value AC Tech SIMPLEServo 41 SECH SimpleServo 500 600 i1000 User Manual Rev 3 4 Note 1 The motors that are entered in this database should have Nominal Bus Voltage between 90 V and 340V Do not enter motors with terminal voltages below 90 V Mechanical constants tab e Rotor Moment of Inertia Jm Must be set for moment of inerti
51. f your system zero voltage drifts making drive shaft drift when commanded to Zero 6 3 8 Adjust analog voltage offset This control button is useful to allow the drive to automatically adjust offset To use it set system output to zero and click this button Any offset voltage at analog input will be adjusted and stored in drive s memory 6 4 Velocity Limits Group These parameters are active in Velocity Mode Only e Zero speed velocity mode only e Speed window velocity mode only e Atspeed velocity mode only ZERO SPEED specifies the lower threshold for motor zero speed in RPM When motor shaft speed is below specified value zero speed condition is set to true in internal controller logic Zero speed condition can also trigger programmable digital output if selected SPEED WINDOW speed window width AT SPEED speed window center These two parameters specify speed limits If motor shaft speed is within these limits then condition AT SPEED set to true in internal controller logic AT SPEED condition can also trigger programmable digital output if selected For example if AT SPEED is set for 1000 Rpm and the SPEED WINDOW is set for 100 then AT SPEED will be true when motor velocity is between 950 1050 Rpm 6 5 Position limits e Position error e Max error time POSITION ERROR specifies maximum allowable error in motor quadrature encoder counts before Position Error Excess fault generated MAX ERROR TI
52. final determination as to the validity of a warranty claim and sole obligation is to repair or replace only components that have been rendered defective due to faulty material or workmanship No warranty claim will be accepted for components which have been damaged due to mishandling improper installation unauthorized repair and or alteration of the product operation in excess of design specifications or other misuse or improper maintenance AC Technology Corporation makes no warranty that its products are compatible with any third party equipment or to any specific application to which they may be applied and shall not be held liable for any other consequential damage or injury arising from the use of its products This warranty is in lieu of all other warranties expressed or implied No other person firm or corporation is authorized to assume for AC Technology Corporation any other liability in connection with the demonstration or sale of its products B Product Changes AC Technology Corporation reserves the right to discontinue or make modifications to the design of its products without prior notice and holds no obligation to make modifications to products sold previously AC Technology Corporation also holds no liability for losses of any kind which may result from this action Instruction manuals with the most up to date information are available for download from the SimpleServo website www simpleservo com C Receiving Inspect
53. for a special function it functions as a normal input Input C3 Registartion sensor input This input can be used for registration sensor connection Upon activation of the input current actual position is recorded and is available for User Program This input also used in all registration move commands Refer to Programmer s Manual for details 5 3 2 Digital outputs SSi drives have 5 digital outputs numbered 1 to 5 Outputs 1 4 can be configured as general purpose outputs or can be configured for special functions selection made via MotionView program in I O folder Section 7 3 1 of this manual Output 5 is dedicated as READY which is ON when SSi is enabled and OFF when SSi is disabled or at fault Output 5 is not accessible via User Program or Host Interface All outputs are optically isolated from SSi circuitry and each other and are open collector type They have 30mA load capability Both Collector and Emitter of each output are available for customer connection AC Tech SIMPLESetvo 32 SimpleServo 500 600 i1000 User Manual TABLE 10 TB507 PIN ASSIGNMENTS Rev 3 4 Pin Function Aux function Pin Function Aux function number number 1 Input A1 Left limit 14 Output 1 C 2 Input A2 Right limit 15 Output 1 E 3 Input A3 Enable 16 Output 2 C 4 Input A4 17 Output 2 E 5 Common for A 18 Output 3 C section 6 Input B1 19 Output 3 E 7 Input B2 20 Output 4 C 8
54. gle ended mode one of the inputs must be connected to voltage source while the other one must be connected to Analog Common If used in differential mode the voltage source is connected across IN and IN inputs and driving circuit common if any needs to be connected to drive Analog Common terminal Reference as seen by drive Vref VIN VIN Note 1 In SSi1000 drives Vref is available by reading System Variable AIN 5 4 2 Analog output Analog out TB502 10 Analog output is single ended 10 10V span signal which can represent different quantities of the drive 88500 600 only For SS500 600 drives MotionView SetUp program can be used to select signal source for the analog output as well as its scaling SSi1000 indexing drives can set analog output directly from User program Sysytem Variable AOUT or via Host Interface command Load capability of that output is 10mA 5 5 Communication interfaces SS500 600 drives Drives are equipped with RS232 communication interface Communication speed is fixed at 38 400 baud 5 6 Communication interfaces SSi1000 drives In addition to standard RS232 interface SSi indexing drives have RS485 and Ethernet communication interfaces Communication speed for RS232 485 can be 115200 or 38400 baud and DIP SWITCH DS501 6 selectable 5 6 1 RS232 interface This interface is available on SSi drives for communication with Host computer The SSi RS232 is addressable wi
55. h of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal e l gain Integral The output of the I term portion of the integral gain compensator is proportional to accumulative error over cycle time with I term controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in velocity 7 5 2 Position Loop filter e P gain Proportional Proportional gain adjusts the system s overall response to position error Position error is the difference between the commanded position of the motor shaft and the actual shaft position By adjusting the proportional gain the bandwidth of the drive is more closely matched to the bandwidth of the control signal ensuring more precise response of the servo loop to the input signal e D gain Differential The output of the I term portion of the integral gain compensator is proportional to accumulative error over cycle time with I term controlling how fast the error accumulates Integral gain also increases overall loop gain at the lower frequencies minimizing total error Thus its greatest effect is on a system running at low speed or in a steady state without rapid or frequent changes in position e l gain Integral Th
