rol-20012 - Kollmorgen
Contents
1. Figure 3 5 Ringing RO L INSTALLATION MANUAL ADVANCED CURRENT LOOP TUNING Theory of Operation Tuning is the process of optimizing several parameters of operation including response bandwidth and noise Tuning is based on control theory the goal is to set loop gains with sufficient gain phase margin while attaining the required response The Frequency Domain A common way to specify response is measuring the response of the current loop to a sinusoidal command over a wide range of frequencies That is measuring the loop response in the frequency domain The response of current loops gets poorer as the command frequency increases which is to be expected When the command is at very low frequencies below 10 Hz for example the loop is nearly perfect that is the actual current will look very much like the commanded current At very high frequencies above 10 000 Hz for example the system will not be able to respond at all the command may represent substantial current but the actual current will be very small The basic measure of response is referred to as bandwidth The bandwidth of a system is defined as the frequency at which the command is attenuated to 70 3dB of its low frequency response Figure 3 6 shows the response of a properly compensated current loop with a bandwidth of 1000 Hz This graph illustrates a few key points to understanding response in the frequency domain The frequen2. When the motor is shorted its own generated voltage may produce very high current flow The short and associated arcing may damage the motor and the amplifier Mode Selection The RO L amplifiers can operate in the following modes Open Loop Mode e Velocity Mode e Current Torque Mode The RO L control section is shown in Figure 3 1 Note that switches SW1 4 and 6 control mode selection 23 RO L INSTALLATION MANUAL CHAPTER 3 CHECK OUT Vel Loop SW1 9 Gain J6 4 W1 4 ANALOG CMD 4 out nt Vel 5 Loop Peak Cont 50K 7 Current 10K mai Limit 100K o 01uF SW1 8 J6 5 zg Scaling gt Peak Cont ANALOG CMD K WZ Limit 15VDC 500K Offset 4 Test SWh1 1 Current 10K Limit 15VDC Test Offset Encoder Tach 10K SW2 7 Velocity to Direction Sense Velocity Monitor Out SW1 3 Current Power Scaling Stage lt Current Sense Non isol J9 5 J9 2 94 67 RIS B nc T 10K Stage to Encoder R26 C69 C67 can be soldered in by IMonitor Monitor Return customer if standard adjustments do not J6 8 J6 15 provide acceptable performance Always follow proper ESD protection procedures Note IMonitor and Monitor Return are referenced to bus not control ground Figure 3 1 Control Loop Function Diagram Open Loop Mode Current Torque Mode In open loop mode ANALOG CMD directly In current loop
3. 8 ChannelB 9 SILVERLINE line driver module is shipped loose in the same bag as the loose motor When attaching the line driver proper ESD precautions should be observed The line driver attaches so that the body of the connector fully lies between the metal hoops on the encoder It is possible to install the line driver module incorrectly On SILVERLINE motors strain relief for the encoder cable is provided with a wire tie which secures the ribbon cable connector and line driver to the encoder body Use a 0 1 wide 4 5 long wire tie such as Richo WIT 18R This wire tie fits securely in notches of the standard SILVERLINE encoder ribbon cable connector Amp 746285 1 Two steel hoops are attached to the encoder body through which the wire tie is threaded Note that the connector does not have an integral strain relief as the version with strain relief cannot be fastened reliably with a wire tie Since the connector does not provide strain relief for the cable this function is also provided by the Wire tie Assemble as shown below fold the ribbon cable across the back of the connector to form a small loop and install the wire tie securely preferably with a wire tie gun or similar device 11 CHAPTER 2 MOUNTING AND WIRING Wire Tie Ribbon Cable Strain 4 Relief 4 amp Ribbon Cable Loop Connector Line Driver Hoops lt Encoder Body Side View Application of wire tie to secure and
4. MOUNTING AND WIRING RO L INSTALLATION MANUAL Control Status and Hall Sensors JL AC Power and Fuse Amplifier Power ROL only and Motor Leads Figure 2 3 RO L Connector Layout Main PCB 18 RO L INSTALLATION MANUAL CHAPTER 2 MOUNTING AND WIRING JL ROL Only AC Line In Connector ROL only Bus Power and Logic Power HALL POWER HALL COMMON Hall Sensors S3 Hall 46 12 Sensor 51 Inputs RO L Amplifier SILVERLINE RBE Motor Figure 2 4 Connectors J1 and J6 for SILVERLINE RBE Motors J6 Hall Sensors shown remainder of J6 connections shown in Figure 2 5 19 CHAPTER 2 MOUNTING AND WIRING Amplifier Status Input J6 16 AMP OK J6 4 ANALOG CMD J6 5 ANALOG CMD J6 9 ENABLE J6 2 COMMON Positioner Analog gg Optional J6 1 Input J6 4 RO L INSTALLATION MANUAL Amplifier lt Status Input 10 Volts Full Command POT 10V 5 mA POT 10V 5 mA Note IMonitor and IMonitor Return are referenced to bus not to logic ground IMonitor IMonitor Return RO L Amplifier Figure 2 5 Connector J6 Amplifier Enable Command and Status Hall Sensors shown in Figure 2 4 Do not short IMONITOR J6 8 or IMONITOR RET J6 15 to ground N CAUTION Do not connect to oscilloscope ground IMONITOR J6 8 and IMONITOR RET J6 15 are not isolated they are referenced to bus There is normally 70 VDC be
5. Check the power input voltage for a value in excess of those listed in the data sheet If larger than listed value is observed check the AC power line connected to the power supply for the proper value Under Voltage Shutdown Verify power supply voltages for minimum conditions per specifications Short Circuit Fault Check each motor lead for shorts with respect to motor housing and power ground Measure motor armature resistance between motor leads with the amplifier disconnected Ensure that it is at least 0 2 ohms Verify that motor inductance lead to lead is at least 250 uH Status e Check ENABLE for correct polarity low to enable e Check for proper grounding For example ensure that either ANALOG CMD J6 5 or ANALOG CMD J6 4 is connected to COMMON J6 2 Mechanical backlash dead band slippage etc 29 RO L INSTALLATION MANUAL e Check for excessive noise on encoder inputs These inputs should be 0V 5V square waves Noise spikes or high frequencies gt 100 kHz should not appear on these lines e Check for noise on ENABLE STABILITY AND PERFORMANCE Feedback systems such as motor controllers require tuning to attain high performance If you want to tune the current loop or velocity loop you will need to determine loop gains according to a three part criterion e Noise Susceptibility e Response e Stability In a broad sense the performance of a system is characterized by its
6. BKO 10 and then connect discrete wires from the BJ BKO 10 screw terminals to J9 You can also use discrete wires directly from J9 to the encoder by using a CHAPTER 2 MOUNTING AND WIRING connector such as AMP 102387 1 on the encoder If you are using a standard Silverline encoder or any other encoder that supplies differential signals connect only the non inverting signals as shown in Figure 2 6 The customer is responsible for providing 5 VDC for the encoder For Silverline encoders this normally requires approximately 100 mA If you are using a non Silverline encoder be aware that many encoders use much more than 100 mA when selecting the encoder power supply Table 2 4 Connector J9 1 NC Channel A of q a E B of quadrature encoder COMMON Reference common for customer supplied encoder power Switch SW1 SWI is a 10 position surface mount switch block These switches control operational modes such as loop type velocity or current test gains scaling and commutation type The settings are detailed below Chapter 3 discusses how to set up the amplifier for various modes of operation 15 CHAPTER 2 MOUNTING AND WIRING RO L INSTALLATION MANUAL Table 2 5 SW1 Settings SWI 1 Test Offset Normally off If on greatly increases sensitivity to offset pot to allow testing SWI 2 Normally on Off for high inductance 22 mH motors Gain SW1 3 Current On for 12 ADC units Off for 4 AD
7. Loop Mode 25 Ventilation 8 Vibration 11 36 Warranty 37 Wiring 9 Encoder 13
