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User's Manual

1. aids User s Manual 024 8080 D ST1 9 5 LIO LINK BOARD WIRING Part number 024 7040 9 5 1 FUNCTIONAL DIAGRAM 24VDC 9 external source 18b RESET IN O IN 1 OUT7 ok closed d 16 inputs 8 outputs UART Fault output RESET 8K 8 input EEPROM LIO Board sequence memory Address selector 2 RESET ST1 O BUS ok om mm gt Voltage HIGH 19 30 VDC admissible when open cutting capacity LOW 16 45 VDC 0 3 43 VDC DC 150 VDC 35 W 125 VA 54 STI User s Manual 024 8080 D 9 5 2 BINARY INPUTS AND OUTPUTS SCHEMATICS JUNCTION MODULE LIO BOARD 100k RESET 22 RESET L INPUT fe U IN10 IN11 IN12 IN13 IN14 TOWFROM SEQUENCER IN15 OUTO OUT1 OUT2 OUT3 OUTPUT OUT4 OUT5 OUT6 OUT7 H 1 gt n gt T N P6KE51 0 Delays due to the RC filter Raising edge Falling edge User s Manual 024 8080 D STI 9 5 3 JUNCTION MODULE OUTLINES AND SCHEMATICS 2 5 63 135 f G 5LL Ex G 222 WH 2 2 228 Flat ribbon cable to OIO or LIO board 56 STI User s Manual 024 8080 D 9 5 4 SERIAL LINK WIRING Machine control equipment With active transmission and active reception 57 User s Manual 024 8080 D ST1 9 6 LS LINK BOARD
2. CADBIN Variable selection for igital output 024 8068 A 7 7 2 CMPBIN Test device enable and disable 024 8068 A 7 7 2 CADMAIL Variable selection for analog output 1 024 8068 A 7 7 3 CMPMAIL Gain selection for analog output 1 024 8068 A 7 7 3 CADMA2 Variable selection for analog output 2 024 8068 A 7 7 4 2 Gain selection for analog output 2 024 8068 A 7 7 4 24 STI User s Manual 024 8080 D 3 3 2 LPO LINK BOARD PAM SPECIFIC PARAMETERS Length Units Velocity Profile Acceleration range and Motion reversal Inverse of CKA Velocity range 1st conversion cste for position set values 2nd conversion cste for position set values Required travel speed for moves Required acceleration Required deceleration Specific deceleration for stops Left limit for absolut position Right limit for absolut position 3 3 3 LIO LINK BOARD SPECIFIC PARAMETERS CKA CKAINV CKV CKR CKH Velocity Profile LSMRI LSMR2 ADAXE TIMOUT ENDBYT CINACL CINMAS ZMANAL Acceleration range and Motion reversal Inverse of CKA Velocity range 1st conversion cste for position set values 2nd conversion cste for position set values Required travel speed for moves Required acceleration Required deceleration Specific deceleration for stops Left limit for absolut position Right limit for absolut position Transmission type Baudrate selection Peripheral address Time out Answer terminat
3. Refer to document 024 8034 for optic fiber cable confection 62 STI User s Manual 024 8080 D 9 9 OEI OPTIONAL BOARD WIRING Part number 024 7045 9 9 1 WIRING DIAGRAM Encoder connector X61 tc C slo S 5 gt Ni R V X61 lis dia dis 42 dat dodo ds 47 PE ADT T 45V Out 1 ua JN S 5 6 d5 d4 1 12 VET ovn Ua2 Ual Power connector X62 24V 5VDC ov External supply Converter OUT IN Reference enable of tof 11 12 x62 drm e g 3 T eg Gee DC DC converter Option zd User s Manual 024 8080 D ST1 9 9 2 INCREMENTAL INPUT TYPES The OEI Option Board is available in 3 different hardware versions depending on the application and more particularly the kind of incremental input it has to interface Actually the only difference resides within a programmable IC and can also be checked reading the tag on it Part Number Typical Use Input Signals at X61 Resolution PAL tag Counting Up Counting Down 024 7111 Incremental Encoder old 024 7045 quadrature signals Filtre V2 4 x Line Count 024 7113 Step Motor Input 1 input for pulses up and Filtre V4 1 for pulses down 2 x Line Count 024 7112 Step Motor Input Line Count 1 pulse and 1 direction m Filtre V3 input nm 64 STI User s Manual 024 8080 D 9 10 OIO OPTI
4. 22 3 2 7 EMERGENCY BRAKE RESISTORS SELECTION 22 3 2 8 COOLING THE BA4 AND STI UNITS 23 3 3 DEFINING THE STI PARAMETERS 24 3 3 1 STI PARAMETERS NECESSARY FOR ALL APPLICATIONS 24 3 3 2 LPO LINK BOARD PAM SPECIFIC PARAMETERS 25 3 3 3 LIO LINK BOARD SPECIFIC PARAMETERS 25 3 3 4 LS LINK BOARD SPECIFIC PARAMETERS 26 3 3 5 LA LINK BOARD SPECIFIC PARAMETERS 26 3 3 6 PARAMETERS FOR OPTIONAL FUNCTIONS 26 4 APPLICATION TESTING 28 4 1 FRONT PANEL DISPLAYS 28 4 2 STATUS INDICATORS FOR REMOTE DIAGNOSIS 29 4 2 1 STATA 29 4 2 2 STATB 30 4 2 3 STATC 30 4 2 4 STATD 31 4 2 5 STATE 31 4 2 6 STATF 31 4 3 TEST DEVICE 31 4 3 1 DIGITAL MEASURING 31 4 3 2 ANALOG MEASURING 32 4 4 PUTTING INTO SERVICE 32 5 PREVENTIVE MAINTENANCE 33 6 TROUBLE SHOOTING 34 7 EMC 35 7 1 GENERAL 35 STI User s Manual 024 8080 D 7 2 CABINET DESIGN 36 7 3 CABINETS CONFIGURATION 37 7 3 1 EXAMPLE 1 37 7 3 2 EXAMPLE 2 38 7 4 DETAILS 39 7 4 1 RESOLVER S CABLE WIRING ST1 SIDE 39 7 4 2 MOTOR S CABLE S WIRING ST1 SIDE 39 7 4 3 MOTOR AND RESOLVER CABLE WIRING MOTOR SIDE 40 7 4 4 SUPPLY S AND BRAKING RESISTOR S CABLE WIRING BA4 SIDE 41 7 4 5 BRAKING RESISTOR S CABLE WIRING RESISTOR SIDE 41 7 4 6 CONNECTION BETWEEN CONTROL CABINETS AND THE MACHINE 42 8 OUTLINES 43 8 1 BA4 AND ST1 OUTLINES 43 8 2 STI LINK AND OPTION BOARD ASSEMBLY 44 8 3 STI AND BA4 BOTTOM VIEW 45 8 4 ST1 UPPER VIEW 46 8 5 DYNAMIC BRAKIN
5. 231 3693 231 3095 FWTA 40 300 231 3740 3 231 3744 f 231 3750 FWTA 40 400 3 231 3827 231 3835 5 231 3843 FWTA 60 300 231 3886 231 3888 231 3890 FWTA 60 400 231 3933 231 3937 231 3941 FWTA 60 500 231 4014 231 4022 231 4030 16 STI User s Manual 024 8080 D 2 6 6 EMC FILTERS EMC filters shall be chosen so that national electrical regulations are fulfilled in the country where the system is to be used The filters used shall be tested to comply with the EMC regulations ACC SA recommends the filters listed in below Other filters will be added in a next issue of this manual Type Rated current Leakage curr Losses L Cx Cy R2 p n Recommended at 40 C At 400V 50Hz for FA4 Arms max mA W uF uF MQ MQ FN351 25 33 25 160 8 2 2 4 4 1 8 1 5 1 1 410 0125 BA4 30 50 310 FN351 50 33 50 175 11 0 8 4 4 2 1 5 1 1 410 0129 4 60 80 310 FN2010 3 6 3 0 4 2 5 0 1 4 7 1 410 0031 Auxiliary supply of all BA4 FN351 a Load dp c Me IEEE PE sta005_a dsf 18 12 96 FN2010 EN Load Line P E sta006_a dsf 18 12 96 f User s Manual 024 8080 D ST1 3 APPLICATION DESIGN CHECK LIST 3 1 MECHANICAL AND STRUCTURAL DESIGN 3 1 1 DRIVE AND CONTROL CONCEPT a Determine which machine moving parts are to be
6. 80 116 430 40 404 23 a FWA 60 500 550 80 116 530 40 504 23 6 5x9 FWDA 40 150 200 130 85 180 60 154 23 FWDA 40 200 250 130 85 230 60 204 23 FWDA 40 300 350 130 85 330 60 304 FWDA 40 400 450 130 85 430 60 404 5 5 9 FWDA 60 300 350 180 116 330 90 304 23 6 5x9 FWDA 60 400 450 180 116 430 90 404 23 6 5x9 FWDA 60 500 550 180 116 530 90 504 23 6 5x9 L B H D E F bi FWTA 40 150 200 190 85 180 120 154 FWTA 40 200 250 190 85 230 120 204 FWTA 40 300 350 190 85 330 120 304 FWTA 40 400 450 190 85 430 120 404 FWTA 60 300 350 270 116 330 180 304 23 6 5x9 FWTA 60 400 450 270 116 430 180 404 23 6 5x9 FWTA 60 500 550 270 116 530 180 504 23 6 5x9 Refer to the 3 2 5 for rating and to 2 6 5 for their normalized values 47 User s Manual 024 8080 D STI 8 6 EMC FILTERS FN351 25 33 and FN351 50 33 lt 8 Sy f 115 gt Xi q NET a ap V 8 9 g 92 HB Y Y sta002_a dsf 9 12 96 EN 2010 3 6 33 64 54 44 3 15 sta004 a dsf 16 12 96 48 STI User s Manual 024 8080 D 9 WIRING DIAGRAMS 9 1 POWER
7. Contactors e o 158 lt From to sensors actuators I Os From to motors and grid supply and resolvers remarks mentioned for the first example are valid too a8 STI User s Manual 024 8080 D 7 4 DETAILS 7 4 1 RESOLVER S CABLE WIRING ST1 SIDE o ic Screws must be locked d b n di N 4 EA ER NUR Metallic or metallized V plastic case N J Grounding of the resolver cable shield is PIN 1 No paint here 7 4 2 MOTOR S CABLE S WIRING ST1 SIDE No paint here AR E L ci Motor thermal protection Individualy shielded wires No paint here 39 User s Manual 024 8080 D STI 7 4 3 MOTOR AND RESOLVER CABLE WIRING MOTOR SIDE Protective earth wiring Module Cable gland If relevant plugs with same shield grounding system must be used The connectors on motor side must then be metallic 40 STI User s Manual 024 8080 D 7 4 4 SUPPLY S AND BRAKING RESISTOR S CABLE WIRING BA4 SIDE No paint here The drives earth bar must not be used as earth connection for other circuits Grounding of the braking resistor cable s shield Ground bar Conducting and not painted No paint here DM A x Ne eae Conductive material bo X1 oe No paint here ud c 7 4 5 BRAKI
