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1. Sr Bonded to Back Plane D D 8 To Motor Sx Drive Clamp Cx Drive Clamp Terminal Clamp Alternative Bonding Methods Another option is to use cable bonding clamps offered by Phoenix Contact and others When using the Phoenix Contact parts make sure that a low impedance high frequency ground is connected from the ground bus bar to the back panel This can be done with a flat braid or a copper bus bar The SK parts from Phoenix SK8 SK14 amp SK20 slide onto the bus bar The cable with exposed shield is inserted through the SK piece and the thumbscrew on top of the SK piece is used to tighten the connection between the cable shield and the bus bar Phoenix Contact Part Cable Diameter Range 3025163 Shielded terminal block for SK8 Type SK8 placing the shield on bus bars up to 8mm or 0 315 inches 3025176 Shielded terminal block for SK14 TypeSK14 placing the shield on bus bars 8mm to 14mm or 0 551 inches 3025189 Shielded terminal block for SK20 Type AB SS mount ground bus Type NLS CU 3 10 copper at varying lengths SERVOSTAR S and CD Product Family 11 Danaher Motion Wiring The next two figures represent a side and top view of the SK device that clamps down on the shield of the cable The Phoenix SK device
2. _ BUS Module PA LM Multiple Sx 28 5 S and CD Product Family 5 Danaher Motion Contents Specifications Cable Lengths Resolution and Accurac Digital Encoder prn T Cable Re solution and Accuracy ENCODER EQUIVALENT OUTPUT pITWDINTIINERERUENUNDOECDRMEC UM neeesser rnes EEEN 37 37 iISine encoder 3 casettine Drive Address esie Fab 41 SENDING RETRIEVING SYSTEM DATA oue copa e rom 421 OTIONEINK INSTALLATION ees 421 QU HCM M MUN 42 MOTIONLINK Screen niet trece 44 pR TT ECL DUERME 46 COMMUNICATION 47 es caches psa sapis uad MEME E 50 EXERCERE COMMUNICATIONS i uu ice 51
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4. Establish New Commutation using MENCOFF Drive establishes commutation angle Hall Code Change End Adjust Commutation Angle Marker Channel Occur Establish New Commutation using MENCOFF MEN and Halls has hall channels aligned to the motors back EMF This is accomplished by rotating the motor via an external source monitoring the signals from the hall effect channels while monitoring the voltage generated by the motor and rotating the encoder housing until the SERVOSTAR S and CD Product Family 96 Danaher Motion Appendix C waveforms overlap The encoder mounting screws are then secured This aligns the hall channels and the marker channel must then be aligned using the MEC NOFF variable Caution must be exercised as motors may generate lethal voltages when n Perform MENCTYPE 3 amp 4 Drive puts IENCSTART current through 2 phases Read Hall algorithm Codes Establish and waits for motor to stop Commutation Angle as though in the middle Position is read by drive Drive puts current through other phase Wait for stop Marker Channel Occur Marker Channel Occur Establish New Commutation using MENCOFF Drive establishes commutation angle Hall Code Change End Adjust Commutation Angl
5. 2 3 MEM E MIO A are not robust and are subject to varying amounts of error Incorrect commutation alignment also causes differences in efficiency according to direction In an exaggerated example a misaligned commutation angle may allow a 1500 RPM motor to go 2000 RPM in one direction and only 1000 RPM in the other 5 S and CD Product Family 95 Danaher Motion Appendix C Physical Encoder Alignment The SERVOSTAR provides a number of features variables to allow adjustment of the encoder signal alignment through the software These features can be very useful but you must be careful when using them If the alignment of the encoder to the motor is left to chance swapping out the motor or encoder requires that these variables be recalibrated for the new alignment Is this acceptable in the given application You may not be certain that the knowledge to do so will remain in the future A better method is to align the encoder on the motor This makes swap out a simpler process Perform MENCTYPE 3 amp 4 Drive puts JENCS TART current through 2 phases algorithm and waits for motor to stop Position is read by drive Drive puts current through other phase Wait for stop Codes Establish Commutation Angle as though in the middle Marker Channel Occur Marker Channel Occur
6. Danaher Motion Kollmorgen s patented Torque Angle control to maximize motor output power MTANGLC MTANGLP MVANGLF MVANGLH Motor speed and current limits MSPEED MICONT Thermal protection control MFOLD MFOLDD MFOLDDIS MFOLDR MFOLDT adaptable to any motor Auto configuration feature ACONFIG ACONFIGST MFBDIR automatically configures the motor s power and feedback cables It checks warns and corrects for incorrect wiring of these cables Configurable positive motion direction DIR Feedback Devices Device zeroing mode that rotates the motor to an electrical null point ZERO IZERO SERVOSTAR S and CD Product Family 69 Danaher Motion System Description RESOLVERS Variety of motor and resolver pole combinations MPOLES MRESPOLES Resolver zero offsetting MPHASE e System accuracy s better than 20 arc minutes reduced when resolver pole count is increased Inter LSB interpolation between least significant bits ILSBMODE allows 18 bit velocity control and 16 bit positioning capability Automatic resolution configuring based on application speed requirements RDRES VMAX ENCODERS Maximum frequencies to 3 MHz before quad Upto 10 million counts per motor electrical cycle MENCRES e Configures automatically ENCINIT ENCINITST ENCSTART IENCSTART e Index pulse offsetting capability MENCOFF e Variety of encoder types MENCTYPE 1 Encoder with
7. TWH3VNOlLdO 8 TIVH ANI VETIVH HLIM STIVH ONILOANNOO 33s OL Q3S012 38 LSNW LVLSOWYSHL HOLOIN S3HO LIMS 3HVMLJOS ONISN STANNVHO LNOHLIM 9NIJVH3dO SNOISIAOHd AYVA SNOLLdO S3dAL NOISS3A H3GOON3 3NIS H3OOON3 AYLINOID 051 guTIVH YVLSOAYIS 051 OILVIN3HOS TIVH WOIdAL IH ANIS 02 5 21 33S AVW HOLIMS 1V LSOWH3H L OllVH X S90 5 15 QVOTH3AO HOLOW TvNH31X3 NOILO3 OHd TIVIAH3SH L TV93 NI 3AVH 5 SHOLOW NOILO3 LOHd QVO TH3AO HOLOIN 33S OL 5019 38 ASNW LVLSOWYSHL HOLOW NOISSH3A H3AT10OS3H asza ovaaaad ONISN NI 5 38 13S 3NO ANO 318VO NI IZIWINIW OL SNOLLOSNNOO AlddNS OML 1 0000000000000 5 e o o 9 o 9 o SALON 31 5 S and CD Product Family Danaher Motion Wiring Feedback Devices The SERVOSTAR can receive resolver encoder with or without halls or sine encoder feedback Danaher Motion Kollmorgen offers a variety of motors with options for these various feedback device
8. corresponding to the DIP address setting of that desired drive For example to communicate to drive Z8 DIP setting 01000 you would type at the prompt 8 lt gt To globally address all drives on the chain type at the prompt se cr When globally addressing the drives no character echo to the terminal occurs SERVOSTAR S and CD Product Family 47 Danaher Motion System Communication Power Up Sequence Upon powering up the SERVOSTAR performs a series of self tests If the Status Display illuminates a solid number no errors were found and the EEPROM has loaded its variable parameters or loaded with default values in case of invalid EEPROM data into RAM The Remote Enable switch on the I O connector C3 may now be energized thus enabling the servo loops Enabling the System The drive enable logic is based on the following variable switches and flags ACTIVE This is the overall readiness flag indicating the enable disable state of the drive If high 1 the drive is enabled and power is being applied to motor The following equation must hold true for ACTIVE to go high ACTIVE READY AND REMOTE AND DIPEN where READY DRIVEOK AND SWEN READY flag that indicates the drive is free of faults and ready to hardware enable DRIVEOK switch indicates the status of the drive faults SWEN switch indicates the status of the software enable EN or DIS REMOTE switch indicates the status of the ha
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12. REGEN Resistance SERVOSTAR S and CD Product Family 106
13. t ae ERR EA EISE bd 96 keca E 98 B Determining Keststance Valen 05 Determining Dissipated Power 1061 SERVOSTAR S and CD Product Family 8 Danaher Motion Read Before Installing READ BEFORE INSTALLING These installation steps are designed to lead you through the proper installation and setup of a SERVOSTAR S SERVOSTAR CD system They were developed with the assumption that you have a fundamental understanding of basic electronics computers mechanics and proper safety practices However you do not have to be an expert in motion control to install and operate the drive system It is recommended that you read the entire manual completely before attempting installation or operation 1 High voltage can present dangerous and hazardous conditions if not performed by qualified electrician Be certain to follow all national and local codes during installation Follow all safety precautions outlined in the accompaning CD ROM documentation 1 Open the box es and remove all the contents Check to ensure there is no visible damage to any of the equipment 2 Mount the SERVOSTAR 5 and SERVOSTAR CD to the back panel Refer to the appropriate Outline Dimensions in this manual Metal to metal contact is important for electrical noise control 3 Wire SERVOSTAR 5 and SERVOSTAR CD according to the appropriate System Wiring Diagram Connect
14. za A8vmixny nado 2 VIS 01 QI3193NNOO 38 LON Q2 318 2 IHL 22 SI 4 eii 123433 404 3186509 SY NAYI S1N3S3d43d kin 8 1 JHL 103415 JAYA IHL OL 35070 SY O3INSIN3 dl ONY IHL OL s 1 GINOHS S318v2 OL 310N to 5 NO WOO 1 oLviva4 2 AVIdSIG 1115 YYLSOAYIS vivo a xdi 1 171926 9 30 LNOYS QOd uasdu 9 LO kn mi 1 lt lt NOWWOO 21901 TVNOILdO AfidNI H3009N3 ALOWSY 85 Cx Wiring Diagram Danaher Motion ANNOYS 9310N GALSIML 38 SJAM OV VIY SILON 4015 4 4 380338 330 5030935 06 MOTIV 6 3LON 43333 TWYLNAN SI 3NI133A Od 3HL LON HOLOV INOO ANY C 3515 LILON 9 N393H 3ALLSIS3H TVNu3 LX3 25 5 S and CD Product Family iring Danaher Motion Sx with 08 14 or 28 Wiring Diagram SALANINS OL df AVIW3OV L IOA SOW BH
15. The PA LM unit is a logic supply only and should be used in multi axis applications where the number of drives exceed the logic capabilities of the BUS Module This unit comes with three green LED s that verify the presence of the 15 V 15 V and 8 V sources See the Bus Module Electrical Specifications for details on these features SERVOSTAR S and CD Product Family 74 Danaher Motion Troubleshooting TROUBLESHOOTING Technical papers and publications about the SERVOSTAR and its associated applications complete the information package necessary for you to become well versed with the product Danaher Motion Kollmorgen s engineering and technical resource staffs have prepared these notes The PSP CD ROM contains technical content stored in an electronic PDF format You must have Adobe s Acrobat Reader also available on the CD ROM installed on their computer to view and print these documents This package is available on the CD ROM The most recent versions of all the material contained in this PSP manual and CD ROM can be downloaded from Danaher Motion s website www danahermotion com Troubleshooting Tools The SERVOSTAR s MOTIONLINK package comes with a comprehensive monitoring and troubleshooting help set For troubleshooting the drive it provides a Status screen click on Status button in the upper right hand corner of Main MOTIONLINK screen The Status screen allows you to check the drive enable switches the Status
16. Product Model e External Shunt Regulator Minimum resistance ohms 20 Watts wm 0 Application Information Vins eeen creiamo 3m vus Ress ciuitas 38 For guidance on application sizing of Regen Kits see the SERVOSTAR S and CD Series Regeneration Requirements Application Note SERVOSTAR S and CD Product Family 21 Danaher Motion Wiring BUS Module Regen Internal Shunt Peak current amps N A 30 32 N A N A m a RR MUN External Shunt Peak current amps pem Minimum resistance ohms ESEEIEE 0 i m Application 5 ELT BIN EUM Information BUS Voltage nominal Vims Regen turn off VDC s Vix Regen turn on VDC 396 O PowerRating Wati NNI T C 4 ERH 26 For guidance application sizing of Regen Kits see the SERVOSTAR S CD Series Regeneration Requirements Application Note Kit Parts and Models Kit Parts Kit Models Resistor Resistance 4 5 4 4 22 2 2 8 8 8 8 ohms two in two in RE Watts Kollmorgen Part A 79916 007 A 93317 027 79916 007 93317 027 A 84776 001 P 97742 No UA Fast Trip Setting amps Kollmorgen P
17. Drive d e o ey e ote 52 CP Run up Pu M CPO Initialization 9 Operational Notes Urana ara a a a anam Equation Notes SERVOSTAR S and CD Product Family 6 Danaher Motion Contents Fault Output Relay RELAY RELAYMODBE eene rers 59 _ Motor Thermostat Input THERM THERMODE CONTROL LOOPS Processors 60 _ OAN ree trei 65 FOLDBACK esolvers ur 8 ncoders Monitoring and Troubleshooting Tools eese emnes 72 Fault and Safety Detection entrent rere eerte rere 805 MODULE aee Eu Features a aa ym i neg ee pr a 73 koee MESSAGE FAUL ICE 801 FAULT MONITORING 5 MMMMMMMMMMMMMEMEEMEMEMMEMEMEMEKfSu San2aNMNMMMMMMMWMWMWMWWWuuUUUuuuuaag 80 IMotor Power 8 5 5 53505 631 E ISR CR RESOLVER E 631 SERVOSTAR S and CD Product Family 7 Danaher Motion Contents MENCTYPE 4 MENCTYPE 5 Physical Encoder Allgnmeht etit ei be HE EE HEP
18. The input to the SERVOSTAR is electrically closed through the thermostat for proper operation The drive normally flashes an in the Status Display when this input is electrically opened If a motor thermal device is not used set THERMODE to 3 to disable the feature turns the status display indicator off SERVOSTAR S and CD Product Family 59 Danaher Motion System Operation Control loops This section describes the servo control loops their characteristics and how to configure them Core Processors A 40 MHz embedded Controller and a 40 MHz DSP controller are the heart of the SERVOSTAR They use its internal operating system to monitor inputs adjust outputs communicate serially maintain servo control and monitor faults The flash memory firmware that controls the core processor and gives the SERVOSTAR its operating characteristics is saved in EPROM The version number of the firmware can be read using the VER command When calling Danaher Motion for technical support be sure to have the firmware version number readily available The most recent version of firmware is available for purchase and is easily field upgradable through a PC It can be obtained by contacting a sales representative or by contacting Danaher Motion Customer Support Servo Loop Description The SERVOSTAR provides high performance motor control by controlling up to four distinct closed loop systems within the DSP the current commutation ve
19. This condition causes t to be displayed and disables the drive The drive will eventually cool enough to allow reset of this condition RMS OverCurrent FoldBack The FoldBack detection system can clamp the available output current This is not a true fault condition but may cause undesired performance due to the command current being limited below what is required to achieve the desired performance This condition is indicated with a flashing in the status display and can be detected by monitoring the FOLD switch variable Bus OverVoltage An over voltage condition shuts down the drive and displays lower case in the status display This fault will occur mostly during regen operation where the BUS is raised to higher values than that produced by the power supply Bus UnderVoltage An under voltage condition shuts down the drive and displays an in the status display This fault normally occurs when the incoming line voltage drops out or a fault occurs in the power supply PowerStage Fault OverCurrent Hardware circuitry monitors load short circuit transistor failure and instantaneous OverCurrent In general toggling the Remote Enable cannot reset a power stage fault Power must be cycled A flashing in the status display indicates this condition Feedback Loss Hardware is used to detect wire break condition in encoder based systems or the presence of the Sine and Cosine
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21. environmental IP rating of the end product To ensure proper grounding and to optimize EMC the enclosure should have continuous ground continuity maintained between all metal panels This ground continuity 15 intended to be both a safety ground and a high frequency ground The units should be mounted on a back plane which is installed into the enclosure Ideally the back plane should be an unpainted metallic surface to optimize electrical bonding of the frame and provide the lowest possible impedance path to earth ground These enclosures also provide added safety SERVOSTAR S and CD Product Family 9 Danaher Motion Wiring Grounding System grounding is essential for proper performance of the drive system A ground bus bar may be used as a single point ground for the system Safety grounding should be provided to all pieces of the system from star point In addition to the safety grounding a high frequency ground must be provided that connects the back panel to the enclosure and ultimately to earth ground The objective 15 to provide an extremely low impedance path between the filters drives power supplies and earth ground This high frequency ground is accomplished with the use of a flat braid or copper bus bar It is important not to rely on a standard wire for the high frequency ground In general a wire has an inductance of 8nH per inch regardless of diameter At higher frequencies this unwanted inductance between grounds eq
22. large inertial loads MENCTYPE 5 Not supported SERVOSTAR S and CD Product Family 92 Danaher Motion Appendix C MENCTYPE 6 Incremental with A B and Hall Channels MENCTYPE 6 supports encoders as described in MENCTYPE 0 MENCTYPES 1 amp 2 MENCTYPES 3 amp 4 Drive puts IENCSTART Perform S amp 4 current through 2 phases Roada algorithm Codes Establish and waits for motor to stop Commutation Angle as though in the middle Position is read by drive Drive puts current through other phase Wait for stop Marker Channel Occur Marker Channel Occur Establish New Commutation using MENCOFF Drive establishes commutation angle Hall Code Change Adjust Commutation Angle Marker Channel Occur Establish New Commutation using MENCOFF SERVOSTAR S and CD Product Family 93 Danaher Motion Appendix C MENCTYPE 9 but lacking the marker or index channel This device is selected using MENCTYPE 6 and follows the same process used in MENCTYPE 0 MENCTYPES 1 amp 2 MENCTYPES 3 amp 4 Drive puts IENCSTART MENC TYPE 3 64 current through 2 phases Read Hall algorithm Codes Establish and waits for motor to stop Commutation Angle as though in the middle Position is read by drive D
23. the enclosure should have an unpainted metallic surface This allows for more surface area to be in contact with the filter housing and provides a lower impedance path between this housing and the back plane The back panel in turn has a high frequency ground strap connection to the enclosure frame or earth ground Input Power Filtering The Danaher Motion Kollmorgen SERVOSTAR S and SERVOSTAR CD electronic system components require EMI filtering in the input power leads to meet the conducted emission requirements for the industrial environment This filtering blocks conducted type emissions from exiting onto the power lines and provides a barrier for EMI on the power lines Care must be taken to adequately size the system The type of filter is based on the voltage and current rating of the system and whether the incoming line is single or three phase One input line filter is used for multi axis control applications These filters are mounted as close to the incoming power as possible so noise is not capacitively coupled into other signal leads and cables Similarly care should be taken when routing wires from the load side of the filter to the BUS Module These lines may be noisy and should be separated from other sensitive cabling to avoid unwanted coupling of noise Several manufacturers of these filters are listed below They should be able to recommend the best filter design for most typical motor control applications Danaher Motion Kollmorge
24. 0 or higher Other types will work with all firmware versions Firmware version 4 0 0 and higher is not compatible with the older versions of IGNITE firmware loading software Attempting to load incompatible firmware will result in the IGNITE program generating an error To obtain the latest firmware version or receive additional help contact Danaher Motion Customer Support www danahermotion com SERVOSTAR S CD Product Family 82 Danaher Motion Appendix A APPENDIX A Motor Pinouts The SERVOSTAR 5 and SERVOSTAR CD product family can be mated with a variety of motors Cable sets motor and feedback can be purchased directly from Danaher Motion Kollmorgen which gives you a complete plug n play system However you may find it necessary to manufacture your own cable sets This Appendix provides pinout information between the drive s power and feedback connections and the motor receptacles for most of Danaher Motion Kollmorgen s motor products Motor Power Connections Lees GOLDLINE B M EB amp XT SILVERLINE RBHR RBE H DRIVE B M EB XT WIRE Color Motor Wire Color Motor Wire Color Wire Color Motor Motor Receptacle Receptacle E Receptacle Receptacle eceptacle eceptacle eceptacle MA 3 Brown Black Pin 2 Gmewvelow im Green Pin Eum SR CR RESOLVER connection GOLDLINE EB XT RBHR B M EB XT XT
25. 2 or compatible computer 16 Windows Windows98 or Windows NT 4 0 with Service Pack 3 CD ROM player Standard Video Adapter MDA EGA MCGA and VGA Serial Port for communication link with SERVOSTAR The serial communications port may be COMI 2 COM3 COMI is the normal configuration COMI Address 3F8h Interrupt Request 4 COM2 Address 2F8h Interrupt Request 3 COM3 Address 3E8h Interrupt Request 4 Address 2E8h Interrupt Request 3 SERVOSTAR S and CD Product Family 39 Danaher Motion System Communication Drive Communication Review and be familiar with this section completely before applying power to the system Most drives are shipped from the factory already configured for a particular motor You can verify this by applying logic power and monitoring the Status Display A factory configured drive will go through a power up sequence flashing all segments of the display before settling out to a number indicating the mode of operation If the drive is not configured with a particular motor the display will flash a minus sign indicating that you must enter drive motor and application variable parameters The remainder of this section will describe the process of setting up a non configured drive Caution must be taken when applying power to the drive It is factory configured to enable upon application of power Verify that the hardware Remote