8. This can be accomplished by using separate conduits or wiring trays for control wiring and power wiring Follow good grounding practices when wiring the RO L Be careful not to create a grounding loop with multiple ground paths Follow the NEC s provisions on grounding Radio Frequency Energy This equipment is susceptible to and can radiate radio frequency energy It must be installed and used in accordance with this installation manual to limit possible interference with radio communications or other electronic equipment PERIODIC MAINTENANCE Periodically you will need to inspect your equipment for possible problems to ensure ongoing safe and efficient operation Periodic maintenance should be performed at scheduled intervals to ensure proper equipment performance It must be performed by qualified personnel familiar with the construction operation and hazards involved with the RO L and its application Power should be disconnected during all maintenance procedures Periodic maintenance includes the following Check that no screw terminals have vibrated loose Check fan operation Check integrity of wiring Check PCBs for accumulation of contaminants such as fluids dust or shavings Check all external circuit breakers to assure that they are within their original ratings as specified by the manufacturer Grounding Integrity The method employed for grounding or insulating the equipment from gr
9. capacitance internally PWM amplifiers generate current surges from the reservoir capacitors For single phase AC input to a diode bridge a bus capacitance of 2000 uF amp maximum output current is recommended this value reduces ripple to 4V which will keep capacitor temperature low Lower values of bus capacitance can be used for three phase input Also lower values can be used with high grade electrolytic capacitors Contact capacitor manufacturers for guidelines Twist leads from reservoir capacitor For RO amplifiers customer must provide adequate bus capacitance Inadequate capacitance will degrade system performance and generate excessive heat in bus capacitors CAUTION The bus capacitors should be within three feet of the amplifier If they are farther an additional 10 RO L INSTALLATION MANUAL bypass capacitor 21000 uF must be placed within three feet of the servo amplifier When multiple RO amplifiers are installed in a single application avoid ground loops by observing the following guidelines 1 Run separate power supply leads from each amplifier to the bus capacitor s 2 Run separate twisted pair shielded cables to ANALOG CMD and of each amplifier Regeneration During braking the amplifier returns the servo motor s kinetic energy to the power supply capacitor This process raises the capacitor voltage If the returned energy is sufficiently large an over voltage fault will b
10. for the DC bus to come loose These wire when loose present a shock hazard For the ROL J1 has two terminals hidden by the frame Do not inadvertently loosen these screws or internal WARNING Wiring may come loose This is a shock hazard Table 2 2 Connector J1 Power Signal Name 4 RO only BUS Common 5 RO only BUS Wiring Bus Leads RO only RO amplifiers operate from a single polarity unregulated DC power supply This supply does not need to be galvanically isolated from the line so that a suitable power supply may be constructed without a transformer The customer must supply all components including diode bridge reservoir capacitor and regenerative energy shunt if required Note that these components are integral to the ROL Connect bus to J1 5 connect bus to J1 4 Bus must be 135 200 volts DC Note for ROL amplifiers these connections are made internally Do not reverse the power supply leads WARNING Severe damage will result RO L INSTALLATION MANUAL CHAPTER 2 MOUNTING AND WIRING Wiring Motor Leads for Other BLDC Observe proper ESD protection procedures when Motors handling encoder and hall The graphs below show the commutation WARNING sensor leads sequence for 120 commutation SW1 10 on and 60 commutation SW1 10 off respectively Match the commutation of your motor as specified by the manufacturer to these graphs If Wiring Motor
11. in personal injury or death CAUTION directs attention to general precautions which if not followed could result in personal injury and or equipment damage NOTE highlights information critical to your understanding or use of these products CHAPTER 2 MOUNTING AND WIRING UNPACKING AND INSPECTION Electronic components in this amplifier are static sensitive Use proper procedures when handling component boards CAUTION Upon receipt of the equipment closely inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Carefully remove packing material and remove the equipment from the shipping container Do not dispose of shipping materials until the packing list has been checked Parts contained within the shipment but not physically attached to the equipment should be verified against the packing list If any parts are missing notify Kollmorgen at once INSTALLATION REQUIREMENTS Proper installation and field wiring are of prime importance in the application of servo amplifiers Many problems will be avoided if installation is done properly Users should familiarize themselves with and follow these instructions in addition to all applicable codes laws and standards Pay special attention to the following topics when installing Kollmorgen equipment Environmental Considerations The environment in which this equipment is placed can dramaticall
12. mode ANALOG CMD controls controls motor voltage through the PWM section the current into the motor For servo motors This is not a closed loop configuration the such as KOLLMORGEN SILVERLINE Motors output voltage varies in proportion to the bus current is approximately proportional to torque voltage In open loop mode do not connect the Torque mode is used frequently where the encoder to the amplifier machine controller closes the position and velocity loops and the amplifier closes the Open loop provides low performance speed current loop In current loop mode do not control for set up and for less demanding connect the encoder to the amplifier applications 24 CHAPTER 3 CHECK OUT Velocity Mode In velocity loop mode ANALOG CMD controls motor speed A speed feedback signal tachometer is synthesized from the encoder signal and used for loop feedback Velocity loop mode is the most complex mode because a current loop runs inside the velocity loop both loops must be tuned In velocity loop mode the encoder must be connected to J9 In most cases the encoder is connected to both the amplifier and the controller Be aware that the performance of the RO L velocity loop is not ideal for all applications The RO L is designed for low cost and some features have been omitted First the encoder inputs are single ended rather than differential Differential inputs are less susceptible to electrical noise and are particularly we
13. motor and the load or at the motor mounting plate The frequency of oscillation is less than 100 Hz Compliance can be corrected by the following actions Reduce the bandwidth of the system Stiffen the machine so the load is not springy Non Linearities Tuning is based on linear control theory The most important requirement of a linear controller Is that the total reflected inertia should not change substantially during operation Load inertia includes all the inertia reflected to the motor such as inertia through gearboxes and leadscrews Inertia can change in ways that are easy to understand such as the inertia of a spool of cable decreasing when the cable is unrolled It can also change in less intuitive ways such as chain drives which have load in one direction but are unloaded in the other and systems with RO L INSTALLATION MANUAL excessive backlash where there is no load when gear teeth are not touching When the inertia changes the system has the following characteristics System performance is excellent when the motor is in some positions and unacceptable when the motor is in other positions Reducing the bandwidth eliminates the problem If the system performance is poor because of changing inertia you can make the following corrections Correct the system mechanics so that inertia Is constant Detune that is reduce the bandwidth of the system Resonance Resona
14. noise susceptibility response and stability These quantities tend to be mutually exclusive The system designer must decide what noise susceptibility in the form of a busy motor is acceptable Busyness is random activity in the motor and can often be felt on the motor shaft Busyness in a motor should not be confused with PWM noise PWM noise is high pitched relatively constant noise and is too high in frequency to be felt on the motor shaft Response is a measure of the system s quickness Response can also be characterized by bandwidth and by rise time in response to a step command Normally designers want high bandwidth though sometimes the response is purposely degraded to reduce stress on mechanical components This is called detuning Typical current loop bandwidths range from 1000 to 2500 Hz Typical velocity loop bandwidths range from 20 to 60 Hz Stability measures how controlled the system is Stability can be measured with damping ratio or with overshoot in response to a step command A discussion of different levels of stability follows 30 CHAPTER 3 CHECK OUT Critical Damping Generally the most desirable amount of damping is Critical Damping Critically damped systems respond as fast as possible with little or no overshoot The graph in Figure 3 2 shows the velocity response of a system to a square wave input when the system is critically damped 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0