56. hen done This will dismiss dialog and return back to MotionView e Select motor Vendor from the right list box and desired motor from the left list box s If you want to use custom motor instead of available motors from supplied database then go to Selecting custom motor topic below e Finally click OK button to dismiss dialog and return to Motion View main program 5 8 Using custom motor 5 8 1 You can load custom motor from file or you can create new custom motor To create custom motor click Create custom and follow instruction in topic Setting custom motor parameters below To load custom motor click lt Open custom gt button then select motor file and click OK to dismiss file dialog Click OK to return to Motion View program or Cancel to abandon changes Setting custom motor parameters WARNING A Use extreme caution when entering custom parameters Incorrect settings may cause damage to the drive or motor If you are unsure of the settings refer to the materials that were distributed with your motor or contact the motor manufacturer for assistance Enter custom motor data in the motor parameters dialog fields Complete all sections of dialog Electrical Mechanical Feedback See Section 6 8 3 for explanation of motor parameters and how to enter them Note If you don t know or are unsure of the motor halls order and encoder channels A and B relationship leave B leads A for CW Halls order
57. here 6 MA Step Step or master encoder channel A input 7 MA Step Step or master encoder channel A input 8 MB Dir DIR or master encoder channel B input 9 MB Dir DIR or master encoder channel B input 10 Analog Output Programmable analog output 11 AUX INPUT Programmable digital input 12 EN Enable Input 13 OUT_RDY Ready output O C 14 OUT_AUX Programmable Output O C 15 GND Logic common SIMPLEServo 21 AC Tech member of the Lenze Group Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 TABLE 6 TB502 PIN ASSIGNMENTS SSi10XX only Vcc Vcc bmA REF Negative reference input differential REF Positive reference input differential TVCC Vcc 5mA AGND Analog ground attach shield from signal source here SPARE SPARE SPARE 2 3 4 5 6 7 8 9 SPARE O Analog output Programmable analog output SPARE N SPARE Co SPARE P SPARE oa GND Logic common AC Tech SIMPLESetvo 22 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 1 3 Encoder feedback An encoder needs to have power supplied to it Both front end controllers and the SimpleServo each have a 5 VDC supply voltage that may be used to power the encoder The SimpleServo contains patent pending automated switching circuitry which will power the encoder from a front end controller if it is present through the ENC pin If no supply volt
58. hole of the enclosure AC Technology Corporation recommends the use of the special SimpleServo cables provided by AC Technology Corporation If you specify cables other than those provided by AC Technology Corporation please make sure all cables are shielded and properly grounded It may be necessary to earth ground the shielded cable Figure 6 Ground the shield at the SimpleServo end and at the motor end If the SimpleServo continues to pick up noise after grounding the shield it may be necessary to add an AC line filtering devices and or an output filter between drive and servo motor 4 4 2 EMI Protection Electromagnetic interference EMI is an important concern for users of digital servo control systems EMI will cause control systems to behave in unexpected and sometimes dangerous ways Therefore reducing EMI is of primary concern not only for servo control manufacturers such as AC Technology Corporation but the user as well Proper shielding grounding and installation practices are critical to EMI reduction 4 4 3 Enclosure The panel in which the SimpleServo is mounted must be made of metal and must be grounded using the SPG method outlined above Proper wire routing inside the panel is critical power and logic leads must be routed in different avenues inside the panel If you use drives that output over 8 amps you must ensure that the panel contains sufficient clearance above and below for the cooling fan to circulate ai
59. hown in Figure 5 Ensure that a 30 mm 1 2 inch DIN rail is installed horizontally in the rear of the panel prior to mounting the SS500 Ensure that the upper mounting tab on the back of the SS500 is in the UP position Hook the SS500 S lower mounting tab under the DIN rail as shown in Figure 4a The tab fit should be snug Rotate the SS500 upward flush against the DIN rail ensuring that the lower mounting tab remains engaged by the DIN rail Once the SS500 is flush against the DIN rail push down on the mounting tab atop the drive Figure 4b The mounting tab will latch onto the top of the DIN rail Install the bumpers as follows 1 Peel off the adhesive cover from the clear bumper Apply to the DIN rail tab of the SimpleServo the moveable tab on the rear of the control that clamps onto the top of the DIN rail Mount the drive as indicated above Peel off the adhesive cover from the black bumper Lift the bottom of the control while it is still clamped to the DIN rail to open a slightly larger air gap between the SimpleServo and the enclosure Apply the black bumper to the back of the SimpleServo the side facing the enclosure approximately one inch above the bottom Release the drive It should come to rest on the newly applied black bumper 4 3 Wiring WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board
60. ices are Zero speed In speed window Current limit Run Time Fault 5 2 3 Digital inputs ENABLE amp ENABLE TB506 17 18 Optically isolated input Compatible with 5 24V voltage source or open collector sinking output For connection guidelines refer to the application note in Section 12 See figure below for electrical diagram ENABLE ENABLE AC Tech SIMPLESENO 30 SimpleServo 500 600 i1000 User Manual Rev 3 4 AUX INPUT TB502 11 EN TB502 12 EN Functions same as ENABLE ENABLE This is a single ended input compatible with 5V TTL open collector sinking output and switch or relay contacts The input is referenced to drive logic common These inputs are active low i e connecting it to drive logic common or supplying logic 0 referenced to drive logic common activates this input For connection guidelines see application note in Section 12 See figure below for electrical diagram AUX INPUT EN EN ENABLE ENABLE Drive enable input Activating this input enables the drive AUX INPUT Programmable input Function of this input is software selectable Use MotionView program to select the function for this input Possible choices are e External fault e Stop e Reverse AC Tech SIMPLESetvo 31 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 3 Digital I O details SSi1000 drives SSi10XX indexing drives have 25 pin D sub digital I O connector Dig
61. ights when drive s current limiting is active OVER VOLTAGE O V Red Red LED lights when the drive bus exceeds threshold limit caused by motor regeneration energy flowing back into the drive If this LED lights frequently you will need to connect a dumping resistor POWER Green Green LED lights when power is applied to the drive 8 1 2 Bottom side LEDs Green LED This LED lights up when drive receive data over any interface RS232 485 or Ethernet Red LED This LED shows state of the user program Steady ON no valid user program in the drive s memory Blinking user program is running Off program in memory and valid but not running AC Tech SIMPLESENVO 57 SimpleServo 500 600 i1000 User Manual Rev 3 4 8 2 Faults 8 2 1 Fault Event When drive encountered any fault following events occur e Drive is disabled e nternal status set to Fault and Run Status to Stopped Fault number is logged in drives internal memory and can be interrogated later by MotionView or via Host Interface SSi drives only e Digital outputs if configured for Run Time Fault turns ON e Ready outputs turns OFF e Fault LED start blink out error code as outlined in Table 15 except for codes 1 and 3 e Ready LED turns OFF e Optionally OVER CURRENT or OVER VOLTAGE LED will turn ON e Note 1 SSi drives have more then 9 faults If the fault LED turns on permanently then the fault code is higher then 9 In this case you need to use MotionView
