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XSL Manual - Copley Controls

1. 198 H 5 3 XSL RA 01 02 Discontinued Specifications 199 H 5 4 XSL RA 01 02 Discontinued Dimensions sis 199 Copley Controls Corp 193 Ordering Guide and Accessories Xenus XSL User Guide H 1 Amplifier Model Numbers Model Number Description XSL 230 18 Xenus Servoamplifier 6 18 A XSL 230 18 HL Xenus Servoamplifier 6 18 A with factory fitted low profile heatsink XSL 230 18 HS Xenus Servoamplifier 6 18 A with factory fitted standard heatsink XSL 230 36 Xenus Servoamplifier 12 36 A XSL 230 36 HL Xenus Servoamplifier 12 36 A with factory fitted low profile heatsink XSL 230 36 HS Xenus Servoamplifier 12 36 A with factory fitted standard heatsink XSL 230 40 Xenus Servoamplifier 20 40 A XSL 230 40 HL Xenus Servoamplifier 20 40 A with factory fitted low profile heatsink XSL 230 40 HS Xenus Servoamplifier 20 40 A with factory fitted standard heatsink XSL 230 18 R Xenus Servoamplifier 6 18 A with resolver feedback XSL 230 18 R HL Xenus Servoamplifier 6 18 A with resolver feedback and factory fitted low profile heatsink XSL 230 18 R HS Xenus Servoamplifier 6 18 A with resolver feedback and factory fitted standard heatsink XSL 230 R 36 Xenus Servoamplifier 12 36 A with resolver feedback XSL 230 36 R HL Xenus Servoamplifier 12 36 A with resolver feedback and factory fitted low profile heatsink
2. ServoTube Setup OK Cancel G 1 1 2 Click ServoTube Setup 9 ServoTube Setup will change your Basic Setup configuration w forthe ServoTube linear motor Do you wantto continue G 1 1 3 Click Yes The software automatically sets motor and feedback options appropriate for the ServoTube motor G 1 1 4 On the Basic Setup screen click OK 186 Copley Controls Corp Xenus XSL User Guide ServoTube Motor Setup G 1 2 ServoTube Motor Feedback Setup G 1 2 1 On the CME 2 Main screen click Motor Feedback Meere to open the Motor Feedback Rotary Motor screen Motor Feedback Linear Motor xi Motor Feedback Braketstop Manufacturer Fopley Motion Systems be Units Metric C English Series STA hd Force Constant Mass 7 8 amp E 155 kg E Back emf Constant 9 Vins had Peak Force Resistance 156 JN 1 5 ohms Continuous Force Inductance Magnetic Pole Pair Length Velocity Limit 512 mm 4400 mm s Sada ao G 1 2 2 In the Manufacturer field choose Copley Motion Systems from the pull down list G 1 2 3 In the Series field choose STA or STB to match the ServoTube motor G 1 2 4 In the Model field choose the model number to match the ServoTube motor G 1 2 5 Click the Feedback tab and verify the Analog Feedback settings defaults shown below xi Motor Feedback Brake Stop l Analog Feedback Pole Pitch 54 2 mm countsipo
3. Close 5 9 1 2 Set the input Configuration options described below Option Description Scaling Current mode output current produced by 10 Vdc of input Range 0 to 10 000 000 A Default Peak Current value Velocity mode output velocity produced by 10 Vdc of input Range 0 to 100 000 rpm mm sec Default Maximum Velocity value Position mode position change counts or mm produced by 10 Vdc of input Range 0 to 1 000 000 000 counts Default 1 Revolution of a rotary motor or 1 pole pair distance for a linear motor For more information see Scaling p 25 Dead Band Sets dead band Range 10 000 to 10 000 mV Default 0 For more information see Dead Band p 25 Invert Command Inverts polarity of amplifier output with respect to input signal Calibrate Used to offset input voltage error in an open loop system Not recommended for use when the amplifier is part of a closed loop system Range 10 000 to 10 000 mV Default 0 For more information see Offset p 26 5 9 1 3 In position mode open the Trajectory Limits tab KETTE Acl xl Configuration Trajectory Limits Profile Commanded Profile Position Acceleration p Limited Position Max Velocity 12500 rpm Max Accel 4167 rps Max Decel Po e rps Abort Decel 4167 rps Copley Controls Corp 99 Quick Setup with CME 2 Xenus XSL User Guide 5 9 1 4 In position mode set the Traje
4. Wiring 67 Wiring Xenus XSL User Guide Control J7 Mating Connectors Description Manufacturer PN Wire Size 26 Position 050 Mini D Ribbon MDR Solder Style Connector 3M 10126 3000 VE 24 30 AWG standard Molex 54306 2619 rugged 26 position 050 Mini D Connector Plug assembly 28 AWG Molded Insulation Displacement IDC style Molex 52316 2611 Boot cover Molex 52370 2610 Back shell 3M 10326 52F0 008 standard Molex 54331 0261 rugged Standard solder style connector included in Connector Kit PN XSL CK 10 foot cable assembly included in Connector Kit PN XSL CA uses molded IDC style connector NOTE For color codes see Control and Feedback Cable Color Codes p 196 Pin connections are shown here J7 loge to 26 14 68 Copley Controls Corp Xenus XSL User Guide J7 Pin Description Pin Signal Function 1 Frame Ground Cable shield connection 2 Signal Ground Signal ground reference for inputs and outputs Speed Pull Up Pull Down 3 IN1 Enable Standard Group 1 4 IN2 Standard Group 1 5 IN3 Standard Group 1 6 INA Programmable Standard Group2 7 IN6 High Group 3 8 IN7 High Group 3 9 IN8 High Group 3 10 IN9 Mode Dependant High Group 4 11 IN10 See Mode Dependant Dedicated Inputs p 70 High Group 4 12 IN11 Programmable Standard Gro