15. 000 0 025 0 050 0 075 0 100 Time seconds Figure 3 2 Critical Damping Underdamping Sometimes the system is tuned for critical damping and the system is still too slow In these cases you may be willing to accept less than critical damping For applications that can work properly with a slightly underdamped system you may reduce the stability to improve the response The graph in Figure 3 3 shows a slightly underdamped system 1 40 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds Figure 3 3 Underdamping CHAPTER 3 CHECK OUT Overdamping An overdamped system is very stable but has a longer response time than critically damped or underdamped systems Also overdamped systems are noisier than less damped systems with the same response rate The graph in Figure 3 4 shows an overdamped system 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds Figure 3 4 Overdamping Ringing When you are tuning the RO L you may tune it so that the response rings Ringing is caused when you attempt to tune the RO L for too rapid response Normally the best solution is to reduce the bandwidth The graph in Figure 3 5 shows a system that rings 1 60 1 40 1 20 1 00 0 80 0 60 0 40 0 20 0 00 0 000 0 025 0 050 0 075 0 100 Time seconds
16. 5 Mode Current Loop 24 Open Loop 24 Operational 23 Velocity Loop 25 Model Number RO L 2 Motor 13 Encoder Connector 11 Noisy 30 Outline Drawings 39 Protection 10 Noise Susceptibility 30 Noisy 30 Non Linearities 33 Open Loop Mode 24 Operating Temperature 4 8 Operation Mode 23 Outline Drawings 39 Over Current 27 Over current 27 Overdamping 31 Over Temperature 27 Over voltage 27 Part Number Description 1 Peak Current 3 Periodic Maintenance 36 Phasing Motors 34 Preventative Maintenance 35 Pulse Width Modulation 8 PWM 8 PWM Noise 30 Radio Frequency Energy 36 Ratings 2 RBE Motor 13 47 INDEX Regen 4 10 12 27 Regional Sales Offices 45 Resonance 33 Response 30 Reversing Direction 28 Ringing 31 RO L Model Number 2 Outline Drawings 39 Safety information 7 safety alert symbols 7 Single ended Encoder 15 25 Spare Parts 35 Specifications 2 Stability 30 Start up 23 Static Sensitive 8 Storage Temperature 8 Strain Relief 9 11 Encoder Connector 11 System Description 1 System Wiring Diagram Velocity Loop Mode 6 48 RO L INSTALLATION MANUAL Temperature Operating 4 8 Transient Voltages 36 Tuning 30 Criterion 30 velocity loop Problems 33 Tuning Theory 31 Underdamping 30 Unpacking 8 Velocity Loop 3 Detuning 29 Gain Adjust 29 Offset Adjust 29 Scale Adjust 29 Tuning 28 Velocity Loop Limitations 25 Velocity
17. C units Scaling Caution For 4 ADC units turning SW 1 3 on will cause unreliable amplifier operation and may damage the motor On for velocity loop and open loop off for current loop When Integrator on shorts velocity loop integrator SWI 5 Duty Cycle Normally off On for open loop mode SWI 6 Encoder Tach On for encoder based velocity loop Off otherwise SWI 7 Velocity Normally off On to reverse direction Pwr Baci Waning Reversing SWI may mt the motor torum away _ SW1 8 Current Normally on Off to reduce continuous current BE s SWI 9 Velocity Loop Normally off On to detune velocity loop lc ee LIT Commutation motors Table 2 6 RO L Connector Function Nam Type Description O J1 RO Only Bus and 5 Pin Screw Connections for motor power leads and for Motor Power Terminal bus power J1 ROL Only Motor Power 3 Pin Screw Connections for motor power leads only Terminal Status 15 Pin Crimp ANALOG CMD ENABLE AMP OK Control and Connector Hall Sensors Hall Sensors Jo Feedback 5 Pin Crimp Feedback Encoder connection for Velocity EM ANE AND JL ROL Only Line Voltage 3 Pin Pluggable Three prong IEC style connector 115 with Integral VAC line cord Fuse 16 RO L INSTALLATION MANUAL CHAPTER 2 MOUNTING AND WIRING N C 5 Supply Common N C Channel A Channel A Channel B Channel B Index Index Silverline Encoder Figure 2 2 Silverline Encoder 17 CHAPTER 2
18. E RO and ROL Amplifier are trademarks of the Kollmorgen Corporation Dangerous voltages currents temperatures and energy levels exist in this product and in the associated servo motor s Extreme caution should be exercised in the application of this equipment Only qualified individuals should attempt to install WARNING set up and operate this equipment Ensure that the motor amplifier and the end user assembly are all properly grounded and current limited per NEC requirements European Community EC Declaration of Conformity We Kollmorgen Corporation Industrial Drives Division 201 Rock Road Radford Virginia USA declare under sole responsibility that this equipment is exclusively designed for incorporation in another machine The operation of this equipment is submitted to the conformity of the machine in which it is incorporated following the provisions of the EC Electro Magnetic Compatibility EMC directive 89 392 EEC RO L INSTALLATION MANUAL TABLE OF CONTENTS CHAPTER1 SYSTEM DESCRIPTION INTRODUCTION PART NUMBER DESCRIPTION RO L Model Number SPECIFICATIONS AND RATINGS CHAPTER 2 MOUNTING AND WIRING INTRODUCTION SAFETY INFORMATION UNPACKING AND INSPECTION INSTALLATION REQUIREMENTS Environmental Considerations Ventilation Minimum Inductance Requirement Noise and System Grounding MOUNTING MOUNTING THE FAN WIRING OVERVIEW Strain Relief Motor Protection Bus Capacitor RO Only Regenerati
19. F 156 500 2 PL REF 2 300 MAX 4 400 Figure B 2 RO Series Outline 41 APPENDIX B OUTLINE DRAWINGS RO L INSTALLATION MANUAL 150 840 2 PL 6 119 124 THRU 31 2 PL THIS SIDE 2 PL 475 2 PL OPP SIDE Figure B 3 Fan Bracket RO L 20012 Only 42 APPENDIX B OUTLINE DRAWINGS RO L INSTALLATION MANUAL SYILIWITIN NI SNOISNaMWIG S31ON3dq 896 oozo ezz ON 1300N ez 96 OS 0087 Oy 8 0 010 2 52999 9292 NO S31OH NYHA Loy s cs6 v 912 0619 Figure B 4 Size 23 Outline 43 RO L INSTALLATION MANUAL APPENDIX B OUTLINE DRAWINGS SH3 L3ATTIIN NI SNOISNAMIC 1 14 021908 0020 6 89812 0020 2 6 iS o1 59 62 or 62188 05256 1713 08 16 6 8 00002 19 182986 5186 NO S310H 11675017 822 12 2 Figure B 5 Size 34 Outline 44 RO L INSTALLATION MANUAL APPENDIX C REGIONAL SALES OFFICES Ascea C CUSTOMER SUPPORT Kollmorgen is committed to quality customer service Note If you are unaware of your local sales representa Our goal is to provide the customer with information and tive please contact us at the number below Misit our resources as soon as they are needed This one number web site for MotionLink software upgrades technical provides order status and delivery information product articles and the most r
20. Leads for Kollmorgen you do not have this information refer to the BLDC Motors empirical method on page 34 Note that hall sensors are connected to connector J6 which is Connect the three motor leads according to the color code shown on Figure 2 4 This figure shows the color code for both Kollmorgen SILVERLINE and RBE motors SW1 10 should Be aware that phase depends also on the be on to select 120 commutation Note that hall encoder if phasing of the encoder or the motor is sensors are connected to connector J6 which is reversed the motor may run away detailed below detailed below Table 2 3 Connector J6 Differential analog input 6 j Notnommalyused IMONITOR If SW1 3 is off 1 333 ADC if SW1 3 is on IV 4 ADC Note IMONITOR is referenced to IMONITOR RET pin 16 not control common There is usually 70 VDC between this signal and the other control signals on this connector o o a O O 130 mA 6 VDC 2106 15 IMONITOR RET Reference common for IMONITOR Pin 8 This signal is connected to BUS through a 10KOhm resistor There is usually about 70 VDC between this signal and other control signals on this connector 16 FAULT TTL Signal High if fault short circuit over voltage over temperature illegal hall combination and power up reset When fault is asserted the red LED on the front panel will light 13 CHAPTER 2 MOUNTING AND WIRING RO L INSTALLATION MANUAL Hall Sen