8. ST1 3 2 c Choose the motor and gearing ratio from the inertia and temperature points of view This choice may be done using the motor selection tool which is available together with The SOCASIN Expert software p n 024 7101 or 024 7102 release 1 5 and runs under Microsoft EXCEL d Select the winding or Kt option in order to reach the peak velocity and peak torque as required This choice may be done using ACC s motor selection guides In most applications consider that the motor must be able to reach this working condition at 170 Vrms phase to phase voltage The difference between this voltage and the BA4 input rated voltage 220 Vrms provides for enough security toward main voltage lowering down to 10 the voltage drops both within the transformer the rectifier and the power electronics Always consider that these choices which are based mostly on machine modelling have to be confirmed by comprehensive machine prototype testings POWER HARDWARE DESIGN 3 2 1 ST1 UNITS SELECTION 20 a Select the ST1 Drive Unit depending on the peak current that the selected motor needs for delivering the peak torque b Estimate for each axis the output current rms value average time adjusted to a typical machine cycle Ls acu ee E reat This is the general form which becomes for a trapeze looking velocity profile _ 1 TP t 7 4T t E oe t In exemple for the profile sh
9. WIRING Part number 024 7025 024 7026 9 6 1 FUNCTIONAL DIAGRAM 24VDC Ext source See fig of 8 6 3 A and 8 6 4 for details NT Closed Fault LS Board output RESET bk 0 BUS ST1 9 6 2 BINARY INPUTS SCHEMATICS 4k7 47k Reset 00k Reset 100n 12V 1k n i 4k7 Delay due to the RC filter E Reset Raising edge Falling edge 58 STI User s Manual 024 8080 D 9 6 3 RS485 SERIAL LINK Part number 024 7025 Each line pair TXD and RXD must be terminated by a 100 resistor to be mounted within plugs at both cable and on the receiver side 9 6 4 MA TTY SERIAL LINK Part number 024 7026 In that case The same connector X42 is used for the serial link and for the direct inputs and outputs Refer to 8 5 2 for chaining several STI on a single line 59 User s Manual 024 8080 D ST1 9 7 LA LINK BOARD WIRING Part number 024 7015 024 7018 024 7019 024 7021 024 7106 9 7 1 FUNCTIONAL DIAGRAM 24VDC Ext source Only in LA5 LAC p n 024 7106 Second analog input only in LA2 p n 024 7021 Closed ok Analog input LA Board l O BUS 4k7 n 4k7 60 STI User s Manual 024 8080 D 9 7 3 ANALOG INPUT SCHEMATICS 261 User s Manual 024 8080 D ST1 9 8 OM AND OS OPTIONAL BOARD WIRING ST1 master ST1 slaves
10. WIRING AND SAFETY DEVICES 24 V ur ae R In Rush current limitation powering on resistor 10 50W RPR Stop 0 Emergency Stop i Ross Dynamic braking resistor Security devices a T refer to 3 2 5 for rating Optional devices MAN Rees Emergency brake resistor CF1 refer to 3 2 7 for rating a i CF2 I F1 Power transformer protection oe refer to 3 2 4 for rating 0 35 Mi i ine Aiea F2 R protection Imax 2 25 EL Rosa protection Kl refer to 3 2 6 for rating ov 3 x 400 V 48V Li L2 Ls PE Two steps powering on optional As soon as ON button is pressed K2 is supplied So CK2 self standing and CK2 supplying the transfo are closed After 0 3 s CK2 is closed so K1 is supplied Thus CK1 is closed supplying the transfo and CK 1 is opened disconnecting the Emergency brake resistors Safety devices As soon as a problem occurs Stop0 Current to high in the transfo or in the Dynamic braking resistor temperature to high in the transfo Kl and K2 are no longer supplied thanks to Stop 0 C1 CF1 CF2 the system is powered down thanks to CK1 and CK23 and the motors are shorted and then stopped thanks to CK1 49 User s Manual 024 8080 D STI 9 2 MOTOR WIRING BAUTZ SEM Ragonot ATB F M506 M713 Terminal HD70 HD92 HD115 Terminal ST1 S
11. driving machines has to take care about different points One of these is the EMC ElectroMagnetic Compatibility The EMC is the capability of a part of a system to work without perturbing emission and being perturbed by immunity the rest of the system with electromagnetic phenomena Electromagnetic interference are propagated by four different ways e Galvanic coupling e Capacitive coupling e Inductive coupling e Radiated electromagnetic field EMC protection and insulation safety requirements can have common aspects such as earthing and protection against overvoltages and lightning It is e important to bear in mind that the safety aspects procedures for personnel Sa protection take precedence over EMC protection procedures Safety must always prevail so that in such cases alternate EMC related measures must be sought Motor cable shields may carry strong capacitively induced high frequency currents These currents are normally routed to the earth and thus produce no e particular danger 2S Should the user fail to connect these motor cable shields to earth than a voltage may appear at places which are normally not IP20 protected and which is dangerous to humans It is recommended to design a meshed earthing network throughout the machine and even throughout the building where it is used Each room of the building should have earthing network conductors to allow bonding of apparatus or systems cable trays structu
12. input No 2 of some link cards If the entry is open no current zero voltage the bit is at 1 If the entry is fed it is at 0 While downloading a software bit 1 indicates that the EEPROM memory filling is under way Bit 0 depends on the state of input No 1 of some link cards as bit 1 While downloading a software bit 0 indicates that the checksum computation is under way STI User s Manual 024 8080 D 4 2 4 STATD The effects of the bits of variable STATD depend on the masks as STATC The listing which accompanies every software version shows all bits having really a meaning other bits remain set to 0 Bit 7 latched indicates excessive motor temperature or that the corresponding input of the ST1 digital motion controller is not connected Bit 6 latched indicates that the internal overheating protection circuitry is active and reducing the current to the motor Bit 5 latched is a latched copy of bit 4 of STATA Bit 4 latched indicates that the real position has exceeded even if only briefly the limits set by parameters PHIL1 PHIL2 Bit 3 latched indicates that the ST1 digital motion controller has initiated a STOP procedure Bit 2 latched indicates a failure of the optional board Bit 1 latched is used to determine if the microprocessorhas been reinitialized RESET or not The validity of the position measurement number of turns and the other variables depends on it After each restart of the micr
13. of any occurrence of excessive friction or a cable rupture for example It is resumed under the memorized format in STATD In certain versions of the software velocity lag DVIT is monitored instead of the position lag if parameter KTEGR 32 768 hexa 8000 Bit 3 signals that the move requested by an instruction ERMOV ERUN START STOP etc is in progress The bit is set to 1 when one of the above instructions is received and returns to 0 when the corresponding move is finished Bit 2 is used by those software versions which require computation time between the receipt of a move order and the execution of it It is set to 1 when the computation is finished which means that a START order will follow immediately It returns to 0 as soon as the move has started 29 User s Manual 024 8080 D ST1 Bits 1 and 0 give information about the status of the motor speed during the execution of a move of the axis Bit 1 Bit 0 Meanin Bir BitO Meaning 0 0 reference speed zero Z Acceleration Acceleration 1 1 At speed reference speed not zero 1 0 Deceleration 4 2 2 STATB The STATB byte indicates such faults which have immediately resulted in the disabling of the power stage It allows you to find the reasons for an undesired stop of the axis Bit 7 latched indicates the amplifier has been disabled due to a failure in the resolver feedback signal Bit 6 latched indicates that the DC bus v