26. 2 pue i Jadhun ay pue aauenstsa1 aoeds 0 s 0j3euuoo Jojstsa 9 pue serias seu py aq uonemuaA Wey Aq 10 au Bununoui aseajd s au L ION seau jou oq uonejedo Buunp yoy zT 26 SERVOSTAR S CD Product Family iring Danaher Motion Sx with 50 75 or 85 Wiring Diagram F Hid 2 40 100 OHY OL 4 Lv 38 TIY 15 oNISh 15 OAYIS 1530 3991 10A JOON SS32X3 1H3A3uUd 01 313H13501 SHOWIN 195 2378 OL LNONY DHIDHTH3J3H NOWWIAOO 20 Adana ganadnawaan idSAOWSY SYH M3MOd 4313 5 S OL d 198 AWN 395 TOA saco 5 v1 ONINSVA 2 aiios 1 ne ANONY i3 40
27. Configurable Input See INT variable Internal DC common reference for ANOUT It is also to tie electrical equipment commons ogether inside the drive to prevent excessive mode voltage from destroying I O internally fused C4 Encoder Equivalent Output Pin Function 4 Channel B Output High ENS 6 hannel B Output Low Shield dex Output High 8 ndexOutput Low Wiring C2 Feedback Connector Pin Resolver Encoder Sine Encoder 4 CosineHigh B B Cosine Low B B 6 Shield Shield Shield 7 5 ESVRetun 3 ESV ESV Rem J HIB C Data HB Cle i HB HBB 6 Ref Low Out 18 ESV Supply ESV Supply 19 Supply 20 ESV Supply ESV Supply 22 HA Data 33 H2A QD ES p HA SERCOS interface Ports Replaces C4 SERVOSTAR S CD Product Family 29 Danaher Motion Wiring Top View C7 MultiDro Communications Notes for DIP switch 10 Pin 0 1 0 1 Female Ribbon Cable Connector and cable are included in the optional CK100 kit The 10 position DIP switch is provided for drive configuration The first 6 switches control communications parameters and are read only at power up Any changes in these settings w
28. GO a on 600 00 1 OO usto 5 5 6 6 508 53215 MS M N3HM MEE MEE ses ces ORT 180831 31000 ze 244 HM MP SAB 34130 rez rez IHL 01 1032538 2 on 5 on on 62 oy HIM 03715 38 LSA JP sean 7 Z 9 an 7 aw 7 508 OL SIAO 2 NEON 7 BASH vL Hi 71 D 2 mec TRS ir 2 sna 21907 JHL HOF 371861 0012 82150305 1821029379 3 130A WORD SINHA OL FOWNOS NYI F SHANS 21907 IWOS 82 HT 5 E gt SMIOMROS 21901 x IHL 31881 SVOLEOIIIO34S 7021510313 NO3H0 WO 324005 93 519510 CIV M HA S niv1S FHL 535590 IWOSAN 19 1 0 JINON 21501 Wd ATddNS 28 5 S CD Product Family Danaher Motion Pin out Connections Front View C1 Communications Connector Pin Function ommon 6 TxD 85485 8 IRxD 9485 9 RxD RS485 C3 User I O Connector Fault Output Relay Contact 7 24 Input Common Rail for return pins 8 9 10 11 RemoeEmbieipu
29. HT 5in 12 7 mm Toroidal Core Recommendations Manufacturer s Part Kollmorgen Part Schaffner RD7137 36 0m5 96843 005 500uH 3 phase common mode choke 36 amps continuous Schaffner RD8137 64 0m5 A 96843 010 500uH 3 phase common mode choke 64 amps continuous Pre wound Common Mode Chokes Filtering I O filtering while not a necessity for CE compliance may be desired depending on system installation application and integration with other equipment It may be necessary to place ferrite cores on I O lines to avoid unwanted signals entering and disturbing the drive system or other associated equipment The following chart lists some ferrite parts that may be used for I O filtering and noise attenuation These parts are ideal for providing an in line common mode impedance for I O lines Fair Rite Products Corporation also has a varied selection for most any application SERVOSTAR S CD Product Family 15 Danaher Motion Wiring Manufacturer s Part Kollmorgen Part Ferrishield 553382032 96770 003 Ferrishield 5533 2036 96769 005 Ferrishield FA28B2480 96771 003 Clamp on core flat cable clamp Ferrishield SA28B4340 A 96772 009 Clamp on core flat cable clamp 2643167251 pO I O Filter Recommendations be applied to the 24 V input power lines and the Remote Enable lines 7 amp 8 on C3 This core must be used with the CD Series of drives for CE compliance It should connecto
30. Length Maximum Line Count Per Motor Electrical Cycle Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels Illegal Hall Code Detection CABLE LENGTHS The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft 15 m Long encoder cables tend to have high DC resistance that may create significant loading effects in the supply lines to the encoder Please consider this carefully when designing the system An option that would allow the use of longer lengths implements a separate supply located at the motor to source the encoder Quadrature signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths RESOLUTION AND ACCURACY A SERVOSTAR encoder based system typically exhibits minimal inaccuracies outside of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used Sine Encoder The SERVOSTAR can receive an analog or sine encoder feedback device to monitor the motor shaft position As opposed to a digital encoder which generates incremental square wave signals a sine encoder outputs analog differential sinusoidal signals These sine signals are quadrature decoded and passed to an interpolation circuit that breaks each 360 cycle into 256 parts before passing it to the drive s control board Thus the resol
31. Product Family 77 Danaher Motion Troubleshooting NON FATAL ERROR CODES No Error 0 35 EXT velocity param warning D R parameters for COMP MODE 3 do not have the proper 40 relationship to each other he velocity loop can t be con figured with given parameters he EEPROM test failed The requested command cannot be executed because it conflicts with a recording in progress data are available for the GET command Data cannot be loaded because the EEPROM 15 empty Variable argument must be a power of 2 The requested function cannot be executed during Burnin a factory function urnin is not active urnin factory function cannot be stopped if it is not active onflicts with ENCOUT he requested value for VLIM conflicts with ENCOUT onflicts with VLIM The requested value for ENCOUT conflicts with VLIM Not available The requested variable value is not available refer to the description Q Vel loop design failed nvalid EEPROM Recording active N Rec data not available EPROM is empty Argument must be binary Burnin is active 5 45 45 45 AJA ny of the variable in section 1 to determine why Drive is in Hold mode Motion was requested with the drive in Hold mode 5 51 2 SERVOSTAR and CD Product Family 78 Danaher Motion Troubleshooting Possible Cause Encoder Initialization Process command cannot be executed because i
32. QUIT 5 Jod Gn B 3 wen E PAON PANO DHOG 232 U WIO DE UD APON D 9 WO L 9 sD UQA an acera AOPE 31300228400 341 1 EW pie 10440040 10822190 333940 vado Ajeuro 4106400 211 V penu ano fii 24192 2326 003 ME 941 t 3H 442 Jod pre 3018131331 IG so 911 3200183 31 sm ewan v saod DIE 30183 731 29035 P A ICO 13 331 EJEd DIE 3341231431 KEJ Paii bar aqJeu tope 10 VEJER Jea LOW ON og aapoy Aan 183 94 Dig uou tai E423 8144013 d PEEN Q L V 27 SERVOSTAR S CD Product Family Wiring BUS Module PA LM Multiple Sx units Danaher Motion INOW 325 1800031 U RST SNOLLVOHIO34S SH 3ABO 21795 3H1 OL 53339 3434410
33. R c rt i k 5 03 06 264 252 00 60 75 5000 125 580 238 202 175 X Sxio 264 25200 60 90 5000 20 5 80 238 202 175 Xx ___5 20 264 25200 60 1186 50 00 343 580 238 202 175 X so 264 25200 60 142 7500 33 5 580 238 210 175 X Sx55 302 28200 6 0 10160 33 0 5 80 264 211 178 X 264 25200 60 63 5 50 00 6 75 5 80 238 202 175 X PAI428 264 25200 60 1244 50 00 372 5 80 238 202 175 X X X X 0 X X SERVOSTAR S and CD Product Family 7 Danaher Motion Mounting Cx Units Cx10 lt 99 1 3 90 Cx 06 lt 83 3 3 28 gt Cx 03 67 3 2 65 36 6 163 0 gt 67 1 44 0 26 642720 305 5 Ze 22 15 5 0 61 2 10 0 0 39 256 0 244 0 216 0 10 08 9 61 8 50 d x uz Io 337 1 33 PA LM Units 185 4 7 30 MAX gt 175 5 26 2 6 91 1 03 3 1 0 12 Motion Technologles Group 158 8 8V Q 6 25 147 3 5 80 C5 LA N C 7 SERVOSTAR S CD Product Family 8 Danaher Motion Wiring WIRING The environment that any electronic control system lives in can effect its operation Danaher Motion Kollmorgen recommends that the SERVOSTAR system be operated and stored unde
34. Status Display TESTLED indicator that communicates operational and fault characteristics Realtime reading of the 10 position DIP switch DIP DIPEN Software status switch indicator provided for configurable inputs IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Fault and Safety Detection Watchdog faults General faults ACKFAULT STAT STATUS Configurable under volt protection UVMODE UVTIME UVRECOVER Speed and current protection VOSPD VLIM ACC DEC ILIM ILIM2 Fatal and non fatal error coding with text explanation to the host ERR FLTHIST FLTCLR A run time counter TRUN that records the time the error occurred is also provided Configurable motor thermal protection that accepts various thermostat types THERM THERMODE THERMTYPE THERMTIME SERVOSTAR S and CD Product Family 72 Danaher Motion System Description Configurable drive thermal protection through the fold back feature FOLD FOLDMODE It sets the maximum time limit the drive can provide peak current 2 1 for Sx or 3 1 for Cx to the motor Configurable motor thermal protection through the motor fold back feature MFOLD MFOLDD MFOLDDIS MFOLDR It sets the maximum time limit the drive can provide continuous current to the motor Hardware position limit switch detection CCWLIM CWLIM LIMDIS IN2 IN3 INIMODE IN2MODE IN3MODE Configurable software position limits PLIM PMAX PMIN Configurable fault relay
35. a system needs a regeneration resistor use the following procedure EQUATION 1 Define the term which is the kinetic energy of the motor load minus the system losses 1 356 2 9 M 3PM Ry 2 t 1 356 T mta Joules Where Ju rotor inertia Ib ft sec load inertia Ib ft sec RPM motor speed before rad sec 9 55 motor current during deceleration Ry motor resistance Q L L ty time to decel sec Tr friction torque lb ft If this energy is less than that which the BUS Module can store then no regen resistor 15 needed Thus the condition for which no regen resistor is required is EQUATION 2 lt 1 2 Where BUS Module capacitance Farads max BUS voltage V Vnom nominal BUS voltage V V 1 1 42 Where all negative are set equal to zero before summation sum all non negative This represents a worst case in which only the motors that are regenerating Ey gt 0 decelerate while those whose system losses exceed their regenerative energy Ey lt 0 remain idle If Equation 2 is not satisfied then a regeneration resistor is required Regeneration Calculations The procedure for calculating regeneration requirements is twofold Both the regen resistance value and the resistor wattage rating must be determined SERVOSTAR S and CD Product Family 104 Danaher Motion Appendi
36. is excellent for providing a low impedance path between cable shield and the back panel Thumb screw to tighten down shield to bus bar cable shield compressed on copper bus bar copper bus bar SK 8 14 20 Shielded terminal block Phoenix Contact Side View SKX for Support for bus bar connecting shield to bus bar Di QD 2 D Copper Bus Bar high frequency ground connection to back panel from bus bar Phoenix Contact Top View SERVOSTAR S and CD Product Family 12 Danaher Motion Wiring CE Filtering Techniques The SERVOSTAR drive system BUS Module drive motor meets the CE Mark standards stated in the front of this manual It is imperative for you to apply proper bonding and grounding techniques described earlier in this section when incorporating EMC noise filtering components for the purpose of meeting this standard Noise currents often occur in two types The first is conducted emissions that are passed through ground loops The quality of the system grounding scheme inversely determines the noise amplitudes in the lines These conducted emissions are of a common mode nature from line to neutral or ground The second is radiated high frequency emissions usually capacitively coupled from line to line and are differential in nature To properly mount the filters
37. live or have hot surfaces Control and power cables can carry a high voltage even when the motor is not rotating Never pull out or plug in the product while the system 15 live There is a danger of electric arcing and danger to persons and contacts After powering down the product wait at least ten minutes before touching live sections of the equipment or undoing connections e g contacts screwed connections Capacitors can store dangerous voltages for long periods of time after power has been switched off To be safe measure the contact points with a meter before touching When these symbols are seen in this manual be alert to the potential for personal injury Follow the recommended precautions and safe operating practices included with the alert symbols Safety notices in this manual provide important information Read and be familiar with these instructions before attempting installation operation or maintenance The purpose of this section is to alert users to possible safety hazards associated with this equipment and the precautions that need to be taken to reduce the risk of personal injury and damage to the equipment Failure to observe these precautions could result in serious bodily injury damage to the equipment or operational difficulty e The safety alert symbols are Warning Alerts users to potential physical danger or harm Failure to follow warning notices could result in personal injury or death Caution Direc
38. max 727 6 5 Vdc Supply 10 mA o orn oooooo HOS E 7 Analog Common SEE NOTE 1 8 AIN 3 9 5 Vdc Supply 10 mA max SVdc 10ma max 5 SEE NOTE 1 5Vde RI Analog 1 0 5 485 J 14 Pin out Signal Name Autobaud 4 Terminal Enable rautLED OKLED RS 232 J 15 Pin out Signal Name Common Data In Data Out External Terminal Enable Enable Supply Vcc Backlight Suppl NOTE 1 The analog input supply in this configuration is the BJP internal 5Vdc supply Customer can supply up to 10Vdc to obtain full range of analog inputs NOTE 2 Refer to BJP to SERVOSTAR diagram for proper wiring of these connectors SERVOSTAR S and CD Product Family 86 Danaher Motion Appendix C APPENDIX C Digital Incremental Encoder Types The SERVOSTAR products include models designed for use with incremental digital encoders Encoders are available in different configurations from a variety of manufacturers using different nomenclature and conventions making this topic somewhat confusing Encoders can be as simple as having only A and B output channels or as complex as 6 channels of outputs The SERVOSTAR supports many of these variants using the variable MENCTYPE The variable is set according to the features of the encoder This document explains the different applications of the various MENCTYPEs basic understanding of encoders is valuable
39. or without index 2 Encoder hall effects with or without index MHINVA MHINVB MHINVC HALLS SINE ENCODERS 256x internal interpolation Up to 128x encoder equivalent output SININTOUT e Most standard encoder features mentioned above System Communications e Serial communications port address setting through DIP switch on top of drive 1 RS 232 single and up to 31 axis multi drop addressing ADDR 2 RS 485 single and up to 31 axis multi drop addressing ADDR 3 Data transmission DUMP GET LIST MLIST GETMODE baud rates of 9600 or 19200 4 Configurable protocol ECHO PROMPT ACKMODE GETMODE MSG 5 Interface through Danaher Motion Kollmorgen s MOTIONLINK or a dumb terminal SERVOSTAR S and CD Product Family 70 Danaher Motion System Description Differential analog input command ANIN 1 10 at 14 bit resolution 2 10 at 15 bit resolution below of input for slow speed operation using the Dual Gain feature ANDG SE units only 3 Input signal filtering ANLPFHZ 4 Flexible analog input scaling VSCALE ISCALE ANOFF ANZERO ANDB SERCOS interface communications port SERCOS interface versions only 1 2 msec update rate 2 Complete set of manufacturer s IDNs 3 MOTIONLINK communication through the serial port Encoder Equivalent Output signal C4 connector eliminates the need for an additional position feedback device The maximum frequency of this output is 3 MHz for stan
40. output RELAY RELAYMODE DISTIME INIMODE IN2MODE IN3MODE Active disable feature ACKFAULT that allows you to determine how the system should react at the occurrence of a fault The system can immediately disable where the motor will coast to a stop or it can be programmed to a controlled decelerated stop DECSTOP DISSPEED DISTIME STOPMODE ISTOP Active enable indicator through the Status Display decimal ACTIVE DRIVEOK SWEN READY REMOTE DIPEN General Many enabling and disabling features K S STOP REMOTE EN DIS Flash firmware memory for easy field upgrade installation Danaher Motion Kollmorgen s patented Torque Angle Control for buried magnet motor designs MTANGLC MTANGLP MTANGLF MTANGLH defined as speed and torque optimization through commutation angle advancing of the drive s output current waveform with respect to the motor s back EMF waveform Firmware and serial number information VER SERIALNO MOTOR via terminal BUS Module The SERVOSTAR family includes a variety of BUS Modules that convert a single phase logic voltage and a three phase AC line into the drive s DC logic power and main DC BUS Features Converts single or three phase AC main lines into a rectified DC BUS check BUS Module Electrical Specifications table to verify specific BUS Module operation The input consists of a 3 diode bridge and BUS capacitors These capacitors help to minimize BUS ripple and therefore BU
41. power up Any discrepancy in this data is noted with an in the status display After power up is successfully completed any subsequent fault in the operation of the EEPROM is noted with an in the status display WatchDogs In addition the SERVOSTAR incorporates a watchdog system to maintain software operation integrity Failure of the watchdog mechanism will display three bars on the status display and cause the drive to halt This normally indicates serious problems Please contact the factory for support Firmware Upgrades From time to time Danaher Motion Kollmorgen adds features to its products that expand their overall capabilities Features added to the SERVOSTAR can be easily implemented at the customer s site This is accomplished by downloading new firmware via the drive s serial port directly from a host computer The customer ordering a firmware upgrade receives a file labeled UPGRADE EXE Click on this file and a Windows program will prompt you to choose an unzipping method baud rate and communications port If the baud rate and communications port selection is incorrect or the drive is set up for MultiDrop communications then a DOS screen will pop up indicating an error has occurred Simply close the window and select another baud rate and or communications port NOTICE Be sure to check the Type specifier on your unit If your unit has the following label UCB1V2 It requires firmware version 4 0
42. previous page are used on a one to one corresponedence with the drive If drives are paralled off one filter it needs to be sized Drives can be ganged off one EMI filter as shown in the Filter and Bonding Diagrams Motor Line Filtering Motor filtering may not be necessary for CE compliance of SERVOSTAR systems However this additional filtering increases the reliability of the system Poor non metallic enclosure surfaces and lengthy unbonded or unshielded motor cables that couple noise line to line differential are just some of the factors that lead to the necessity of motor lead filtering Motor lead noise may be either common mode or differential The common mode conducted currents occur between each motor lead and ground line to neutral Differential radiated currents exist from one motor lead to another line to line The filtering of the lines feeding the motor provide additional attenuation of noise currents that enter surrounding cables and equipment I O ports in close proximity Differential mode currents commonly occur with lengthy motor cables As the cable length increases so does its capacitance and its ability to couple noise from line to line While every final system is different and every application of the product causes a slightly different emission profile it may become necessary to use differential mode chokes to provide additional noise attenuation to minimize the radiated emissions The use of a ferrite core plac
43. solid earth ground to frames of all components 2 Wire the main power 115 230 VAC A For S Series product Wire the logic and DC Bus power from power supply to drive modules B For CDxx260 and CDxx261 product wire the 24 volt supply to the connector at the top of the drive 6 Wire user I O at connector C3 At a minimum 24 volts must be brought in to the enable circuit Be certain that connector C3 is inserted correctly 7 Wire the motor and feedback Refer to the Feedback Wiring Diagram for additional information 8 Wire Regen Resistor kit if applicable 9 Verify that all wiring is correct 10 Verify that earth grounds are connected 11 Verify all electrical and safety codes met 12 Connect the serial cable to connector C2 and PC Refer to the appropriate System Wiring Diagram 13 Install MOTIONLINK on the PC Startup processes cause motor Be certain that all applicable safety precautions are taken to ensure that no harm to personal or machine can occur SERVOSTAR S CD Product Family 1 Danaher Motion Read Before Installing 14 Using the Startup Wizard in MOTIONLINK A Configure the SERVOSTAR S or SERVOSTAR CD for your particular motor if this was not done at the factory Refer to the MOTIONLINK Startup Wizard B Enable the system Use As Directed The restrictions for proper use ofa SERVOSTAR S or SERVOSTAR CD system are These amplifiers are components that a
44. velocity and torque from the motor feedback C2 input SERVOSTAR S and CD Product Family 68 Danaher Motion System Description PID position loop tuning GP GPD GPI with feed forward acceleration gain input to both the velocity and current loops GPAFR GPAFR2 and feed forward velocity gain input to the velocity loop GPVFR Software position limits PLIM PMAX PMIN PEMAX Configurable integrator dynamics through travel range GPISATOUT GPISATIN Cumulative revolution and error position counters PFB HWPOS PRD PE Position indicators INPOS PEINPOS PE PEMAX PFB PFBOFF Profile Ramping Control Electronic Braking STOPMODE ISTOP Separate ACCEL and DECEL linear ramping control in velocity and position mode ACC DEC PROFMODE S curve ACCEL and DECEL ramping control PROFSCRV PROFMODE in the position mode OPMODE Controlled decelerating DECSTOP DISSPEED DISTIME with acceleration feed forward when the drive 15 left enabled STOP HOLD CWLIM CCWLIM LIMDIS or becomes disabled K S ACKFAULT DIS This feature can be used in conjunction with the Electronic Braking feature Torque compensator for coulomb friction and weight counter balancing IFRIC IGRAV Motor Controllability Provides linear and rotary motor control MOTORTYPE MPITCH MENCRES with automatic unit conversion Configurable back EMF characteristics for effective current loop controller design and command MBEMF