21. Monitor case temperature behind regen resistor If case temperature exceeds 60 C regen is overloaded Stop operation immediately Regen resistor is located on the cover Motor Cable For minimal generation of electrical noise use of a twisted shielded conductor for long motor power cables is recommended Ground the shields at both ends to the amplifier s chassis ground and to the motor s frame The motor power input leads are connected to the amplifier s output WIRING THE ENCODER The standard SILVERLINE encoder uses a 10 pin ribbon cable connector It is wired according to the HEDL standard from Hewlett Packard Refer to Figure 2 2 page 17 If you are using a standard SILVERLINE encoder or any encoder compatible with the HEDL standard you may connect the encoder to a BJ BKO 10 breakout terminal strip and from there wire to the RO L Also you can wire from the encoder directly to the RO L using discrete wires and appropriate connectors such as AMP 102387 1 shells Always strain relieve the encoder cable If the encoder cable is disconnected or cable connections are broken the motor will run away Strain relieve at the connectors and along the length of the cable if necessary Be particularly thorough when providing strain relief in environments with significant vibration CHAPTER 2 MOUNTING AND WIRING Table 2 1 Silverline Encoder Signal Name 5 Cust Supplied Common 3 6
22. ONITOR RET J6 15 and adjust until the meter reads near zero volts Command Scaling Adjustment Command scaling is adjusted at the factory so that 10 volts generates peak current or peak voltage if the RO L is in open loop mode You can reduce this scaling by adjusting the GAIN trimpot Peak Current Limit Adjustment To change current limits lock the motor shaft Turn the Current Limit potentiometer counter clockwise to zero then turn clockwise to the appropriate value For this adjustment you can monitor current with a voltmeter from CHAPTER 3 CHECK OUT IMONITOR J6 8 to IMONITOR RET J6 15 The amplifier will produce peak current for about 2 seconds Lower current commands are allowed for longer time periods You must set the current limit so that the instantaneous motor current does not exceed the specified motor peak current rating This can permanently damage the motor For RO L amplifiers peak current is set at the factory at two times continuous current The peak current of the RO L 20004 is normally 8 amps DC the peak of the RO L 20012 is 25 amps DC If your motor peak rating is below these levels you must adjust down the current limit Do not exceed the motor peak current rating Adjust down the current limit to stay within motor ratings CAUTION Improving Current Loop Performance For current loop and velocity loop systems settings from Table 3 1 provide suitable performance for most syste
23. RO L Installation Manual Old Number Manual M96103 Kollmorgen Motion Technologies Group July 1996 New Number MRO000H RO L Installation Manual Manual 96103 Kollmorgen Motion Technologies Group 201 Rock Road Radford VA 24141 July 1996 c Copyright 1996 Kollmorgen Corporation All rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Kollmorgen Corporation All rights reserved No part of this book shall be reproduced stored in a retrieval system or transmitted by any means electronic mechanical photocopying recording or otherwise without written permission from the publisher While every precaution has been taken in the preparation of this book the publisher assumes no responsibility for errors or omissions Neither is any liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Kollmorgen Corporation and furnished for customer use ONLY No other uses are authorized without written permission of Kollmorgen Corporation Information in this document is subject to change without notice and does not represent a commitment on the part of Kollmorgen Corporation Therefore information contained in this manual may be updated from time to time due to product improvements etc and may not conform in every respect to issues NEC is a trademark of the National Electric Code KOLLMORGEN SILVERLINE RB
24. RO L Model Number Scheme SPECIFICATIONS AND RATINGS Specifications Control Outputs AMP OK TTL Level Current Overload Monitor RMS Current ANALOG INPUT Faull Differential 10 volts Type Impedance Approximately 50 kOhm ANALOG INPUT Maximum Current 20mA for AMP OK sink only Voltage Range for TTL 5 10 AMP OK IMonitor 1V 1 33 RO L 20004 1V 4 00 ADC 1 20012 Control Inputs ANALOG CMD Analog ENABLE TTL Level Control Method Switch selectable for Velocity Loop Current Loop Open Loop AC Power Supply Integral on ROL and Regen RO L INSTALLATION MANUAL CHAPTER 1 SYSTEM DESCRIPTION Do not short IMONITOR J6 8 For ROL amplifier or IMONITOR RET J6 15 to ground If load inertia is large or if rapid deceleration occurs Do not connect to frequently regen unit will oscilloscope ground overheat Permanent damage will occur CAUTION IMONITOR J6 8 and CAUTION IMONITOR RET J6 15 are not Monitor case temperature isolated they are referenced behind regen resistor If to bus There is normally 70 case temperature exceeds VDC between these signals 60 C regen is overloaded and ground Stop operation immediately Regen resistor is located on the cover Table 1 1 Specifications RO L 200xx DESCRIPTION RO 20004 RO 20012 ROL 20004 ROL 20012 Main Bus Minimum 50 VDC 50 VDC 30 VAC 30 VAC Maximum 190 VDC 190 VDC 130 VAC 130 VAC Output Current 40 C Ambient Cont
25. cing devices must be properly suppressed NOTE PP Solid state controls of the RO L may be affected by transient voltages These voltages may exceed the specified voltage for any given circuit When these peak voltages occur even for less than a second permanent damage can occur To help avoid transient voltages that may interfere with electronic circuit functions within the RO L all switched inductive devices or their wiring solenoids relay coils starter coils etc must be suppressed A 220 ohm 1 2 watt resistor in series with a 0 5 micro farad 600 volt capacitor is suggested Electrical Noise The low levels of energy in the RO L control circuits may cause them to be vulnerable to electrical noise Sources of electrical noise include equipment having large fast changing voltages and currents when they switch on and off These devices have the capability of inducing current and voltage transients on their respective power lines Accommodation must be made for these transients using noise immunity provisions Error Bookmark not defined Electrical noise is prevented with the same methods as surge current and transient voltages However there are other methods of preventing electrical noise such as Maintain physical separation between electrical noise sources and the RO L amplifier 36 RO L INSTALLATION MANUAL Maintain physical separation between electrical noise sources and the RO L control wiring
26. citance in the ANALOG CMD line Figure 2 1 below shows a typical servo system using the RO L amplifier The main source of noise is usually capacitive coupling Voltage transients generated from power semiconductors couple to the ANALOG CMD lines through parasitic capacitance Ccap Reduce Cecap by using a shielded twisted pair conductor for the ANALOG CMD Also separate signal and motor leads as much as is practical including routing them in separate conduits or wire ways separation also reduces magnetic coupling Finally connect the motor frame to earth ground RO L INSTALLATION MANUAL Controller Figure 2 1 Capacitive Coupling Voltage drops across ground leads become more significant as the distance between the controller and amplifier increase Usually the RO L differential input will correct this problem when connected as shown in Figure 2 1 Bear in mind that even though the commons of the controller and amplifier are electrically connected there usually exists a small voltage difference between the units especially if they are well separated The differential input with the controller common connected to ANALOG CMD compensates for this in most cases The commons of the controller and amplifier must be connected as shown in Figure 2 1 The differential input compensates only for sub volt ground noise The system will not operate properly if there is a substantial potential across the commons of the two units Wh
27. cy shown here is the 3dB point the point at which the response is 70 of the command We assume here that the command and response are scaled the same However in an actual system you will need to adjust your scope so the magnitudes show the same Do this at a low frequency so you can be sure the loop is responding without attenuation After adjusting your oscilloscope you can directly compare the two signals at higher frequencies Notice also in Figure 3 6 that the feedback current lags the command Here the lag is about 1 8 of a revolution or 45 This lag is typical for a well behaved system A large lag at the 3dB point especially over 90 indicates a somewhat unstable system 31 RO L INSTALLATION MANUAL Measurement and Control To observe current loop operation lock the shaft Apply a 10 on time pulse to ANALOG CMD 16 3 4 Monitor current with a DC current probe on one of the two motor leads with current or measure current with an oscilloscope on IMONITOR J6 8 where 1 0 volt is scaled for either 4A RO L 20012 or 1 33A RO L 20004 Do not short IMONITOR J6 8 or IMONITOR RET J6 15 to ground Do not connect to oscilloscope ground AN AUTION rm IMONITOR J6 8 and IMONITOR RET J6 15 are not isolated they are referenced to bus There is normally 70 VDC between these signals and ground CHAPTER 3 CHECK OUT If locking the shaft is impractical configure the drive for a ze