62. ing 1500 m 5000 ft derate by 1 per 300m 1000 ft above 1500m 5000 ft AC Tech 8 member of the Lenze Group Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 2 3 Dimensions and Weight Model SS504A SS604A SS508A SS608A SS610A SS612 3P Dimension Height inches 6 50 7 80 6 50 7 80 7 80 7 80 Width inches 2 60 2 60 3 80 3 70 4 50 4 50 Depth inches 7 50 6 80 7 50 6 80 6 80 6 80 Weight Ibs 2 5 4 0 3 5 5 0 5 6 5 6 Model SSi1004 SSi1008 SSi1010 SSi1012 3P Dimension Height inches 7 80 7 80 7 80 7 80 Width inches 2 60 3 70 4 50 4 50 Depth inches 6 80 6 80 6 80 6 80 Weight Ibs 4 0 5 0 5 6 5 6 2 4 Operating Modes S5500 600 drives e Torque Reference 0 x 10 VDC or 0 to 10 VDC scalable Torque Range 100 1 Current Loop Bandwidth up to 3 kHz e Velocity Reference 0 10 VDC or 0 to 10 VDC Accuracy 1RPM Velocity Loop Bandwidth up to 400 Hz Speed Range up to 5000 1 ppr encoder e Position Reference Step and direction signals or Master Encoder full quadrature signal software selectable Minimum Pulse Width 250 nanoseconds Reference Max frequency 2 MHz Position Loop Bandwidth Up to 400 Hz Accuracy 1 encoder count 2 5 Operating Modes SSi1000 drives e Position PIVFF Position P V inner velocity loop e Gearing e Velocity AC Tech SIMPLESENVO 9 SimpleServo 500 600 i1000 User Manual Rev 3 4
63. ing a CE approved motor the AC filter combined with the recommended SimpleServo motor and encoder cables is all that is necessary to meet the EMC directives listed herein The end user must use the comparable filter see table above to comply with CE specifications The OEM may choose to provide alternative filtering that encompasses the SimpleServo and other electronics within the same panel The OEM has this liberty because CE is a machinery directive 4 6 Heat sinking SimpleServos contain sufficient heat sinking in their basic configuration There is no need for additional heat sinking However drives that output more than 8 amps incorporate a heat sink cooling fan you must ensure that there is sufficient clearance for the cooling fan to circulate air Figure 3 As a minimum you must allow an air gap of 1 inch above and below the drive 4 7 Line fusing External line fuses must be installed on all SimpleServos Connect the external line fuse in series with the AC line voltage input Table 3 lists the recommended line fuse sizes Use fast acting fuses rated for 250 VAC or higher and approximately 200 of the maximum phase current TABLE 2 RECOMMENDED LINE FUSE SIZES Model Number Line Fuse Size AC Amps SSX04 15 SSX08 25 SSX12 30 AC Tech SIMPLESENO 19 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 SimpleServo Connections The standard SimpleServo control contains five connectors two guick connect termi
64. instructions may result in eguipment damage fire severe injury or fatality Have a qualified electrical maintenance technician install adjust and service this equipment Follow the National Electrical Code and all other applicable electrical and safety codes including the provisions of the Occupational Safety and Health Act OSHA when installing equipment The symbol shown at left indicates additional information shortcuts or tips that do not affect the safe operation of the drive Reduce the chance of an electrical fire shock or explosion by proper grounding over current protection thermal protection and enclosure Follow sound maintenance procedures It is possible for a drive to run at full speed as a result of a component failure Please ensure that a master switch has been placed in the AC line to stop the drive in an emergency WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed AC Tech SIMPLEServo Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 1 General Information The AC Tech SimpleServo family of servo amplifiers is an economical solution to today s complex motion con
65. ital UO supplement on these drives consists of 12 inputs and 5 outputs All I O optically isolated from rest of the drive s circuitry 5 3 1 Digital inputs SSi drives have 12 digital inputs which are separated on 4 groups Each group has its own common for inputs in the group All inputs are optically isolated and suitable for 5 24 VDC input control voltage Some of the inputs can be configured to carry out special functions Refer to Table 7 for digital inputs function reference All inputs have same electrical characteristics and the same input circuitry arrangements 5 3 1 1 Special functions Inputs C1 C2 Master Encoder connections Inputs C1 and C2 are suitable for Master Encoder connection for Gear Mode usage Inputs C1 and C2 are capable of handling signals with of up to 2 MHz rate Refer to Programmer s Manual for details Inputs A1 A2 Limit switches connection These inputs can be used for Limit switches connections These two inputs will perform different actions upon activation if programmed to do so When programmed for lt Not assigned gt they function as normal inputs Refer to Section 7 3 2 for details Input A3 Enable A3 input can be programmed for ENABLE function When this input is programmed for ENABLE function it must be active before ENABLE statement is issued otherwise fault will be generated If this input gets deactivated while drive is enabled drive will stop and generate fault When input is not programmed
66. mebase 50mS Trigger Channel 1 Rising Enable the drive Select lt Compensation gt then lt Position Loop filter gt from node tree set P gain to 100 and D gain to 200 Vff gain to 1 0 I gain to O and IL limit to 0 Run indexer and observe position error waveform Slowly increase simultaneously P gain and D gain and watch for Position error waveform Continue to increase both gains until you see noticeable oscillation on flat portion of waveform Now stop increasing P gain and continue to increase D gain until oscillation stops Now the ratio between P gain and D gain is set and if you need to increase or decrease P gain in next steps you will need also increase decrease D gain accordingly to keep their ratio The task is to minimize position error increasing P gain and at the same time avoid oscillation and instability by increasing D gain There could be a case when increasing P gain breaks system to oscillation and you can even hear audible noise Increase of D gain doesn t fix the situation At this point you will need to lower P gain and possibly lower D gain too to the level when noise and instabilities disappear Set up your indexer hereafter to perform a long move at some arbitrary velocity appropriate for your system Observe Position error waveform while running at constant velocity Look at average Position error value and change Vff gain to obtain minimum possible velocity error Generally Vff value is in rang