45. 0 25m of stranded bus ribbon C8 Mating Kollmorgen A 93899 013 Vendor Info Weidmuller BL3 5 13 Cat No 161574 Connector Kollmorgen 4 A 81014 004 Vendor Info PCD ELFP04110 Hardware 2 25 Ib in BUS Module Mounting 10 32 M4 Hardware 20 Ib in 2 26 Nm Line Screw Size Torque 6 32 10 32 M5 Box Lug 12 Ib in 12 lb in 20 lb in 1 35 Nm 1 35 Nm 2 26 Nm BUS Screw Size Torque 5 Connection 20 Ib in Hardware Ground Screw Size Torque 4 12 Ib in 1 35 Nm Control Logic 18 0 75 Main Input gauge based on 14 2 5 12 4 8 6 6 16 2 35 2 35 909 wire BUS bar wire 2 35 Wire Size Spade Terminals 16 14 AWG 1 5 mm Hollingsworth 5509545 OR 55209475 or equiv one Side to Side No Distance Required Distance Top Bottom 63 5 mm 2 5 in CK100 Kit Includes C1 C2 C4 C7 plus 2 of stranded bus ribbon C8 C6 Kollmorgen A 81014 002 Vendor Info PCD ELFP02110 Mating C7 Kollmorgen A 81014 004 Vendor Info PCD ELFP04110 Connectors C8 Kollmorgen A 81014 003 Vendor Info PCD ELFP03110 Connector Screw Torque 2 25 lb in 25 Nm SERVOSTAR S and CD Product Family 6 Danaher Motion Mounting Outline Dimensions Sx and units D gt Not Fan Sx85 MES PHYSICAL DIMENSIONS Inches _ a R c et amp Wu 1 E 810 1039 9 921 024 3 54 1969 079 0228 937 795 689 X Millimeters A
46. 1 96 4 34 37 20 N A 11 30 Continuous Power KVA at 165 VDC 0 55 1 1 1 6 N A N A BUS Input 45 C 113 F Ambient Rated Main Output BUS Input 45 C 113 F Ambient 2 30 55 85 N A 20 55 MO Continuous Current 3 6 Peak Current Arms for 500mSec 6 12 Current Arms for 2See 2 230 uo 17 16 croi 73063 14310155 VDC Supply Current 037 038 05 047 066 037 255 VDC Protective 125 VDC Functions OverVoltage Trip 430 VDC OverTemperature Trip 118 C 90 C Internal heat dissipation in 45 C 113 F 37 w 84w 120 w 240w 254w 465 675w ambient at continuous current not including regen Environment 0 C 32 F to 45 C 113 F Storage temperature 20 C 4 F to 70 C 158 F 10 to 90 without corrosive gasses or dust Derate 5 per 1000 f t above 3300 ft 0 5 g BUS Module Electrical Specifications Voltage 1 Nominal 110 240 110 120 208 240 10 5 19 and 30 230VAC 19 and 36 13 Line Frequency 47 63 115 VAC 0 92 19 1 6 36 2 8 30 3 2 30 11 2 30 20 30 30 3 34 3 109 8 Go 14 30 230 VAC Continuous 8 19 14 19 d 115 VAC Peak Current 1206 162128 amps 16 39 for 2sec 50msec 230 VAC Peak Current 16 12 16 1 21 28 during normal operation 310 20 35 equivalent DC BUS Voltage Nominal 140 3
47. 10 310 1 24 39 2 1 3 Main Output kWat 115 VAC Line Input 1 3 10 2 0 19 2 48 3 8 7 39 15 5 3 23 3 30 26 4 30 Power SERVOSTAR S and CD Product Family 20 Main Input 115 VAC Continuous Power Current amps Source kW at 230 VAC Line Input Danaher Motion Wiring Product Model PA LM 08 14 28 50 75 85 Voltage VAC Nominal 110 to 120 208 to 240 10 Logic Input Current 1 emp 1 1 f 1 f f 13 J 13 f 1 Power Internal Fuse amps 2 5 2 5 2 5 2 5 2 5 2 5 2 5 8VDC Supply Voltage 15 V Supply Voltage 14 25 to 16 Logic Output tVDC Power 15 Supply Current amps 048 Source Internal Fuses amps 1 5 3 5 573 5 3 3 357 3 5 7 3 5 7 15V 48 V Max of Drives Sourced of Drives Sourced Sourced Refer to AppNote ASU000H on the PSP CD ROM 115 VAC Turn Off Level BER 115 VAC Turn On Level ESSET 230 VAC Turn Off Level 70 SoftStart 230 VAC Turn On Level 5 112 35 35 35 oral SOR Max Surge Current amps 30 20 50 40 oH Protection Fault Contact Closing NA 130 200 275 5 C 41 F to 45 113 Storage temperature 09 32 F to 70 158 F Environment Ambient humidity 10 to 90 Atmosphere without corrosive gasses or dust Altitude Derate 5 per 1000 ft above 3300 ft 9 5 g Cx Regen Information
48. 18 Danaher Motion Wiring Cx Electrical Specifications Voltage 1 Nominal 10 110 to 230 115 VAC 1 or 30 39 only 230 VAC 19 or 30 39 only Line Frequency 47 63 kVA at 115 0 44 16 0 89 16 DL eee o Main Input Power 1 4 39 2 8 39 4 6 39 only Continuous Current amps 6 2 19 10 19 o m Peak Current amps for 500 mSec 18 6 1 30 10 UT mcn Peak Current amps for 2Sec 12 4 10 20 19 1 Line Fuses FRN R LPN or equivalent 24 VDC Ext Logic Voltage volts 22 to 27 Logic CxXX26X Models ONLY SoftStart SUC 7625 Continuous Power at 115 VAC 0 35 1 0 7 1 Continuous Power at 230 Rated Main Output Line Input 45 C 113 F Ambient 1 1 30 2 2 30 3 5 3 Mb M Curent Aam ____ 3 J f v Peak Current Arms for 500 59 J 18 20 Current Arms r2 Se PWMFrequency kHz 16 8 8 Protective Functions intemal heat dissipation wan FCT Ayo 45 11349 0 GF to 70 158 Environment NOTE Model Numbers Cx0x200 are single phase only SERVOSTAR S and CD Product Family 19 Danaher Motion Wiring Sx Electrical Specifications Main Input BUS VDC 125 to 360 260 to 360 BUS BUS Rated Power at DC kW 0 63 1 4 1 26 2 79
49. 2 gt lt gt otor parameters FOLD FOLDTIME FOLDMODE MFOLD MFOLDDIS MFOLDD MFOLDT MFOLDR IC 4 ANOUT ISCALE 10r3 DVM ServoStar MotionLink Off Line Ol xi File Edit View Configure Tune Options Help Le SEQ3 160 volts peration Mode Serial Torque Eie Analog Input Curent 2227 Gearing 73 Input 5 UNA Feedback pa E EDA Device O 999 System Motor Device Select B 202 0 z Set C Disable Enable Exit Serial Torque Mode with MOTIONLINK 5 S CD Product Family 63 Danaher Motion System Operation ANALOG TORQUE The SERVOSTAR can be often configured to operate as an analog torque loop controller OPMODE 3 In this case the current loop receives its input from the analog to digital A D conversion system After conversion the input command signal is processed through an algorithm which adjust the signal ANOFF ANDB ANZERO filters it ANLPFHZ and then scales it ISCALE before developing the current command ICMD The current or torque command is then checked against peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calcu
50. Danaher Motion 5 SERVOSTAR CD Installation Manual KOLLMORGEN giving our customers freedom of design M SS 001 0116 Firmware Version 5 0 8 Record of Manual Revisions ISSUE No Date Description of Revision 0 Preliminary issue for review 1 01 05 98 Initial release of UCB hardware 2 03 13 98 Added UCB features 3 09 18 98 Cx and UCB position capability restructure document 4 12 03 98 Additional position features added 5 05 01 99 Restructured SERCOS interface CD ROM transition 6 09 15 99 Appendix A and B added sine encoder features Cx10 added 7 06 30 00 Added information on Firmware upgrade 8 10 10 00 Corrected specifications added clarification 9 02 01 01 Corrected Electrical Specifications and wiring diagrams restructure document 10 02 28 01 Added information for Firmware upgrade 11 09 28 01 Corrected Wiring Diagrams errors in commands and EMI filter information 12 01 16 02 Corrected Outline Dimension Drawing for Cx units and all wiring diagrams 13 03 27 02 Corrected Model Numbers and added Danaher information 14 06 14 02 Added Appendix 15 07 10 02 Added Appendix D clarified digital and sine encoder specifications 16 11 22 02 Standardized units of measure Copyright Information Copyright 1998 1999 2000 2001 2002 Danaher Motion Kollmorgen rights reserved Printed in the United States of America NOTICE Not for use or disclosure outside of Danaher Motion Kollmorgen exc
51. Display LED fault status with complete error history and mode settings for several of the drive s protection features If using the terminal mode you can simply check the contents stored in the STATUS FLTHIST and ERR variables An additional help provided by MOTIONLINK is the screen click on I O button on the side of the Main MOTIONLINK screen The screen gives you the ability to check the status of the hardware position limit switches the motor thermostat and the encoder equivalent output It also allows you to set up the I O on the C3 connector for a variety of troubleshooting and monitoring approaches For monitoring system performance MOTIONLINK comes with a variety of monitoring tools The customer can monitor a variety of variables from the Monitor screen click Monitor button at the top of the Main MOTIONLINK screen to compare up to three variables against themselves at one time The Tune and Record screen allows you to evaluate the system s actual performance against a predefined command profile Also from this screen adjusting the gains until optimum following is achieved can vary the performance SERVOSTAR S and CD Product Family 75 Danaher Motion Troubleshooting Error codes In most cases the SERVOSTAR communicates error codes with a text message via the serial port to the host Some error codes are also transmitted to the Status Display The same message is saved in the EEPROM under an error history lo
52. E Signal Name Signal Name POWER Shield NIC J 101 J 102 Analog In Analog CMD HI CARD T2328 Analog In GND 000 DC Com Analog GND Fault Output Status Input a 7 6 Fault Output Status Input 12 to 24 Vdc in NIC OOOO0QO Remote Enable Amplifier Enable out 4 CW limit input NIC Analog I O CCW limit input N C Position Feedback Interconnect SS C4 Signal BJP J12 CHA 12to 24 CHA NOTE 1 24VDC supply for the DE Com SERVOSTAR remote enable signal CHB 1 1 must have its return connected to the STB logic common of the BJP Shien NOTE 2 Resolver based SERVOSTAR systems must have the ene DIR Variable set to 0 or the motor will runaway LIMIT Switch b 12 or 24 VDCCom SEE NOTE 1 1 1 1 Switch 5 S CD Product Family 85 Danaher Motion Appendix B Verify that the SERVOSTAR motor direction variable DIR is set to zero Otherwise the motor runs away when controlled by the BJP The BJP uses a slightly different interface called MOTIONLINK Plus Install this package from the PSP CD ROM Once proper connection is completed and communication is established through the BJP refer to the User 5 Manual for programming
53. Enable REMOTE enable switch is disabled The SERVOSTAR has the flexibility to be addressed and controlled from a single line or a daisy chain MultiDrop configuration in RS 232 A RS 485 or fiber optic SERCOS interface The first five switches of the 10 position DIP located on the top of the drive sets the binary address number for that particular drive Switch 6 of the DIP determines the serial communication baud rate for either 9600 BPS or 19200 BPS The SERVOSTAR cannot be configured for RS 232 A and RS 485 at the same time RS 232 A Connection The drive can be configured for a RS 232 A single ended connection through the C1 connector by wiring the 9 pin mating connector To configure for multiple units the drives must be daisy chained across the C7 connectors of each drive in that chain When communicating to a single line unit the drive s DIP switch must be set for a binary 0 address When communicating to multiple units the DIP switch can be set for any binary equivalent number from 1 to 31 see table below as desired You can also communicate with any or all drives within the daisy chain configuration from any one RS 232 A port on that chain called Global Addressing RS 485 Connection The drive can also be configured for RS 485 differential connection through the same C1 connector You only need to wire the 9 pin mating connector for RS 485 No software or hardware changes are necessary Setting the drive s DIP address is id
54. FF MEN and 2 To determine the setting for MENCOFF perform the following steps using the MOTIONLINKC terminal mode with power on the drive and unplugged disabled 1 Enter ENCINIT 2 Rotate the motor shaft two turns clockwise by hand SERVOSTAR S and CD Product Family 98 Danaher Motion Appendix C 3 Verify that the process is complete by entering ENCINITST The SERVOSTAR should return 2 if the process has been successfully completed If not repeat steps 2 and 3 Enter SAVE Use caution to continue testing the system SD e The MENCOFF variable may be manually trimmed for best performance When using MENCOFF with MENCTYPEs and 2 the correct value must be determined through trial and error Pick a setting and trim it watching for the speed V to be equal in both directions when applying torque in OPMODE 2 It is common for repeated tries of this procedure to return values that are significantly different due to the software s reference point being different from try to try This 1s normal The motor shaft must be free to rotate uncontrolled without damage to equipment or personnel 5 S and CD Product Family 99 Danaher Motion Appendix C System Phasing With so many signals coming from the encoder back to the drive and then the signals going to the motor It can become quite frustrating to make sure that each signal 15 of the
55. MOTIONLINK screen This method is most convenient when corrections to an existing configuration is needed The third method uses the Terminal Mode screen to directly set or monitor values for the same variables and commands that the other two methods configure through a more friendly user interface You can gain a more thorough understanding of the SERVOSTAR drive MOTIONLINK and its variable and command set by using the context sensitive Help F1 provided in MOTIONLINK MOTIONLINK Startup Wizard This screen appears the first time and any time after should you leave it selected MOTIONLINK is run on a PC It is designed to guide you through a step by step approach to configure a drive Click the START button on the first user screen and walk through the complete sequence of buttons provided to set the drive motor and application Opmode Tune Backup Go variable parameters Should you de activate this screen it can be reactivated by going to the Main MOTIONLINK screen pulling down the Configuration menu and selecting the New Drive 123 option ServoStar MotionLink New Amplifier Startup Off Line Y ou have finished setting up this ServoStar axis You can go back to any setup screen 1 5 by clicking the appropriate button or Click Exit or Go to to the Main MotionLink screen v Don t Show Nest Time Help Startup Wizard SERVOSTAR S and CD Product Family 43 Danaher Motion
56. RCOS interface Torque Units Standard SERCOS interface torque units are based on 0 1 of motor continuous current However when using MOTIONLINK the torque units are based on 0 1 of drive peak current SERCOS interface Velocity Units counts CUCT 256 The following formulas may be used to convert to and from the SERCOS interface units and rpm Vel RPM Vel cnts CUCT 256 1875 8 Cnts Vel 256 Vel RPM 8 Cnts 1875 SERVOSTAR S and CD Product Family 53 Danaher Motion SERCOS Interface Setup EQUATION NOTES 1 Cnts the number of encoder or resolver equivalent counts per revolution Where Encoder counts Encoder lines 4 Resolver counts 2 16 MResPoles 2 2 The control unit cycle time IDN 1 in mS 3 The units CUCT ms is the number of CUCT periods per mS For example a 2 mS CUCT has 1 2 a CUCT per 1 mS Remember the following when monitoring a SERCOS interface drive through the serial 1 the SERCOS interface address is also the serial MultiDrop address 2 SERCOS interface operation changes the UNITS variable to internal units The SERCOS interface version of the SERVOSTAR is not automatically enabled on power up even with the drive address set to 0 SERVOSTAR S and CD Product Family 54 Danaher Motion System Operation SYSTEM OPERATION The SERVOSTAR has a seven segment indicator called a Status Display
57. S and CD Product Family 49 Danaher Motion SERCOS Interface Setup The maximum and minimum cable lengths may be calculated by dividing the maximum and minimum signal attenuations by the cable attenuation The following table shows the cable lengths for 1 mm plastic fiber with an attenuation of 0 18 dBm m Cable Length Specifications Low Power High Power Minimum 103m k Note 1 Fiber optic cable attenuation is 0 18 dBm m 2 Cable length calculations assume that the fiber is not attenuated by intermediate connections For most applications the low power setting is sufficient Longer cable runs or the use of intermediate connectors may require the high power setting Communication problems may occur if the power level at the receiver is too large or too small Receiver power problems may cause erroneous data transfer resulting in the drive returning to or failure to advance out of For more information on SERCOS interface signal attenuation refer to the following sections of the IEC 61491 SERCOS interface specification 5 3 Optical Signals on the Transmission Line e Annex Attenuation on the Transmission Line Status Display After the CP run up sequence has completed the drive will be in OPMODE 5 when communicating on a SERCOS interface ring This is indicated by the number 5 on the Status Display The SERCOS interface version of the SERVOSTAR differs from the standard unit in that errors
58. S drooping during the peak power demands of the load All units have soft start capability to minimize the effect of in rush current spikes inherent in a power up cycle This feature eliminates the need for a costly isolation transformer SERVOSTAR S and CD Product Family 73 Danaher Motion System Description Thelogic BUS Module on all units consists of a SMPS to develop the required 15 V and 8 V from either the main line use La and Lg or a separate AC logic input Most BUS Modules can source up to four standard drives SRxx200 or SExx200 See AppNote ASUOO00H on the PSP CD ROM for details on logic sourcing e Product features are Indicator 08 14 28 50 75 85 Green LED X X X Yellow LED N A X x Red LED N A N A X Fault Relay N A X X SoftStart X X x Regeneration N A Indicates when voltage is on the caps 2 Indicates unit is operating in regen and may flash during aggressive accelerations Indicates unit is still in SoftStart This LED is also used to indicate when an OverVoltage fault has occurred from too much power being pumped back into the system during regen The relay is a normally open contact and closes after the unit is powered up and out of SoftStart The contact opens if there is an improper BUS Module voltage dropping in and out of SoftStart an over heated internal regen resistor or the main heatsink becomes too hot Contains SoftStart capability 5 E external I internal
59. STAR S and CD Product Family 55 Danaher Motion System Operation Operational Modes The SERVOSTAR has the ability to assume different modes of operation It is factory configured in OPMODE 1 Analog Velocity Controller but may be reconfigurd Not all commands and variables are active or meaningful in every OPMODE l Serial Velocity Controller OPMODE 0 the SERVOSTAR 15 configured as a velocity loop controller and is controlled by issuing a velocity command J jog command or STEP step command to the drive via the serial port Analog Velocity Controller OPMODE 1 the SERVOSTAR is configured as a velocity loop controller and is controlled through either 10 V analog input signal or jog J commands stored in the Configurable I O The commanded velocity is proportional to the input voltage Serial Torque Current Controller OPMODE 2 the SERVOSTAR is configured as a torque loop controller and is controlled by issuing a current command using the T command to the drive via the serial port Analog Torque Current Controller OPMODE 3 the SERVOSTAR is configured as torque loop controller and is controlled via a 10 V analog input signal The commanded current is proportional to the input voltage Gearing Position Controller OPMODE 4 the SERVOSTAR is configured as a positioning controller that can operate in one of three settings Encoder Follower Pulse Direction Up Down Counter The setting used is determ
60. System Communication Setting Drive Variable Parameters Click the Drive button This screen allows you to select a BUS value that corresponds to the incoming line voltage This selection actually determines the setting of the variable VBUS Also included is a realtime monitoring of the DIP switch on top of the drive so you can verify the proper setting for the drive address baud rate and various other parameters Click Exit to return to the Startup screen Setting Motor Variable Parameters Click the Motor button This screen allows you to access the MOTIONLINK motor database Select a motor family and then a model within that family Information will appear in the blank parameter fields on the right Click on the To Drive button beneath the fields to send the variable parameters to the drive Click Exit to return to the MOTIONLINK Start Up Wizard If you have a configured drive a From Drive button is provided to retrieve the motor data already in the drive Retrieving this data does not erase it from the drive If the motor cannot be found in the database click on the User Define tab Contact Danaher Motion Customer Support for detailed instructions Customizing to Application Click the Opmode button in the Startup screen to select the mode of loop control desired position velocity or torque Click Exit to return to the MOTIONLINK Start Up Wizard Click on the Tune button in the MOTIONLINK Start Up Wizard to
61. VOSTAR S and CD Product Family 32 Danaher Motion Wiring RESOLUTION AND ACCURACY The SERVOSTAR calculates motor velocity as the derivative of position change in position over time With its patented technique all readings are extended to a resolution of 16 bit For velocity feedback calculations the drive converts the resolver input to 18 bits of resolution giving smooth motor velocity control The digital resolution RDRES of the Resolver to Digital Converter system is determined automatically according to the application velocity limit VLIM The following is a summary of the SERVOSTAR s resolution capabilities VLIM RPM RDRES Encoder Eqv Output C4 gt 6100 4096 4096 quad counts 1500 to 6100 16384 16384 quad counts 1500 65536 65536 quad counts R D Converter Specifications System accuracy using resolver feedback is effected by several components The following table gives information on the inaccuracy that each of these components contribute to the total accuracy of a standard SERVOSTAR system Components ArcMinutes R D Converter 4 Resolver mechanics rotational 8 Resolver mounting on motor shaft 2 Inter LSB digital dither over the least significant bit 5 Total Worse case 19 Resolver Accuracy Specifications Digital Encoder The SERVOSTAR can use encoder feedback to monitor the motor shaft position As opposed to a resolver which is an absolute position feedback device the encoder is an incremental dev