28. e generated and the amplifier will disable This problem can be corrected two ways for the RO increase the value of capacitance and for the ROL dissipate the energy through a shunt resistor Increasing Bus Capacitor RO For the RO over voltage due to regen can sometimes be corrected by increasing the bus capacitance This works best when the amount of energy to be returned is small That is load inertias are small and overall change in velocity is limited The larger the amount of energy the larger the bus capacitors In some applications the capacitors can become so large as to be impractical This method works only on the RO as the connections to the bus are inaccessible on the ROL Dissipation of Regen Energy ROL The ROL provides a regen unit a circuit to dissipate regenerative energy into a shunt resistor That resistor is mounted on the inside of the ROL cover For 4 ADC units which are convection cooled the regen resistor can dissipate 10 watts continuous For 12 ADC units which are fan cooled that resistor can dissipate 30 watts If you have an application for a 4 ADC unit and there is a large amount of regenerative energy you can order a 12 ADC unit which includes a fan kit and set SW1 3 for 4 ADC operation RO L INSTALLATION MANUAL For ROL amplifier If load inertia is large or if rapid deceleration occurs frequently regen unit will overheat Permanent damage will occur CAUTION
29. ecent version of our product information and literature and application and field manuals techncial assistance Kollmorgen Customer Support Network 203 Rock Road Suite A Radford VA 24141 Phone 888 774 KCSN 5276 Fax 540 639 1640 Inside Sales Fax 540 639 1574 T echnical Suppor t Email servo Kollmorgen com Http wwwKollmorgen com 45 APPENDIX C REGIONAL SALES OFFICES 46 RO L INSTALLATION MANUAL RO L INSTALLATION MANUAL INDEX BJ BKO 10 35 Block Wiring Diagram 5 Bus Capacitor Reservoir 10 Circuit Breakers 9 Commutation 26 Commutation Diagram 120 Degree 14 60 Degree 15 Compliance 33 Connector 36 Connector J1 12 19 Connector J6 15 19 20 Connector J9 15 21 Connector Layout Main PCB 18 Connector Overview 16 Continuous Current 3 27 Convection 8 Critical Damping 30 Current Continuous 3 27 Peak 3 Current Loop Mode 24 Current Monitor 26 Detuning 29 30 Differential Encoder 25 Direction Reversing 28 Electrical Codes 9 Electrical Noise 9 36 EMI 9 36 Encoder 17 Connection 11 Phasing 13 Encoder output Single ended 15 Environmental Considerations 8 Fan 8 Fault Hall Sensor 27 Over current 27 Over voltage 27 Troubleshooting 29 Fuses 9 Grounding Integrity 36 INDEX Hall Sensor Fault 27 Humidity 8 IMONITOR 13 26 32 Installation Requirements 8 Isolation 12 LEDs 27 Limitations Velocity Loop 25 Maintenance 3
30. en wiring your RO L system observe the following guidelines 1 Use shielded twisted pair cable for ANALOG CMD 2 Separate motor and signal leads Run motor and signal leads in separate conduit or wire ways 3 Minimize lead lengths 4 Connect common of controller and amplifier 5 Ground the motor case CHAPTER 2 MOUNTING AND WIRING 6 Provide adequate strain relief for all cables and wires MOUNTING The RO L should be mounted in a cabinet or other suitable enclosure to protect it from physical and environmental damage Convection non fan cooled units must be mounted vertically These units require 25 mm 1 clearance on both sides as well as at least 25 mm 1 above and below See the RO L outline drawing in Appendix B for more information MOUNTING THE FAN A fan is required to cool the 12 ADC RO L RO L 20012 and 4 ADC units RO L 20004 that require more regenerative dissipation than can be obtained with convection cooling The fan mounts in the fan bracket both of which are standard with the RO L 20012 Mount the fan bracket assembly 25 mm 1 below or 25 mm 1 above the RO L with the air stream pointed towards the amplifier and flowing through the heat sink fins See the fan bracket outline drawing in Appendix B for more information WIRING OVERVIEW The customer is responsible for providing proper circuit breaker or fuse protection The customer is responsible for providing prope
31. hould probably be reduced If the motor is below 50 C you should be able to comfortably rest your hand on it If you are operating your RO L in velocity loop mode temporarily configure for current loop mode as discussed at the start of Chapter 3 Phasing by Trial and Error 1 Turn SW1 10 on if your motor uses 120 commutation Turn SW1 10 off for 60 Contact the motor manufacturer to determine which is appropriate 2 Putthe amplifier in open loop mode see Table 3 1 3 Set ANALOG CMD for 1 0 volt 4 Connect the three hall sensor 51 52 and S3 leads arbitrarily Hall power and common must be connected correctly 5 Enable the amplifier 6 Tryallsix combinations of motor lead connections until the motor rotates freely Always remove power from the amplifier when changing motor lead connections Note some incorrect wiring combinations will cause the motor to rotate but inefficiently and with zero torque positions or dead spots Carefully stop the motor by hand and feel torque as you let the motor rotate slowly If the wiring is correct torque will be nearly continuous throughout the rotor rotation 34 RO L INSTALLATION MANUAL Charter 4 MAINTENANCE CHAPTER 4 MAINTENANCE INTRODUCTION Information in this chapter will enable you to maintain the system components ensuring reliable efficient operation of the system Preventative maintenance of the equipment is also specified along with period
32. ic maintenance Follow these practices when operating your servo system SPARE PARTS BJ BKO 10 Silverline Encoder Breakout Terminal The BJ BKO 10 can be used to simplify Silverline encoder connections Mount the breakout near the amplifier and run a ribbon cable between the breakout and the motor Connect J9 to screw terminals as shown in Figure 2 6 Use scissors to cut ribbon cable A bench vise is necessary to make up ribbon cable connectors ROL Slow Blow Glass Fuse Qty 1 Wickman 19195 16 16 Amp Fuse The ROL Fuse is located in JL the line connector PREVENTATIVE MAINTENANCE Preventative maintenance can prevent situations that will damage your equipment Four types of preventative maintenance are presented below Following each of these procedures can reduce problems with and add life to your equipment Electronic components in this amplifier are static sensitive Use proper procedures when CAUTION handling component boards Preventative maintenance should be performed with the RO L system out of operation and disconnected from all sources of power 35 CHAPTER 4 MAINTENANCE Preventative maintenance to this equipment must be performed by qualified personnel familiar with the construction operation and hazards involved with the application CAUTION Always take equipment out of operation and disconnect it from all power sources before performing maintenance Transient Voltages AII transient produ
33. inuous 4 ADC 12 ADC 4 ADC 12 ADC 8 ADC 25 ADC 8 ADC 25 ADC Frequency zounes 15 ooutimeton oneeeime Frequency 22 kHz 15 22 kHz 15 22 kHz 15 22 kHz 15 nuan asop jean __ omo Inductance 250 uH 250 uH 250 uH 250 uH Table 1 2 Velocity Loop Velocity Loop Specification 0 2 Full Scale Velocity Range 2000 1 Max Frequency 125 kHz Encoder Level TTL single ended CHAPTER 1 SYSTEM DESCRIPTION RO L INSTALLATION MANUAL Table 1 3 Integral Power Supply Specifications ROL Only Table 1 4 Environmental Specifications Operating Temperature 0 C to 40 C Storage Temperature 20 C to 70 C Humidity Non Condensing 10 to 90 For operation ambients above 40 C consult the Applications Engineer at your ICP Regional Office Table 1 5 Mechanical Specifications Please see Appendix B for outline drawings Please note that the RO L 20012 requires a separately mounted fan RO L INSTALLATION MANUAL CHAPTER 1 SYSTEM DESCRIPTION ANALOG COMMAND ROL Amplifier JL 115 VAC LINE CORD Rectifier amp Capacitor Regen Controller Sensors 5VDC Power Customer Supplied To Controller Encoder _ Optional ANALOG COMMAND Controller 5VDC Power Customer Supplied To Controller Optional DC Bus For RO Amplifier Rectifier reservoir capacitor and regen shunt are supplied by customer Figure 1 2 B