14. voltages which may be dangerous e to humans wv 2 Servicing and Maintenance require thus sufficiently trained persons according to local laws While servicing ST1 devices handling mistakes may result in fS humans and dangerous toward the machine and the environment P uncontrolled movements of machine parts and thus be dangerous to Servicing and Maintenance personal must thus always refer to the machine manufacturer s instructions first UsiNG THIS DOCUMENT This document provides for summarized information to the machine designer It also informs the machine End User about the ST1 products maintenance and servicing but should only be used then as a complement to the machine manufacturer s instructions For more information please refer to the detailed documentation The latest issue of ACC document 080 8010 Technical Documentation of SOCAPEL s Products lists all the documents which are available also available in German and in French and their part numbers User s Manual 024 8080 D ST1 1 4 MANUFACTURER S DECLARATION TO E U DIRECTIVES Each ST1 and BA4 is delivered with a Declaration of Conformity as the following example MANUFACTURER S DECLARATION according to the directive 89 392 EEC regarding machinery annex II B SOCAPEL Deutschland GmbH declares under her sole responsibility that the product Type ST1 25 310 Part Number 024 7751 B to which this declaration relates according to the Directive 89
15. 10 live 3 3 Ucos2 lt 11 ref 117 15 lt 8 U2 4 4V7 9 7 lt Adapter for 2 resolvers Feeding the potentiometer via pin 9 instead of pin 14 brings better use of potentiometer range 0 10V A voltage source i e CNC analog output may be connected in the same way using pin 1 2 and 10 and leaving pin 15 15V open In that case you have to know that the input inpedance is about 5k It means that by 10 V the input current will be 2 mA It is also possible to wire both the resolver and the potentiometer to the STI using a single plug Refer to document 024 8068 A 8 12 1 EE STI User s Manual 024 8080 D 9 4 LPO LINK BOARD WIRING Part number 024 7066 024 7080 024 7082 9 4 1 FUNCTIONAL DIAGRAM 24 VDC a Ext Source i T LED s Optic Fiber Settings ssa d 8 li z 5 gar 3 332 2 55 a 955 QED 2 gt 50 B o ogg 3 2 35 gr ooo S ERE E PEKT 5 1 56 46 34 24 16 221 g om 69 69 i PAM ring 7 LF I E 77 Interface A Y Y Y 2 Inputs Fault Reset Output Input LPO Board A Y Reset OK l O Bus ST1 9 4 2 BINARY INPUTS SCHEMATICS 22k av7 118 56k 2k2 zt 47n Delays due to the RC filter Reset Inputs Raising edge Falling edge
16. 392 EEC regarding Machinery as well as 91 268 EEC 93 44 EEC and 93 68 EEC Article 4 paragraph 2 is intended to be incorporated into machinery or assembled with other machinery to constitute machinery covered by the here above mentioned Directive Putting this product into service is prohibited until the machinery into which it is to be incorporated has been declared in conformity with the provisions of this Directive The manufacturer Socapel SA En Montillier 4 CH 1303 Penthaz Switzerland The Community established representative Socapel Deutschland GmbH Z hringerstrasse 23 D 77652 Offenburg Germany SOCAPEL SA and SOCAPEL Deutschland GmbH are determined to provide before January 1 1996 a CE declaration of conformity to the EMC and to the Low Voltage Directives for their products Penthaz September 2 1994 Bernard Jaquet Director of SOCAPEL Deutschland GmbH General Director of SOCAPEL SA signature STI User s Manual 024 8080 D 2 PRODUCT DESCRIPTION 2 1 HARDWARE CONCEPT STI drive system is made out of one BA4 Supply Unit and several ST1 Drive Units one for each motor This concept is optimal for multiaxis application but can also be used for single axis machines 3 phase Main PE Protection and switches Isolation transformer Signals Signals Auxiliary supply 3L PE DC bus interconnection DISTANCE LIMITS The BA4 and ST1 units should be assembled as close as possi
17. G RESISTORS 47 8 6 EMC FILTERS 48 9 WIRING DIAGRAMS 49 9 1 POWER WIRING AND SAFETY DEVICES 49 9 2 MOTOR WIRING 50 9 3 RESOLVER WIRING 50 9 3 1 SINGLE RESOLVER WIRING 50 9 3 2 WIRING A SECOND RESOLVERS 51 9 3 3 WIRING A RESOLVER AND A POTENTIOMETER 52 9 4 LPO LINK BOARD WIRING 53 9 4 1 FUNCTIONAL DIAGRAM 53 9 4 2 BINARY INPUTS SCHEMATICS 53 9 5 LIO LINK BOARD WIRING 54 9 5 1 FUNCTIONAL DIAGRAM 54 User s Manual 024 8080 D ST1 9 5 2 BINARY INPUTS AND OUTPUTS SCHEMATICS 9 5 3 JUNCTION MODULE OUTLINES AND SCHEMATICS 9 5 4 SERIAL LINK WIRING 9 6 LS LINK BOARD WIRING 9 6 1 FUNCTIONAL DIAGRAM 9 6 2 BINARY INPUTS SCHEMATICS 9 6 3 RS485 SERIAL LINK 9 6 4 MA TTY SERIAL LINK 9 7 LA LINK BOARD WIRING 9 7 1 FUNCTIONAL DIAGRAM 9 7 2 BINARY INPUT S SCHEMATICS 9 7 3 ANALOG INPUT SCHEMATICS 9 8 OM AND OS OPTIONAL BOARD WIRING 9 9 OEI OPTIONAL BOARD WIRING 9 9 1 WIRING DIAGRAM 9 9 2 INCREMENTAL INPUT TYPES 9 10 OIO OPTIONAL BOARD WIRING 55 56 57 58 58 58 59 59 60 60 60 61 62 63 63 64 65 STI User s Manual 024 8080 D 1 1 1 2 1 3 INTRODUCTION GENERAL DESCRIPTION Associated to three phase AC synchronous DC brushless or asynchronous induction motors the ST1 digital motion controllers with integrated power sections are used for controlling the moving parts of all kinds of industrial machines SAFETY CONSIDERATIONS The ST1 products are using electrical
18. INK AND OPTION BOARD ASSEMBLY 22 1 Cover delivered with basic module 2 IP20 protection set 3 ST basic module 4 Sofwtare and parameter EPROMs refer to doc 024 8008 or 024 8068 for detailed description 5 Link board L several types 6 Option board O several types 44 STI User s Manual 024 8080 D 8 3 STI AND BA4 BOTTOM VIEW Ground X Ground UB UB 48 V ov OV UA 310 V UA Power connection DC bus Support Cooler Grounding strap Power board Thermal connection of the motor X3 connector Power connection of the motor X2 connector KE In ST1 80 connector X3 point 6 is mounted 180 rotated but pinout remains the same see 9 2 It means that cables are compatible with every STI gt 45 User s Manual 024 8080 D STI 8 4 STI UPPER VIEW 46 1 Resolver connection X24 2 Test device connection 3 Reset push button 4 7 segment display 5 Link board connectors 1 e LIO board STI User s Manual 024 8080 D 8 5 DYNAMIC BRAKING RESISTORS PSN d ELE WY Wu Ys Ns mu PAP EOS OXKKKK KKK PSR T CN ZN FWDA FWTA FWA 40 150 200 60 85 180 30 154 23 5 5x9 FWA 40 200 250 60 85 230 30 204 23 5 5x9 FWA 40 300 350 60 85 330 30 304 23 5 5x9 FWA 40 400 450 60 85 430 30 404 23 5 5x9 FWA 60 300 350 80 116 330 40 304 23 FWA 60 400 450
19. MS COMOS CSCAN only with OS Optional Board Operating mode of slave axis 1st conversion constant for master slave ratio 2nd conversion constant for master slave ratio Scale factor for master slave ratio Approximative master slave ratio Master slave delay compensation Operating mode for vel and accel modulation Synchro mode for vel and accel modulation only with OEI Optional Board 1st conversion constant for master slave ratio 2nd conversion constant for master slave ratio Scale factor for master slave ratio Approximative master slave ratio Master slave delay compensation Encoder resolution Encoder filter Acceleration limitation Encoder zero channel enable Operating mode for vel and accel modulation Synchro mode for vel and accel modulation only using a Second Resolver as Master 1st conversion constant for master slave ratio 2nd conversion constant for master slave ratio Scale factor for master slave ratio Approximative master slave ratio Master slave delay compensation Operating mode for vel and accel modulation Synchro mode for vel and accel modulation Cam length Number of steps with repetitive velocity Cam start point pointer Cam output scale factor Cam input offset 1st conversion constant for master slave ratio 2nd conversion constant for master slave ratio Scale factor for master slave ratio Approximative master slave ratio Reference transmitter Master slave delay compens