5. 152 6 10 2 Homing Functions Selttiligs 5 4214 deeds eati ctetuer ene pp ye decia eate da dan dead 152 Copley Controls Corp 121 Using CME 2 6 1 CME 2 Overview 6 1 1 Main Screen Overview Xenus XSL User Guide The CME 2 features called out in the diagram below are described in the following sections CME 2 4 0Beta2 XSL 230 40 Xenus 1 lol File Amplifier Tools Help Main Menu rr Tool Bar Taca E M ad i Copley P gt Copley Neighborhood e operational i CAN Neighborhood ES Virtual Amplifier a Information Amplifier Navigator i Functional Diagram Status Bar P gt Trap Commutation Rotary Motor 6 1 2 Tool Bar Overview Amp Software Disabled Fl2ToDisable Click on any of the tools in the toolbar to access the tools described below Icon Name Description For More Information Basic Setup Opens Basic Setup screen Basic Setup p 84 Control Panel Opens Control Panel Control Panel p 131 Auto Phase Opens Auto Phase tool Auto Phase p 105 Scope Opens Scope Scope Tool p 134 Error Log Opens Error Log Error Log p 142 Amplifier Displays basic amplifier Properties properties Save amplifier data to disk Saves contents of amplifier s volatile RAM to a disk file Restore amplifier data from disk Restores contents of an amplifier file from disk to amplifier s volatile RAM Sav
6. cliide cami n 57 Copley Controls Corp 49 Specifications 3 1 Agency Approvals e CE Compliance 89 336 EEC Electromagnetic EN 55011 Compatibility Xenus XSL User Guide EN 550082 1 98 37 EC Safety of Machinery EN 60204 1 e UL 508C 3 2 Power Input Model XSL 230 18 XSL 230 36 XSL 230 40 XSL 230 18 R XSL 230 36 R XSL 230 40 R Mains Voltage 100 240 Vac 1Sor3S Mains Frequency 47 to 63 Hz Mains Current 15 Arms maximum 20 Arms maximum Current Inrush 15 A peak at 120 Vac 35 A peak at 240 Vac Logic Supply Voltage 20 to 32 Vdc Logic Supply Current 500 mA maximum 3 3 Power Output Model XSL 230 18 XSL 230 36 XSL 230 40 XSL 230 18 R XSL 230 36 R XSL 230 40 R Peak Current 18 Adc 36 Adc 40 Adc 12 7 Arms 25 5 Arms 28 3 Arms Peak Current Time 1 Second Continuous Current 6 Adc 12 Adc 20 Adc 4 24 Arms 8 5 Arms 14 1 Arms Efficiency gt 97 230 Vac and rated continuous current Output Type 3 phase IGBT inverter 15 kHz center weighted PWM space vector modulation PWM Ripple Frequency 30 kHz Minimum Load Inductance 400 uH line to line NOTE See Xenus Filter p 173 Heat sinking and or forced air cooling required for continuous output power rating Consult factory for operation with inductance lower than 400 uH 50 Copley Controls Corp Xenus XSL User Guide 3 4 Control L
7. 1 Verify that the red indicator rotates in the same direction as the motor phase angle and that the transition occurs when the needle is between indicators 30 degrees as shown below Motor Phase Angle amp Hall State Bi an 120 60 Yo Be 0 240 300 E If the needle and Hall states do not track properly use the Hall Wiring list box shown below to swap the amplifier s Hall wire configuration y Halls Invert Input Du pv pw Hall Wiring fV U VW y Hall Offset Encoder M Invert 3 If the red indicator transition leads or lags behind the centered needle by more than 30 degrees then try adjusting the Hall Offset in 30 degree increments Hall Offset E deg 146 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 8 3 Manual Phase Instructions Resolver R Xenus 6 8 3 1 Make sure that no load is connected to the motor 6 8 3 2 Choose Tools Manual Phase to open the Manual Phase window Manual Phase E Xi Configuration j Monitor No Faults Resolver Motor Phase Angle Black Resolver Angle in Red Offset 0 deg A Resolver 121 1 50 Motor Feedback 180 0 Ange 119 deg IV Invert Input 240 300 Motor Phase Angle Odeg Motor Jj Position Q counts T Invert Output ro Actual Current U 1A V 049A W 0514A Control Increment Rate 90 elec deg s Current 18 Enable C Disable Move Motor Rev Fwd Restore Defaults OK Cancel 6 8 3 3 Enable the amp
8. Pp 1000 E Vp 800 a Cp 150 E Aff 0 zi Vi 100 zl Ci 108 z MT 16384 E oil Record Stop Trace Clear Close 225 mm NOTE During tuning observe any warnings that appear to the left of the trace 5 12 2 1 5 12 22 5 12 2 3 5 12 2 4 5 12 2 5 5 12 2 6 5 12 27 5 12 2 8 5 1229 114 Click the Scope button 8 to open the Oscilloscope window On the Function Generator tab choose Velocity from the Apply To list box On the Settings tab make sure Auto Setup is checked Auto Setup automatically sets the following options Function Tab Excitation Square Wave Amplitude 1096 of maximum velocity value Frequency 5Hz Settings Tab Channel 1 Limited velocity green Channel 2 Actual velocity white Verify that the Amplitude value is not excessive for the motor Click Start On the Gains tab adjust velocity loop proportional gain Vp 1 Set velocity loop integral gain Vi to zero 2 Raiseor lower velocity loop proportional gain Vp until desired step response is obtained Typically this means little or no overshoot on a 5 Hz small slow speed square wave Adjust velocity loop integral gain Vi until desired settling time is obtained Press Stop to stop the function generator On the Main screen click Save to Flash sal If the amplifier is to be operated in velocity mode skip the position loop setup procedures and go to Completion Steps p 119 C
9. 244 TYP H P 2X 2 75 N N NN O A Co i Y 30 TYP 25 TYP LINE A Dimensions in inches Copley Controls Corp 199 Xenus XSL User Guide P N 95 00286 000 Revision 7 June 2008 2004 2005 2006 2007 2008 Copley Controls Corporation 20 Dan Road Canton MA 02021 USA All rights reserved
10. Low Level Output Resistance 0 2 Q Function Primary function is brake control May be programmed to other functions 3 11 Encoder Power Supply Output Voltage Output 5 Vdc 2 Maximum Current Output 400 mA Short Circuit Protection Fold back current limiting Function Provides power for motor encoder and or Hall switches 3 12 Primary and Secondary Encoder Inputs Channels 3 Type Differential RS 422 line receiver w RC filter Non isolated Signals A A B B X X Input Voltage Range 7 Vdc Differential Input Threshold 0 2 Vdc Differential Input Impedance 1210 Maximum Frequency 5 MHz Line 20 Mcount sec Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation X is equivalent to Marker Index or Z channels depending on the encoder manufacturer This channel is only required in certain homing modes while under CAN control 3 13 Analog Encoder Inputs Channels 2 Type Differential non isolated Signals Sine cosine Nominal Voltage 1 Vdc pk Maximum Voltage Differential 0 6 Vdc Input to Ground 0 to 3 5 Vdc Differential Input Impedance 1210 Bandwidth 230 kHz Interpolation 1 to 256 programmable Function Incremental or analog encoder or resolver required for sinusoidal commutation and positio