34. it will overheat Permanent damage will occur CAUTION Monitor case temperature behind regen resistor If case temperature exceeds 60 C regen is overloaded Stop operation immediately Regen resistor is located on the cover If you exceed the RO L continuous current rating for an extended period of time allow your unit to cool it will re enable automatically If this happens regularly your amplifier may be too small for the application or your cooling may be insufficient Ensure that the ambient temperature does not exceed the specified maximum 40 C For fan cooled units RO L 20012 ensure that the fan is operational and that air paths are not blocked For convection cooled units RO L 20004 ensure that the unit is mounted vertically and that sufficient room is provided on all sides of the amplifier to allow air to draft up through the heat sink Any fault will inhibit the amplifier When the condition is corrected the amplifier will automatically enable WARNING This may cause unexpected operation and motion 27 RO L INSTALLATION MANUAL CHAPTER 3 CHECK OUT Table 3 2 SWI1 Settings Velocity Control Switch Function Position SWI I SWI 2 Current Loop Gain Normally ON SWI 4 Velocity Loop Integrator SWI 3 Current Scaling OFF for 4 ADC Cont ON for 12 ADC Cont SWI 5 Duty Cycle Feedback Current or Velocity Loop OFF Open Loop ON SWI 6 Velocity Feedback SWI 7 SWI 8 Cu
35. ll suited RO L INSTALLATION MANUAL when the motor and amplifier are in a noisy environment or separated Second the range of adjustment is limited Velocity loop operation may be unacceptable for some applications particularly those with large inertial loads and those requiring high bandwidth However the RO L provides locations for various discrete components which you can solder directly into the PCB see C67 C69 and R26 in Figure 3 1 Start up the Current Open Loop Controller Configure and test current loop or open loop modes If you plan to use velocity loop mode complete this section with your RO L amplifier in current loop mode See Table 3 1 below Table 3 1 SW1 Settings Non Velocity Control Switch Function Position SWI I SW1 2 Current Loop Gain Normally ON SW1 3 Current Scaling OFF for 4 ADC Units RO 20004 and ROL 20004 ON for 12 ADC Units RO 200012 and ROL 200012 SWI4 Velocity Loop Integrator SWI 5 Duty Cycle feedback Velocity or Current Loop Modes OFF Open Loop Mode ON 5 1 6 Velocity Feedback SWI 7 Normally OFF for Silverline Motors SWI1 8 Current ON 2 1 Normally ON Peak Continuous SWI1 9 Velocity Loop Gain OFF SWI1 10 120 Commutation Normally ON The amplifier will be enabled and the motor will turn Make WARNING Sure the motor is secured THE MOTOR MAY MOVE UNEXPECTEDLY STAND CLEAR OF THE MOTOR BE PREPARED TO REMOVE POWER FROM THE RO L WARNING Thi
36. lock Wiring Diagram for ROL and RO Amplifiers CHAPTER 1 SYSTEM DESCRIPTION RO L INSTALLATION MANUAL Error No topic specified Figure 1 3 ROL System Wiring Diagram Velocity Loop Mode RO L INSTALLATION MANUAL Charter 2 MOUNTING AND WIRING INTRODUCTION This chapter provides information concerning safety unpacking inspection and installation for the RO and ROL amplifiers Read the entire chapter carefully because most installation problems are caused by incorrect wiring or poor wiring practices SAFETY INFORMATION This section will alert you to possible safety hazards associated with this equipment and the precautions you can take to reduce the risk of personal injury and damage to the equipment Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational difficulty CHAPTER 2 MOUNTING AND WIRING A A WARNING CAUTION NOTE The safety alert symbols are illustrated above When you see these symbols in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols WARNING refers to personal safety and alerts you to potential danger or harm Failure to follow warning notices could result
37. ms The current loop is stable and should have a bandwidth in excess of 1000 Hz If you wish to modify the loop performance please refer to discussions on tuning theory later in this chapter LEDs The RO L provides one red green light emitting diode LED on the front Green indicates that bus power is applied and that the amplifier is OK Red indicates a fault Faults disable the amplifier and turn off the amplifier OK LED Removal of the fault condition enables the amplifier and turns the green LED on Faults The RO L includes protection against excessive voltage current and temperature Also if you provide an invalid Hall sensor pattern e g all sensors on in 120 commutation a fault is generated Any fault will turn on the red LED on the front panel and force AMP 76 16 high If you exceed the RO L bus voltage J1 4 and 5 on the RO the amplifier will fault The most common cause of this fault is bus voltage elevation due to regenerative energy The ROL power supply provides a regen unit which can RO L INSTALLATION MANUAL dissipate up to 10 Watts convection or 30 Watts fan cooled of regenerative energy If you are using an ROL and you are still experiencing this fault your system is probably overloading the regen unit Contact your regional office for more information see Appendix C For ROL amplifier If load inertia is large or if rapid deceleration occurs frequently regen un
38. nce is a high frequency gt 500 Hz where the system mechanics oscillate Normally systems with resonance will be very stable when you tune with lower target bandwidths As you increase the target bandwidth you will begin to hear a fairly pure high pitch If you want to decrease resonance use shorter larger diameter driving shafts When your system has a resonance it will have the following characteristic The system will emit a clear high pitch gt 500 Hz Do not confuse this problem with compliance which has a low pitch If the system performance is poor because of resonance you can make the following corrections Reduce the bandwidth of the system Shorten the length and increase the diameter of shafts and lead screws 33 RO L INSTALLATION MANUAL CHAPTER 3 CHECK OUT EMPIRICAL METHOD PHASING NON KOLLMORGEN MOTORS This section discusses how to determine empirical phasing for non Kollmorgen motors Chapter 2 discussed how to connect non Kollmorgen motors in Wiring Motor Leads for Other BLDC Motors That section is based on using sequences for either 60 or 120 commutation However if the corresponding information for the motor is not available use the following trial and error procedure During this procedure ensure that the motor does not overheat Depending on the motor the specified analog command voltage may be too large If the motor frame temperature exceeds 50 C the command s
39. ng SWI 9 on detunes the velocity loop Checking the Velocity Loop Response The response can be monitored on the TACH MONITOR J6 7 Attach an oscilloscope and monitor the motor velocity feedback Velocity loop response should be tested by monitoring the TACH feedback on large velocity transitions Quickly switch the velocity command from 0 to max Observe the motor velocity feedback for overshoot and ringing Adjust the GAIN pot or change the integrator value by turning on SW1 9 Setting Velocity Offset Short the velocity command J6 4 and 5 Enable the RO L amplifier The motor should not be moving but should have holding torque If the motor is rotating slowly adjust the offset pot until motion ceases Check Velocity Command Scaling Attach velocity command reference to J6 4 and J6 5 Apply the maximum velocity command which is to be used Adjust scaling pot until motor velocity is at the maximum velocity desired This sets the ratio between RPM and velocity command voltage RO L INSTALLATION MANUAL Troubleshooting Fault e Verify that the motor shaft rotates freely with no power applied when uncoupled from the load e Verify that the minimum inductance requirement is met Heat Sink Temperature Verify that the amplifier base plate temperature does not exceed 60 C A thermostat monitors the plate Check for air blockage For fan cooled units ensure that the fan is operational Over Voltage Shutdown
40. on Motor Cable WIRING THE ENCODER WIRING THE AMPLIFIER Wiring JL Line Cord ROL only Wiring J1 Bus Power and Motor Leads Wiring J6 Amplifier Status and Control Wiring J9 Encoder Switch SWI CHAPTER3 CHECK OUT AND COMMISSIONING START UP AND CHECK OUT Mode Selection Start up the Current Open Loop Controller Start up the Velocity Controller TABLE OF CONTENTS 23 25 28 TABLE OF CONTENTS RO L INSTALLATION MANUAL Velocity Loop Tuning 28 Troubleshooting 29 STABILITY AND PERFORMANCE 30 Critical Damping 30 Underdamping 30 Overdamping 31 Ringing 31 ADVANCED CURRENT LOOP TUNING 31 Theory of Operation 31 Measurement and Control 32 VELOCITY LOOP PROBLEMS 33 Compliance 33 Non Linearities 33 Resonance 33 EMPIRICAL METHOD PHASING NON KOLLMORGEN MOTORS 34 CHAPTER4 MAINTENANCE 35 INTRODUCTION 35 SPARE PARTS 35 PREVENTATIVE MAINTENANCE 35 Transient Voltages 36 Electrical Noise 36 Radio Frequency Energy 36 PERIODIC MAINTENANCE 36 Grounding Integrity 36 APPENDIX WARRANTY INFORMATION 37 APPENDIX B OUTLINE DRAWINGS 39 APPENDIX C REGIONAL SALES OFFICES 45 SOUTHERN REGION 46 EASTERN REGION 46 MIDWEST REGION 46 WESTERN REGION 46 INTERNATIONAL 46 INDEX 47 vi RO L INSTALLATION MANUAL LIST OF TABLES Table 1 1 Table 1 2 Table 1 3 Table 1 4 Table 1 5 Table 2 1 Table 2 2 Table 2 3 Table 2 4 Table 2 5 Table 2 6 Table 3 1 Table 3 2 Specifications Velocity Loop Integral Power S