20. NG RESISTOR S CABLE WIRING RESISTOR SIDE 27 No paint here No paint here 41 User s Manual 024 8080 D ST1 7 4 6 CONNECTION BETWEEN CONTROL CABINETS AND THE MACHINE To improve electromagnetic compatibility it is recommended to connect machine on which motors are mounted to control cabinet in which drives are mounted This can be done either connecting the machine and the cabinet to the meshed earthing network of the building or connecting machine and cabinet with a metallic conduit into which motors and resolvers cables run through Control cabinets configured as 7 3 Motor on the machine Meshed earthing network conductors Metallic conduit Control cabinet configured as 7 3 Motor in the machine 42 STI User s Manual 024 8080 D 8 OUTLINES 8 1 BA4 AND STI OUTLINES sues 35 3u 25 5 9 29 15 STI25 310 332 311 283 86 18 281 13 5 1 80 310 420 400 371 86 18 281 13 STI 40 310 420 400 379 174 18 88 285 18 BA4 30 5 310 332 311 283 86 18 281 13 BA4 60 80 310 420 400 371 86 18 281 13 subi User s Manual 024 8080 D STI 8 2 STI L
21. ONAL BOARD WIRING Part number 024 7047 24VDC external source ee OIO BOARD zi Refer to 8 5 LIO Link Board for detailed schematics 65
22. OR ALL APPLICATIONS Refer to ACC s motor libraries 024 8038 C G NPPOL Motor pole nb Resolver pole nb ratio 024 8068 A 7 3 3 G KTINV Motor torque constant 024 8068 A 7 4 3 G KIGLIN 0 synchr mot or dlip adjustment ind 024 8068 A 7 4 4 mot G Magentizing current induction motor only 024 8068 A 87 4 5 Nominal Velocity induction motor only 024 8068 A 7 4 6 G VITMAX Peak velocity 024 8068 A 87 4 7 COUMA Peak torque 024 8068 A 7 4 8 CURES Resolver Supply 024 8068 A 7 3 1 COULIM Temporary reduced peak torque 024 8068 A 7 5 14 CDEPHA Angle offset between motor and resolver 024 8068 A 7 4 2 Refer also to 6 2 for the meaning of all status bits CMASKU Power stage desabling mask Stop 0 024 8068 A 6 3 CMASKA Controlled stop Stop 2 024 8068 A 86 3 CMASKS Mask for status signalling to host 024 8068 A 86 3 KPOS Position controller P gain or vel contr I gain 024 8068 A 7 5 4 KVIT Position controller D gain or vel contr P gain 024 8068 A 7 5 5 KTEGR Position controller I gain 024 8068 A 7 5 6 DPOMA Position lag measurement limit 024 8068 A 7 5 11 SEUIL1 Position lag warning threshold 024 8068 A 7 5 12 INERT Feed forward inertia modelisation 024 8068 A 7 5 7 FVISC Feed forward viscosity modelisation 024 8068 A 7 5 8 FSEC Feed forward dry friction modelisation 024 8068 A 7 5 9 FEXT Feed forward weight modelisation cst torque 024 8068 A 7 5 10 Test Board
23. RESISTORS SELECTION a Take the motor speed constant and its maximum speed and calculate the corresponding effective voltage between phases b From the maximum torque or the demagnetisation determin the maximum braking current Ij effective current in a phase c Calculate the ohmic value of the resistor 222 STI User s Manual 024 8080 D Interphase motor s resistance d Caluculate its power value 1 60 0 J System inertia and Motor speed rad s This approximation is valid up to two emergency braking per minute For more details refer to the latest edition of document p n 024 8028 The Motor 3 2 3 2 8 COOLING THE 4 AND ST1 UNITS Refer to the latest edition of document p n 024 8054 Thermal Dimensioning zs User s Manual 024 8080 D ST1 3 3 DEFINING THE ST1 PARAMETERS Once the proper software has been chosen refer to 2 4 each ST1 has to be configured It means that several application dependent settings have to be defined and loaded as parameters The following tables shows which parameters are concerned depending on the application and in which document additional information can be found The shaded ones have absolutely to be defined even for a preliminary test the others can be used for enhanced performance parameters which are not concerned for an application should remain unchanged at their default value 3 3 1 STI PARAMETERS NECESSARY F
24. Socapel ST1 A Digital Motion Controller User s Manual Ordering Number 024 8080 D Rev February 1997 This upgraded and improved version replaces all the previous We reserve the right to amend this document without prior notice and decline all responsibilities for eventual errors Doc No 024 8080 D Atlas Copco Controls SA En Montillier 4 February 97 CH 1303 PENTHAZ by Atlas Copco Controls SA Switzerland rights reserved STI User s Manual 024 8080 D TABLE OF CONTENTS 1 INTRODUCTION 7 1 1 GENERAL DESCRIPTION 7 1 2 SAFETY CONSIDERATIONS 7 1 3 USING THIS DOCUMENT 7 1 4 MANUFACTURER S DECLARATION TO E U DIRECTIVES 8 2 PRODUCT DESCRIPTION 9 2 1 HARDWARE CONCEPT 9 2 2 BA4 SUPPLY UNITS 10 2 3 STI DRIVE UNITS 12 2 4 ST1 SOFTWARE 14 2 5 SERVICING TOOLS 14 2 6 ACCESSORIES 15 2 6 1 MOTORS 15 2 6 2 POWER TRANSFORMERS 15 2 6 3 CONNECTOR SETS 16 2 6 4 COOLING HEATSINKS 16 2 6 5 DYNAMIC BRAKING RESISTORS 16 2 6 6 EMC FILTERS 17 3 APPLICATION DESIGN CHECK LIST 18 3 1 MECHANICAL AND STRUCTURAL DESIGN 18 3 1 1 DRIVE AND CONTROL CONCEPT 18 3 1 2 MOTOR AND GEARING SELECTION 19 3 2 POWER HARDWARE DESIGN 20 3 2 1 STI UNITS SELECTION 20 3 2 2 BA4 UNITS SELECTION 2 3 2 3 POWER TRANSFORMER SELECTION 22 User s Manual 024 8080 D STI 3 2 4 POWER TRANSFORMER AND BA4 PROTECTION 22 3 2 5 DYNAMIC BRAKING RESISTOR SELECTION 22 3 2 6 DYNAMIC BRAKING RESISTOR PROTECTION
25. TI software ATTENTION 7n both cases digital and analog the CMPBIN parameter must different of zero to enable any measuring 4 4 PUTTING INTO SERVICE Text to be added in a next edition 330 3 STI User s Manual 024 8080 D PREVENTIVE MAINTENANCE The ST1 digital Drive Units provide the user with plenty of informations which may be used for preventive maintenance of the machine refer to 6 2 for the list of all status flags The most obvious one is the motor torque which can be required i e every time the axis is running at constant speed and which can help the machine control equipement to detect an unnormal load increase It is also possible to monitor the ST1 heatsink temperature in order to warn the machine user that the heatsink has to be cleaned up It is absolutely necessary to protect the ST1 and 4 units agains dust and moisture Be sure that the cubicles are hermetically closed and that the cooling air filters if any be regularly cleaned up and replaced Should the air humidity be high and the temperature be suddenly lowered then a risk of water condensation appears which is not allowed The units themselves require no preventive maintenance actions as long as they are used within their operating ranges 233 5 User s Manual 024 8080 D ST1 6 TROUBLE SHOOTING text to be added in a next edition 230 STI User s Manual 024 8080 D 7 1 EMC GENERAL Mounting STI into cabinets for