11. Poulse max The maximum pulse power Viegen The voltage at which the regen circuit turns on Choose a standard value of resistance less than the calculated value This value must be greater than the minimum regen resistor value specified in Regen Circuit Output p 51 156 Copley Controls Corp Xenus XSL User Guide Regen Resistor Sizing and Configuration A 1 10 Calculate Continuous Power to be Dissipated Use the following formula to calculate the continuous power that must be dissipated by the regen resistor Use each deceleration where energy is dissipated by the regen resistor Poont E regen 1 Eregen 2 E regen JJ T cycle Where Pcont The continuous power that will be dissipated by the resistor in watts Eregen n Energy being dissipated during decelerations in joules Toycle Total cycle time in seconds Choose a resistor with a power rating equal to or greater than the calculated continuous power Verify that the calculated power value is less than the continuous regen power rating specified in Regen Circuit Output p 51 A 1 11 Select Fuses For custom regen resistors Cooper Bussman KLM fuses or equivalent should be selected The peak and continuous currents as well as the peak current time must be taken into consideration for proper fuse selection The duration of the peak current is the deceleration time Tdece1 associated with the maximum pulse power regen event Use the following formulas to determi
12. Amplitude 1 0 A Trace Time 25 mS Sample Rate 504S di Record Stop Trace clear Close NOTE During tuning observe any warnings that appear to the left of the trace Frequency 100 Hz NOTE Some users prefer the Auto Tune feature See Auto Tune Current Loop p 149 5 11 2 1 Click the Scope button B to display the Oscilloscope window 5 11 2 2 On the Function Generator tab choose Current from the Apply To list box 5 41 23 On the Settings tab make sure Auto Setup is checked Auto Setup automatically sets the following options Function Generator Tab Excitation Square Wave Amplitude 10 of continuous current setting Frequency 100 Hz Settings Tab Channel 1 Commanded current green Channel 2 Actual current white 5 11 24 Verify that the Amplitude value is not excessive for the motor 5 11 2 5 Click Start On the Gains tab adjust current loop proportional gain Cp 1 Set current loop integral gain Ci to zero 2 Raiseor lower Cp until desired step response is obtained Typically this means little or no overshoot with a 100 Hz low current square wave If the Cp value is too large ringing may occur If the Cp value is too low bandwidth decreases ia l Then enter value directly use TIP To change a value highlight the value mouse and arrow controls OR use Page Up Page Down keys to move in increments of 10 To undo a change type Ctrl Z
13. DANGER Do not ground mains connected circuits With the exception of the ground pins on J1 J2 and J3 all of the other circuits on these connectors are mains connected and must never be grounded Failure to heed this warning can cause equipment damage WARNING Do not plug or unplug connectors with power applied The connecting or disconnecting of cables while the amplifier has 24Vdc and or mains power applied is not recommended Failure to heed this warning may cause equipment damage WARNING 4 1 2 Grounding Considerations Primary Grounding Functions A grounding system has three primary functions safety voltage reference and shielding J1 3 Primary Ground The primary ground at J1 3 is the safety ground and is intended to carry the fault currents from the mains in the case of an internal failure or short circuit of electronic components This ground is connected to the amplifier chassis Wiring to this ground should be done using a conductor of the same gauge wire as that used for the mains This wire is a bonding conductor that should be connected to an earthed ground point and must not pass through any circuit interrupting devices The pin on the amplifier at J1 3 is longer than the other pins on J1 giving it a first make last break action so that the amplifier chassis is never ungrounded when the mains power is connected 60 Copley Controls Corp Xenus XSL User Guide Wiring J2 and J3 Grounds The grou
14. Each amplifier represented in the Copley Neighborhood amplifier tree has a name The default name for an amplifier is unnamed Use this procedure to rename an amplifier 6 1 7 1 Choose Main Menu Amplifier Rename to open the Rename Amplifier screen Rename Amplifier x Enter the new name for this amplifier MM OK Cancel 6 1 7 2 Enter the new name 6 1 7 3 Click OK to close the screen and save the new name or click Cancel to close the screen without saving the name Copley Controls Corp 125 Using CME 2 Xenus XSL User Guide 6 2 Manage Amplifier and Motor Data 6 2 1 Memory To maintain amplifier and motor settings the amplifier uses volatile RAM memory and non volatile flash memory Data can also be saved to disk for backup and distribution Volatile and Flash Memory Volatile memory holds status data and certain user entered information data during operation whereas flash memory permanently stores the data for loading into volatile memory at 24 Vdc power up or reset as described below Volatile Flash Contents erased when amplifier is reset or powered off Permanent Contents retained when the amplifier is reset or powered off Initial contents read from flash on 24 Vdc power up Contents then updated in real time to reflect certain operational conditions and changes entered with CME 2 Modified only by using a Save to Flash tool or by closing certain screens Motor Feedback Basic