67. mensions and Weight eee 9 2 4 OperatingModesSS500 600drives nennen nn 9 2 5 OperatingModesSSi1000drives eee 9 2 6 SSi1000drivesfeatures eee 10 2 7 ConnectionsandlW O een 11 3 DIMENSIONS serisi eee nemna 12 3 1 SS500SeriesDimensions eee 12 3 2 SS604 SS608 SSIi1004 SSI1008 Series Dimenslons eee eee 13 3 3 SS610 SS612 3P SSi1010 SSi1012 3P Dimensions with Heat Sink Fan Kit Installed 14 3 4 Suggested Clearance for Cooling Air Circulation All Model 15 4 INSTALLATION assis isen ak al dan lana az b EA ANR sev eve sass vases Ban ek pen air ama id aa 16 41 Stam Up stp n ittm pi 17 42 Motulniiig ener dete tere tired etes eere ti ie edi e te Ee e 17 GC ET 17 44 Shielding and grounding eren enne nnne nennen trennt enne enne 18 441 General guidelines ener enne nnne einen nnns 18 AAD EMI Prot ction m M 18 2 43 ele EE 18 45 linefiltering eee eannsennennan 18 46 Heat SiNKNg EE 19 A Ka Ts EE 19 5 SIMPLESERVO CONNECTIONS cesses ee essere esser ennenen eenn nenen 20 5 External COMNMGCIOIS esen EEN EENS 20 5 1 1 TB501 Power MotorandFuseConnections
68. nal blocks and three subminiature type D connectors These connectors provide power communications and external feedback to the motor SimpleServo control and host controller Figure 8 Prefabricated cable assemblies may be purchased from AC Technology Corporation to facilitate wiring the control motor and host computer Contact your SimpleServo Sales Representative for assistance 5 1 External Connectors 5 1 1 TB501 Power Motor and Fuse Connections TB501 is an 8 pin guick connect terminal block used for motor power and fuse connections Refer to Table 3 for connector pin assignments Where referenced in the table below refer to Connector Wiring Notes for more information WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds before servicing drive Capacitors retain charge after power is removed DO NOT connect incoming power to the output motor terminals U V W Severe damage to the SimpleServo will result All conductors must be enclosed in one shield and jacket around them The shield on the amplifier end must be terminated at TB501 pin 6 chassis ground the other end should be properly terminated at the motor shield To satisfy CE requirements AC Technology Corporation recommends that
69. nput AUX C Programmable output OC Collector N O AUX E Programmable output OC Emitter N EXTPOWER 5 V 20mA max N N Drive Common N IN Positive of Analog signal input N IN Negative of Analog signal input N oa Analog Ground Reference Signal Ground Analog Shield AC Tech SIMPLESetvo 26 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 1 7 TB506 Encoder repeat and analog input connections SSi1000 drives TB506 is a 25 pin DB connector that includes buffered motor encoder repeat and analog input connections TABLE 9 TB506 PIN ASSIGNMENTS D Sub Pin Name Function Encoder Channel A Encoder Channel A Not Encoder Channel B Encoder Channel B Not Encoder Channel Z Encoder Channel Z Not GND Drive Common SHLD Shield olo NIO O A OJN SPARE O SPARE SPARE N SPARE 99 SPARE R SPARE C1 SPARE Oo SPARE N SPARE SPARE SPARE N O SPARE N SPARE N N GND Logic Common N IN Positive of Analog signal input N IN Negative of Analog signal input N oa Analog Ground Reference Signal Ground Analog Shield AC Tech SIMPLESetvo 27 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 1 8 Connectors and Wiring Notes Note 1 An external pulse t
70. o correctly determine relation between phase voltage and hall sensor signals eliminating the need to use a multi channel oscilloscope 5 7 1 Setting Up motor MotionView Motor Group on the left tree shows currently selected motor You can click CLICK HERE TO CHANGE to view selected motor parameters or select new motor ED Untitled Motion View Iof x Project Node Tools View Help pE x 8 v Ae def Parametername lale its JM bes Motor B Click here to change the motor 3 Parameters Motor ID 519 mio Motor model 520 10 200 Li Limits Motor vendor ADVANCED DIGITAL a Compensation Torque constant 0 15 Nm S Faults Voltage constant 8 80 V KRpm H A Tools g P Inductance phase phase 1 81 mH Resistance phase phase 2 22 Ohm Max phase current 2 88 Amp Terminal voltage max 325 VDC Rotor moment of inertia 0 000016 Kart Max velocity 6000 Rpm Hall code 3 Number of poles 4 Encoder 1000 PPR i vi For Help press F1 Off line MotionView s Motor Group folder and its contents Note 1 If drive is ENABLED a new motor cannot be set You can only set a new motor when the drive is DISABLED AC Tech SIMPLEServo 38 SimpleServo 500 600 i1000 User Manual Rev 3 4 To View selected motor parameters or make a new motor selection e Click CLICK HERE TO CHANGE Selection dialog opens See figure above If you are just viewing motor parameters click Cancel on Motor Parameters dialog w
71. of following steps Motor Selection Mode of operation selection Drive parameters i e current limit acceleration deceleration setup Operational limits velocity or position limits setup Input Output I O setup Velocity position compensator setup Optionally store your settings in the file and exit the program To configure drive 1 2 3 4 5 Ensure that the control is properly installed and mounted Refer to Section 4 for installation instructions Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements Refer to system configurations diagram in Section 12 for various system configuration examples Connect drive serial port TB505 to your PC serial port Make sure that the drive is disabled Launch MotionView software on your computer AC Tech S MPLEServo 59 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 6 From the MotionView menu select lt Project gt lt Connection setup gt 7 Select lt Properties gt and select computer s serial port drive connected to Leave baud rate selected at 38400 and rest of the parameters at default 8 Click lt OK gt to dismiss dialog 9 From lt Node gt menu choose lt Connect Drive gt Drive connects and its icon appears in the left node tree of the MotionView s screen e Note You only have to set up properties the first time or whenever you change the port Refer
72. on has been assigned for digital output Zero Speed Motor is at zero speed threshold set by ZERO SPEED parameters in Velocity Limits Group In Speed Window Motor shaft RPM is within specified speed window as specified in Velocity Limits Group Current Limit Drive current output has exceeded the limit established by the CURRENT LIMIT setting in the Drive Parameters dialog box Run Time Fault A fault has occurred Refer to Section 8 2 for details on faults Current limit Motor has reached maximum current as set by current limit parameter Analog output SimpleServo has one analog output with 10 bit resolution Signal scaled to 10V The analog output can be assigned to following functions 6 3 4 Phase current RMS Phase current Peak Motor Velocity Phase R current Phase S current Phase T current Iq current Torque Id current Direct component Analog output current scale Volt amps Applies scale for functions representing CURRENT values AC Tech SIMPLEServo 49 TENUTI SimpleServo 500 600 i1000 User Manual Rev 3 4 6 3 5 Analog output velocity scale mV RPM Applies scale for functions representing VELOCITY values 6 3 6 Analog input offset parameter Allows you to adjust system zero It works as balance trim potentiometer found in analog drives 6 3 7 Analog input dead band Allows you to set voltage window in mV in such manner that any voltage value in that window will be treated as zero This is useful i