26. ation 024 8068 A 8 11 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 6 2 024 8068 A 8 4 10 024 8068 A 8 4 10 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 6 2 024 8068 A 8 5 7 024 8068 A 88 5 4 024 8068 A 8 5 5 024 8068 A 8 5 6 024 8068 A 8 4 10 024 8068 A 8 4 10 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 5 2 024 8068 A 8 6 2 024 8068 A 8 4 10 024 8068 A 8 4 10 024 8088 84 2 1 024 8088 5 2 1 024 8088 5 2 2 024 8088 5 3 1 024 8088 5 2 3 024 8088 A 84 2 2 024 8088 A 84 2 2 024 8088 A 4 2 2 024 8088 A 4 2 2 024 8088 A 7 2 024 8068 A 8 6 2 When the cam shaft function is used in a master slave application parameters CKS CRANS and CKMS have to be determined according to the specific document 024 8088 ST1 Cam Shaft Function and not according to the general document 024 8068 A Software for the synchronization of axes 27 User s Manual 024 8080 D STI 4 APPLICATION TESTING 4 1 FRONT PANEL DISPLAYS The front panel display shows a 7 segment sign and a decimal point Its reading is to be interpreted as follow Display Validity Signification dark all versions Auxiliary supply is missing all versions Auxiliary supply is ok and CPU is running In order to make sure that the dot is alight and not half alight depress the reset button and release aft
27. ble to each other The whole extend of the DC bus should not exceed 1 meter or 2 meters if the BA4 is in the middle Should longer distances be required than additional isolated 48 VDC supplies might be needed The distance between any ST unit and its motor has been tested up to 100 meters Distances up to 200 meters are assumed to be possible but may produce an additional resolver reading inaccuracy User s Manual 024 8080 D STI 2 2 BA4 SUPPLY UNITS Isolation Isolation transformer transformer Auxiliary supply option AC or floating 310V DC supply Main power supply 3 50 60 Hz Dynamic braking resistor with protection Grounding strap PE PE UA OV UB 310V DC 48V DC 7 Interconnection to ST1 In order to protect the lower edges of all BA4 and ST1 units it is necessary to attach one IP20 protection set p n 024 7820 below each unit once the wiring 15 realized Forgetting or removing this protection produces potential danger as one of the DC bus terminal is at a 310 VDC potential Normally the negative rail of the DC bus is grounded thanks to the built in grounding strap All BA4 Supply Units must be used together with an isolation transformer one floating secondary for each BA4 Exceptionally some BA4 Supply Units may be used together with an autotransformer Then the negative rail of the DC bus may not be grounded and the grounding strap must be remo
28. d User s Manual 024 8080 D STI 2 4 STI SOFTWARE APPLICATION SOFTWARE All STI Drive Units are now fitted with a non volatile EEPROM for memorizing the appropriate software This software is supplied separately as a PC file on a 3 5 floppy which has to be downloaded using the maintenance PC or the operation serial link Elder ST1 Drive Units were fitted with an EPROM as software memory which had to be plugged on CONFIGURATION PARAMETERS The Drive configuration is also memorized within a non volatile EEPROM and can also be download using the same links Single parameter changes are possible CONFIGURATION SEQUENCER AND CAM SHAFT If the LIO Link Board is used a sequence program and in some cases a cam shaft table are memorized in a similar way into an EEPROM non volatile memory They are also downloadable FOR MORE INFORMATION ABOUT REFER TO DOCUMENT latest edition program software firmware p n 024 8072 Software Versions p n 024 8008 basic software or 024 8068 software for synchronization parameter 3 4 of this document p n 024 8008 or 024 8068 basic software cam shaft table p n 024 8088 cam shaft function downloading from servicing PC p n 024 8038 Socasin Expert downloading from operation link p n 024 8068 A basic software 10 9 The STI Drive Unit operation depends from the software and the S configuration which were loaded Using for any application a software or a config
29. drate selection Peripheral address Time out Answer terminating byte 024 8012 5 2 024 8012 5 3 024 8012 5 4 024 8012 5 5 024 8012 5 6 3 3 5 LA LINK BOARD SPECIFIC PARAMETERS COEPOS COEVIT COEACC MGAIN ZMANAL DIFANA INERT DECZER 024 8016 4 2 024 8016 4 3 024 8016 4 4 024 8016 3 4 024 8016 3 5 024 8016 3 6 024 8016 4 4 024 8016 4 2 Input gain for use as position set value Input gain for use as velocity set value Input gain for use as torque set value Input gain mode Analog input dead band Slew rate limitation Scale factor for use as torque set value Input offset for use as position set value 3 3 6 PARAMETERS FOR OPTIONAL FUNCTIONS Potentiometer COEPOT OFPOT using 2nd resolver input Input gain for potentiometer Input offset for potentiometer Input filter for potentiometer Input dead band for potentiometer Operating mode for vel and accel modulation Synchro mode for vel and accel modulation 024 8068 A 8 12 4 024 8068 A 8 12 2 024 8068 A 8 12 3 024 8068 A 8 12 5 024 8068 A 8 4 10 024 8068 A 8 4 10 PILTPOT ZMPOT MRATE SRATE only with OM Optional Board COMOS Selection and scaling of master value to transmit 024 8068 8 11 2 26 STI User s Manual 024 8080 D CKM CKS CRANS CKMS CSCAN NIMPEI FILTEI ACCLIM PISTEI MRATE SRATE CKM CKS CRANS CKMS CSCAN MRATE SRATE CLGCAM CNBREP CSTCAM CRCAM OFCAM CKM CKS CRANS CK
30. elf directly connected to the ground plane with large section or directly on the device it must be connected to ii One EMC filter must be used for each BA4 unit Please refer to paragraphs 2 6 6 and 8 6 for filter selection and outlines STI User s Manual 024 8080 D 7 3 CABINETS CONFIGURATION 7 3 1 EXAMPLE 1 This first example shows a cabinets in which two rows of drives are mounted The control part PLC and PAM are then mounted in another cabinet The advantage is that the separation between control and power part is done naturally Unshielded Cable Shielded Cable Cable gland or other device which connects shield to ground bar on 360 I Os and supply cables are not shielded and are mounted in the same conduit Motors resolvers and braking resistor cables must be shielded and are mounted in the same conduit 12 1 25 Drives enclosures must be electrically well connected to the back panel Power supply and auxiliary filters see the list must be as close as possible max 30 cm to the drives power supply and their carcass well connected to the backpanel Motors and braking resistor cables shields must be connected to a ground bar which is itself well connected to the backpanel 4 60 ST1 80 ST1 80 ST1 80 The backpanel must be conducting
31. er 1 second the dot should show different brilliancy any all versions Auxiliary supply is ok but CPU is not running or software is not dot half available alight see the remark above about dot alight or half alight z The power stage has been disabled as the result of an external command and not because of a fault Power stage has been enabled all versions all versions downloadable software No firmware available boot program only is running ga boot software Reboot after completion of software download all versions Unit is ready user s initial parameter values are active all versions Unit is ready default parameter values are active all versions Power stage has been desabled Auxiliary supply missing all versions Power stage has been desabled Resolver failure all versions Power stage has been desabled Internal supply failure boot software Parameter memory IC or jumper not ok or bad memory type boot software Memory overrun while downloading a software or Checksum error after software download all versions except LA Power stage has been desabled out of position end limits boot software Internal hardware error all versions except LA Power stage has been desabled refer to CMASKU parameter setting all versions Power stage has been desabled DC bus overvoltage all versions except LA Power stage fault test has been completed successfully all versions PAM with new ASIC PAM with new ASIC PAM with new ASIC PAM