15. Jog mode controls 6 4 2 Status Indicators and Messages The Status area includes status indicator lights described below and a message box All green lights indicate the amplifier is enabled and ready to accept motion commands Indicator States Description Motor Output State of the PWM output stage Red indicates the output stage is inactive disabled Hardware State of the hardware enable input s Red indicates one or more enable inputs are inactive Enable Software State of the software enable Red indicates the amplifier is disabled by software Enable POS Limit State of the positive limit switch input Red indicates an activated positive limit switch NEG Limit State of the negative limit switch input Red indicates an activated negative limit switch Motor Phase Indicates a motor phasing error Red indicates a motor phasing error exists CAN Network The status of the CAN Bus Yellow indicates a CAN warning limit reached Red indicates a bus error detected CVM Control Status of the CVM Control Program Indexer Program When running the Indexer program is ready to Program accept a Go command Home Indicates whether the axis has successfully been referenced homed The message box below the indicators displays the most recent active fault or warning message Copley Controls Corp 131 Using CME 2 Xenus XSL User Guide 6 4 3 Monitor Functions The Monitor area of the contr
16. Regen Circuit Protections 2 15 5 Configurable Custom Resistor E zu T i E s x 3 Specificato NS r A Ai A A een eu 3 15 Agency olo o cR 3 2 Power Input ut ET est c a zu ix y NAS O E NO AE COMMOL OOPS NEMPE 3 5 Regen Circuit Output 3 6 Digital Command Input 5 aa Re 2 Zi T e 9 7 Analog Command MPU aa rc n tte cat ie to dr nn ea lees te M doe ie tab hy ceva eoe E EXT ANS elite DO o do ra aN 3 09 Digitali ajo t ccc CE 3 9 Digital Outputs ps oe 2s is dns ES T T 9 10 Brake Output rece tee vta te e b nee OE ex tv eed o A a guod deae eer cu chew Mes va ave aia 3 11 Encoder Power S pply OUtDUEs cdit e tede Ene REIR etr eene att 3 12 Primary and Secondary Encoder Inputs 3 13 Analog Encoder Inputs is iss e bus S ne 3 14 HalESWICINpUISE zt ca me a AN RU Rd ob uh e ee aea 3 15 Resolver InterfaCe iint teer dde tee Rx Ha ds cutis EA YR EXE ERU Xa COR TER RES AAA E A XR e ZR den agree 3 16 Encoder Outputs dul T zu ix des i 3 17 Serial Interface nere ette ec tr i reed une ee AE ETUR EE EAT Ean EAA AA CAE een 3 18 GANIIMtertace A A ne 3 19 Status Indicators 3 20 Fault Levels see E ds Er n T 3 21 Power Dissipation ccc icv ded eodd ee aber by tet LA DES e bote et b ou deed etes 3 225 Thermal mpedafiCe 5 er ee ce Leod cese reete ntes tette un ese fente Le er eos Cuin ee taka Ness drei aute et 3 23 M
17. Right Angle 722 204 026 000 Wire Size 22 12 AWG Recommended Wire 12 AWG 600V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 Ground Motor frame ground and cable shield 2 W Phase W output of amplifier 3 V Phase V output of amplifier use for DC motor connection 4 U Phase U output of amplifier use for DC motor connection Brushless Motor Wiring Diagram Brushless Motor Case Ground Brush Motor Case Ground Copley Controls Corp Wiring 63 Wiring Xenus XSL User Guide 4 4 Regen Resistor J3 Optional Mating Connector Description Euro style 5 position 5 0 mm pluggable male terminal block Manufacturer PN Wago 721 605 000 043 Wire Size 22 14 AWG Recommended Wire 14 AWG 600 V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 Regen DC Bus to one side of regen resistor 2 N C No connection 3 Regen Collector of regen transistor to one side of regen resistor 4 N C No connection 5 Ground Enclosure ground and cable shield Regen Resistor Wiring Diagram Resistor Enclosure R
18. ServoTube Setup and Configuration sise 186 G 1 1 ServoTube Basic Setup Screen Options sise 186 G 1 2 ServoTube Motor Feedback Setup 187 G 1 3 Calculating ServoTube Initial Values 188 G 1 4 Setting Up the Motor Over Temperature Input 188 G 1 5 Other ServoTube I O and Fault Latching Setup Steps 188 G 2 ServoTube Auto Phase and Manual Phase c cccceeseeceeeeeeceseeeeeeeeeeecaeeeseeaeeeseaaeeeseaeeeeeeaeeeseeeeeseaeeeeeeaeeeeseeeeseieeeensaee 189 3 21 ServoTube Au to Phase utri te trous revue ae editer cessa ydg e nest e Ug pe a ER PN d eines 189 G 2 2 ServoTube Manual Phase siennes 192 G 3 Special ServoTube Setup Completion sise 192 Copley Controls Corp 185 ServoTube Motor Setup Xenus XSL User Guide G 1 ServoTube Setup and Configuration G 1 1 ServoTube Basic Setup Screen Options G 1 1 1 Click the Basic Setup button Zl to display the Basic Setup screen Basic Setup Motor Options Family Brushless C Brush Type Rotary Linear Commutation Sinusoidal C Trapezoidal Hall Type Distal y V Hall Phase Correction T Brake Use back EMF for Velocity Use halls for Velocity Position Loop Input can Encoder Motor Encoder Primary Incremental Position Encoder pl Position Encoder Type Rotary Linear Encoder Output Source Motor Encoder Position Encoder
19. XSL 230 36 R HS Xenus Servoamplifier 12 36 A with resolver feedback and factory fitted standard heatsink XSL 230 40 R Xenus Servoamplifier 20 40 A with resolver feedback XSL 230 40 R HL Xenus Servoamplifier 20 40 A with resolver feedback and factory fitted low profile heatsink XSL 230 40 R HS Xenus Servoamplifier 20 40 A with resolver feedback and factory fitted standard heatsink NOTE Heatsink kits may be ordered separately H 2 Accessory Model Numbers Software Model Description CME2 CME 2 Drive Configuration Software CD ROM CML Copley Motion Libraries CD ROM CMO Copley Motion Objects CD ROM Connector Kit with Solder Cup Feedback and Control Connectors Model Qty Ref Description Mfr Model No 1 J1 Plug 4 position 7 5 mm female Wago 721 204 026 045 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 1 J3 Plug 5 position 5 0 mm male Wago 721 605 000 043 1 J4 Plug 3 position 5 0 mm female Wago 721 103 026 047 XSL CK 4 J1 4 Tool wire insertion and extraction Wago 231 131 1 4 Connector 26 position solder cup 3M 10 10126 3000VE 1 Back shell for 26 pin connector 3M 10 10326 52F0 008 1 j Connector 20 position solder cup 3M 10 10120 3000VE 1 Back shell for 20 position connector 3M 10 10320 52F0 008 Connector Kit with Molded Cables for Feedback and Control Model Qty Ref Description Mf