41. ound should be checked to assure its integrity on a regular basis This check should be performed with the power off and the testing equipment grounded RO L INSTALLATION MANUAL APPENDIX A WARRANTY INFORMATION Arrenpix A WARRANTY INFORMATION Kollmorgen Corporation warrants that equipment The terms and conditions of this Warranty are delivered by it to the Purchaser will be of the kind provided with the product at the time of shipping or and quality described in the sales agreement and or in advance upon request catalog and that the equipment will be free of defects in design workmanship and material The items described in this manual are offered for sale at prices to be established by Kollmorgen and its authorized dealers 37 RO L INSTALLATION MANUAL APPENDIX B OUTLINE DRAWINGS OUTLINE DRAWINGS This appendix contains outline drawings for H Series motors and RO L electronics 39 A PPENDIX B OUTLINE DRAWINGS RO L INSTALLATION MANUAL o N H o 12 ra 2 T e E e gu qa u gi 9 TN 40 AN CAUTION HIGH VOLTAGE 25 130 VAC 50 60 Hz INPUT amp FUSE Figure B 1 ROL Series Outline 6187 250 HEATSINK RO L INSTALLATION MANUAL APPENDIX B OUTLINE DRAWINGS i e 0 x u z N E o ee x E a o0 Son l 2 PL REF 7 038 3 230 2 PL RE
42. r wire gauge and insulation rating for all wiring including motor AC line and DC bus The customer is responsible for making sure that all system wiring and electrical protection comply with applicable national and local electric codes Strain Relief cables that connect to the RO L must be properly strain relieved Excessive strain causes damage to the connectors cables or PCB and may result in failure or in unreliable operation Ribbon cables must be properly strain relieved Absent or inadequate strain relief of insulation displacement connector IDC systems causes unreliable interconnects CHAPTER 2 MOUNTING AND WIRING Strain relieve all cables leading to the RO L Strain may cause damage which will result in failure or in unreliable operation CAUTION Motor Protection Be aware that fusing the power supply input lines does not necessarily limit current in the individual motor leads especially when the motor is stalled or rotating slowly The pulse width modulation PWM topology used in this amplifier can produce large motor currents from small line currents Do not rely on power supply fusing to limit current in the motor leads If motor leads must be current limited then protect the motor leads with motor overload relays or fuses in addition to fusing the power supply input lines Bus Capacitor RO Only The customer must provide bus capacitance for RO amplifiers the ROL provide sufficient
43. ro torque position set for 60 commutation turn SW1 10 off and remove the HALL POWER J6 10 to disable hall sensors This allows current to be commanded without generating torque In this procedure always apply current in one direction or the shaft will turn Use very low current rather than zero current Observe the response to the pulse it should be rapid and not overshoot more than 10 If the response is not as you desire change the current loop gain switch SW1 2 If response is still inadequate turn SW1 2 off and install R26 and C69 with appropriate values For tuning install them temporarily one at a time and in increments of about 20 until you achieve the desired response Command 2 Feedback Figure 3 6 3dB Point 70 Attenuation 32 CHAPTER 3 CHECK OUT VELOCITY LOOP PROBLEMS The mechanical construction can limit the performance of your velocity loop The problems caused by the mechanics fall into three categories 1 Compliance 2 Non Linearities 3 Resonance Compliance In compliant systems the load is not tightly coupled to the motor shaft If you move the load by hand you can feel springiness Compliant systems often are very stable when you tune with lower target bandwidths However they oscillate vigorously at low frequencies when you try to tune them for higher bandwidths A compliant system has the following characteristics There is springiness between the
44. rrent Limit ON 2 1 Normally ON Peak Continuous SWI 9 Velocity Loop Gain SW1 10 120 Commutation Start up the Velocity Controller This section describes how to start up the velocity controller Before proceeding in this section you should complete the Start up the Current Controller section above Disable the RO L Check out the Encoder Connect a meter or oscilloscope probe to TACH MONITOR J6 7 Rotate the motor by hand Verify that TACH MONITOR changes as you rotate the motor The generated voltages will be small since TACH MONITOR is scaled for 1 0 volt 22 kHz of encoder line frequency about 1300 RPM for 1000 Line encoder Rotate the motor both directions and verify that the tach changes sign Do not proceed until your system passes this test Running a velocity loop system with the encoder disconnected or improperly connected may cause the motor to run away a condition where the motor accelerates to full speed without control Do not proceed until the encoder checks out properly Running a system with a WARNING disconnected or improperly connected encoder may cause the motor to run away 28 Normally ON Configure for Velocity Loop Change your configuration according to Table 3 2 Velocity Loop Tuning Be prepared for the motor to run away when you enable the system If the encoder or amplifier are wired incorrectly the motor will run full speed If this happens it may be becau
45. s procedure will enable the RO L The system may be unstable The motor may begin oscillating or it may run away 25 RO L INSTALLATION MANUAL THE MOTOR WILL RUN AT FULL SPEED In current mode an unloaded or lightly loaded motor will run at full speed Load the WARNING motor or lock the shaft if high speed rotation is a safety hazard Use a non conductive device to switch SW1 N A conductive device may slip CAUTION and short connections which may damage the amplifier Apply Power and Enable Apply bus power to your RO L Enable the RO L by shorting ENABLE J6 9 to COMMON J6 2 Check that the LED is green indicating normal operation Running the Motor Adjust a separate power supply to about 1 VDC Connect the negative side of that power supply to ANALOG J6 5 and to common J6 2 connect the positive side to ANALOG CMD 16 4 If the RO L is in current mode an unloaded motor should rotate at near full speed If the RO L is in open loop mode the motor will rotate at about 1096 of full speed In either case rotation should be smooth Slowly reduce the command power supply to zero and let the motor come to rest Disable the amplifier and reverse the power supply and adjust back to 1 VDC Enable the amplifier The motor should rotate in the opposite direction at approximately the same speed If you do not have a power supply you can put the RO L in test mode close
46. se the system is phased backwards If so inverting SW1 7 will correct this problem If the encoder or amplifier are wired improperly the motor may run away Be prepared for the motor to WARNING un full speed To reverse direction of rotation invert SW1 7 The velocity loop may be unstable N If the velocity controller is CAUTION unstable reduce the velocity loop GAIN pot by turning it counterclockwise CCW CHAPTER 3 CHECK OUT Setting Velocity Loop Gain Adjust the velocity command reference until the motor speed is approximately 300 400 RPM If an adjustable command reference is not available the OFFSET pot Pot 4 can be used as a command Turning SWI 1 on will raise the sensitivity to the OFFSET pot allowing a much greater range than normal for offset adjustment However you must adjust offset error out after each use of the pot for this purpose To increase the response of the velocity loop turn the velocity loop GAIN pot Pot 1 CW until the motor is unstable or undesirably noisy Back off approximately one turn or until the motor is stable again Detuning the Velocity Loop Detuning reduces the velocity loop response This can be accomplished two ways 1 reduce GAIN pot or 2 slowing the velocity loop integrator The GAIN pot Pot 1 can be manually adjusted by the user CCW for less gain while the velocity loop integrator value is increased by turning SW1 9 on Turni