32. ewing solution is chosen it prohibits naturally any paint or other insulating material between the planes The connection of the sixth plane closing the cabinet the door must be also done without interruption longer than 5 cm It can be done with a conductive joint The control cabinet and the machine on which the motor are used must be linked with a good electrical connection e g a ground plane or a metallic conduit in which the cables are Refer to IEC 1000 5 2 guideline Oct 1995 commitee draft 77B 168 CDV The power and the control devices must be placed in two different areas which are minimum 30 cm apart The back plane must not be painted to be used as ground plane on which all the devices must be mounted with good electrical connection The contact area between devices and the ground plane must be as large as possible If not shielded power and the control cables must be minimum 30 cm apart They must be as close as possible to the ground plane in order to reduce the area of the loop they make with the latter Power cables must not cross the control area and control cables must not cross power area The sensitive cables as well as the perturbed cables must be shielded In addition the sensitive cables have to be twisted pairs When shielded cables are used the shield must not be twisted and connected to a terminal pig tail but a clamp with 360 contact on the shield must fix the cable on a ground bar which must be its
33. fitted with electrical motors and which kinds of gearings are to be used b Determine which motors are to be fitted with AC servo motors and to be driven by ST1 units c Determine also the safety requirements and the way each axis is to be mechanically protected d Determine the coordination or synchronisation relations between the axes and the relations toward other equipments actuators sensors graphical interactivity etc e Determine the machine control concept and how the different equipment communicate f Don t forget that machine design is an itterative process and that detailed design may require reconsidering concept decisions and machine requirements 18 STI User s Manual 024 8080 D 3 1 2 MOTOR AND GEARING SELECTION a Investigate the mechanical load for each axis inertia friction erratic forces or torques etc Here are some helpful formulae As a first approximation Nm nor Nm ii kem a por raa E ROTARY MOTION LINEAR MOTION msc001_a dsf 8 10 96 Speed O mor rad I s Oy rad s i e rad 1 5 rpm T hm Torque T N IN mot Nm mot Nm Foja a GERE i 27 Inertia kem h b Define the dynamic requirements worst case and average movement cycles and represent them if possible in terms of equivalent trapeze looking velocity profiles Q 246 User s Manual 024 8080 D
34. ide Motor Side Box HD142 Box a 1 1 1 1 B A U U U Motor M2 mm 3 2 2 2 G B V V V aw m 4 3 3 3 A G W W W 2 PE H H GND T 1 Lam 1 Thermal l i om A 5 5 4 C C K1 C om 7 6 5 K2 T3 p EE D D Ce m m C 4 7 E E B1 A Auxiliary X M Brakes 24VDC_ om D 6 8 F F B2 B EDS E 1 Must have CDEPHA parameter set to 10992 hexa 2AAA C 2 only HD115 HD142 and BMR 190 pin 1 is for PTC interface pin 2 for temperature switch For shield connection see 7 4 9 3 RESOLVER WIRING 9 3 1 SINGLE RESOLVER WIRING 15 pins D Sub Motor side ST1 connector X24 connector line 4 m Usi 4 AMI t line 5 ref 13 2 6 D D For shield connection see 7 4 50 STI User s Manual 024 8080 D 9 3 2 WIRING A SECOND RESOLVERS X241 to 1st resolver as fig 8 3 1 live 3 Ucos2 ref 11 15 lt 4 4 U2 4 4V7 9 7 lt ia a to 2nd resolver T 9X adapter for 2 resolvers Ee User s Manual 024 8080 D STI 9 3 3 WIRING A RESOLVER AND A POTENTIOMETER to the resolver as S 8 3 1 li sud v ref 13 1 Connector X241 live 4 TED Nn ONS oz E j P Connector X242 to the ST1 connector X24 1 live 2 2 Usin2 lt 10 ref
35. ing byte LIO board only Initial input active level mask Initial input validation mask Dead band for output OUT6 motor speed 0 024 8068 A 8 4 3 024 8068 A 8 4 3 024 8068 A 8 4 4 024 8068 A 8 4 13 024 8068 A 8 4 13 024 8068 A 88 4 6 024 8068 A 8 4 8 024 8068 A 8 4 8 024 8068 A 8 4 9 024 8068 A 7 8 2 024 8068 A 7 8 3 024 8068 A 8 4 3 024 8068 A 8 4 3 024 8068 A 8 4 4 024 8068 A 8 4 13 024 8068 A 8 4 13 024 8068 A 88 4 6 024 8068 A 8 4 8 024 8068 A 8 4 8 024 8068 A 8 4 9 024 8068 A 7 8 2 024 8068 A 87 8 3 024 8020 A 5 2 1 024 8020 A 5 2 2 024 8020 A 5 2 3 024 8020 A 5 2 4 024 8020 A 5 2 5 024 8020 A 5 3 1 024 8020 A 5 3 2 024 8020 A 85 3 3 25 User s Manual 024 8080 D ST1 3 3 4 LS LINK BOARD SPECIFIC PARAMETERS 024 8068 8 4 3 024 8068 8 4 3 024 8068 8 4 4 024 8068 A 8 4 13 024 8068 A 8 4 13 Acceleration range and Motion reversal Inverse of CKA Velocity range 1st conversion cste for position set values 2nd conversion cste for position set values Velocity Profile 024 8068 A 88 4 6 024 8068 A 8 4 8 024 8068 A 8 4 8 024 8068 A 8 4 9 024 8068 A 7 8 2 024 8068 A 7 8 3 Required travel speed for moves Required acceleration Required deceleration Specific deceleration for stops Left limit for absolut position Right limit for absolut position Serial Link LSMRI LSMR2 ADAXE TIMOUT ENDBYT Transmission type Bau
36. its are to be used the peak positive and the peak negative powers Assuming that all axes accelerate and decelerate together at the same time is the worst case condition More accurate figures may be computed if that is not the case lt P P lt P peak DOS decel peak T NB peak All Axes All Axes accel Estimate in the same way as a for each axis the average values of both the positive and negative power which is required for each axis 1 At constant speed P od Ty 1 TL o0 While accelerating EE n 2 T 0 dec max While decelerating Pisas negative aly E padi f P wed i Dt NN Average positive power Pu average T full cycle Pecans dec Average negative power T T full cycle Estimate also in the same way as b for the whole machine the average positive and negative powers for all axes together Select the smallest BA4 Supply Unit that yet fits to the machine power values above Check that this BA4 size meets the 48 VDC auxiliary supply requirement of all STI units 2 21s User s Manual 024 8080 D STI 3 2 3 POWER TRANSFORMER SELECTION a Select the smallest power transformer whose power rating yet is larger than the average positive power required for all axes Refer to 82 6 2 for the list of ACC standard transformers b Make sure that the peak positive power of the machine is not more than about 4 times the transformer ra
37. not painted X Filter Aem The protective earth rail For security aspects the Filter N devices have to be connected g Contactors to it This connection have to S be as short as possible e ot 2 Avoid chained earth x Q ler From to sensors actuators I Os From to motors and grid supply and resolvers the devices enclosures must be well connected to the metallic backpanel which acts as functional reference ground which is different than Protective Earth even if both are connected Inside the cabinets all the cables must be as close as possible to the backpanel BE ge User s Manual 024 8080 D STI 7 3 2 EXAMPLE 2 In that case only few drives are used so the control part PLC and PAM can be mounted in the same cabinet BEEBE EE RRR EERE EEE EERE REE Unshielded Cable Shielded Cable gt lt Cable gland or other device which connects shield to ground bar on 360 24VDC PLC and PAM p PAM PLC enclosures must be well connected to the backpanel o o t q lt a For security aspects all the devices including PLC 1 N V24DC supply etc are 3 Mabel connected to the PE gj LL