20. amplifier to normal operating condition If the amplifier is receiving position commands from the digital inputs then the amplifier must be disabled and then re enabled using a hardware input or though CME 2 software commands After re enabling the amplifier will operate normally Amplifier Response to a Latched Following Error Fault When a latched following error fault occurs the amplifier disables the output PWM stage without first attempting to apply a deceleration rate Resuming Operations After a Latched Following Error Fault A latched following error fault can be cleared using the steps used to clear other latched faults e power cycle the 24 Vdc to the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel al and press Clear Faults or Reset e clear the fault over the CANopen network or serial bus Copley Controls Corp 39 Operational Theory Xenus XSL User Guide 2 11 6 Tracking Window Details Proper Tracking Over Time As described earlier position error is the difference between the limited position output of the trajectory generator and the actual position Velocity error is the difference between commanded and actual velocity When the position or velocity error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the error remains within the tracking window for the program
21. and this operation does not affect any ccx files al Restore motor data from disk Restores only motor data from a disk file with a ccm filename extension to the amplifier s flash memory Amplifier data that is not represented on the Motor Feedback screen is not affected 4 Save motor data to flash Saves the contents of the Motor Feedback screen from a buffer in the PC s RAM to the amplifiers flash memory Amplifier data that is not represented on the Motor Feedback Screen is not saved Can be used to assure that all changes are saved to flash without closing the Motor Feedback screen a Restore motor data from flash Restores only motor data from the amplifier s flash memory to the amplifier s volatile memory Amplifier data that is not represented on the Motor Feedback screen is not affected Can be used before closing the Motor Data screen to restore settings to the previously saved values To use a data management tool click the icon and respond to prompts Copley Controls Corp 127 Using CME 2 Xenus XSL User Guide 6 2 4 Quick Copy Setup Procedure Use this procedure to configure an amplifier motor pair by copying a ccx file that was prepared for the amplifier motor combination 6 2 4 1 6 2 4 2 6 2 4 3 6 2 4 4 6 2 4 5 128 Make sure the amplifier is connected to the PC using the J5 RS 232 connector For wiring instructions see RS 232 Serial Communications J5
22. depend upon the load inertia and peak current Min 0 Default 0 5 x velocity loop Accel Limit value Position Mode and Position Loop p 24 Abort Decel Deceleration rate used by the trajectory generator when motion is aborted Min 0 Default 0 5 x velocity loop Accel Limit value See Brake Operation p 33 5 9 3 5 Click Close 5 9 3 6 Click Save to Flash sal 5 9 3 7 Proceed to Auto Phase p 105 Copley Controls Corp 103 Quick Setup with CME 2 Xenus XSL User Guide 5 9 4 CAN Interface For more information see CAN Addressing p 31 5 9 4 1 Verify that the following connections are wired according to the instructions in CAN Bus J6 p 67 1 J6 CAN CANopen cable 2 J6 CAN Termination plug 5 9 4 2 Click CAN Configuration temen to open the CAN Configuration screen If CAN is not the Position Loop Input choose Amplifier CAN Configuration instead x Address Configuration Input Mapping Number of inputs 4 E o El E Use Switch ero fn 1 F use Inputs B ws gt E v Use Programmed Value B2 fms x o era ns 1 Input Lines Value 1 Bit4 None x Programmed value 1 Ets None y x New resulting address 12 Bt6 None y X OK Cancel 5 9 4 3 Choose a Bit Rate Help 5 9 4 4 Check the appropriate buttons to choose any combination of address sources Switch Inputs and Programmed Value The address is the sum of the val
23. or velocity loop velocity limit values are not optimal for the application change these limits during the tuning process Load the values into volatile memory by clicking OK OR to close the screen without saving changes click Cancel NOTE If the motor wiring configuration in the motor file does not match the configuration currently stored in the amplifier CME prompts for verification on which configuration to use Select the file configuration by clicking Yes The configuration will be tested later in Auto Phase p 105 Click Save to Flash Si Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 8 Amplifier Configuration 5 8 1 Digital Inputs 5 8 1 1 Click Input Output Lees on the Main screen to open the nput Output screen Red light inhibited motion or active input depending on input function Grey light motion not inhibited No light not configured Lo Hi Indicates state of output Input Output Digital Inputs 6 12 Digital Outputs Debounce time CAN address IN 1 amp Enable LO Enables With Clear Faults V 0 mS Lo Pull up 5Y C Pull down IN2 Not Configured v o mS Hi BIT 0 IN3 vet Configured Y 0 mS Hi BIT 1 Pulup 5v INA Not Configured 0 mS Lo BIT 2 C Pull down INS Not Cc Configured 0 mS Hi BIT 3 Restore Defaults Indicates input is used as a CAN address bit 5 8 12 Enter the following options Opt