73. ore servicing drive Capacitors retain charge after power is removed Choose communication interface and setup communication parameters Note See MotionView User s Manual for details on connections through various interfaces From MotionView menu lt Project gt select lt Connection Setup gt Choose lt RS232 RS485 gt option and select lt Properties gt button Select serial port number cable connected to Look on SSi DIP switch DS501 6 located on the SSi s bottom side near RS485 interface connector to verify Baud Rate selection Select proper Baud Rate from drop down list box that corresponds to your DIP Switch setting Click lt OK gt to dismiss dialog Note You don t have to do step 13 every time you start MotionView until you change DIP switch DS501 6 setting 14 15 16 17 26 27 28 29 30 Set DIP switches DS501 1 on down and switches 2 3 4and 5 off up This setting selects drive address 1 Note that if you use more than one drive with RS485 interface you have to set different addresses for each drive Refer to User s Manual for farther details on how to set up for RS485 interface Click lt OK gt to confirm settings and dismiss dialog Establish communication between MotionView and SSi a From lt Node gt menu choose lt Connect Drive gt b Click lt Connect one gt type SSi address must match address set by DIP switch and click lt Connect gt
74. put sensitivity for velocity reference used when drive operates in Velocity mode Units for this parameter are RPM Volt To calculate value use following formula Vscale VelocityMax Vin max Velocitymax maximum desired velocity in RPM Vin max max voltage fed to analog input at Velocitymax Example Velocitymax 2000 RPM Vin max 10V Vscale Velocitymax Vin max 2000 10V 200 RPM Volt gt value to enter 6 2 6 ACCEL DECEL Limits Velocity mode only The ACCEL setting determines the time the motor takes to ramp to a higher speed The DECEL setting determines the time the motor takes to ramp to a lower speed If the ENABLE ACCEL DECEL LIMITS is set to disable the drive will automatically accelerate and decelerate at maximum acceleration limited only by current limit established by the CURRENT LIMIT setting 6 2 7 Reference Velocity mode only The REFERENCE setting selects the reference signal being used Select Internal only when you using drive s built in digital signal generator for tuning purposes Select External for normal operations 6 2 8 Reset Option RESET OPTION selects the type of action you must take to reset the drive after a FAULT signal has been generated by the drive ON DISABLE clears the fault when the drive is disabled This is useful if you have a single drive and motor connected in a simple servo system The ON ENABLE option clears the fault when the drive is re enabled Choose ON ENABLE if you hav
75. r Refer to Figure 3 for minimum suggested cooling air clearance 4 5 Line filtering In addition to EMI RFI safeguards inherent in the SimpleServo design external filtering may be required High frequency energy can be coupled between the circuits via radiation or conduction The AC power wiring is one of the most important paths for both types of coupling mechanisms There are many AC line filter manufacturers whose filters can be successively integrated AC Tech recommends Schaffner filters based on our test results AC Tech SIMPLESetvo 18 SimpleServo 500 600 i1000 User Manual Rev 3 4 In order to comply with EN50081 1 and EN50082 2 the following filters must be installed within 20cm of the drive power inputs TABLE 1 LINE FILTER PART NUMBERS SimpleServo P N Schaffner AC filter P N SS504 FN350 8 SS508 FN350 12 SS608 3P FN350 12 FN351 8 SS1008 3P FN350 12 FN351 8 SS610 FN350 20 SS1010 FN350 20 SS612 3P FN351 16 SS1012 3P FN351 16 For 3 phase 3P models Line filters should be placed inside the shielded panel Connect the filter to the incoming power lines immediately after the safety mains and before any critical control components Figure 6 Wire the AC line filter as close as possible to the SimpleServo If you add separate fuses add them after the AC line filter Note e 1 The ground connection from the filter must be wired to solid earth ground not machine ground If the end user is us
76. r See Section 5 7 for detailed information how to set up motor 7 2 Parameters 7 2 1 Drive mode SSi drives always operate in primary positioning mode however two different configurations are available e PIVFF mode P roportional l intgral Welocity F eed F orward regulator configuration This mode using tunable position loop Velocity feedback is used as dumping term and adjusted automatically Velocity feed forward gain is adjustable e P V mode P osition V elocity regulator configuration This mode is generally slower than PIVFF and used with lower performance mechanics Regulator consists of outer position loop followed by independent velocity loop followed by current loop Position and Velocity loop gains both are active in this mode 7 2 2 Current Limit The Current Limit setting determines the nominal current in Amps RMS per phase 7 2 3 Peak Current Limit Sets RMS per phase peak current limit This current limit is allowed for 2 Seconds After that it will be folded back to the level that is set by Current limit parameter 7 2 4 Autoboot If this option is selected after Power Up SSi will start execution of the user program currently stored in drive s memory Otherwise program must be started manually via MotionView software or via Host Interface 7 2 5 Feedback loss detection When this option is enabled the SSi will detect feedback loss disable and then generate fault 7 2 6 RS485 configuration Switches be
77. rain signal for step supplied by an external device such as a PLC or stepper indexer can control the speed and position of the servomotor The speed of the motor is controlled by the freguency of the step signal while the number of pulses that are supplied to the SimpleServo determines the position of the servomotor DIR input controls direction of the motion Note 2 SS500 600 drives only The enable EN pin TB502 pin 12 or TB506 pin 17 18 must be wired to one of the output terminals on the front end controller i e if the controller is present it must supervise the enable function on the SimpleServo The SimpleServo will accept open collector outputs for use as a switch TTL or CMOS outputs 5V programmed for active low operation Note 3 Each of the encoder output pins on TB506 is buffered pass through The encoder channel A pin on TB504 for example is buffered and routed to the encoder channel A pin on TB506 inside the SimpleServo If you reguire encoder information wire your controller to TB506 The encoder and Hall sensor feedback from the motor must be wired to the 15 pin Type D receptacle connector through the feedback cable Note 4 The complement of A is sometimes written as not A The B C and Z encoder channels are annotated in a similar fashion Note 5 WARNING A Use only 5 VDC encoders Do not connect any other type of encoder to the SimpleServo reference voltage terminals When using a front