38. oltage UA has exceeded its upper limit Bit 5 latched indicates that a saturation fault in the power transistors is the source of the disabling Possible causes short circuit or overload Bit 4 latched signals that an internal failure in the auxiliary voltage is the source of the disabling Bit 3 latched indicates that a momentary interruption of the auxiliary supply is the source of the disabling Bit 0 indicates that the boot program is running 4 2 3 STATC 30 The effects of the bits of variable STATC depend on the masks The listing which accompanies every software version shows all bits having really a meaning All the other bits remain set to 0 Bit 7 latched indicates that a not valid instruction code has been received Bit 6 latched indicates that implausible instruction code or data has been received Bit 5 latched reserved Bit 4 latched indicates after powering up or resetting that the present link card is not compatible with the present software version or that the card is missing Afterwards it indicates a serial link transmission failure Bit 3 is 1 as long as the SAVE routine is in progress which saves all parameter actual values into the EEPROM parameter memory It returns to 0 as soon as saving has been completed Bit 2 indicates that the master shaft has overrun the limit of one period or that the zero track of an incremental encoder has been detected Bit 1 reproduces the state of
39. olver adapter p n 024 7063 should be used Pre confectioned fiber optic cables are also available in different lengths as follow e LPO and PAM interconnection e OM and OS interconnection 2 6 4 COOLING HEATSINKS text to be added in a next edition 2 6 5 DYNAMIC BRAKING RESISTORS ACC suggests the use of following power resistors for Dynamic Braking see 3 2 5 They are IP40 protected and may be assembled on the roof of the enclosure for getting rid in an easier way of their thermal load The dimensions of these resistors are shown in 7 5 BA4 30 50 310 BA4 60 80 310 Pinst 20 25 kW Pinst 12 16 kW Pinst 8 10 kW E Ref ACC EG Ref ACC OE Ref ACC FWA 40 150 231 1051 231 1053 231 1055 FWA 40 200 231 1086 231 1088 5 231 1089 40 300 231 1119 231 1122 231 1123 FWA 40 400 231 1153 231 1156 231 1158 FWA 60 300 231 1189 231 1192 231 1194 FWA 60 400 231 1223 231 1226 231 1228 60 500 231 1258 231 1260 231 1263 Komi Ref ACC om Ref ACC Ref ACC FWDA 40 150 231 2154 231 2157 231 2159 FWDA 40 200 231 2189 231 2191 231 2193 FWDA 40 300 231 2238 231 2242 231 2244 FWDA 40 400 231 2319 231 2327 231 2335 FWDA 60 300 2 231 2384 231 2386 231 2388 FWDA 60 400 231 2429 231 2435 231 2437 FWDA 60 500 231 2506 i 231 2514 231 2522 EU FWTA 40 150 231 3657 231 3659 231 3000 FWTA 40 200 231 3691
40. oprocessor this bit is worth 1 It is put back to 0 by one of the initialization commands of status and particularly when the power stage is enabled Then it can only go back to 1 with a new restart of the microprocessor Bit 0 indicates if the power stage is enabled 0 or disabled 1 4 2 5 STATE Bit 7 indicates that a motor speed has exceeded the limit set by the parameter VITMAX 4 2 6 STATF This status is only used by the PAM version Bit 5 CRC NODE indicates that ST1 has detected a CRC error in a tram destinated to it Bit 4 NO TRAM indicates that any tram is arrived for 50 ms Bit 3 CARRIER FAIL indicates that a CRC error has been detected by a ST1 upstream in the ring Bit 2 FAIL RING indicates a ring error Bit I CRC RING indicates that the ST1 has detected a CRC error in a tram destinated to another 571 Bit 0 COUNT indicates that more than two commands have been sent to the STI during one PAM cycle 4 3 TEST DEVICE The test device allows you to measure variables in digital 8 bits or in analog 2 channels form 4 3 1 DIGITAL MEASURING Two parameters are necessary to define which variables you want to measure CADBIN is the address of the variable to be monitored digitally Default value 128 hexa 80 STATA 2314 User s Manual 024 8080 D ST1 CMPBIN specifies which part of the variable has to be monitored 0 to disable the measuring also the two analog channels 16 Hexa 10 f
41. or the most significant byte 4096 Hexa 1000 for the least significant byte 4 3 2 ANALOG MEASURING As for the digital two parameters for each channel have to be set to define a variable analog measuring CADMAI CADMA2 is the address of the variable to be monitored on pin Al respectively pin A2 CMPMA2 is the scale factor for the Al respectively A2 analog output It could be set according to the following table Speed variable Torquee variable CMPMAx t min V CMPMAx deg V CMPMAx Nm V 72 2 82 5 2000 144 Hexa 48 Hexa 90 Hexa 52 144 1000 288 1 205 2 90 120 Hexa CD 288 500 722 0 5 410 1 Hexa 120 Hexa 2D2 Hexa 19A 722 200 1444 0 2 820 0 5 Hexa 2D2 Hexa 5A4 Hexa 334 1444 100 2888 0 1 1444 0 2 Hexa 5A4 Hexa B48 Hexa 5A4 Intermediate value are allowed The relation between output voltage and value in internal units is CMPMAx U our val 208 0 078 Address of the most important variables Address PHIB actual angular position of the resolver 37 Hexa 25 PHIREB angular reference position of the resolver 50 Hexa 32 DPOS angular position lag 53 Hexa 35 VIRB actual angular speed of the resolver 41 Hexa 29 VIREFB setangular speed of the resolver 47 Hexa 2F COCOU required motor torque 55 Hexa 37 DVIT angular speed lag 52 Hexa 34 The addresses of the other variables could be found in the variable list furnished with each S
42. ormed by ACC Ask for more information Using motors without previous acceptance by ACC may result in incorrect operation or poor performances 2 6 2 POWER TRANSFORMERS ACC provides also for power transformers for supplying ST1 systems Their main data are Nominal Power 0 85 2 0 4 0 7 0 12 18 or22 kVA Primary Voltage 400 VAC 50 or 60 Hz three phase several adjustment terminal configurations Secondary Voltage 220 V AC at rated load 228 VAC max at no load Other transformers can also be supplied Ask ACC for additional information SZ xS The no load secondary voltage must be lower or equal to 228 VAC when the primary voltage is at its nominal value i e 400 VAC in order to allow a 10 main voltage change Use isolation transformers only Autotransformers may be used for special applications but the ST1 system specifications are no more guaranted by ACC Refer to 2 2 gt 215 User s Manual 024 8080 D ST1 2 6 3 CONNECTOR SETS The ST1 Drive Units are supplied with the mating motor and thermoswitch plugs All other mating plugs are supplied separately as connector sets Refer to price list for part numbers The user may also order these connectors anywhere else he is then responsible for their compatibility Connector sets are available as e Resolver to ST1 connector set e Link board connector set e Option board connector set Motor connectors When using the 2nd resolver input the 2 res
43. own on page 16 zd 1 EUR REA VE k ERE I If this rms current is close to the peak current the ST1 cooling design 3 2 8 below may show that the next larger ST1 size has to be chosen instead d Check that the motor inductance stray inductance for induction motors fits to the STI optimal load inductance refer to 2 3 technical data STI User s Manual 024 8080 D 3 2 2 BA4 UNITS SELECTION a b c d Estimate for each axis the peak value both of the positive acceleration and the negative deceleration power which are required The positive peak power must be devided by the motor efficiency the electrical power need from the main is higher than the motor shaft output power 1 1 r O peak 1 POS max POS max 8 max NER max pos The negative peak power must be multiplied by the motor efficiency the electrical power returned to the DC bus is lower than the motor shaft input power IST us us OF n T NG peak OS max 8 max The formulae above are true for trapeze profile point to point movements axis which follows a cam shaft profile requires generally smaller peak powers which are reached when the products 00 d dt are maximum positive and minimum negative Considering all the axes and their individual movement cycles within the whole machine cycle estimate for the whole machine or for each group of ST1 Units if several BA4 Supply Un