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63. Wire Color Resolver Wire Wire Color 50X amp 70X 30X from resolver to Connector from resolver to motor receptacle motor receptacle fi 6 Shica NENNEN EN 14 PmT Pn2 Yellow Pa2 Pms Yellow Red 7 12 50 SERVOSTAR S and CD Product Family 83 Danaher Motion Appendix A SE CE Encoder Connection Connection Encoder Receptacle Wire Color 0802 Encoder 0802 Encoder at Motor Receptacle Wire Color Receptacle Receptacle B M EB Series XT Series XT Series Piste a a QT T T Pin7 amp 8 Pns Pns Pinio Pini Bow ___ ___ Pil5 White Pii4 ___ 13 __ Pin T Yelow Pin Yellow 7 Pin25 Yelow __ Pin2 NOTE 1 Must shorted to C 2 pin 18 for proper operation SERVOSTAR S and CD Product Family 84 Danaher Motion Appendix B APPENDIX B Programmable Positioning Some users need a higher level of programming cap
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65. ability than the SERVOSTAR S and SERVOSTAR CD Series can offer through its buffer memory as triggered through the Configurable Inputs Designed to be a compact and low cost solution the BJP and SERVOSTAR system provides full programmable servo performance for many single and multi axis applications This Appendix provides system wiring diagrams to specifically interface with the SERVOSTAR system For a detailed explanation of the BJP s operation refer to the BJP Series Positioners Publication BJP Installation Manual BJx User s Manual and MOTIONLINK Plus Software Interface located on the PSP CD ROM Installation For system setup you will need to interface with the SERVOSTAR drive through MOTIONLINK as described in Section 4 Once communication is established select the analog torque mode of operation OPMODE 3 Connect the BJP to the drive Feedback 12 24 Vdc Encoder Master Encoder Jumper J 10 1 Stepper Input J11Main J 12 13 Serial Communications BJP RS 485 44 7 Communications J 14 Autobaud 5 n emni Enable J 20 4 Fault LED 2 OK LED 5 88 232 Communications motor Feedback See Note 2 for Resolver system instructions User I O Interconnect Bp E
66. adimct Lhe cabinet gaing ta the maar shauld be separaked as muchas paszible the use d separate canduks provides good fabian which can limi coupling fram maar ta Cabinet Enclosure Back Plane Controller Routed to Motors Controller 1 0 Routed to Motors Wiring SERVOSTAR S and CD Product Family 17 Danaher Motion Wiring Sx Filter and Bonding Diagram Note 1 1 Input pawer enters Cabinet Enclosure ram metal candua This eliminates the need far input power cable Hote 2 Single paint graund A bus ter graund bus iz an Back Plane Contactor excellent way la achieve Fuses his Xformer Hote 3 High frequency graund nancanductive tect panel and enclosure Absa high frequency graund fs required balween Une enckrsure and earth CNC PLC Controller graund Hote 4 as er Banding of the maar cables The use d armared screened maar cables V are banded as clase ta he drive as paysible is essential far C E cam pliance and rocam mended a baller Lhe EMI Filter parfarmance and relizbilie 3 phase 5 ex Screened and banded feedimct cabling is mandad far im muniy and kwer rist o Since the maar and cable are praxim zi the maar thi
67. al initialization process known as wake and shake When using MENCTYPE 4 the process for initialization is automatically triggered on power up when the drive is enabled or by using ENCSTART During the initialization process wake and shake the SERVOSTAR puts current through two phases of the motor causing the motor shaft to rotate into a torque detent The magnets simply align the motor shaft to a position the SERVOSTAR understands The motor is then rotated to the next pole position by energizing the windings in a slightly different manner The SERVOSTAR then has enough information to establish an appropriate commutation angle using the number of motor poles MPOLES and the number of counts for the encoder MENCRES This method of initialization has the advantage of allowing an extremely cost effective feedback device However the requirement to pull the motor into these torque detents is subject to outside influences such as friction and can prevent the motor motion from occurring very effectively or even at all Additionally large inertia loads can overshoot and oscillate during this pull in position giving the microprocessor false readings These are best for systems with specific criteria requirements such as low friction low cost and low inertial loads The amount of electrical current used in this initialization mode is adjustable using the IENCSTART variable and may need to be adjusted to optimize performance for
68. and faults are not communicated through this display only through the SERCOS interface ring to the controller Therefore if an error occurs the 5 remains on the display The Status Display decimal point operates identically to that of the standard unit in that it turns ON and OFF when the drive is enabled or disabled The SERCOS interface version of the SERVOSTAR is not automatically enabled on power up no matter what the address SERVOSTAR S and CD Product Family 50 Danaher Motion SERCOS Interface Setup Connection The mating connector selected for the Tx and Rx ports follow the IEC 874 2 specification which recommends an F SMA type connector A hand tight connection is adequate Danaher Motion Kollmorgen offers 30 60 and 100cm plastic fiber optic cables with SERCOS interface compatible F SMA connectors The following specifications provide general cable information Cable Characteristics Cable Type lt 0 184 Fiber Also refer to the following 61491 specification for more connector and cabling information 5 2 2 Structure of the Transmission Lines 5 3 3 Fiber Optic Cable 5 3 4 Connectors Communications The SERVOSTAR SERCOS interface drive offers two communication approaches for drive configuration The first approach is to communicate via a multi axis SERCOS interface controller all the drive parameters through the fiber optic ring during the CP2 and CP3 run up stages This requi
69. andard 201 SERCOS Custom Variations C Series Hardware Options 250 Standard w 230V logic input see Note 251 SERCOS w 230V logic input 260 Standard w 24V logic input 261 SERCOS w 24V logic input 250 replaces previous standard option 200 originally intended for 1 phase 3 6 amp units SERVOSTAR S and CD Product Family Motor Winding Motor Frame amp Stack Length Motor Family D DDR Series 0 No comp G Goldline B M EB X Goldline XT R RBE H Silverline L Linear Ironless C Linear Iron Core P Platinum XT S Goldline Submersible Voltage Level 0 No Comp 1 115 Vac 160 Vdc 2 230 Vac 325 Vdc J low inductance motors with SSV Variable file only Y Special Compensation three digit extension follows the Y designator Danaher Motion Mounting MOUNTING For proper ventilation the SERVOSTAR 5 or the SERVOSTAR CD and BUS Module units should be mounted vertically No horizontal distance between the drive and BUS Module is required In systems using more than two SERVOSTAR units per BUS Module divide the drives equally on either side of the BUS Module These products are designed for mounting in an electrical enclosure to protect them from physical and environmental damage Hardware Specifications SERVOSTAR Cx Mounting 10 32 M4 Hardware 20 Ib in 2 26 Nm Line Screw Size Torque BUS Screw Size Torque Connection Motor Scr
70. appropriate phase This diagram shows the commutation phasing PFB counts down for Motors with shafts counter clockwise rotation viewing shaft end Motors without shafts clockwise rotation viewing lead exit end Linear motors with armature moving away from leads Vec Vea 02 HALL 1B pin 9 C2 HALL 2B pin 10 HALL 3B pin 11 INDEX 16 A pint C2 pin2 B pin4 E SERVOSTAR S CD Product Family 100 Danaher Motion Appendix C Troubleshooting Several problems can occur with encoder based systems The most common problem is miswiring The section on system phasing above provides the necessary troubleshooting information Miswired Hall channels can cause intermittent problems With miswired Hall channels the motor operates correctly sometimes but will occasionally not operate correctly after cycling power It is very important to physically verify the Hall effect channels There is a command in the SERVOSTAR manual called HALLS It returns the hall code as read It is important that the installation and startup procedures for the machine sequence the motors through all the appropriate hall codes to make sure they are present and in the right sequence An illegal hall code error occurs if the Hall channels go to all low or all high conditions A broken wire or misphased channel can cause this problem It is important that t
71. art A 93142 007 A 93142 008 93142 010 93142 010 93142 006 Auto Manual Manual Manual Manual Manual Manual N A N A Setting Thermostat Thermal Rating Internal to Internal to Kollmorgen Part Hookup Wire Gauge 8aweg 125 C Temp Rating SERVOSTAR S and CD Product Family 22 Danaher Motion Wiring Product Family Control Specifications Product Model Control Specifications Commutation Frequency Sinusoidal Velocity Loop 250 15 4k Hz 400 Hz Serial 1 RPM Analog 1 6554 0 01 clock tolerance Position Loop 500 uS 2 kHz Connector by pinout Analog Input 2 3 13 V differential 14 1 2 53 mV min Voltage Range 10V to 10V 120 Motor rated speed to 120 Motor rated speed Adjustable Vscale parameter Long term Drift 100 ppm 0 075 C Input Impedance CMR gt 10 50 dB Fault Output Relay 5 6 Max Capacity 1 Aat24 VDC Remote Enable 7 8 Bandwidth 2 5 kHz Opto isolated Configurable Inputs 7 9 10 11 Input Voltage Range 12 V to 24 V Nominal bi directional Min On Max Off 10 Current Demand per Input 20 mA max Configurable Digital Output 7 12 Output Voltage max 0 V to 48 V Nominal bi directional Open Collector lt ULIS Configurable Analog Output 13 4 mA internal series resistance 49 mV 12 Bit 10 V to 10V Encode
72. atically Setting Motor Variable Parameters Locate the motor parameter group of variables in the VarCom Reference Guide At the prompt enter values for the variable parameters listed in this group by typing the name of the variable space and the numerical value Customizing to Application Locate the following variable groups in the VarCom Reference Guide Analog Input Related Current Parameters Velocity Parameters Position Parameters Loop Compensation and Gains Parameters Motion Control Parameters SERVOSTAR S and CD Product Family 46 Danaher Motion System Communication At the prompt enter values for the variable parameters listed in these groups by typing the name of the variable space and the numerical value You are strongly encouraged to develop a full understanding of these variables before finalizing the configuration Saving Variable Parameters to EEPROM At the prompt type SAVE This will save the variable parameters stored in the RAM to the EEPROM of the variables listed in the VarCom Reference Guide indicate whether its contents can be saved to EEPROM Saving Variable Parameters to SSV file At the prompt type DUMP The DUMP command causes the drive to output variables and their contents to the serial port in the format of a variable file this includes the trailing CONFIG command This variable file format is an ASCII file consisting of a series of variable assignment statements The re
73. ce Encoders consume 5V The 5V is typically regulated inside the drive through a cable to the encoder Tolerances on the 5V must be considered for IR loss within the cable An 18 AWG conductor pair providing the 5V at a 250 mA drive result in approximately V drop and become the limits from the encoder s 5V rating perspective Consideration of cable length 5V current draw is extremely important for good system design The SERVOSTAR s encoder supply is 5V 2 with 250mA maximum draw When using incremental encoders the SERVOSTAR receives the encoder pulses buffers them electrically and then outputs them to the encoder equivalent output port The phase delay in the transport of these signals is extremely small Be sure to run all encoder cables in conduit or wire tray that is free from wires carrying or emitting electrical noises such as solenoid wires and armature cables SERVOSTAR S and CD Product Family 101 Danaher Motion Appendix C Reference Variables For additional information on any of these commands refer to the SERVOSTAR S and SERVOSTAR CD VarCom Manual ENCINIT This command triggers the encoder initialization process ENCINITST This variable may be queried and returns status of the initialization process This variable assumes one of three values 0 The initialization process has not started 1 The initialization process is in progress 2 The index position has been determined and the initialization process
74. cise low speed control and high speed performance Current loop adaptive gain MLGAINC MLGAINP MLGAINZ System current limiting capability ILIM ILIM2 IMAX MICONT Exponential current vs Time limiter FOLD FOLDMODE e Back EMF compensator MBEMFCOMP Velocity Control e Digital velocity loop control Velocity Mode OPMODE 0 or 1 receiving serial J analog ANIN or I O triggered commands MISPEED1 MISPEED2 MISPEED3 IN1 IN2 IN3 INIMODE IN2MODE IN3MODE Velocity stepping and jogging capability STEP J e Serial control through stored commands triggered through the Configurable I O IN2 IN3 INIMODE IN2MODE IN3MODE SERVOSTAR S and CD Product Family 67 Danaher Motion System Description Automatic control loop tuning through the auto tune feature TUNE Configurable application and system speed limits VLIM VOSPD VMAX Advanced control algorithms COMPMODE 1 Proportional Integral GV GVI 2 Pseudo Derivative with feed forward KV KVI KVFR 3 Standard Pole Placement BW MJ LMJR TF 4 Extended Standard Pole Placement BW MJ LMJR TF First and second order low pass filtering capability FILTMODE LPFHZ1 LPFHZ2 COMPFILT Notch filtering capability HILTMODE NOTCHHZ NOTCHBW Bandwidths up to 400Hz On the fly homing capability HOMETYPE in analog velocity mode OPMODE 1 through either the Configurable Inputs or terminal On t
75. counts Transmitting the signals differentially provides the largest margin of noise rejection and the best signal fidelity The SERVOSTAR 15 designed to receive only differential signals Some less expensive encoders provide TTL or Open Collector signals These are not compatible with the SERVOSTAR SERVOSTAR Encoder Types The idea of obtaining velocity or position information from the series of pulses generated from the encoder is not difficult to understand Permanent magnet brushless DC servo motors require commutation As stated earlier commutation is simply the positioning of the electromagnetic fields in alignment with the permanent magnet fields such that optimal torque is produced This requires that the motor shaft position be known at all times The use of incremental encoders requires some form of initialization to determine this motor shaft position at power up It is this commutation initialization process that can lead to confusion Since the SERVOSTAR supports operation with many encoder types it must be told which signals to expect to see and which initialization algorithm to perform This is the purpose ofthe MENCTYPE variable The following section explains the MENCTYPE variable and its setting for each encoder type The next figure shows the initialization flow chart for the various MENCTYPEs 5 S and CD Product Family 89 Danaher Motion Appendix C MENCTYPE 0 MENCTYPES 1 amp 2 MENCTYPES 3 amp 4 Perf
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77. dard encoders and 1 2 MHz for sine encoders 1 Resolver based systems developed through R D hardware circuitry for minimal phase lag it provides a before quad resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft dependant on motor speed This signal resolution is configurable ENCOUT Index pulse can be varied as much as one complete revolution INDEXPOS 2 Encoder based systems actual encoder signals are exported through this output MENCRES and can be scaled down by multiples of two ENCOUTO 3 Sine encoder systems developed through the interpolator circuit SININTOUT and encoded to a quadrature signal A frequency limiter MSINFRQ is provided with fault protection MOTIONLINK Software Environment Easy setup commanding and monitoring techniques Contains an extensive database for many of Danaher Motion Kollmorgen s motor series A backup screen that provides automatic loading of system parameters Realtime metering of many system parameters PC scope feature for profile recording and realtime motion performance measuring Optional terminal mode feature for keystroke commanding and monitoring Status screen indicating system operation and fault error checking Extensive on line help file F1 designed to assist you in MOTIONLINK s intuitive nature A set of limits folders allowing you to manipulate the position velocity current and filtering limits from one screen An I O screen f
78. dex with C D once per revolution Signal Level peak to peak System Voltage DD After Internal Drive Interpolation 31 25 MHz line 125 MHz quad Maximum Line Count per Motor 39 000 Line counts the SERVOSTAR for encoders Protection Separate Voltage Regulator Broken wire detector for A B Index and Hall channels Illegal Hall Code Detection A B signals out of range burst pulse overflow Maximum Drive Internal x256 before quad Interpolation input CABLE LENGTHS The recommended cable length when using the SERVOSTAR to source the encoder is no longer than 50 ft 15 m Long encoder cables tend to have high DC resistance that may create significant loading affects in the supply lines to the encoder Consider this carefully when designing the system An option that would allow the use of longer lengths would be to put a separate supply at the motor to source the encoder Except for noise susceptibility signals returned to the drive are differentially connected which normally do not constitute a problem with longer cable lengths RESOLUTION AND ACCURACY Internal resolution of the system can be derived through the following calculation Encoder line resolution x 256 x 4 quadrature System accuracy is largely dependent upon the accuracy of the encoder itself To get an approximate total value the customer need only look to the specifications listed for the encoder being used SERVOSTAR S and CD Product Fa
79. do Derivative Feedback with Feed Forward PDFF Standard Pole Placement and Extended Standard Pole Placement SERVOSTAR S and CD Product Family 61 Danaher Motion System Operation POSITION LOOP The final control configuration is the position loop The purpose of this loop is to maintain motor shaft position Like the previous loops the position loop is fully digital and uses resolver encoder and sine encoder feedback signals to determine actual motor position The drive can also accept a position signal from an external feedback device e g load encoder It samples at a rate of 2 kHz and can be configured for three different modes of operation OPMODE 4 This mode of operation sets the SERVOSTAR up to run as a pulse or master encoder follower by using the Electronic Gearing feature The pulse input can either be applied through the Configurable Inputs on the C3 connector up to 2 5 KHz max opto isolated or through the Remote Encoder Input on the C8 connector up to 3 MHz on top of the drive OPMODE 8 This mode of operation configures the SERVOSTAR as a simple positioning controller Once in this mode position commands can be given through the serial port through the Configurable I O or through the analog input determined by the PCMDMODE variable The position loop has been enhanced to a full PID controller with acceleration and velocity feed forward gains Two integral gain variables have been added to limit the action of th
80. ds of many servo applications such as machine tooling packaging electronic assembly and document handling It has been designed to be a multifaceted amplifier capable of driving Danaher Motion Kollmorgen s vast product basket of motors and their assorted feedback devices The S series of drives come in standard packages of 3 6 10 20 30 55 and 85 amps A C series Compact Drive that includes an integrated BUS Module is available in 3 and 6 amp sizes All are packaged in a small frame size for minimizing cabinet space This product can be commanded through analog serial and SERCOS interface user interfaces and has its own tailored software environment in Danaher Motion Kollmorgen s MOTIONLINK for Windows Product Features The SERVOSTAR 5 or SERVOSTAR CD includes a vast array of features Its various control techniques interfaces and user tools give the customer a compatible drive to meet most motion control applications User features include Bulleted words that begin in capital letters indicate formal feature names Words that are capitalized indicate the software variables and commands associated with the feature This section is designed to direct you to the VarCom Reference Manual for details on these features Current Torque Control e Digital current loop control Torque Mode OPMODE 2 or 3 receiving serial T or analog commands Width Modulated PWM sine wave commutation PWMFRQ providing smooth and pre
81. e Marker Channel Occur Establish New Commutation using MENCOFF MEN C FYPE 0 but does not require that MENCOFF be set When it is not practical to perform mechanical alignments the software adjustment method can be used The MPHASE variable holds an offset for the Hall channels and can be used to effectively shift the Hall channel position It is possible to invert the effective direction as established by the A and B channels 5 S and CD Product Family 97 Danaher Motion using the MFBDR variable It is also possible to invert any one or all of the hall channels The MHINVA MHINVB MHINVC variables allow the drive to receive the hall channels and act upon them from an inverted nature MECNOFF Appendix C Perform MENCTYPE 3 8 4 Dive puts IENCSTART current through 2 phases peal algorithm Codes Establish and waits for motor to stop Commutation Angle as though in the middle Position is read by drive Drive puts current through other phase Wait for stop Marker Channel Occur Marker Channel Occur Establish New Commutation using Drive establishes commutation angle Hall Code Change End Adjust Commutation Angle Marker Channel Occur Establish New Commutation using MENCO