78. re called Vrs Vst Vtr Halls are usually called HALL A HALL B HALL C or just Halls 1 2 3 A motor s phase diagram is supplied by motor vendor and usually can be found in motor datasheet or making a request to motor vendor A sample phase diagram is shown below AC Tech SIMPLESetvo 42 SimpleServo 500 600 i1000 User Manual Rev 3 4 Fe Me SV The Halls Order is obtained as follows 1 Look at the R Output Voltage Determine which Hall Voltage is lined up with or in phase with this voltage We can determine which Hall Voltage is in phase with the R Output Voltage by drawing vertical lines at those points where it crosses the horizontal line Zero The dashed lines at the zero crossings above indicate that Hall B output is lined up with and in phase with the R Output Voltage 2 Look at the S Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall C output is in phase with the S Output Voltage 3 Look at the T Output Voltage Determine which Hall Voltage is in phase with this Voltage As can be seen Hall A output is in phase with the T Output Voltage hall sensor waveform edge aligns with phase phase voltage waveform but positive hall sensor cycle matches negative phase phase waveform or visa versa you must check Inverted check box Note e 1 If hall sensors are in phase with corresponding phase voltage but inverted 180 degrees 4 The
79. s per thousand RPM V KRPM The motor voltage constant will typically be between Ke 1V kRPM and Ke 70 V kRPM This entry should be made to 3 significant places Include the decimal places if the number is given as a whole number for example if Ke is given as 34 V kRPM then enter 34 0 The program expects to enter Ke voltage constant for Phase Phase voltage RMS value If you have Ke for peak sine wave then multiply by 0 707 to get correct Ke RMS value e Phase to phase winding Resistance R in Ohms C This is also listed as the terminal resistance Rt The phase to phase winding Resistance will typically be between R 0 5 Ohms and R 200 Ohms e Phase to phase winding Inductance L This must be set in milliHenries mH The phase to phase winding Inductance will typically be between L 0 5 mH and L 150 0 mH Note 1 If the units for the phase to phase winding Inductance L are given in microHenries uH then multiply by 1000 to get mH e Nominal phase current RMS Amps Maximum continuous phase current rating Imax in Amps RMS Do not use the peak current rating Note e 1 Sometimes the phase current rating will not be given The equation below may be used to obtain the maximum continuous phase to phase winding current from other variables Imax Continuous Stall Torque Motor Torque Constant Kt The same force x distance units must be used in the numerator and denominator in the equation above I
80. s you can increase I gain and allow overshoot caused by excess of I gain to approximately 15 20 Finally you will need to check the motor Iq current Set oscilloscope Channel 1 source to Ig current Observe current waveform and make sure that there is no significant oscillation On the Run panel click the Set to Zero button and disable the drive The motor will stop Disable drive Optionally select lt Parameters gt from node tree then set parameter lt Reference gt to INTERNAL so next time you enable drive it will use analog input for reference AC Tech S MPLEServo 64 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 9 7 Tuningin position PVFF mode Note In this mode the settings for Velocity compensation have no effect W GJ Q EG M A 17 18 19 Stop indexer and disable drive 21 Make sure that drive is online connected Make sure that the drive is disabled Set up your indexer run program for SSi drives to perform following move Move forward N steps where N number of steps to perform full motor shaft revolution Move backward N steps where N number of steps to perform full motor shaft revolution Set acceleration deceleration to maximum your system allows Select lt Tools gt then lt Scope gt tool from node tree to engage oscilloscope On the Scope tool select Motor Velocity as source for Channel 1 Position error as source for Channel 2 Ti
81. se current and RMS voltage are consistent with the motor ratings For additional assistance contact your local SimpleServo authorized distributor Problem External line fuse blows Possible Cause Line fuses are the wrong size Motor leads or incoming power leads are shorted to ground Nuisance tripping caused by EMI noise spikes caused by poor grounding and or shielding Suggested Solution Check that line fuses are properly sized for the motor being used Check motor cable and incoming power for shorts Check that you follow recommendation for shielding and grounding listed in section shielding and grounding early in this manual AC Tech SIMPLEServo 80 SimpleServo 500 600 i1000 User Manual Rev 3 4 Problem Suggested Solution Problem Possible cause Suggested solution Ready LED is on but motor does not run If in torque or velocity mode except SSi10XX drives Reference voltage input signal is not applied Reference signal is not connected to the SimpleServo input properly connections are open In MotionView program check lt Parameters gt lt Reference gt set to lt External gt For Velocity mode only In MotionView check lt Parameters gt lt Compensation gt lt Velocity loop filter gt P gain must be set to value more then 0 in order to run Without load motor will run with P gain set as low as 20 but under load might not If P gain is set to 0 motor will not run at all In step and direction mo
82. ser Manual sg 8 G E 9 EYE a O E S J AOPE 08 OG Si A0vZ 001 OV zn LT OND diNna dI Ana n xn pps gt sia Losg wm Tue uid 6 po2u pue szosues TTeH OND jndino xny JISVN3I Se 11 2 Simple Torgue and Velocity System TESTIS TeATIp SUTT jndino Apeay TV J8P09UF HIa7 8NW ENEE V Jepoous NO Apesy jndu xny g 19p09U3 3 no Apesy jndino Bojeuy g Jepoouj3 3 18VN3 HIG 8IN ZJ9poou3 JI8vN3 YIQ 8N REESEN Rea d3LSHYN AND THEY d31S VIN EWO AG ANDV Jamod jepoou3 OND AOL ODIN 74299 JdH dALSH VN WER J3H d3lS VIWN QNOV AOL zosal HIQ 98NnN Euiuue uid GL UAFLNANOD od member of the Lenze Group Drive for Global Excellence 76 SIMPLEServo SimpleServo 500 600 i1000 User Manual Rev 3 4 Analog reference connection options for simple torgue and velocity system 1 1 2 2 5 R S R 4 5 25K 4 5 25K 5 5 6 6 7 7 8 8 9 9 10 10 11 11 12 12 13 13 14 14 15 15 BI DIRECTIONAL REFERENCE SINGLE DIRECTION CONNECTION REFERENCE CONNECTION lt 0 to 10V OMNSIDAURVN EXTERNAL VOLTAGE REFERENCE CONNECTION AC Tech SIMPLESENO 7 Rev 3 4 SimpleServo 500 600 i1000 User Manual 3epooue pue Saosues TPH 11 3 Position Follower 40 Ohm 100W NN Dump
83. signments all models D Sub Pin Name Function Reserved TX RS232 TX RX RS232 RX Reserved GND Common Reserved Reserved Reserved Reserved WARNING A Do not make any connection to Reserved pins Note If you purchase serial cables from a third party you must use a pass through cable not Null Modem not crossover me AC Tech SIMPLESetvo 25 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 1 6 TB506 Controller Interface SS500 600 drives TB506 is a 25 pin DB connector for interfacing to front end controllers It is strongly recommended that you use OEM cables to aid in satisfying CE requirements Contact your SimpleServo representative for assistance TABLE 8 TB506 PIN ASSIGNMENTS D Sub Pin wee Function Encoder Channel A Encoder Channel A Not Encoder Channel B Encoder Channel B Not Encoder Channel Z Encoder Channel Z Not Drive Common Shield oloo NIO OJA WIND Positive Terminal of Encoder Power zech O Spare MA Step Master Encoder A Step input N MA Step Master Encoder A Step input X 99 MB Dir Master Encoder B Direction input P MB Dir Master Encoder B Direction input oa READY C Output Ready OC Collector zech O READY E Output Ready OC Emitter N ENABLE Enable Input X ENABLE Enable I