44. res etc Earth loops are not only allowed they are effective mitigation measures against interference Refer also to IEC 1000 5 2 Installation and mitigation guidelines Earthing and cabling for the moment it is only available as a commitee draft 77B 168 CDV dated October 1995 This standard is still under study and subject to change but pro vides for very valuable information 35 User s Manual 024 8080 D ST1 7 2 CABINET DESIGN The goal while building a cabinet is to reduce as much as possible all electromagnetic propagation ways To do that there are some rules to follow The first and most important 36 1S Regarding EMC GROUNDING is not only connecting a wire to the ground As the perturbations are high frequency current is concentrate at the periphery of the conductor So to have good EMC grounding connection one must use conductors with flat section e g flat braided wire and large contact area In the schematics we have then the two following signs ref IEC617 2 and EN61131 2 C Protective Fu nctional Earth Earth EMC Then more particular rules have to be followed a b d f wa 5 i The cabinet must be perturbations proof It must be build of five plane I inked together as the longest electrical connection interruption do not exceed 5cm It means that the connection could be done either by soldering or screwing the planes each 5cm If the scr
45. rotect the lower edges of all BA4 and STI units it is necessary to e attach one IP20 protection set p n 024 7820 below each unit once the wiring wv 1s realized Removing this protection produces a potential danger as one of the DC bus terminal is at a 310 VDC potential 712 STI User s Manual 024 8080 D TECHNICAL DATA Positioning resolution 25 736 increments per resolver revolution Position measurement accuracy 1 8500 rev 2 5 arc min not including resolver accuracy Speed range 0 to 22 500 rpm Cycle time 0 33 ms Velocity signal bandwidth up to 600 Hz Current loop bandwidth gt 1000 Hz Power stage ST1 10 ST1 25 ST1 80 ST1 140 DC bus voltage up to 360 VDC up to 360 VDC up to 360 VDC up to 360 VDC Max RMS output 18A 56 100A current Ims Switching frequency 9 8 kHz 9 8 kHz 9 8 kHz 9 8 kHz Auxiliary supply 48 VDC 48 VDC 48 VDC 48 VDC voltage 1 96 Max consumption at 48 VDC Optimal Toad 11 43 mH 4 6 18 mH 1 8 8 2 mH 0 4 1 5 mH inductance Power dissipation typical No load power dissipation dissipated in the housing Additional dissipation at max load through mounting plate General data information Ambient operating temperature 0 to 50 C 0 to 122 F Storage temperature 25 to 70 C 13 to 158 F Maximum relative humidity 95 without condensing For outlines connector position and markings please refer to chapter 7 z
46. ted power in order to limit its voltage drop 3 2 4 POWER TRANSFORMER AND 4 PROTECTION a Select the protective elements fuses etc according to the rated primary current of the Power Transformer b Check that this protective elements meet the standard requirements for short circuit protection coordination Several ACC s standard Power Transformers are fitted with thermal protection switches which take care of the secondary wiring protection If such a thermal protection is not available then fuses or alike are also necessary on the transformer secondary side d If the Power Transformer power rating is larger than 2 BA4 30 50 310 or 4 5kVA BA4 60 80 310 an external in rush current limitation is necessary Refer to the figure of 8 1 3 2 5 DYNAMIC BRAKING RESISTOR SELECTION a The average negative power 2 6 5 gives you the power of the resistor Py in table neg average b Choose the ohmic value considering the BA4 Unit size and the peak negative power P the table 2 6 5 of the machine NEg peak gt inst 3 2 6 DYNAMIC BRAKING RESISTOR PROTECTION a Estimate the max continuous DC current that the Resistor stands under 360 VDC I A ES eiue rating W m 3eo V b Select a thermal relay which can be adjusted to this current Its signalling contact has to be used for switching off the main power supply to the BA4 Unit See figure of 8 1 3 2 7 EMERGENCY BRAKE
47. uration file which correspond to another application may lead to incorrect operation and damage the motor and the machine 2 5 SERVICING TOOLS The PC DOS software The SOCASIN Expert p n 024 7101 or 024 7102 which includes the corresponding documentation p n 024 8038 provides for a comprehensive interface between the user and the ST1 Drive Units Following devices are necessary Test Device p n 024 7701 B PC refer to document p n 024 8038 Socasin Expert for more information Cable p n 024 7059 Multimeter digital storage oscilloscope 244 STI User s Manual 024 8080 D 2 6 ACCESSORIES 2 6 1 MOTORS ACC provides for several ranges of motors which differ by their technology their data and their price to performance ratio BAUTZ motors Permanent magnet synchronous servo motors 0 4 to 20 Nm rated torque range FLENDER ATB LOHER motors Asynchronous induction servo motors 0 4 to 30 kW rated power range Gear fitted motors also available RAGONOT motors Permanent magnet synchronous servo motors 0 6 to 30 Nm rated torque range SEM motors Permanent magnet synchronous servo motors 0 4 to 60 Nm rated torque range others in preparation These motors have been tested together with ST1 Drive Units their assembly and particularly their built in resolver comply with ACC specifications Using motors made by other manufactures is generally possible but requires previously some sample tests to be perf
48. ved Check then that the supply neutral is properly grounded 10 STI User s Manual 024 8080 D TECHNICAL DATA Cont power output 8kW 16 kW 48 VDC auxiliary suppl Auxiliary DC voltage output 48 VDC 48 VDC Dynamic braking resistor chopper Switch on threshold 355 VDC 1 96 355 VDC 1 96 Peak braking power 17 kW 28 kW Min braking resistor value 7 9 V x 10 96 4 9 2 10 96 Power dissipation typical No load power dissipation dissipated in the housing Additional dissipation at full load mounting plate rectifier shunt regulation General data information Weight 4 5 kg 6 5 kg 10 Ibs 14 Ibs Ambient operating temperature 0 to 50 C 0 to 122 F Storage temperature 25 to 70 C 13 to 158 F Maximum relative humidity 95 without condensing For outlines connector position and markings please refer to chapter 7 711 User s Manual 024 8080 D STI 2 3 STI DRIVE UNITS i Servicing PC RS232 Machine control eS es sj I Y I Test device RR Link Option supplies board board UA 310V DC Interconnection from BA4 and to other ST1 Main 2nd resolver resolver Please note that each ST1 must always be fitted with a link board as required by the application It has moreover to be fitted with the proper firmware and the application depending configuration Refer to 2 4 bellow In order to p
49. with new ASIC Power stage has been desabled output had a short circuit Ring error has been detected Fail Ring A ring error has occured Carrier Fail A CRC error has been detected by another STI No frame received during 50 ms g g E H 5 4 LED s GREEN Auxiliary supply OK Temperature to high YELLOW DC bus high 28 STI User s Manual 024 8080 D 4 2 STATUS INDICATORS FOR REMOTE DIAGNOSIS Status indicators or flags are grouped within 6 bytes 3 words They read as follow msb Isb msb Isb STATA STATB msb Isb msb Isb msb Isb msb Isb STATE STATF STAT3 not available in several versions 4 2 1 STATA The STATA byte provides essential information on the status of the ST1 digital motion controller and its software Bit 7 latched signals that the power stage has been disabled as a result of a fault Normal disabling will not have any effect on this bit Bit 6 latched informs that there has been a change in the two bytes of the STATC and STATD status as a function of the mask MASKS Bit 5 indicates whether the real position is less than 1 or greater than 0 the value set by the instruction SPWARN Bit 4 signals that the position lag variable DPOS is greater than 1 or less than 0 the value set by the parameter SEUIL 1 It provides an overall functional control of the axis allowing the disclosure

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