82. e four position counts per line of the encoder is called quadrature decode SERVOSTAR S and CD Product Family 87 Danaher Motion Appendix C Additionally since the encoder signals and are phase shifted by 90 it 15 easy to design electronics that recognize whether A came before B or B came before A thus supplying directional information Encoders are often provided with an additional channel called a Marker channel Zero Pulse or an Index channel different names for the same function This channel outputs one pulse per revolution and is typically an extremely narrow pulse equating to roughly of the width of an A or B channel pulse but can be wider This is a reference position marker used for homing absolute position reference and commutation alignment One challenge when using encoders is that they are incremental rather than absolute devices When using an absolute device such as a resolver to determine the motor shaft position within the rotation the transmitted code is unambiguous In other words at power up the system knows the position of the motor shaft Incremental encoders only detects how far the motor shaft has moved from its original position This presents a problem with three phase brushless motors in terms of commutation alignment Generally it is extremely important to establish the appropriate commutation angle within the controller Commutation refers to the alignment of the electromagnetic field arma
83. e integral term during selected parts of the profile This helps to minimize overshoot and settling problems Using a serial command PCMDMODE O the SERVOSTAR executes simple absolute incremental or indexing and homing motion profiles This is done either by direct commands through the serial port MI MA MH or by pre configuring a profile in memory to be used in conjunction with the Configurable I O MASPEED MISPEEDO 3 MAPOS O1 INx INXMODE Using an analog command PCMDMODE 1 the SERVOSTAR scales the analog input GEARI GEARO to establish a wide range of relationships between an analog input adjustment and a corresponding shaft movement Homing types are available that home to particular analog input level and position count triggering either through the Configurable Inputs or the Remote Enable In this mode of operation the drive can also accept an external load feedback signal through the C8 connector DUALFB 1 This helps eliminate the positional inaccuracies due to gear backlash and poor coupling by positioning according to the load s position not the motor shaft s position The SERVOSTAR also operates in the position mode when the drive is in the hold position state HOLD 1 Torque Loop Operation The design of the control loops was discussed in the previous section Now the operation as a system is presented The SERVOSTAR has many internal variables that are used to exami
84. e output signal 15 the actual encoder feedback signal that is pre configured MENCRES in the drive s motor parameters It can be scaled down by multiples of two ENCOUTO 1 2 4 8 16 and has a maximum frequency limit of 3 MHz Sine encoder Systems This output signal is developed for a resolution that is determined by a divisor SININTOUT 128 64 32 16 8 4 2 1 of the actual sine encoder line resolution MENCRES It is then encoded to a quadrature signal before being exported out of the drive The maximum frequency limit is 1 2 MHz frequency limiter MSINFRQ is provided with burst frequency fault protection EEO Phasing The EEO signals are not phased the same for resolver and encoder systems The following demonstrates these phasing relationships SERVOSTAR S and CD Product Family 37 Danaher Motion Wiring RESOLVER SYSTEMS A Leads B convention for clockwise rotation Channel A Channel B dede Index AB high ENCODER AND SINE ENCODER SYSTEMS B Leads A convention for clockwise rotation Channel A s Index determined by encoder Recommended Manufacturers List Schaffner Electronik AG North America Nordstrasse 11 Schaffner EMC Inc CH 4708 Luterbach 9 B Fadem Road Switzerland Springfield NJ 07081 Phone 065 802 626 Phone 201 379 7778 Fax 065 802 641 Fax 201 379 1151 Corcom World Headquarters East Coas
85. ed at the drive end on each motor lead shown in the diagram below attenuates differential mode noise and lower frequency 30 60 MHz broadband emissions to within specifications Danaher Motion Kollmorgen recommends a Fair Rite P N 2643665702 or equivalent ferrite core You should wrap each motor lead through the core several times as shown in the next figure y Never wrap a ground lead through a core SERVOSTAR S CD Product Family 14 Danaher Motion Wiring Differential Mode Filtering Common Mode Filtering To motor To Motor From Drive From Drive Output Ferrite Core Wrapping Common mode currents commonly occur from noise spikes created by the PWM switching frequency of the drive The use of a ferrite or iron powder toroid places common mode impedance in the line between the motor and the drive The use of a common mode choke on the motor leads increases signal integrity of encoder outputs and associated I O signals The following is a list of toroidal and ferrite cores that can be used to make common mode chokes Manufacturer s Part T400 26D OD 4in 102mm ID 2 25 in 57 2 mm HT 1 3in 33 mm ST 102 267 1 025 in 26mm ID 6 in 15 2 mm HT 475 in 12 1 mm OD 1 52 in 38 6mm ID 835 in 21 2 mm 825 in 21 mm OD 2 01 in 51 1mm ID 1 24 in 31 5 mm HT 1 025 in 26 mm OD 1 09 in 27 7mm ID 555 in 14 1 mm HT 472in 11 99 mm OD 2 4in 61mm ID 1 4 in 35 55 mm
86. ed in the Status Display enunciated over the serial port and in most conditions causes a drive disable Many faults can be reset by toggling the hardware remote enable REMOTE input The following provides a list of some of the more frequent faults the drive may detect in the unit hardware and operating system Motor OverTemperature The Motor s External Thermostat input is monitored for an open circuit condition You can define using THERMODE what happens under this fault condition The worst case event is a power stage disable when an appears in the status display and the fault relay contacts RELAY are open SERVOSTAR S and CD Product Family 80 Danaher Motion Troubleshooting Hardware Position Limit Inputs The IN2 IN3 Inputs are constantly monitored If INxMODE set these inputs for CW CCW hardware position limits they are monitored for an open circuit condition Although not necessarily an error condition motor operation can be affected by these inputs The SERVOSTAR can ignore the hardware position limits if you set LIMDIS 1 The worst case event is that further motion in the given direction is not allowed with an L illuminated in the status display If both CW and CCW position limit inputs have detected an open circuit condition the SERVOSTAR enters into Hold position state HOLD 1 Drive OverTemperature The internal heatsink temperature is monitored for an unsafe condition
87. entical to that described for the RS 232 When addressing multiple units the drives must be daisy chained across You cannot daisy chain across the C7 connector in RS 485 configuration Termination hardware is provided internal to the drive for those applications where noise becomes a problem or the host connection is single ended Contact the factory for instructions on how to set the drive s hardware for proper termination SERVOSTAR S and CD Product Family 40 Danaher Motion System Communication Setting Drive Address The following table shows the MultiDrop DIP switch address settings Note OFF 0 Drive Address Switch 5 Switch 4 Switch3 Switch 2 Switch 1 o9 p Note When the switch setting is set for binary 0 the drive assumes a single line serial configuration SERVOSTAR S and CD Product Family 41 Danaher Motion System Communication Sending Retrieving System Data The following chart describes the flow of data between the PC and the SERVOSTAR When logic power is applied to the drive it loads the variable parameters stored in EEPROM into the dynamic RAM for fast and easy access You can read and write these variable parameters to and from the PC by one of several methods described in the INITIAL STARTUP section below USER SETTING VARIABLE FILE SSV OR TERM DUMP command LOAD command or Power up EEPROM variables SAVE comma
88. ept under written agreement rights are reserved No part of this book shall be reproduced stored in retrieval form or transmitted by any means electronic mechanical photocopying recording or otherwise without the written permission from the publisher While every precaution has been taken in the preparation of the book the publisher assumes no responsibility for errors or omissions Neither 15 liability assumed for damages resulting from the use of the information contained herein This document is proprietary information of Danaher Motion Kollmorgen that is furnished for customer use ONLY No other uses are authorized without written permission of Danaher Motion Kollmorgen Information in this document is subject to change without notice and does not represent a commitment on the part Danaher Motion Kollmorgen 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 former issues and are registered trademarks of International Business Machines Corporation Windows 95 98 and Windows are registered trademarks of Microsoft Corporation ENDAT is a registered trademark of Dr Johannes Heidenhain GmbH GOLDLINE SILVERLINE MOTIONEERING MOTIONLINK PLATINUM and SERVOSTAR are registered trademarks of Danaher Motion Kollmorgen Safety Instructions Only qualified personnel are permitted to transp
89. ers To restore the original factory variable parameters pull down the Configure menu select Motor and select the motor family and motor model Click the To Drive button to send the variable parameters to RAM and the SAVE button to save to EEPROM Restoring Custom Variable Parameters This process assumes that you saved the custom variable parameters to a SSV file as described above To restore the custom parameters pull down the Edit menu select Backup Variables and click on Open Highlight the custom SSV file to import variable parameters into editor Click Xmit to send variable parameters to drive Terminal Mode Use the MOTIONLINK Terminal Mode or any other dumb host to directly monitor or modify the variable set and command the drive This approach should only be taken when a PC with a Windows operating system 15 not available or you well versed with the SERVOSTAR variable and command set The VarCom Reference Guide contains the complete variable and command set Each variable or command must be referenced for its syntax and parameter definition The variables and commands are grouped by function for terminal users Clear EEPROM If a does not appear and you wishe to enter a new set of variable parameters type CLREEPROM at the terminal prompt to clear the EEPROM memory Setting Drive Variable Parameters At the prompt enter a value for VBUS Other drive parameters are determined autom
90. erved Must be set to 0 See section Position Loopjon page 62 for features using this input Note Setting the switch to 1 means Closed or On Configuration Switch Switch Function Settings MultiDrop Bit 0 of MultiDrop Address LSB Addressing Bit 1 of MultiDrop Address Bit 2 of MultiDrop Address Bit 3 of MultiDrop Address Bit 4 of MultiDrop Address MSB 24 VDC Input CD onl nput CD only Optional Logic Supply Input 7 HOLD Mode Switch 0 Hold Mode Inactive Hold Mode Active Drive Enable Disable 0 Drive Enable 1 Drive Disable SERCOS Transmit Power 0 Low Power 1 High Power 10 Factory Reserved SERVOSTAR S and CD Product Family 30 iring Danaher Motion System Feedback Diagram 02 5 21 335 HOLIMS 1VLSOWS3H L LSNW HOLOW IVNH3LX3 TV AH3H L LSNW 5 ST3NNVHO 3AVH INIS HOF SLNANI NOILOSLOYd QVOTHSAO HOLOIN NOWWOO 81 Nid MVISOAH3S va YOLOATIOO N3dO S TIVH 9NILO3NNOO gt SLON 33s NOMWOO VU TIVH Alddns MVISOAH3S 8 2 v g8uTIVH pese a Z ana IH
91. ew Size Torque M3 5 12 Ib in 1 35 Nm Hardware Ground Screw Size Torque Control Logic AWG 16 1 5 mm Wire Size AWG Configurable I O wire 22 18 AWG 0 3 0 75 mm Ferrules recommended gauge 18 AWG Type 75 14 Weidmuller 4629 0 or equivalent 20 AWG Type 5 14 Weidmuller 6907 0 or equivalent 22 AWG Type H0 34 12 Weidmuller 902577 or equivalent Spade Terminals 16 14 AWG 1 5 mm Hollingsworth XSS0954S OR SS20947SF or equivalent 12 10 AWG 4 6 mm Hollingsworth XSS20836 OR SS20832F or equivalent Clearance 0 5in 12 7mm Distance Mating Connector C3 Kollmorgen A 93899 013 Vendor Info Weidmuller BL3 5 13 Hardware Cat No 161574 Kollmorgen A 81014 004 Vendor Info PCD ELFP04110 Connector Screw Torque 2 25 Ib in 0 25 m 24 V Logic optional Kollmorgen A 81014 002 Vendor Info PCD ELFP02210 or equiv SERVOSTAR S and CD Product Family 5 Danaher Motion Mounting SERVOSTAR Sx Mounting Hardware 20 Ib in 2 26 Nm Connection Hardware Size Torque AWGH mm in Configurable I O wire 22 18 AWG 0 3 0 75mm gauge Ferrules recommended 18 AWG Type 75 14 Weidmuller 4629 0 or equivalent 20 AWG Type 5 14 Weidmuller 6907 0 or equivalent 22 AWG Type H0 34 12 Weidmuller 902577 or equivalent 12 10 AWG 4 6 mm Hollingsworth 5520836 OR SS20832F or equivalent No Distance Required Clearance 2 5 in 63 5 mm Distance CK100 Kit Includes C1 C2 C4 C7 plus 2ft
92. ffers an automatic analog input zeroing function Invoking the ANZERO command while the drive is enabled or disabled samples motor velocity over a 32 mSec period and updates ANOFF accordingly to the analog input offset This command also incorporates an internal offset mechanism that has finer resolution than ANOFF is capable of providing SERVOSTAR S and CD Product Family 57 Danaher Motion System Operation Remote Enable Input REMOTE The opto isolated Remote Enable input REMOTE provides a hardware drive enable switch This 12 VDC to 24 VDC input will disable or enable the power stage output to the motor The signal must be customer supplied in order to get the drive to enable in combination with other parameters ACTIVE and operate Tapping the signal off the logic supply C5 is not recommended The toggling of this switch will also initiate an attempt to recover from a fault condition It can also be used to trigger various position homing features HOMETYPE Configurable Inputs INI IN2 IN3 These 12 VDC to 24 VDC inputs are defined by the INXMODE variable Placing the appropriate value in INXMODE See the VarCom Reference Guide for details sets up the inputs to be used for such features as CC CCW hardware position limits Electronic Gearing serial and analog position triggering for incremental moves and homing fault output relay configuration MOTIONLINK scope triggering and more When set for the CC CCW hardware position li
93. for this discussion Encoder Basics A Review Encoders used with the SERVOSTAR provide incremental motor position information via two channels referred to as the A Channel and B Channel These channels output pulses for a unit of shaft motion These pulses are typically generated within the encoder using an optical disk that is directly connected to the motor shaft The disk has etchings that either transmit or block light passing through the disk An optical transmitter and receiver are on either side of the disk The rotation of the disc and motor shaft interrupts light transmission from source to receiver creating the pulses The interruptions on the disk called lines and result in the encoder ratings of lines per revolution LPR or pulses per revolution PPR The two channels provide the same information pulses per unit of motion but have a phase shift of 90 between each other as shown in the figure below Index gt T5 The 90 electrical phase shift between the two channels is referred to as quadrature encoded The encoder output appears as a frequency but the pulse rate 15 dependent on the motor s rotational velocity not time Since the two channels are phase shifted by 90 there are actually four states available per electrical cycle of these signals The SERVOSTAR 15 able to receive four counts for position feedback for one line of motion of the encoder The actual decode of th
94. g FLTHIST ERR so that nothing is lost when power is removed Not all errors reflect a message back to the host In these cases the no message errors communicate to the Status Display only The response of the SERVOSTAR to an error depends on the error s severity There are three levels of severity 1 Warnings simply called errors are not considered faults and do not disable operation 2 Non fatal errors or simply faults that disable the drive and indicate a fault status 3 Fatal errors or fatal faults that disable almost all drive functions including communications command DIS or K followed by the EN command or toggling the Remote Enable line REMOTE resets the fault latch and if the fault condition is no longer present re enables the system s The drive is automatically disabled at the occurrence of a fault Executing a drive disable 5 S and CD Product Family 76 Danaher Motion Troubleshooting FATAL FAULT ERROR CODES Status Fault Message Possible Cause Err Display o OverVoltage excessive decel rate 2 P OverCurnt power stage surge current OS o 3 T r r r r r u H A A J J E d d d Excessive position deviation gt PEMAX Communication interface communications fault has occurred These faults can only be cleared by cycling power 0 1 2 3 4 5 6 7 8 9 10 1 2 1 F 5 1 2 SERVOSTAR S and CD
95. he and the B channels be wired appropriately to the SERVOSTAR drive to ascertain the correct directional drive information This can be verified by displaying the PFB variable while rotating the motor shaft clockwise The PFB variable should be counting in a more positive direction If it counts in a negative direction the A and B channels are inverted This can be fixed by swapping the A and A wires from the encoder or by using the MFDIR command Line Break errors may occur and be misleading The SERVOSTAR receives the A B I channels LINE DRIVERS RECEIVERS AND TERMINATIONS Counting pulses sent over cables going through an industrial environment requires that care be taken to prevent noise induction on the cable that looks like an encoder pulse Running wires in a clean raceway Is one requirement Another common sense approach is to use differential transmission for the signals to provide the highest degree of noise immunity Differential line drivers are required by the SERVOSTAR The differential line signals follow the RS 485 format where pulses are sent up and down a 120 2 cable Termination is expected at both ends and the SERVOSTAR provides the required termination Deviations from a 1200 characteristic impedance cable when using long cables can result in poor performance Design Considerations The SERVOSTAR has a maximum frequency input for incremental encoders of 2 5 MHz This cannot be exceeded under any circumstan
96. he saem Hote 6 Feedtzct cable banding is required far compliance As with the maar cables the foadtoct cabks yhauld be banded ta the back panel This banding dogs Wwa Lhings First dawn radiian fram Lhe drive which may be inthe farm df high frequency energy internal processar Secand provides im munity far the drive Since the device located internal lathe maar is gaing ta pick up currents and ram m i alang the feadtmct cable The birg dreds the cures fram Lhe shield of Lhe eedtect cable ta tect panel ground This reduces he naise entering the drive Hote 7 AC power lings Ut must be raved a her lings such ae maar cables ar lings should cross a X angle This minimizes the coupling tne power lings should be rowed as chase lathe back panel a passible Any noise currents an the lings are capaciively caupked ta Lhe graund plane and not ta other lings Hote 8 Carral signals should be tep separe fram all power and maar cables passibke Keep wiring as shan as possible and use screened wire Banding i alsa recam mended but not required far C E cam pliance A venation diwane of 20 cm 8 in cases Where m usi crass power cables they cross 2 X angle Hote 9 Maar cables and fe
97. he fly switching between velocity and current torque control IN2 IN3 INIMODE IN2MODE IN3MODE Position Control Serial positioning loop control Position Mode OPMODE 8 amp PCMDMODE receiving serial or I O controlled command IN2 IN3 INIMODE IN2MODE IN3MODE Analog positioning loop control Position Mode OPMODE 8 amp PCMDMODE over a 10 V range with scaling capability PSCALE GEAR GEARI GEARO and I O triggering Incremental and absolute positioning with an position indicator MI MA INPOS PEINPOS Simple absolute and incremental indexing with I O triggering capability MAPOS MASPEED MIDIST1 MIDIST2 MIDIST3 MISPEEDO MISPEEDI MISPEED2 and MISPEED3 through either the serial port the hardware configurable inputs INI IN2 IN3 INIMODE IN2MODE IN3MODE Position homing with I O triggering capability MH HOMESPD HOMESTATE through either the serial port or the configurable inputs IN2 IN3 INIMODE IN2MODE IN3MODE Electronic Gearing Position Mode OPMODE 4 featuring pulse following or master encoder capability with resolution up to 3mhz through C8 connector 2 5khz through opto isolators in C3 GEAR GEARMODE GEARI GEARO PEXT PEXTOFF VEXT XENCRES XENCDIR Homing capability is provided Dual loop mode DUALFB capable of positioning from a load feedback C8 input PEXTOFF PEXT VEXT XENDIR device while controlling
98. her each IDN listed within IDN 18 has been written by the master If any IDN has been written with illegal values then the drive will not allow a transition to CP3 If the drive fails to transition then IDN 21 will contain a list of IDNs that are not configured properly The following IDNs should be configured during CP2 2 Communication cycle time transmission starting time 0 o Position of data record in MDT 10 89 MDTtmansmissonsuring me G Some masters do not support togeling the control unit synchronization bit control word bit 10 during and CP4 In this case initialize the control unit synchronization bit monitoring IDN P152 to 0 during CP2 Refer to the IDN descriptions for more information CP3 INITIALIZATION IDN 19 contains a list of IDNs that must be written to the drive during CP3 If the drive was properly configured using MOTIONLINK IDN 19 should be empty and the master requires no IDN initialization during this phase OPERATIONAL NOTES Remember that the hardware enables DIP switch 8 and the Remote Enable line must be enabled before the drive can be system enabled through the MDT control word during CP4 If system enabling fails refer to 15 for a list of conditions that prevent this action e Ifa fault occurs the drive will not allow the master to clear faults while any of the MDT control bits 13 15 are set SE