24. p 66 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop da tess CME 2 Gicme 2 4 0 Beta 9 Engineering Release 6 XSL 230 40 Xenus 1 nl xj File Amplifier Tools Help Gy wd CiBE E uad mia cd EHH Copley Neighborhood lifier CAN Network Address 12 State Pre operational No Hall Sine Commutation Rotary Motor On the Main screen click Restore amplifier data from disk al When prompted navigate to the folder containing the appropriate ccx file Highlight the file name and then click Open to load the file data into volatile memory On the Main screen click Save to Flash adi to commit the new settings to flash memory Copley Controls Corp Xenus XSL User Guide Using CME 2 6 3 Downloading Firmware 6 3 1 6 3 1 1 6 3 1 2 6 3 1 3 6 3 1 4 6 3 1 5 Acquiring Firmware from Web Site Optional In an internet browser navigate to http Awww copleycontrols com Motion Downloads firmware html Click on the appropriate firmware name When prompted save the file to the Firmware Image folder in the CME 2 installation folder The default installation folder is C Program Files Copley Motion CME 2 Firmwarelmage The folder should now contain a file named Xenus_Firmware zip Extract the contents of the zip file to the same location The folder should now contain the files Xenus_Firmware zip and the latest cff file If desired delete Xenus_Firmware zip to
25. 2 6 Click Cancel to close the screen without saving the settings 152 Copley Controls Corp APPENDIX A REGEN RESISTOR SIZING AND CONFIGURATION This chapter describes the formulas used to determine if a regen resistor is required and what the optimal resistor characteristics would be for a given application For an overview of regeneration and regen resistors see Regen Resistor Theory p 47 The contents of this chapter include Title Page AT Sizing a Regen Resistot M 154 A 2 Configuring Custom Regen Resistor 1 es edet la cil lea dean poe epu gp dre une 158 Copley Controls Corp 153 Regen Resistor Sizing and Configuration Xenus XSL User Guide A 1 Sizing a Regen Resistor A 1 1 Gather Required Information Calculating the power and resistance of the regen resistor requires information about the amplifier and the rotary or linear motor application A 1 1 1 For all applications gather the following information 1 Details of the complete motion profile including times and velocities 2 Amplifier model number 3 Applied line voltage to the amplifier 4 Torque constant of the motor 5 Resistance line to line of the motor windings A 1 1 2 For rotary motor applications gather this additional information 1 Loadinertia seen by the motor 2 Inertia of the motor A 1 1 3 For linear motor applications gather this additional information 1 Mas
26. Adjust position proportional gain Pp to minimize following error Note that too much position loop proportional gain Pp might cause oscillation 1 Onthe Gains tab set velocity feed forward Vff and acceleration feed forward Aff to zero 2 On the Profile tab click Start On the Gains tab adjust position loop proportional gain Pp until best result is obtained 3 Click Start after each adjustment to test the new value on a new profile move NOTE If a following error occurs open the CME 2 Control Panel 55 and click Clear Faults 5 13 2 4 Adjust velocity feed forward Vff Velocity feed forward Vff reduces following error in the constant velocity portion of the profile Often a velocity feed forward Vff value of 16384 10096 provides best results 1 Click in the Vff field and adjust the value 2 Click Start after each adjustment to test the new value on a new profile move 5 13 25 Adjust acceleration feed forward Aff Acceleration feed forward Aff reduces following error during profile acceleration and deceleration 1 Click in the Aff field and adjust the value 2 Click Start after each adjustment to test the new value on a new profile move NOTES 1 If after tuning the position loop the motor makes a low frequency audible noise while enabled but not moving the velocity loop gains Vp and Vi may be lowered to reduce the noise If the gain values are set too low the response to instantaneous rates of chang
27. Check for mechanical jamming 5 10 5 3 Check for smooth motion with no mechanical jerking 5 10 5 4 Check for good connections to the motor power wires 5 10 5 5 Disconnect motor power wires 5 10 5 6 Measure for proper motor resistance 5 10 6 Trouble Shoot Halls Wiring Setup If Halls wiring setup step failed 5 10 6 1 Check Halls power and signals 5 10 6 2 Check for smooth motion with no mechanical jerking 5 10 6 3 Check shielding for proper grounding 5 10 7 Other Problems If the auto phase procedure fails despite these corrective measures see Manual Phasing p 145 Copley Controls Corp 109 Quick Setup with CME 2 Xenus XSL User Guide 5 11 Current Loop Initial current loop proportional gain Cp and current loop integral gain Ci values were calculated in a previous step For an introductory overview of the control loops see Operating Modes p 19 NOTE For Copley Controls digital amplifiers the current loop gain is independent of the power supply voltage 5 11 1 Current Loop Settings For more information see Current Mode and Current Loop p 20 5 11 1 1 5 11 12 110 Click Current Loop am to open the Current Loop screen KS current Loop Current Commanded Current Peak Current Limit FT Time Limit Continuous Current Limit Current Loop Offset 101 x Correcting Torque 13 95 EA Cp 897 E 1000 mS EZ E 468 A ro Auto Tune Set the follow