84. ssion networks are needed All conductors must be enclosed in one shield and jacket around them AC Technology Corporation recommends that each and every pair for example EA and EA be twisted In order to satisfy CE requirements use of an OEM cable is recommended Contact your SimpleServo representative for assistance The SimpleServo buffers encoder feedback through TB504 to TB506 Encoder channel A on TB506 for example is buffered channel A pin of TB504 inside the SimpleServo The Hall sensors from the motor must be wired to the 15 pin connector AC Tech SIMPLESENO 23 SimpleServo 500 600 i1000 User Manual Rev 3 4 TABLE 7 TB504 PIN ASSIGNMENTS D Sub Pin Name Function Encoder Channel A Encoder Channel A Not Encoder Channel B Encoder Channel B Not Encoder Channel Z Encoder Channel Z Not Drive Common Encoder Ground Shield 2 3 4 5 6 7 8 9 Encoder supply 5VDC e Hall Sensor A Hall Sensor A N Hall Sensor B 99 Hall Sensor C P Hall Sensor B C1 Hall Sensor C AC Tech SIMPLEServo 24 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 1 5 TB505 Serial Communications Port TB505 is a 9 pin D sub connector that is used to communicate with a host computer via standard RS232 interface This port is present on all SimpleServo drives All levels must be RS 232C compliant TB505 Pin As
85. t from node tree and set P gain to 100 and gain to 20 Select lt Compensation gt then lt Position Loop filter gt from node tree set P gain to 10 and D gain to 5 Vff gain to 1 0 l gain to O and IL limit to 0 Enable the drive Using Velocity loop filter Slowly increase P gain and watch for Velocity error waveform Continue to increase P gain until you see that error waveform until you can make it look like as narrow pulse as possible Stop increasing gain if you see noticeable oscillation on a flat portion of either scope channels Slowly increase I gain to minimize Velocity error on the flat portion of the Velocity error waveform Change source for oscilloscope s Channel 2 to Position Error Using Position loop filter Slowly increase P gain and watch for Position Error waveform Continue to increase P gain until you get minimum acceptable position error at the flat portion of the Position Error waveform without oscillation Keep on checking for Channel 1 waveform It should be no presence of any oscillation In some system you can try to increase D gain a little bit to suppress oscillation caused by excess of P gain but you should use it as a last resource Vff gain normally should be at its default value of 1 0 I gain normally should stay at 0 infinity and l limit should stay 0 as well Stop indexer and disable drive Note Remember that these are only initial settings for your system Your application will likely
86. tep and Direction type Direction inputs should be shorted together to avoid noise penetration To obtain necessary gearing ratio you should set Step Per Revolution parameter Here is how to calculate SpR MEppr 4 G where SpR step per revolutions parameter Meppr Master Encoder resolution pre quad desired gear ratio Example 1 500 ppr pre guad master encoder Desired ratio G i e on every master encoder revolution slave motor will rotate 74 of the revolution SpR 500 4 74 500 4 0 25 8000 Example 2 1000 ppr pre quad master encoder Desired G 1 24 SpR 1000 4 1 24 3225 8 round up to nearest integer number 3226 Calculated gear error 3225 8 3226 0 99993 or 99 993 100 99 993 0 007 gearing error 1 24 0 99993 1 239923 real gear ratio e Step amp Direction P V mode using inner velocity compensator and outer position loop compensator Both Velocity and Position loop filters are active This mode is recommended for general purpose mechanisms Especially helpful when instantaneous velocity precision is required e Step amp Direction PIVFF mode using integral position regulator which embeds velocity loop This mode recommended for rigid servo mechanisms while trying to accomplish maximum performance Mode is recommended for mechanisms with low inertial ratio match 1 4 or less AC Tech SIMPLESetvo 46 SimpleServo 500 600 i1000 User Manual Rev 3 4 TABLE 14 PA
87. th the address set by DIP SWITCH DS501 See RS485 interface paragraph below to see how address should be set The SSi RS232 has a unigue re transmitting feature If you send commands using RS232 interface to the drive with a different address the drive will retransmit this command to the RS485 network so the other drive might pick it up This allows the possibility of connecting a network of SSi drives to a Host computer via RS232 on one of the drives in the network There is no special adjustments or setups needed to start using this feature AC Tech SIMPLESetvo 35 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 6 2 RS485 interface RS485 interface is available at the 4 pins screw terminal connector TB508 Up to 32 drives can be daisy chained by connecting their and terminals using twisted pair wire Connect termination resistor between and terminals of the last drive in network See figure below for connection TABLE 11 TB508 RS485 CONNECTOR PIN Function 1 RS485 Data 2 RS485 Data 3 RS485 Data 4 RS485 Data RS485 Network connection Use twisted pair wire with optional shield Connect shield to the earth ground optional RS485 Data Last Drive in the network terminated with resistor Network Master Computer or PLC Additional Drives Up to 32 total AC Tech SIMPLEServo p Drive for Global Excellence SimpleServo 500 600 i1000 User M
88. to retrieve the fault code Refer to Programmer s manual for details on fault codes for SSi drives 8 2 2 Fault Reset Fault reset is accomplished by disabling or re enabling drive depending on settings performed during drive set up For SSi drives fault recovery handled by user s program Refer to Programmer s manual for details TABLE 15 FAULT CODES Fault Code Fault Description 1 Overvoltage Drive bus voltage reached maximum level due to regen 2 Bad Halls code One or more motor hall sensors inoperable or not connected 3 Overcurrent Drive reached absolute maximum in rush current limit and couldn t control it 4 Overtemperature Heatsink temperature reached maximum 90 100 degree C 5 External fault input activated Digital input was programmed as external fault input and has been activated 6 Overspeed Motor reached velocity above its specified limit 7 Position error excess During following in step and direction mode following error in motor encoder counts was more and longer time then specified 8 Bad motor data Motor profile data invalid or no motor was selected for operation 9 Subprocessor failure Internal failure Drive need to be sent for repair AC Tech SIMPLESENO 58 SimpleServo 500 600 i1000 User Manual Rev 3 4 9 1 9 Operation Minimum Connections In order to operate you must perform minimum connections As a very least you need to connect you PC serial
89. trol needs The SimpleServo combines a Digital Signal Processor DSP controller heat sink and power supply in one standalone DIN rail mountable or panel mounted unit The SimpleServo can be operated as a stand alone unit or as a digital amplifier The SimpleServo controls brushless motors with a high switching carrier frequency for virtually silent operation Most servo motors used today require high precision control and a smooth sinusoidally commutated signal An on board DSP provides commutation by generating the three phase sine wave using feedback information from an optical encoder The SimpleServo will accept feedback from an encoder that includes Hall sensor feedback information It accepts commands from a variety of sources including analog voltage PWM and internal reference signals The control will operate in current torque mode velocity mode or position step and direction mode Upon initial start up the motor is commutated using the hall sensors for the first two or three mechanical degrees of motor rotation to map the encoder the Hall effect information is unnecessary thereafter The SimpleServo s built in RS 232 serial communications port and SimpleServo control program MotionView make programming extremely simple In fact you could be up and running in less than thirty minutes Each SimpleServo unit is an amplifier power supply controller and heat sink integrated into a single standalone package The SimpleSer