99. ice that indicates changes in position The encoder resolution of the SERVOSTAR and therefore the drive s encoder equivalent output 15 fixed because it 1s a hardware characteristic of the encoder device The encoder interface includes three groups of wires l and complements lines make up the encoder quadrature signals The signals are received differentially through line receivers before being passed through a wire break detection circuit 2 The narrow Index pulse normally appears once per revolution and indicates known physical position of the shaft This pulse is received differentially through a line receiver before being passed through a wire break detection circuit This signal is hardware capturable 3 Hall signals provide information representing the approximate absolute location of the motor shaft From this information the motor can sinusoidally commutate forward until the index signal is detected at which time true position is known These signals are isolated by an opto coupler and can be differential or open collector type signals SERVOSTAR S and CD Product Family 33 Danaher Motion Wiring SPECIFICATIONS Required Signals Types A B with or without Index pulse A B Index with or without Hall Channels Halls may be integral or discrete Signal Type A quad B and Marker Differential do not connect single ended Halls Differential or Open Collector ysem Voltage Maximum Input Frequency Maximum Cable
100. ill require cycling the power The other two switch functions 7 8 control the motor operation and are monitored in realtime This switch provides the following functions This connector functions only when using the R S232 interface It will NOT function using RS 485 C8 Remote Encoder Input Pin Function n A Input High A Input Low 6 Shield Connection o 9 MultiDrop Address Select Switches 1 through 5 set the drive s address A drive having address 0 powers up in the addressed state If these five switches are set to anything but 0 the drive will assume an address code indicated by the switch settings Baud Rate Switch 6 sets the Serial SERCOS interface baud rate to either 9600 2M switch off or 19200 4M switch on Position Hold Activating switch 7 causes the drive to enter a position hold mode The condition is denoted by a flashing status display The display maintains its current OPMODE code If the drive is running during a HOLD command detection the motor will ramp to a stop at the DECSTOP rate e Enable Switch 8 is an input to the drive enable circuitry and can be used to force the drive to a disabled state SERCOS interface Power Level Functions only on SERCOS interface products If switch 9 is set to 0 the SERCOS interface transmitter uses a low power setting so the receiver is not overdriven when using short cables Long cables require more power Factory Res
101. ined by the GEARMODE variable Position Controller OPMODE 8 the SERVOSTAR is configured as a serial or an analog positioning controller depending on the value of PCMDMODE that can receive simple absolute incremental indexing homing and analog commands SERCOS interface Controller OPMODE 5 the SERVOSTAR must be ordered from the factory as a SERCOS interface unit to establish communications in this OPMODE The drive is shipped with Connector C4 as the Transmit Receive port no longer the Encoder Equivalent Output SERVOSTAR S and CD Product Family 56 Danaher Motion System Operation System This section discusses the I O features of the C3 connector except for the Thermostat input on C2 For further explanation on how to use these features refer to the VarCom Reference Guide Analog Input ANIN The position velocity or torque loop can receive its command from an analog voltage source and is selectable through the OPMODE variable The analog input to the SERVOSTAR is differential This means that the signals received at the two inputs are subtracted from each other to create a difference which is then used to command the rest of the system This type of input has a high degree of noise immunity and in many cases will allow for ground isolation between systems This analog input also has a low pass filter ANLPFHZ to prevent high frequency noise from entering the system The input voltage from the diffe
102. instructions The figure below shows the external interface to the BJP Reference the User s Manual for detail explanations 10 AOUT SEE NOTE 1 Master Encoder Stepper Input o m h2 J11 Main Pin out Signal Name n4 Feedback h5 Encoder T SEE NOTE 2 h6 te te 12 24 Vac V lx In8 Jumper J 10 d4 J11Main ni 1 J 1 Vdc for Input power So dni Output 1 Input Supply In 12 Output 2 12 or 24 Vdc 2 P Output Supply 41 191 2 24 4 Output 5 fpes OK output OK output Ho J 20 J 16 Analog Pin out Pin s Signal Name J 15 05 Analog Common POWER J 101 J 102 2 ani CARD 23 3 3 5 Vdc Supply 10 mA max OK 4 Analog Common TET m T ru 5 AIN 2 SVdc 10ma
103. is complete The flag 1s reset to zero when you manually set the index position ENCSTART Selects automatic or manual wake and shake initialization HALLS Read the states on the Hall channels IENCSTART Set the wake and shake initialize current level MENCOFF Tell the SERVOSTAR where the marker is relative to commutation angle 0 MENCRES Tell the SERVOSTAR how many lines there are on the encoder MENCTYPE Tell the SERVOSTAR what encoder signals are present MHINVA Invert the active level of Hall channel A MHINVB Invert the active level of Hall channel B MHINVC Invert the active level of Hall channel C MPHASE Allows commutation offset SERVOSTAR S and CD Product Family 102 Danaher Motion Appendix D APPENDIX D Resistive Regeneration Sizing Shunt regeneration 15 required to dissipate energy that is pumped back into the DC bus during load deceleration The loads need to be defined in terms of system inertia maximum speed and deceleration time In addition the duty cycle must be known Regen Resistor Example is Kollmorgen s ERH 26 67 19 175 215 7 6 89 8 46 T 5 3 21 Black Hormally Closed Black The black wires are for the thermostat and the white wires are for the regen resistor on the external regen resistor pictured above 5 S and CD Product Family 103 Danaher Motion Appendix D Energy Calculations To determine if
104. isy chained as described later in this section The SERVOSTAR comes with its own software interface called MOTIONLINK MOTIONLINK is a Windows based program designed to effectively assist you in setting up and controlling the drive s operation It is highly intuitive in nature and contains an extensive context sensitive on line Help F1 tool The on line Help describes how to use the program in detail and serves as a valuable reference for the drive s variable and command set setup process and troubleshooting techniques This software package can be downloaded from the PSP CD ROM accompanying this manual Also provided on this CD ROM is the VarCom Reference Guide detailing the complete variable and command set This guide is a great added resource to MOTIONLINK when using the package in the Terminal mode of operation Since the software is designed to guide the customer through the operation process of the drive the MOTIONLINK discussion in this section will cover only general steps of use dumb terminal can also be used to communicate to the drive You will find this method of communication very awkward until a certain level of familiarity with the drive s operation is achieved MOTIONLINK also provides a terminal emulation feature that contains many useful editing tools for this type of communication Computer Requirements MOTIONLINK requires an IBM PC or compatible computer with the following features IBM PC XT 386 486 PS
105. ive Variable Parameters From the Configure menu click the Drive option The same screen appears as described in the Startup screen section Click Exit to return to Main MOTIONLINK Screen Setting Motor Variable Parameters selecting the Motor option under the Configure menu you can obtain the same parameter screen found in the Startup screen Click Exit to return to Main MOTIONLINK Screen Customizing to Application By dropping down the Operational Mode listing you can select the mode of loop control desired position velocity torque Clicking the Tune button you can select the system bandwidth the type of loop control and the filtering necessary for the application These are the same parameter screens found in the Startup screen Click Exit to return to Main MOTIONLINK Screen Saving Variable Parameters to EEPROM At the top of this screen you can click the button labeled RAM E to save the modified variables from RAM to EEPROM SERVOSTAR S and CD Product Family 45 Danaher Motion System Communication Saving Variable Parameters to SSV file Occasionally you may desire to backup the variable parameters from one drive for use in another To do this pull down the Edit menu and select Backup Variables request the information from the drive button into the editor and save button the contents in a SSV format to a specified disk location Restoring Factory Variable Paramet
106. lates a current error This error is then fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC BUS Module typical 325 VDC bus to supply the required current to the motor windings The actual motor current is updated and the process begins again ANOFF ANDB analog input gt 1 Control Limits IMAX DIPEAK DICONT MICONT Compensator based ANLPFHZ ANIN ISCALE H ILIM ILIM2 gt X gt Motor parameters Neun FOLD FOLDTIME FOLDMODE k MFOLD MFOLDDIS MFOLDD MFOLDT MFOLDR Y T iscALE H ANOUT f ServoStar MotionLink Off Line File View Configure Tune Options ESL JEN EJ HER SE03 160 volts Operation Prccctoge zi Gearing 27 Input Encoder Oc BT System Motor 0 Device Select B 202 A Axis 0 Set MEE C Disable Enable Exit Analog Torque Mode with MOTIONLINK SERVOSTAR S CD Product Family 64 Danaher Motion System Operation Current Sa
107. ld be used when handling some connector kits and other equipment pieces may be quite small and can be accidentally discarded if care is not observed when unpacking the equipment Do not dispose of shipping materials until the packing list has been checked Remove all packing material and equipment from the shipping container Be aware that Upon receipt of the equipment inspect components to ensure that no damage has occurred in shipment If damage is detected notify the carrier immediately Check all shipping material for connector kits manuals diskettes and other small pieces of equipment Bus Module Model Numbers Month Manufactured A January B February Year Manufactured L December Unit Manufactured 98A 589 PAOS800 SERVOSTAR BUS Module Hardware Variations 00 Standard Rated Current Amps 08 14 28 50 75 85 LM SERVOSTAR S and CD Product Family 3 Danaher Motion Year Manufactured Manufacturing Location MODEL NO CR03000 26G204 Unpacking and Inspecting SERVOSTAR S CD Model Numbers Month Manufactured January B February L December Unit Manufactured 598 589 SERVOSTAR Amplifier Family S 5 Series C Series Compact Drive Feedback Resolver E Encoder B Sine Encoder Rated Current Amps S Series 03 06 10 20 30 55 85 C Series 03 06 10 S Series Hardware Options 100 199 Custom DCB variations 200 St
108. locity and position loops The next figure depicts the control loops graphically POSITION LOOP EE te COMMUTATION LOOP 3 pee CURRENT LOOP 330VDC Control Loop Structure SERVOSTAR S and CD Product Family 60 Danaher Motion System Operation CURRENT LOOP Since current and torque are proportional in a Permanent Magnet PM motor the current loop is often referred to as the torque loop The function of the current loop is to regulate motor current as directed by a current command signal The current command signal from the microprocessor can either come from a direct user input OPMODE 2 amp 3 or from the output of the velocity loop There are actually three current loops one for each motor phase Each current loop receives its own command input from the commutation loop The SERVOSTAR uses a fully digital pole placement current loop with high bandwidth and a current loop sampling rate of 16 kHz 62 5 uS coefficients of the current loop are digitally calculated inside the drive for a given set of motor and drive characteristics The current loop also includes adaptive gain terms to compensate for some non linear effects The current loop incorporates electrical isolation for protection from the high voltage BUS These current loops also convert the output voltage to a Pulse Width Modulated signal providing the highest efficiency
109. locked shaft and uses only the incremental signals to commutate forward until the index is found Hall signals provide information representing the approximate location of the motor shaft 6 transitions per electrical cycle of the motor From this information the motor can six step commutate forward until the index signal is detected at which time true position is known and sinusoidal commutation begins These signals are isolated by an opto coupler and can be differential or open collector type signals lines are an alternative to Hall signals These lines provide a SIN COS sinusoidal signal where one electrical cycle equals one mechanical revolution identical to single speed resolver feedback Interpolation is performed on these signals thus absolute position is known within 256 parts of a mechanical revolution The motor can commutate forward until the Index signal 15 detected Sine encoders with Endat capability add another approach to communicating commutation position Here absolute position information is stored in the encoder and is serially communicated to the drive upon power up The data is received synchronously by a clock signal provided by the drive Absolute position is known immediately therefore an index signal is not needed SERVOSTAR S and CD Product Family 35 Danaher Motion Wiring SPECIFICATIONS Required Signals Types A B with or without Index A B Index with discrete Hall Channels A B In
110. mily 36 Danaher Motion Wiring Encoder Equivalent Output The SERVOSTAR provides a motor position output to you in the form of quadrature encoder signals eliminating the need for an additional position feedback device The outputs are differential line drivers There is an associated DC common output C4 pin 3 which can connect to your port to keep common mode noise and voltage spikes minimized for device protection Because there are normally differences of potential between your controller and the drive connection is recommended if ground loops occur disconnect and retest The source of the Encoder Equivalent Output EEO signals depends on the type of motor feedback device Resolver Systems The output signal is developed through the R D hardware circuitry for minimal phase lag and has a maximum frequency determined by the motor speed and R D limits It provides a configurable ENCOUT resolution of up to 16384 lines 65536 quad counts per revolution of the motor shaft The placement of the index pulse INDEXPOS can be varied on resolver systems within 360 electrical degrees of the feedback signal For single speed resolvers this means you can vary the position of this signal over one mechanical revolution For multi speed resolvers the mechanical position variation is determined by the pole pair count of the resolver e g three speed resolver gives mechanical variation of the pulse within 1 3 of a revolution Encoder Systems Th
111. mits the inputs prevent any further motor travel in their respective direction but do not disable the drive or prevent motion in the opposite direction Note that if acceleration control is in place PROFMODE 1 the motor will ramp to a stop after the opening of the End Travel Limit These inputs are opto isolated and considered active enable meaning current must flow through these signals to allow the system to operate This provides a dead man safety feature Energizing both the CW and CCW hardware position limits causes the SERVOSTAR to enter the HOLD mode These inputs can also be inverted ININVx where x 1 2 3 The default settings of these inputs are for the hardware position limits The Status Display may flash an 1 upon power up indicating that a travel limit has been tripped If these position limits are not in use set LIMDIS 1 Configurable Outputs ANOUT OI The 10 V 12 bit analog output ANOUT is normally off used for monitoring The setting of this variable will allow you to meter various feedback quantities such as velocity current horse power position feedback and following error and more This pin must be referenced to DC Common pin 4 The digital output O1 OTMODE can be toggled in an On Off state to indicate various drive motor and variable conditions These include absolute speed and current levels FoldBack conditions motor braking motion complete and zero speed conditions position overshoo
112. mpling The current loop receives corrective feedback from the current sampling circuitry The current sensors use closed loop hall sampling techniques in all units The current sample is used by the current loops to regulate the current in each of the three motor phases Two phases A and C of the current signal are sampled by the microprocessor at a 16kHz rate The momentary A phase current and C phase current can be monitored by examining the IA and IC variables respectively The microprocessor calculates the equivalent absolute current which can be monitored as I This value can be averaged for 2 4 8 16 32 or 64 samples Foldback The SERVOSTAR offers two types of FoldBack protection for both the motor and the drive The drive s microprocessor monitors the current feedback signal and develops a RMS value of this signal for the purpose of providing a value that represents the current in the motor The system is similar to an I squared T accumulator Drive FoldBack This FoldBack algorithm monitors current feedback and if the feedback exceeds the continuous current rating of the drive motor combination ICONT will decrease the system s current to the ICONT level For example under a step command input condition the FoldBack algorithm will allow maximum peak current IMAX output from the drive for 2 seconds or second for Cx units After two seconds the drive enters FoldBack mode FOLD 1 and begins an exponentially F
113. mply align the motor shaft to a position the SERVOSTAR understands The motor is then rotated to the next pole position by energizing the windings in a slightly different manner The SERVOSTAR then has enough information to establish an appropriate commutation angle using the number of motor poles MPOLES and the number of counts for the encoder MENCRES This method of initialization has the advantage of allowing an extremely cost effective feedback device However the requirement to pull the motor into these torque detents is subject to outside influences such as friction and can prevent the motor motion from occurring very effectively or even at all Additionally large inertia loads can overshoot and oscillate during this pull in position giving the microprocessor false readings These MENCTYPEs are best for systems with specific criteria requirements such as low friction low cost and low inertial loads The amount of electrical current used in this initialization mode is adjustable using the IENCSTART variable and may need to be adjusted to optimize performance for large inertial loads SERVOSTAR S and CD Product Family 91 Danaher Motion Appendix C MENCTYPE 4 Encoders with A and B channels only The simplest of encoders provide only an A and B Channel MENCTYPE 4 configures the SERVOSTAR for these signals These encoders provide no power up information about where the motor 15 positioned so this information 1s obtained through a speci
114. n has also provided specific filters recommendations that adequately attenuate the conducted noise to levels well below the CE limits The implementation of the EMI filter should be done in accordance with the following guidelines Filter should be mounted on the same panel as the drive and BUS Module Filter should be mounted as close as possible to incoming cabinet power Filter should be mounted as close as possible to BUS Module If separation exceeds 30cm 1 ft flat cable braid is used for the high frequency connection between filter and BUS Module When mounting the filter to the panel remove any paint or material covering Use an unpainted metallic back panel if possible Filters are provided with an earth connection All ground connections are tied to ground Filters can produce high leakage currents Filters must be earthed before connecting the supply Filters should not be touched for a period of 10 seconds after removing the supply SERVOSTAR S and CD Product Family 13 Danaher Motion Wiring BUS Module Model Recommended EMI Line Filter Kollmorgen Part PALM Corcom F7202A A 97181 14 single phase Filter Concepts SF15 n a 14 3 phase Schaffner FN258 30 07 96776 003 Cx03 Filter Concepts SF7 n a ____ ______ Cx06 Filter Concepts SF15 n a ____ ______ Recommended Line Filters The filters called out in the table on the
115. nd operating parameters MIERO PROCESSOR The PC transmits serial data to the drive and stores it in dynamic RAM However any variable data changed from the PC is lost when logic power is lost if it is not saved into non volatile EEPROM Each variable listed in the VarCom Reference Guide indicates whether it can be saved to the EEPROM If you are configuring the same system on similar applications the variables can be saved on disk in an SSV file for convenient downloading into other drives MOTIONLINK Installation Installing on PC Insert the SERVOSTAR PSP CD ROM to load MOTIONLINK for Windows The CD ROM should AUTORUN If not select Start Run or browse your CD ROM drive Type D AUTORUN EXE and hit the Enter key this assumes your CD player has a D letter designation Select a product and follow the instructions on the screen Running the Program Go to your Start Programs listing and select SERVOSTAR MOTIONLINK from the menu or click on the SERVOSTAR MOTIONLINK icon if loaded on the desktop SERVOSTAR S and CD Product Family 42 Danaher Motion System Communication Using MOTIONLINK MOTIONLINK gives you three methods to configure the drive The first uses the Startup screen and is the easiest and most highly recommended approach Its main purpose is for initial startups The second approach allows you to more indirectly perform the same configuration as the first using the Main