47. sitive applications RO L amplifiers have these important features Small package Direct 115 VAC line operation ROL only Integral regen dissipation unit ROL only High linearity Differential 10 volt input User selectable operation modes High performance current loop mode Open loop mode Velocity loop mode e Switch selectable 60 or 120 commutation Over current protection Over voltage protection Continuous current limit e Fully heat sinked e Upto 190 VDC input for RO Up to 130 VAC input for ROL Upto 12 amp continuous 25 amp peak output This manual provides information for installation and operation PART NUMBER DESCRIPTION A model number is printed on a tag on the top of your RO L The model number identifies how the equipment is configured Each component is described in Figure 1 1 Verify that the model numbers represent the equipment required for your application CHAPTER 1 SYSTEM DESCRIPTION RO L Model Number RO L RO Analog Amplifier ROL Analog Amplifier Line Operated Input Voltage 200 135 190 VDC RO only 200 90 130 VAC ROL only Continuous Output Current 04 4 ADC 12 12 ADC RO L INSTALLATION MANUAL 4 0000 Ls eserved 000 Standard ADC refers to DC Amps This unit is used on six step systems to indicate the current in the two motor leads which are enabled in six step one lead is always open circuit 1 ADC 1 1 22 amps RMS Phase Figure 1 1
48. sors S1 J6 13 S2 J6 14 S3 J6 12 Step 1 2 3 4 5 6 Phase B C C A A B Phase A A B B C C 120 Degree Commutation E assumes CW Torque CW Rotation Hall Sensors 51 J6 3 S2 J6 4 S3 6 5 Step 1 2 3 4 5 6 4 Phase B A A C C B Phase C C B B A A 60 Degree Commutation pros assumes CW Torque CW Rotation 14 RO L INSTALLATION MANUAL Motor may run away if motor or encoder leads are connected incorrectly WARNING Wiring J6 Amplifier Status and Control J6 is a 16 pin Molex crimp connector with connections on 2 4 mm 0 1 centers See Figure 2 5 page 20 The mating connector part for J6 is Molex plastic body 22 01 3167 Insert terminals 08 50 0114 Crimp tool 11 26 0009 Wiring J9 Encoder J9 is a 5 pin crimp style connector The mating connector part for J9 is Molex plastic body 22 01 3057 Insert terminals 08 50 0114 Crimp tool 11 26 0009 Refer to Figure 2 6 page 21 If you are using a standard SILVERLINE encoder you can use a BJ BKO 10 a 10 pin ribbon cable DIN rail mounted breakout from Kollmorgen The breakout provides screw terminal connectors for wiring to J9 Connect the encoder via ribbon cable to the BJ
49. strain relieve ribbon cable If the encoder cable is disconnected the motor will run away Vibration can loosen and WARNING disconnect this cable Strain relieve the encoder cable at both ends and along its length WIRING THE AMPLIFIER Refer to Figure 2 3 page 18 for an overview of all RO L connectors Wiring JL Line Cord ROL only Install standard three prong IEC style connector cord which provides 115 VAC line cord in connector JL Note that integral to the JL connector is a line fuse The fuse holder can be removed with a small screw driver The fuse is a 5 mm x 20 mm series 16A fuse such as Wickman 19195 16 If you are using the ROL with a DC bus connect the bus leads to hot and neutral of JL In this case the ROL provides regen for DC input Wiring J1 Bus Power and Motor Leads J1 is a 5 circuit screw terminal with connections on 5 mm 0 2 centers Note that in high vibration environments it is often preferable to crimp a ferrule onto each connection of J1 Refer to Figure 2 4 for wiring page 19 12 RO L INSTALLATION MANUAL For the ROL when using J1 you will need a long narrow blade Insert the blade carefully into the opening in the package above J1 Be careful not to inadvertently unscrew any leads in J1 and not to disturb wiring internal to the ROL Be aware that J1 has two connections hidden by the frame and you must not loosen those connections Doing so will allow internal wiring
50. switch SW1 1 and adjust the offset to create a command voltage However using this method disturbs the offset potentiometer position so that after each use you will need to adjust out offset error If the motor does not turn or does not turn smoothly the hall sensors or motor leads may be 26 CHAPTER 3 CHECK OUT connected improperly Verify motor wiring according to Figure 2 4 Also the commutation method may be selected incorrectly Verify that SWI 10 is properly set ON for SILVERLINE and RBE motors and for most other brushless motors off for brush motors If you are using a non Kollmorgen motor refer to the Non Kollmorgen Motor Phasing section at the end of this chapter Often when the hall sensors are miswired or when the selected commutation method does not match the commutation of the motor the fault LED will flash red and green as the motor rotates Do not short IMONITOR J6 8 or IMONITOR RET J6 15 to ground Do not connect to oscilloscope ground N CAUTION IMONITOR J6 8 and IMONITOR RET J6 15 are not isolated they are referenced to bus There is normally 70 VDC between these signals and ground Offset Adjustment To adjust offset short ANALOG CMD and ANALOG CMD to COMMON J6 4 and J6 5 to J6 2 and adjust trimpot 4 OFFSET until motor torque is minimized An unloaded motor should not turn Optionally you can monitor current with a volt meter across IMONITOR J6 8 and IM
51. tween these signals and ground 20 RO L INSTALLATION MANUAL CHAPTER 2 MOUNTING AND WIRING 10 pin ribbon cable no connect 5 Supply 5 Volt DC Power Supply Common 5 0 Cust Supplied no connect gt J9 5 Common Channel A Channel A 5 5 0 J9 2 Channel B gt Chan A Channel B 7 2 0 D J9 4 Index Chan B Index SILVERLINE Encoder BJ BKO 10 Breakout Feedback Encoder Figure 2 6 Connector J9 Feedback Encoder Velocity Loop Mode Only 21 CHAPTER 2 MOUNTING AND WIRING 22 RO L INSTALLATION MANUAL CHAPTER 3 CHECK OUT Charter 3 RO L INSTALLATION MANUAL CHECK OUT AND COMMISSIONING START UP AND CHECK OUT You should now be ready to test your system functions Be prepared to remove power at any time Limit switches and safety devices should be operational In multi axis systems work with one axis at a time Do not spin the motor without power Unexpected operation may occur The amplifier may be damaged WARNING Do not spin a motor when the amplifier is disabled The motor can act as a generator and charge the power supply This will cause unreliable operation and may damage the amplifier Also the ROL may become operational unexpectedly because it has an internal power converter that operates from the high voltage supply Do not short the motor at a high speed This may damage the motor and the amplifier WARNING
52. upply Specifications ROL Only Environmental Specifications Mechanical Specifications Silverline Encoder Connector J1 Power Connector J6 Connector J9 SW1 Settings RO L Connector Function SW1 Settings Non Velocity Control SWI Settings Velocity Control TABLE OF CONTENTS 11 12 13 15 16 16 25 28 vil TABLE OF CONTENTS RO L INSTALLATION MANUAL LIST OF FIGURES Figure 1 1 RO L Model Number Scheme 2 Figure 1 2 Block Wiring Diagram for ROL and RO Amplifiers 5 Figure 1 3 ROL System Wiring Diagram Velocity Loop Mode 6 Figure 2 1 Capacitive Coupling 9 Figure 2 2 Silverline Encoder 17 Figure 2 3 RO L Connector Layout Main PCB 18 Figure 2 4 Connectors J1 and J6 for SILVERLINE RBE Motors 19 Figure 2 5 Connector J6 Amplifier Enable Command and Status 20 Figure 2 6 Connector J9 Feedback Encoder Velocity Loop Mode Only 21 Figure 3 1 Control Loop Function Diagram 24 Figure 3 2 Critical Damping 30 Figure 3 3 Underdamping 30 Figure 3 4 Overdamping 31 Figure 3 5 Ringing 31 Figure 3 6 3dB Point 70 Attenuation 32 Figure B 1 ROL Series Outline 40 Figure B 2 RO Series Outline 41 Figure B 3 Fan Bracket RO L 20012 Only 42 Figure B 4 Size 23 Outline 43 Figure B 5 Size 34 Outline 44 viii RO L INSTALLATION MANUAL 1 SYSTEM DESCRIPTION CHAPTER 1 SYSTEM DESCRIPTION INTRODUCTION The Kollmorgen RO L series amplifiers are six step modules designed to bring high performance to cost sen
53. y affect its operation Kollmorgen recommends that the RO and ROL be operated and stored under the following conditions e Operating Temperature 0 C to 40 C e Storage Temperature 20 C to 70 e Humidity 10 to 90 Non Condensing RO L INSTALLATION MANUAL Ventilation Convection non fan cooled units should be mounted vertically to allow maximum ventilation of the components This configuration allows hot air to vent through the top and draft in cooler air through the bottom Allow at least 25 mm 1 on all sides for ventilation Ensure that ventilation paths are not constricted Minimum Inductance Requirement The RO L requires a minimum motor line to line inductance of 250 to ensure that the motor current is properly filtered If the motor inductance is too small add external inductors Contact your regional office for more information Noise and System Grounding Electrical noise can degrade the performance of the entire system Most electrical noise is caused by improper wiring There are four ways noise is coupled into the amplifier 1 Capacitive or electrostatic coupling from motor leads to signal wires The path is shown below in Figure 2 1 as parasitic capacitance Ccap This type of noise is usually the predominant one in motor controllers 2 Magnetically coupling from motor leads to signal wires 3 Voltage drops across ground connections 4 Op amp oscillation due to excessive capa
Download Pdf Manuals
Related Search