28. Copley Controls Corp 111 Quick Setup with CME 2 Xenus XSL User Guide 5 41 26 Adjust current loop integral gain Ci until desired settling time is obtained 51127 Press Stop to stop the function generator 5 11 2 8 On the Main screen click Save to Flash sal 5 1129 If the amplifier is to be operated in current mode skip the velocity and position loop setup procedures and go to Completion Steps p 119 112 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 12 Velocity Loop Initial velocity loop proportional gain Vp and velocity loop integral gain Vi values were calculated in a previous step 5 12 1 Velocity Loop Settings For more information see Velocity Mode and Velocity Loop p 22 5 12 121 5 1212 Click V Loop xem to open the Velocity Loop screen velocity Loop 101 xd nded ent Commanded Comma Puls t a E a Vel Limit 25000 rpm Tracking Window 343322 75 rpm Time 100 mS Actual poe Accel Limit 3333 ps vp EE Output Fitter Decel Limi 8333 Has v MES Fast Stop Ramp 8333 tps IV Enable Gains Scalar Command Fitter Close Enter the following options as needed Option Description Velocity Limit Top speed limit Max value may depend upon the back EMF amp the Encoder value Min value 0 Acceleration Limit Maximum acceleration rate Max value may depend upon load inertia amp peak current Min value 1 Does not ap
29. Duty Cycle PWM Input Direction Input Amplifier Output 0 Min Failsafe Protection from 0 or 100 Duty Cycle Commands In both formats the amplifier can be programmed to interpret O or 10096 duty cycle as a zero command This provides a measure of safety in case of a controller failure or a cable break Copley Controls Corp 27 Operational Theory Xenus XSL User Guide 2 5 8 Digital Input Three Formats In position mode the amplifier can accept position commands via two digital inputs using one of these signal formats pulse and direction count up count down and quadrature In all three formats the amplifier can be configured to invert the command Pulse Smoothing In position mode the amplifier s trajectory generator ensures smooth motion even when the command source cannot control acceleration and deceleration rates When using digital or analog command inputs the trajectory generator can be disabled by setting the Max Accel limit to zero Note that when using the CAN bus serial bus or CVM Control Program setting Max Accel to zero prevents motion Pulse and Direction Format In pulse and direction format one input takes a series of pulses as motion step commands and another input takes a high or low signal as a direction command as shown below Pulse Input CID Pill Direction Input Velocity Command The amplifier can be set to increment position on the rising or
30. Files p 141 1 0 Line States Opens I O Line States window Help Using CME 2 with Overview of CME 2 and guide to quick setup of amplifier Xenus Downloads Web Page Software Web Page Opens default web browser with relevant pages from Copley Controls website View Release Notes Opens latest CME 2 release notes in a text viewer About Displays CME 2 version information Copley Controls Corp 123 Using CME 2 Xenus XSL User Guide 6 1 4 Functional Diagram The functional diagram shown below provides button click access to most of the screens used to configure an amplifier It also indicates the flow of control from input across all active control loops to motor feedback Only those control loop buttons that are appropriate to the operational mode appear on the diagram Control Loops Name Description For More Information Opens Input Output screen Theory Inputs p 42 and Outputs p 44 Input Output Programming instructions Amplifier Configuration p 93 CVM Control Opens Copley Virtual Machine Copley Indexer Program User Guide Program Screen Input Command Configure the input command Button label varies depending on the selected control loop input Button not present when amplifier programmed to use CVM Control Program for Control Loop Input Otherwise the button will be labeled with one of the following CAN Configuration Digital Position Inputs Fun
31. Limits of Motion Stage A Negative Home Positive Limit Switch Limit Sw itch Sw itch 2 7 3 How the Amplifier Responds to Limit Switch Activation The amplifier stops any motion in the direction of an active limit switch as described below The response is identical in current and velocity modes and slightly different in position mode Mode Amplifier Response to Active Positive or Negative Limit Switch Current Amplifier prohibits travel in positive or negative direction Travel in the opposite direction is still allowed Velocity Amplifier status indicator flashes green at fast rate Warning is displayed on CME 2 Control Panel and CME 2 Control Panel limit indicator turns red Position Amplifier stops responding to position commands until the amplifier is disabled and re enabled or the fault is cleared over the CANopen interface Amplifier status indicator flashes green at fast rate Warning is displayed on CME 2 Control Panel and CME 2 Control Panel limit indicator turns red If after re enabling the amp the limit switch is still active the amplifier will only allow movement in the opposite direction 2 7 4 Using Custom Output to Signal Limit Switch Activation In addition to the response described above any of the amplifier s digital outputs can be configured to go active when a positive or negative limit switch is activated For more information see Custom Output Functions p 45 32 Copley Con