116. ne and dictate system operation Many of these variables and their locations in MOTIONLINK are presented graphically in the following discussions to help disclose meanings and relationships SERVOSTAR S and CD Product Family 62 Danaher Motion System Operation SERIAL TORQUE The SERVOSTAR can be operated as a serial torque controlled amplifier OPMODE 2 It receives a serial command T via a host to a command generator which in turn creates a current command ICMD The current or torque command is checked against peak IMAX ILIM and continuous FoldBack features ICONT current clamp limits Sinusoidal commutation modulation is added to the command and then fed to the three phase current loop regulator which calculates a current error This error is then fed through a digital pole placement compensation algorithm The output of the compensator is converted to a PWM signal and fed to the power transistor bridge The power bridge uses the high voltage DC BUS Module typical 325 VDC bus to supply the required current to the motor windings The actual motor current is updated and the process begins again The following graphic is a representation of the serial torque loop operation refer to the VarCom Reference Guide for details on all variables and commands Control Limits IMAX DIPEAK MIPEAK CMD wm d Command ICONT DICONT MICONT KON ee or based on Generator gt ILIM ILIM
117. of the standard SERVOSTAR drive Through these switches the drive s address and communication power levels are set Setting Drive Address Up to 31 SERVOSTAR drives can be configured on the SERCOS interface ring The first five switches of the DIP set the drive address When the address is zero 00000 the drive operates as a SERCOS interface repeater and as a single axis unit with serial communication You can monitor and configure the drive through the serial port Any other address setting 1 31 00001 11111 establishes the drive as an active SERCOS interface ring participant with communications through the Tx Rx ports When the drive has a non zero address you can communicate through the serial port only for monitoring purposes Setting Transmission Power Levels The SERCOS interface transmitter power level DIP switch 9 should be set according to the expected signal attenuation between a SERCOS interface transmitter and the next receiver Signal attenuation is based upon cable length cable type and intermediate connection losses e g bulk head connectors The following table may be used to calculate the maximum allowable and minimum required signal attenuation for a given power level and cable attenuation Power Level Attenuation Specifications Low Power High Power 9 5 dBm 2 m 12 5 dBm 2 m Minmm 154 2 Note Ac Fiber optic cable attenuation in dBm m SERVOSTAR
118. oldBack to the system s continuous current It will take approximately six seconds for the exponential decay to drop from the system s peak current to its continuous level For drive currents that exceed ICONT but are below IMAX the system period before FoldBack occurs is extended beyond two seconds Two seconds is the shortest time period that will elapse before the drive enters FoldBack and only occurs when maximum peak current IMAX is drawn Configurable Output O1 pin 12 can be configured to indicate a drive FoldBack condition s This FoldBack feature is designed to protect the drive electronics not the motor The SERVOSTAR S and CD Product Family 65 Danaher Motion System Operation Motor FoldBack This FoldBack algorithm is designed to provide motor protection in cases where the drive s continuous current rating is above the motor s continuous rating This combination is often desired in applications where maximum peak motor torques are required However the possibility exists that the drive could source current on a continuous basis indefinitely to the motor and would force it beyond its thermal capability Unlike the drive FoldBack you have complete configurability over this feature MFOLD MFOLDD MFOLDDIS MFOLDR 5 S and CD Product Family 66 Danaher Motion System Description SYSTEM DESCRIPTION The SERVOSTAR 5 or SERVOSTAR CD is a digital servo motor amplifier that meets the nee
119. or easy manipulation of the drive s thermostat options encoder output and hardware position limits capabilities SERVOSTAR S and CD Product Family 71 Danaher Motion System Description A feedback device screen that provides realtime pictorial positioning information It also includes a resolver zeroing routine and an encoder initialization folder A tuning screen designed to allow you to adjust control loop gains quickly while visibly watching the affects on performance A control loops screen that provides direct manipulation of velocity and position loop gain parameters Monitoring and Troubleshooting Tools Performance recording RECDONE RECING RECOFF RECORD RECRDY RECTRIG System status checking STAT STATUS STATUS2 Control loop monitoring 1 Current torque 1 IC ICMD IMAX ICONT DICONT DIPEAK 2 Speed V VCMD VE 3 Position PCMD PFB PE HALLS HWPOS INPOS PRD PEXT PEINPOS Analog output ANOUT with 12 bit resolution and scaling flexibility PSCALE that can be configured to monitor speed torque current power velocity error following error and position feedback PFB Should be used as a monitoring tool only Dual state digital output 01 OTMODE OIRST O1TRIG that toggles according to various absolute current speed and position parameter settings Also can be used to communicate occurrences of fold back motor braking and the status of the Remote Enable hardware switch
120. orm MENCTYPE 3 amp 4 Drive puts IENCSTART Read Hall algorithm current through 2 phases Codes Establish and waits for motor to stop Commutation Angle as though in the middle Position is read by drive Drive puts current through other phase Wait for stop Marker Channel Occur Marker Channel Occur Establish New Commutation using MENCOFF Drive establishes commutation angle Hall Code Change End Adjust Commutation Angle Marker Channel Occur Establish New Commutation using MENCOFF End MENCTYPE 0 Incremental with A B I and Hall Channels MENCTYPE 0 is the most robust encoder system The drive expects the signals as feedback from the motor The hall channels is synthesized either in the encoder or discrete devices Hall sensors integrated in the motor windings On power up the hall effect channels are read and a code is sent to the microprocessor to give it a coarse position for the motor This position is accurate to within 30 electrical degrees of the optimal commutation angle The SERVOSTAR assumes the actual motor position is half way between the hall code settings for a maximum commutation error of 30 electrical degrees Even with this amount of error the motor is capable of producing torque with 86 efficiency As the motor rotates the first hall boundaries quickly tra
121. ort assembly commission and maintenance this equipment Properly qualified personnel are persons who are familiar with the transport assembly installation commissioning and operation of motors and who have the appropriate qualifications for their jobs The qualified personnel must know and observe the following standards and regulations IEC 364 resp CENELEC HD 384 or DIN VDE 0100 IEC report 664 or DIN VDE 0110 National regulations for safety and accident prevention or VBG 4 Read all available documentation before assembly and commissioning Incorrect handling of products in this manual can result in injury and damage to persons and machinery Strictly adhere to the technical information on the installation requirements e 15 vital to ensure that all system components are connected to earth ground Electrical safety is impossible without a low resistance earth connection The SERVOSTAR product contains electro statically sensitive components that can be damaged by incorrect handling Discharge yourself before touching the product Avoid contact with high insulating materials artificial fabrics plastic film etc Place the product on a conductive surface During operation keep all covers and cabinet doors shut Otherwise there are deadly hazards that could possibility cause severe damage to health or the product In operation depending on the degree of enclosure protection the product can have bare components that are
122. possible The PWM center frequency can be 8 or 16 kHz according to the drive size COMMUTATION LOOP This loop converts a single phase current command signal into a three phase position modulated sine wave input to the current loops The SERVOSTAR has a patented sinusoidal wave form generator which uses a technique called Torque Angle Advance to get top performance out of its motors The waveform generator is part of the microprocessor and is updated at a 16 kHz rate This provides hi fidelity sinewave commutation at both low and high velocities The sinewave output must be aligned to the back EMF characteristics of the motor This is why resolver or encoder alignment to the motor is critical VELOCITY LOOP The purpose of the velocity loop is to regulate motor speed Like the current and the commutation loops the velocity loop is fully digital and uses the resolver or the encoder feedback signals to calculate actual motor velocity The command for the velocity loop can come from a direct user input OPMODE S 0 amp 1 or can be the output of the position loop The velocity loop is a digital sampling system operating at 4 kHz The difference between actual and desired velocity is filtered through a compensator algorithm and fed to the commutation loop The SERVOSTAR offers four velocity compensators methods of regulating velocity and are selectable through the COMPMODE variable The four are Proportional Integral PI Pseu
123. r the environmental conditions stated in the product specification tables The system may be operated in higher temperature ambient conditions with a derating applied Please check with the factory for derating information Attention to proper installation and field wiring are of prime importance to ensure long term and trouble free operation Users should familiarize themselves with and follow the installation and wiring instructions listed in this section In addition to these practices some localities and industries may require applicable electrical and safety codes laws and standards Particular care should be used when layout of an enclosure is designed Efforts to separate power wires from small signal wires should be taken The following guidelines highlight some important wiring practices to implement Control and signal cables must be separated from power and motor cables Distance of 20cm 8 in 15 sufficient in most cases Control and signal cables must be shielded to reduce the effects of radiated interference Where control cables must cross power or motor cables they should cross at a 90 angle if possible This reduces the field coupling effect Enclosure The Danaher Motion Kollmorgen SERVOSTAR series of electronic system components are designed for panel assembly This panel assembly should then be mounted in a metallic enclosure Enclosures are supplied by the manufacturers of the final product and must meet the
124. r with approximately three turns through the core The following figure illustrates the use of multiple turns through a clamp on core The more turns created the more impedance is added to the line Avoid putting the shield in a clamp on core It is undesirable to place an impedance in line with the shield The use of ribbon cable may be common in many cabinets Some ferrite clamps are designed just for ribbon cable use as shown below Flat cable clamp used with ribbon cable I O Filtering Techniques 5 S and CD Product Family 16 Danaher Motion Cx Filter and Bonding Diagram Hote 1 Input power enters fram metal canduk This elim ines the need far input power cable Hote 2 Single paint graund A bus bar graund bus an excellent way la achieve this Hote 3 High frequency graund beween narcanductive tact panel and enzlasure high frequency graund iz required between Lhe Contactor enckrsure and earth ground Fuses Hote 4 EM I filer graunding Safety graunds must be pravided the likers Hazard patentia even when the pawer is because of he capaciarns inernal tathe fiers Hote 5 Banding maar cables The use d armared screened matar cables banded as ckrse ta the drive zr passibke are essential far compliance and rocam mended la baller Lhe overall per armance and reliability of L
125. r Equivalent Output C4 by pinout amp Complements 1 2 4 5 7 8 2 5 V min at 20mA Differential RS 485 Line Drive Type DS26C31TM Remote Encoder Input C8 by pinout amp Complements 1 2 4 5 7 8 5 V Differential 0 2V 1002 RS 485 Line Receiver Type SN75173 See the section on Position Loop in Section 6 for features using this input Note A flyback diode is necessary for inductive loads connected across the 01 output SERVOSTAR S and CD Product Family 23 Wiring Danaher Motion 11074 N3938 e amp qii MONIA N393M S SAG OL LINVA E sna 9 ANO Vd a sngoa uojouwusdWnr ATIVNYALXS N393H TWNYALX3 1VNOLLdO a snd LO 9 D iring Bus Module Simplified Schematic W ul NOW IOS 3 TWOILdO o4 b PNO u y JUALINDJEAQ JO UO JOJUO A HEISHOS 24 5 S and CD Product Family iring C3AOMGS SI 39V LIOA LNdNI YALAY SALNNIA 5 OL 151 39v L 10A d l 500935 NO 5 1434 LINSNVYL NOWWOO ONISN4 TWNYSLND ONIAONLSAG S39v110A NOWMWOO SS35X3 OL
126. rangement of filters treatment of connectors and the laying out of cabling can be found within this documentation Conformance with the EC Directive on EMC 89 336 EEC and the Low Voltage Directive 73 23 EEC is mandatory for the supply of servo drives within the European Community An authorized testing laboratory in a defined configuration with the system components has tested the servo drives Any divergence from the configuration and installation described in this documentation means that you are responsible for the performance of new measurements to ensure that the regulatory requirements are met Danaher Motion Kollmorgen s SERVOSTAR S Series and C Series drives and systems have been successfully tested and evaluated to the limits and requirements of the EC Directive on EMC 89 336 EEC and the EC Directive on Low Voltage 72 73 EEC The product lines have been evaluated to EN50178 and EN60204 as a component of a machine and other relevant standards The EMC of a system can be identified by emissions and immunity Emissions refer to the generation of EMI electromagnetic interference and immunity refers to the susceptibility levels of the equipment Limits were derived from generic standards EN55081 2 and EN55082 2 for heavy industrial environments The SERVOSTAR 5 and SERVOSTAR CD series of drives and BUS Modules have been tested for radiated emissions conducted emissions EFT ESD surge conducted immunity and radiated immunity These te
127. rdware Remote Enable line on the C3 connector DIPEN switch indicates the state of the DIP enable disable switch 8 fault status software enable drive ready 0 fault exists 0 0 0 0 fault exists ____ 1 enable LO C 1 no faults 0 disable no faults 1 enable READY REMOTE DIPEN ACTIVE drive ready hardware enable DIP switch enable power to the motor T1 If the drive will not enable you can check the state of the switches and flags by clicking the Status button in the upper right hand corner of the Main MOTIONLINK screen If using a terminal you can query the drive for the value stored in the STATUS variable refer to VarCom Reference Guide for an explanation on STATUS parameters The Status Display indicates an enabled drive when the decimal point is illuminated solid SERVOSTAR S and CD Product Family 48 Danaher Motion SERCOS Interface Setup SERCOS INTERFACE SETUP The SERVOSTAR S and SERVOSTAR C Series drives comes with SERCOS interface communication capability It must be ordered from the factory with this option The Encoder Equivalent Output D9 connector C4 is replaced with two fiber optic ports transmitter Tx and receiver Rx This section provides the SERCOS interface specific information needed to complete the installation and setup of a SERCOS interface SERVOSTAR drive to the fiber optic ring DIP Switch Configuration DIP switch configuration is similar to that
128. re built into electrical equipment or machines and can only be commissioned as integral components of such equipment The servo amplifiers are to be used only on earthed three phase industrial mains supply networks TN system TT system with earthed neutral point The servo amplifiers must not be operated on power supply networks without an earth or with an asymmetrical earth If the servo amplifiers are used in residential areas or in business or commercial premises you must implement additional filtering measures The servo amplifiers are only intended to drive specific brushless synchronous servomotors from Danaher Motion Kollmorgen with closed loop control of torque speed and position The rated voltage of the motors must be at least as high as the DC link voltage of the servo amplifier The servo amplifiers may only be operated in a closed switch gear cabinet taking into account the ambient conditions defined in the environmental specifications Danaher Motion Kollmorgen guarantees the conformance of the servo amplifiers with the standards for industrial areas stated in the front of this manual only if Danaher Motion Kollmorgen delivers the components motors cables amplifiers etc SERVOSTAR S and CD Product Family 2 Danaher Motion Unpacking and Inspecting UNPACKING AND INSPECTING Electronic components in this amplifier are design hardened to reduce static sensitivity However proper procedures shou
129. rential receiver is applied to a precise 14 bit Analog to Digital A D conversion system The A D conversion system 15 read by the microprocessor every 500 5 for the position loop modes every 250 for the velocity loop mode and every 62 5 uS for the torque current loop mode of operation Encoder based units come with the additional benefit of a Dual Gain ANDG input When enabled the system uses two 14 bit A D inputs to read the user supplied analog signal One input is a direct reading of the 10V signal while the other incorporates a 2x gain term When the input voltage is less than 4 V the 2x channel is used to determine the input voltage which extends the resolution to a 15 bit equivalent Above 4 V the system uses the straight 14 bit conversion Special software algorithms are used to minimize cross over distortion and add 0 25 V of hysterisis Analog systems often require scaling and offset bias The SERVOSTAR adds an analog offset ANOFF variable to this reading performs an analog deadband ANDB adjustment and scales it through the either the position loop input scaling GEARI GEARO velocity loop input scaling VSCALE or torque loop input scaling ISCALE before passing the data to the selected control loop The analog input ANIN variable indicates the analog reading after the offset ANOFF and the deadband ANDB adjustments but before the loop scaling The ANIN variable range is 22500 counts or mV The SERVOSTAR also o
130. res a broad understanding of the controller functionally and knowledge of the SERCOS interface standard and manufacturer s IDN set The standard and manufacturer IDNs supported by Danaher Motion Kollmorgen are functionally categorized to make this method of configuring easier The second approach gives you the ability to configure each axis separately through the serial port using MOTIONLINK MOTIONLINK is very intuitive and guides you through the setup stages of the configuration process It provides interactive setup screens for easy manipulation of the drive s parameters while giving you realtime monitoring and recording tools that help in optimizing axis performance Once performance is optimized the parameters can be stored in the drive s EEPROM memory before establishing communication through the SERCOS interface SERVOSTAR S and CD Product Family 51 Danaher Motion SERCOS Interface Setup Drive Configuration Before you can begin the CPx where x 0 1 2 3 4 run up process the drive should be configured and tuned for the axis of operation To accomplish this follow the guidelines below 1 Power down the drive 2 Set the drive address to zero for single axis operation 3 Select a serial baud rate 4 Connect a serial cable from the drive to a host 5 Power up the drive 6 Install MOTIONLINK and communicate with the drive 7 Follow the user screens to configure the drive and motor combination 8 Enable the drive 9 Tune the
131. resolver feedback signals in resolver based systems The SERVOSTAR disables and displays an r in the status display when either of these signals are not present Low voltage power supply faults Out of tolerance values on the 12 VDC analog supplies will cause an to be displayed and cause the drive disable OverSpeed fault Software continuously monitors the actual feedback speed If the motor speed exceeds the VOSPD limit a J will be displayed and the drive will be disabled This normally occurs when there is an improperly tuned system and the load overshoots its commanded speed SERVOSTAR S and CD Product Family 81 Danaher Motion Troubleshooting No compensator In case the SERVOSTAR cannot design compensator such as after a RSTVAR command CLREEPROM or any change in the motor or drive parameters a flashing minus sign will be displayed and will cause the drive to disable This display normally indicates that the drive does not have a compensation file loaded Memory reliability During the initialization process upon power up the run time variables memory RAM Random Access Memory and the program memory EPROM Electrically Programmable Read Only Memory are tested If a RAM fault is detected an is displayed and the drive is halted If an EPROM fault is detected 15 displayed and the drive 15 halted The non volatile memory EEPROM is also checked for integrity upon
132. rive puts current through other phase Wait for stop Marker Channel Occur Marker Channel Occur Establish New Commutation using MENCOFF Drive establishes commutation angle Hall Code Change Adjust Commutation Angle Marker Channel Occur Establish New Commutation using MENCOFF End MENCTYPE 0 with the exception of the final search for the marker pulse The system establishes the commutation angle based on the Hall effect edge MENCTYPE 6 is most commonly used with linear motors Commutation Accuracy The accuracy of the commutation alignment within the drive affects the overall system efficiency Misalignment also causes greater torque ripple As a general estimator the following equation holds effective Ki Cosine Alignment Error 5 S and CD Product Family 94 Danaher Motion Appendix C Inaccuracy of commutation alignment can occur from multiple sources when using encoders The accuracy of the hall channel devices if they are provided from an encoder using an optical disc are typically accurate to 5 or better electrically When they are integral to the motor they may have an error of up to 15 Using the above equation a 15 error would still provide more than 96 of the motor s torque The accuracy of the wake and shake algorithms used