90. tween different protocols can be used over RS485 interface In normal mode PPP protocol described in Host Interface manual is used Modbus slave is another alternative protocol can be used to communicate with SSI drive Modbus primarily supported for compatibility with industry standard operator interfaces and terminals For all another control tasks PPP is recommended AC Tech SIMPLESetvo 53 SimpleServo 500 600 i1000 User Manual Rev 3 4 7 2 7 Group ID This parameter is used to combine different SSIs in functional groups SSIs with the same group ID can be communicated simultaneously with statement SENDTO See statements SEND and SENDTO in Programmer s manual for farther explanations 7 2 8 IP properties command button Clicking this button opens dialog with IP properties of the drive You can choose to obtain values automatically from DHCP or manually See Section 5 6 3 for details on IP properties 7 3 UO 7 3 1 Outputs 1 2 3 4 functions Every digital output except output 4 can be assigned special function Possible choices are e Not assigned Output controlled by User s program e Motion completed All motion commands completed Motion Queue empty s n position window Current position in specified window e Fault Drive at fault e In motion Invert of Motion Completed flag e Ready Drive stops first then disabled and generate fault Refer to the Programmer s Manual for additional details 7 3 2 Hard limit
91. ure the drive for your particular motor and additional features if used Drive configuration consists of following steps exo Motor Selection Mode of operation selection Drive parameters i e current limit acceleration deceleration setup Input Output I O setup Velocity position filters compensator setup Optionally store your settings in the file and exit the program Ensure that the control is properly installed and mounted Refer to Section 4 in this manual for installation instructions Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements Connect drive serial port TB505 to your PC serial port You can use any supported interface See MotionView User s Manual for details on how to make a connection Make sure that the drive is disabled Launch MotionView software on your computer Connect RS232 serial cable or perform RS485 connection between SSi and PC see User s Manual for details on how to make RS485 connection Apply power to SSi and Start MotionView program AC Tech S MPLEServo 60 Drive for Global Excellence SimpleServo 500 600 i1000 User Manual Rev 3 4 WARNING A Hazard of electrical shock Circuit potentials are at 115 VAC or 230 VAC above earth ground Avoid direct contact with the printed circuit board or with circuit elements to prevent the risk of serious injury or fatality Disconnect incoming power and wait 60 seconds bef
92. ves support both manual and automatic IP parameters assignment Automatic DHCP assignment of IP properties is possible if there is a DHCP server on the network This is the default setting You can quickly connect drive s to floor corporate network and configure it for further operation In manual mode you need to supply the IP address Subnet mask and Default gateway Default gateway address is needed only if drives are located on different subnets If drives are on the same network and there is no gateway supply to this field address of the host computer or address on the same subnet but not used by any of the devices IP Setup x Specify IP Address IP Address 192 158 24 40 Subnet Mask 255 255 255 0 Default Gateway 192 168 24 239 Cancel AC Tech SIMPLESENO 37 SimpleServo 500 600 i1000 User Manual Rev 3 4 5 7 Motor Selection SimpleServo drives are compatible with many servo motors both AC Technology Corporation motors and motors from the other manufacturers We have tested many motors with the SimpleServo and put their parameters in a database for customer convenience If you opted for the motor which is in the database you do not need to provide any motor data to set up motor for the use However if your motor is not in the database you can still use it but need to provide some electrical and mechanical data to make a custom motor profile The auto phasing feature of SimpleServo allows you t
93. vo will only accept an encoder with Hall or an encoder with hall commutation tracks encoded on the feedback device AC Tech SIMPLEServo 7 SimpleServo 500 600 i1000 User Manual Rev 3 4 2 Specifications 2 1 Electrical Characteristics Maximum Continuous Peak Input Voltage Continuous Phase Current 10 50 60 Hz Drive Current AC in Current AC Amps VAC AC Amps SSX04 6A 4 8 90 240 SSX08 12A 14 90 240 SSX10 15A 10 20 90 240 SSX12 3P 19A 12 20 90 240 Notes 3P 3 phase input power models Phase RMS current Peak current allowed for up to 2 Sec Applies to all models AC Output Voltage Range Sinusoidal Three Phase 0 240 VAC RMS Minimum Output Voltage Range Acceleration Time Range Zero to Max Speed Deceleration Time Range Max Speed to Zero Speed Regulation typical 0 340 VAC 0 1 5000000 Rpm sec 0 1 5000000 Rpm sec 1 RPM Input Impedance REF to COM and REF to REF 47 kohms Power Device Switching Frequency sinusoidal commutation 16 kHz Encoder power supply max Maximum encoder feedback frequency 2 2 Environment Vibration SS500 Series SS600 and SS1000 Series Ambient Operating Temperature Range Ambient Storage Temperature Range Humidity Altitude SIMPLEServo 5 VDC 300 mA 2 1 MHz 0 1 G all frequencies 0 5G max 20 50 Hz 0 1G max gt 50 Hz 0 to 40 C 10 to 70 C 5 90 non condens
94. you purchase SimpleServo cables for both the motor and AC line Contact your SimpleServo representative for assistance Wire size If current draw is less than 8 amps 16 AWG 1 0 mm or 14 AWG 1 6 mm If current draw is greater than 8 amps but less than 12 amps 14 AWG 1 6 mm or 12 AWG 2 6 mm If current draw is greater than 12 amps 12 AWG 2 6 mm TABLE 3 TB501 PIN ASSIGNMENTS single phase models Terminal Block Pin Name Function Motor Power Out Motor Power Out Motor Power Out Dump resistor out Dump resistor out Chassis ground AC Power In AC Power In 1 2 3 4 5 6 7 8 AC Tech SIMPLEServo 20 SimpleServo 500 600 i1000 User Manual Rev 3 4 TABLE 4 TB501 PIN ASSIGNMENTS 3 phase models Terminal Block Pin Name Function oO ON O Om BEN gt W T V S U R DUMP DUMP GND L1 L2 L3 Motor Power Out Motor Power Out Motor Power Out Dump resistor out Dump resistor out Chassis ground AC Power In AC Power In AC Power In 5 1 2 TB502 Analog Digital O Terminal Block TB502 is a 15 pin quick connect terminal block used for analog and digital I O functions in standalone mode TABLE 5 TB502 PIN ASSIGNMENTS all models except SSi10XX Terminal Block Pin Name Function 1 REF 10V 5mA 2 IN Positive of analog signal input 3 IN Negative of analog signal input 4 REF 10V 5mA 5 AGND Analog ground attach shield from signal source

Operating Instructions IMSS500+__Simple Servo 500 600

Contents

Download Pdf Manuals

Related Search

Related Contents