133. s eedtzct cable E banding necessary Alva 0 Ol mi semra the and IO LLL LL o enl Keep all wiring as as muchas O passible This el O Lhe chances of the o el signals galing carrupied o 6 signals WO tep separate ram all IL TNI Di power and maar cables Z A g gt e shar as passible and use screened wire veparatian distance of 20cm ain is zdficie in canes Where cantral cables crass pawer cables they should cross zi a angle Hote 7 Canned safety graunds ta fikerz This criicalta gord camis fram causing persanal in urs Hote 8 Where maar cables exi enckrsure toep in separe canal from feedtzct and other wiring A veparakian disiance of 20 cm ara in is sicion Hole S Routed to Routed to ckar of VO and signal motors motors wires System Interconnect The following sections provide connector information and the system connections up to the motor power and feedback connections Cabling purchased from Danaher Motion Kollmorgen directly completes the system connections Customers making their own cables can refer to Appendix A for drive motor pinout connections SERVOSTAR S and CD Product Family
134. s The device preference and the associated model number must be determined when the order is placed Resolver The SERVOSTAR uses either single two poles or multi speed multiple poles resolver feedback to monitor the motor shaft position A resolver can be thought of as a transformer whose output is unique for any given shaft position an absolute position feedback The transformer is driven with a sinewave reference signal Two AC signals are returned from the resolver into the Sine and Cosine inputs three of these sinewave signals are low level and susceptible to noise SPECIFICATIONS Resolver Requirements Max DC Resistance 120 Ohms stator SSm ACRMS Output Voltage To Drive 2 CABLE LENGTHS It is important to use properly shielded cable and to keep it away from other noise radiating devices and cables It is not recommended to run the feedback and motor cables in the same conduit Danaher Motion Kollmorgen has tested cable lengths up to 75 ft 22 9 m without degradation of performance However performance may vary depending on motor and resolver type Tests were performed with standard Danaher Motion Kollmorgen cable and its low impedance and Danaher Motion Kollmorgen GOLDLINE motor resolver Please consult the factory for cable and resolver impedance specifications when long cable runs above 250 ft 76 m are desired Danaher Motion Kollmorgen recommends twisted shielded pair for feedback cables SER
135. set the system bandwidth the type of loop control and the filtering necessary for the application Caution should be used when executing the AutoTune feature Some applications are not capable of handling the vibration caused as the shaft senses its load If this is in question manually tune the drive Also when the load inertia is very large and the selected bandwidth is high this feature may fail to perform Setup Completion Click EXIT to go to the Main MOTIONLINK screen saving Variable Parameters to EEPROM saving Variable Parameters to SSV For an explanation on these functions Restoring Factory Variable Parameters refer to the Main MotionLink screen Restoring Custom Variable Parameters Main MOTIONLINK Screen This screen appears the when you exit out of the Startup screen the screens mentioned in the method above can be accessed from this screen and should be used to make corrections in the current system configuration SERVOSTAR S and CD Product Family 44 Danaher Motion System Communication ServoStar MotionLink Off Line ES File Edit View Configure Tune Options Help Current 2 27 Gearing 2 Input AML amu Encoder BILL Feedback 5 n Output Device 999 System Motor oee 0 m Device Select 202 0 Set in Disable Enable Exit Main MOTIONLINK Screen Setting Dr
136. sts have been done in accordance with EN55011 EN61000 4 2 ENV50140 IEC 1000 4 4 EN61000 4 5 and 50141 electromagnetic compatibility EMC You must apply the installation recommendations and the CE filtering Practices when mounting and installing the drive system for CE conformance 1 Installation of the equipment is critical in designing for system and machine Danaher Motion Contents Table of Contents WNon insulated Cable Campos cu mE EEUU 11 Alternative Bonding Methods eene ehem enne nenne en etes Regen 21 BUS Module Regen Parts and MOGEIS sssesccsccccscesssssscsccccscvessssnccccescvsvsnsececessossssssenecescescessencusseeescosssssseecsescosssssacessscosssssseees 22 ee _ Product Family Control Specifications 23 Cx Wiring uut int ua cia tte 25 Sx with PAOS 14 or 28 Wiring 26 Sx with 50 75 or 85 Wiring emere eere 27
137. sulting transmission of data from the drive can then be saved with a SSV extension Restoring Factory Variable Parameters If you have not saved any changes stored in RAM to EEPROM type LOAD at the prompt and the original parameters will be loaded from the EEPROM into RAM If changes have already been previously saved contact the factory to obtain a set of motor variable parameters for the motor specified in the model number At the prompt re enter all the motor variable parameters Type the CONFIG command followed by the RSTVAR command Restoring Custom Variable Parameters At the prompt type RSTVAR Transmit to the drive the custom variable SSV file The contents of this file should have the CONFIG command as its last statement The drive will execute this command and configure itself to the parameters that were just transmitted Follow this by a SAVE command to store the contents into EEPROM MultiDrop Communication When you run MOTIONLINK the opening communication screen displays a Scan For Drives button Selecting this forces the software to scan for any active drives and the address location on the chain Any addresses detected is then listed in the Device Select drop down menu at the bottom of the Main MOTIONLINK screen You need only highlight the desired drive to begin communications To communicate with individual drives in a daisy chain from a terminal you must type at the prompt cr where xe 10 9
138. system as desired 10 Save the drive parameters to EEPROM 11 Power down and reset that actual DIP address Any non zero address will set the drive up for communication on the SERCOS interface ring Each drive on the ring must have a unique non zero address 12 Setthe SERCOS interface baud rate DIP switch 6 off on for 2 4Mbits s 13 Depending on the ring configuration link the fiber optic cables from drive to drive or drive to master as follows Tx to Rx to etc 14 Power up the drive It is now prepared to ascend through the SERCOS interface communication phases under the master s control CP Run up Upon power up the Status Display should alternately flash a P and a 0 to indicate SERCOS interface communication phase 0 As the drive ascends through each communication phase the display will alternately flash a P and a number indicating the next sequential communication phase phase 0 4 Upon reaching communication phase 4 CP4 the display will briefly flash P and 4 before displaying a steady state 5 This indicates that SERCOS interface has been initialized and the drive and motor system is ready for commanding motion SERVOSTAR S and CD Product Family 52 Danaher Motion SERCOS Interface Setup CP2 INITIALIZATION IDN 18 contains a list of IDNs that must be written to the drive in CP2 The CP2 transition procedure IDN 127 verifies the drive s readiness to transition from CP2 to CP3 and checks whet
139. t flagging programmable limit switch detection and an enable ACTIVE flag Condition reset and triggering levels are established through OTMODE OIRST OITRIG SERVOSTAR S and CD Product Family 58 Danaher Motion System Operation Fault Output Relay RELAY RELAYMODE The SERVOSTAR provides a drive ready drive up output in the form of a relay RELAY output The relay RELAY output is controlled by the SERVOSTAR s microprocessor There is a software switch that configures the relay RELAY output to act as a Drive Ready or Drive Up indicator 1 If RELAYMODE 0 the relay is closed when the drive is error free and ready to run This is a Drive Ready configuration 2 If RELAYMODE 1 relay is closed only when the drive is enabled This is a Drive Up configuration 3 If RELAYMODE 2 the relay opens during fault when the drive is disabled You can program this fault output to open on any system fault by triggering the Configurable Inputs INIMODE IN2MODE IN3MODE INI IN2 IN3 Motor Thermostat Input THERM THERMODE The SERVOSTAR provides a motor thermostat input on the C2 connector that is configured for different types of thermal protections THERMTYPE as well as manipulation of how the drive responds to a motor thermal condition THERM THERMODE THERMTIME Danaher Motion Kollmorgen GOLDLINE motors and cables connect the thermostat through the feedback cable
140. t Family 79 Danaher Motion Troubleshooting NO MESSAGE FAULTS Fatal Display Display Wahkgis Sv s Wamo NeCompmaln Y 2 Invalid Velocity Control 3 Encoder not initialized onatiempttoenable __ 4 Encoder Initialization failure 7v v 5 AutoConfigfailure v LI Hardware CW limit switch open Y L2 Hardware CCW limit switch open _______ v Y L3 Hardware CW and CCW limit switches open v wv SISISSSSIS L4 Software CW limit switch is tripped A gt amp PLIM 2 L5 Software CCW limit switch is tripped A PFB lt PMIN amp PLIM 2 A3 Positive and negative analog supply i v RAMBiweQwigi c EPROM checksum during niy E101 Alera Toad failure during ini _ v_ E102 Altera DPRAM failure during _ E103 __ DSP load fail E104 DSP alive failure during mi v _ reem B Indexed position with zero vdody v _ Fault Monitoring System The SERVOSTAR s microprocessor is constantly monitoring the status of many different components In general the philosophy of the SERVOSTAR is to latch all fault conditions so you can readily determine the source of the problem When a fault is detected it is logged in the internal error log indicat
141. t Sales Office West Coast Sales Office 844 E Rockland Road 17 Sarah s Way 6700 Fallbrook Ave Suite 160 Livertyville 60048 Fairhaven MA 02719 West Hills CA 91307 Phone 708 680 7400 Phone 508 992 4495 Phone 818 226 4306 Fax 708 680 8169 Fax 508 992 3798 Fax 818 704 1757 Filter Concepts Inc Phoenix Contact Inc 2624 South Rouselle Street P O Box 4100 Santa Ana CA 92707 USA Harrisburg PA 17111 0100 Phone 714 545 7003 Fax 714 545 4607 Phone 800 888 7388 Fax 717 948 3475 FerriShield Interference Control Components Magnetics Empire State Building P O Box 391 350 Fifth Ave Suite 7505 Butler PA 16003 0391 New York NY 10118 7591 Phone 412 282 8282 800 245 3984 Phone 212 268 4020 Fax 212 268 4023 Fax 412 282 6955 Fair Rite Products Corp P O Box J One Commercial Row Wallkill NY 12589 Phone 914 895 2055 Fax 914 8985 2629 E Mail ferrites fair rite com Micrometals Iron Powder Cores 5615 E La Palma Anaheim 92807 Phone 800 356 5977 Fax 714970 0400 Worldwide 714 970 9400 SERVOSTAR S CD Product Family 38 Danaher Motion System Communication SYSTEM COMMUNICATION You communicate with the SERVOSTAR through either the serial port or on a SERCOS interface fiber optic ring SERCOS interface versions only The serial port can transmit data at baud rates of 9600 or 19200 DIP switch 6 in either RS 232 or RS 485 configurations Multiple drives can be addressed simultaneously when da
142. t has been requested while Active the encoder initialization process is active Tune failed no rotation Tune cmd failed because motor could not rotate 60 Tune failed current sat Tune cmd failed because the current loop saturated 62 66 70 74 Tune failed no vel design Tune cmd failed because the vel loop could not be designed 6 77 78 79 Drive in Dual Feedback mode Command cannot be accepted because dual feedback is active 80 U Functionality is occupied Selected INXMODE function is already assigned to another INxMODE Warning A B Line not routed Selected GEARMODE requires A B inputs to be routed using INxMODE 5 and 6 Warning Limit sw not routed Limit switches must be routed using INXMODE and 2 Move is pending The last ordered move command has not been completed yet T Password protected command or variable requested is password protected and intended for factory use only Capture during homing position capture occurred during homing Homing during capture homing request was made during position capture 92 93 being complete requested command can t be processed due to pos capture not EUM being active 96 Capture process not enabled Position capture cannot be executed ENCSTART while ACONFIG he password entered was incorrect 90 91 92 93 94 95 SERCOSinterface test failure 99 5 S and CD Produc
143. that indicates four types of states Power up Steady State Flashing State and Momentary State The decimal point directly relates to the global drive enable Status Displa DRIVE DISPLAY APPEARANCE STATE Momentarily illuminates all display segments forming an 8 and the decimal point Steady State Displays the operational mode of the drive 0 8 No Faults Used to indicate an abnormal operating state If the position hold feature is active the OPMODE number will flash at a 1 Hz rate Flashing State If a fault was detected a flashing code will be displayed to identify the fault Some codes consist of a sequence of two or more digits see Troubleshooting section In general these faults will cause a latched disable sometimes controllable through software switches To clear fault toggle remote enable except for OverCurrent If the encoder initialization function ENCSTART is active the OPMODE number will flash at a 3 Hz rate Displays a character momentarily for 500 ms before returning to the steady state Momentary The timer is resetable Fault C Communications Error F Drive is in FoldBack mode Status Display States Status Display Decimal Point DECIMAL POINT DRIVE STATUS STATE Steady OFF Steady ON Drive enabled power to the motor Flashing Drive enabled power to the motor but a motor safety feature has been disabled for example LIMDIS 1 Status Display Decimal Point SERVO
144. ts attention to general precautions which if not followed could result in personal injury and or equipment damage Note Highlights information critical to your understanding use of the product Directives and Standards The SERVOSTAR S and SERVOSTAR CD product series have been successfully tested and evaluated to meet UL cUL 508C for both U S and Canadian markets This standard describes the fulfillment by design of minimum requirements for electrically operated power conversion equipment such as frequency converters and servo amplifiers which 15 intended to eliminate the risk of fire electric shock or injury to persons being caused by such equipment CE Mark Conformance Servo drives are components that are intended to be incorporated into electrical plant and machines for industrial use When the servo drives are built into machines or plants drives cannot be operated until the machine or plant fulfills the requirements of the EC Directive on Machines 89 392 EEC and the EC Directive on EMC 89 336 EEC EN 60204 and EN 292 must also be observed In connection with the Low Voltage Directive 73 23 EEC the harmonized standards of the EN 50178 series are applied to the amplifiers together with EN 60439 1 EN 60146 and EN 60204 The manufacturer of the machine or plant is responsible for ensuring that they meet the limits required by the EMC regulations Advice on the correct installation for EMC such as shielding grounding ar
145. ture winding to the permanent magnet fields to create optimal torque For this reason encoders or motors are often provided with additional channels sometimes called commutation tracks or Hall emulation tracks which provide 1 part in 6 absolute position information as shown in the figure below 001 011 010 110 100 101 000 and 111 are Illegal Codes SERVOSTAR S and CD Product Family 88 Danaher Motion Appendix C The hall channels can be synthesized in the encoder or can be discrete devices integrated in the motor windings Commutation tracks hall channels provide three digital channels that represent alignment to the A phase B phase and C phase back EMF of the motor An encoder with Hall channels must have the correct output for the given pole count of the motor as the Hall signals are referencing the motor s BEMF waveform Some systems use only hall channels for motor feedback data The channels provide enough information to commutate a motor in an ON and OFF trapezoidal format but do not provide enough information to properly commutate a motor using sinusoidal control Further the coarse data is insufficient to control velocity below a few hundred RPM The SERVOSTAR product is a high performance controller and does not support hall only operation Since encoders are incremental devices a loss or gain of a pulse creates system errors Electrical noise is the single biggest factor in miss
146. uates to limited filter performance When connecting high frequency grounds use the shortest braid possible Bonding The proper bonding of shielded cables is imperative for minimizing noise emissions and increasing immunity levels of the drive system Its effect is to reduce the impedance between the cable shield and the back panel Danaher Motion Kollmorgen recommends that all shielded cables be bonded to the back panel Power input wiring does not require shielding screening if the power is fed to the cabinet enclosure via metallized conduit If the metallized conduit is used with proper high frequency grounds bonding technology and recommended wire routing then power input wire shielding has no affect In the event that metallized conduit is not implemented into the system shielded cable is required on the power input wires and proper bonding technologies should be implemented The motor and feedback cables should have the shield exposed as close to the drive as possible This exposed shield is bonded to the back panel using one of the two suggested methods below SERVOSTAR S and CD Product Family 10 Danaher Motion Wiring Non insulated Cable Clamp The following figures shows how cable bonding is implemented using non insulated metallic cable clamps S From the drive Cx H D Bil Terminal Strip
147. ution seen by the drive is 256 times the fundamental sinusoidal track on the motor s encoder The advantage of this approach 15 the ability to obtain much high encoder resolution while maintaining a relatively low input frequency through the cable and into the SERVOSTAR The encoder interface includes three groups of wires 1 and complements lines make up the encoder quadrature signals The signals received differentially at peak to peak amplitudes before being processed by the interpolation circuitry SERVOSTAR S and CD Product Family 34 Danaher Motion Wiring 2 The narrow Index pulse normally appears once per mechanical revolution and indicates a known physical position of the shaft This pulse is received differentially through an op amp before being squared up and sent to the control board 3 Upon power up commutation signals are used to communicate coarse position information The first three signal types give approximate position information so the drive can commutate the motor forward until the Index pulse is found There are situations where the index signal is not available Course position information is used to commutate the motor indefinitely The fourth gives absolute information bypassing the need for the Index signal They are No Hall signals exist if power up commutation signals are available The SERVOSTAR can excite two phases and lock the shaft in place It then approximates position of the
148. verse providing the SERVOSTAR with information to better establish commutation angle The SERVOSTAR corrects the commutation 5 S and CD Product Family 90 Danaher Motion Appendix C MENCTYPE 1 Encoders with A B I channels Some systems do not have hall channels so this mode tells the command The wake and shake initialization process is not required if the marker location can be traversed without requiring the SERVOSTAR to move the motor to traverse the marker MENCTYPE 2 Encoders with A B I channels Some systems do not have hall channels so this mode tells the when the 18 enabled The wake and shake initialization process is not required if the marker location be traversed without requiring the SERVOSTAR to move the motor to traverse the marker MENCTYPE 3 Encoders with A and B channels only The simplest of encoders provide only an A and B Channel MENCTYPE 3 configures the SERVOSTAR for these signals These encoders provide no power up information about where the motor is positioned so this information is obtained through a special initialization process known as wake and shake When using MENCTYPE 3 initialization is required but it is triggered by the serial command ENCSTART During the initialization process wake and shake the SERVOSTAR puts current through two phases of the motor causing the motor shaft to rotate into a torque detent The magnets si
149. x D DETERMINING RESISTANCE VALUE The maximum allowable resistance of the regen resistor 15 that value which will hold the BUS under its maximum value when the regen circuit is initially switched on For an AC servo system the maximum allowable regen resistance 1s given by EQUATION 3 Rmax Where maximum BUS voltage motor back less motor losses EQUATION 4 KBN Iu Ra 2 Where back EMF constant L L KRPM N motor speed prior to decel KRPM deceleration current in motor phase motor resistance QL L 1 deceleration current in motor Arms phase SERVOSTAR S and CD Product Family 105 Danaher Motion Appendix D DETERMINING DISSIPATED POWER The average wattage rating of the regen resistor is a function of energy to be dissipated and the time between decelerations This average wattage rating for a single axis system 5 given by EQUATION 5 E 5 0 ers Pay t cycle Where t cycle time between time to decel sec Vuys hysteresis point of regen circuit When the time between decelerations becomes very large Equation 5 become very small In cases such as these the average wattage is not a meaningful number Peak wattage and the time which the resistor will see peak wattage become the main concerns The peak wattage of the regen resistor is Vy 2 Where

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