32. One or more serial ports on a PC can be used to connect amplifiers Use the following instructions to add enable ports for amplifiers to choose baud rates for those ports and to remove disable ports for amplifiers 5 2 4 1 5 2 4 2 5 2 4 3 80 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop If a serial port has not been selected the Select Devices screen appears communications Wizard 4 x Select Devices Add the communications devices you wantto use by selecting them from the Available Devices list on the left then pressing Add or Add All You may remove devices by selecting them from the Selected Devices box on the right then pressing the Remove button Press Nextto continue or Cancel to exit the Wizard Available Devices Selected Devices au COM3 Add All gt lt Remove Next If the CME 2 Main screen appears instead of Select Devices choose Tools Communications Wizard cme 2 v3 0 File Amplifier Communications Lo ea Copley Neighb a 0g LR Virtual a Wowhidad FTTIWATE Mannal Phase From the Available Devices list on the Select Devices screen choose the serial ports that will be used to connect to amplifiers 1 Toallow connection of an amplifier through a port highlight the port name and click Add or click Add All to enable all available ports 2 Toremove a port from the Selected Devices list highlight the port name and click Remove
33. Setup Homing or CAN Configuration whose contents are automatically software At any time the user can use CME 2 to restore certain data from flash into volatile memory saved to flash upon closing of the screen How the Amplifier Uses Volatile and Flash Memory As described below some data resides in flash only some in volatile memory only and some in both Data Resides In Data This category includes all data represented on the Motor Feedback screen Basic Setup screen and CAN Configuration screen This data is automatically saved to flash as soon as its entry is confirmed when the user clicks the appropriate Save to Flash button or closes the screen Flash only Flash and Volatile Includes all user entered data represented on other screens such as gains limits and I O faults and regen settings Initial values for this data are factory set in flash They are loaded from flash to volatile memory with each 24 Vdc power up or amplifier reset This data is saved to flash only when a user clicks the appropriate Save to Flash button It is flushed from volatile memory with each 24 Vdc power down or amplifier reset Includes operating status data such as actual position actual current and amplifier temperature Such data is never stored in flash It is flushed from volatile memory with each 24 Vdc power down or amplifier reset Volatile only 6 2 2 Disk Storage Amplifier Data Files an
34. Start to begin the Halls wiring setup The message area displays the messages Microstepping Test Complete Motor has been properly phased During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate The field produced should push on the permanent magnet s magnetic field causing the motor to move As the motor moves the Hall lines are decoded for proper commutation If the step fails see Trouble Shoot Halls Wiring Setup p 109 Copley Controls Corp 107 Quick Setup with CME 2 5 10 2 11 5 10 2 12 5 10 2 13 5 10 2 14 5 10 2 15 108 For a resolver R version of Xenus click Next to open the Resolver Phase Angle Setup screen x Resolver Phase Angle Setup Resolver angle in red Commanded Position your motor in center ofits range motor phase angle in black The software will now micro step the motor Make sure the motor is free to move Press Start when ready 120 60 Auto Phase Current 284 180 0 Ett 240 300 Offset 0 deg Resolver Angle 119 deg Testing Phase Angle Motor Actual Position 11 counts lt Back Finish Cancel Click Start to start the resolver phase angle setup The message area displays status messages Click Finish to close the screen and save values to flash memory OR to close the screen without saving changes click Cancel If the Auto Phase algorithm does not produce desired results try adjusting the Auto Ph
35. The magnitude of the command generated by an input signal is proportional to the input signal voltage Scaling controls the input to command ratio allowing the use of an optimal command range for any given input voltage signal range For example in current mode with default scaling 10 Vdc of input generates a command equal to the amplifier s peak current output 5 Vdc equals half of that Scaling could also be useful if for example the signal source generates a signal range between 0 and 10 Vdc but the command range only requires 7 5 Vdc of input In this case scaling allows the amplifier to equate 7 5 Vdc with the amplifier s peak current in current mode or maximum velocity in velocity mode increasing the resolution of control Dead Band To protect against unintended response to low level line noise or interference the amplifier can be programmed with a dead band to condition the response to the input signal voltage The Copley Controls Corp 25 Operational Theory Xenus XSL User Guide amplifier treats anything within the dead band ranges as zero and subtracts the dead band value from all other values For instance with a dead band of 100 mV the amplifier ignores signals between 100 mV and 100 mV and treats 101 mV as 1 mV 200 mV as 100 mV and so on 200 100 Dead Band Output e 100 200 200 100 0 100 200 Input Offset To remove the effects of voltage offsets between the controller a
36. a E operation at E 1 No Heatsink lt 55 C lt 20 20 1 2 3 4 5 6 1 2 3 4 5 6 Continuous Output Current Adc Continuous Output Current Adc Model XSL 230 36 XSL 230 36 R Mains 120 Vac Mains 240 Vac 60 60 5 5 Standard cal Standard Heatsink w fan Heatsink w fan 50 3 Low Profile 50 Heatsink w fan Low Profile Heatsink w fan 2 i F 40 Low Profile Heatsink 40 Low Profile Heatsink or no Heatsink w fan or no Heatsink w fan 1 Standard Standard 30 Heatsink 30 Heatsink 1 No Heatsink 1 No Heatsink Ambient Temperature C Ambient Temperature C 20 20 1234567 89101112 1234567 89101112 Continuous Output Current Adc Continuous Output Current Adc Model XSL 230 40 XSL 230 40 R Mains 120 Vac Mains 240 Vac 60 60 Standard ue 5 Standard o Heatsink w fan o Heatsink w fan o 50 Low Profile g 50 Low Profile 2 Heatsink w fan 2 Heatsink w fan D Low Profile Heatsink Low Profile Heatsink 40 or no Heatsink w fan E 40 or no Heatsink w fan o o E Standard E Standard E 30 1 Heatsink E 30 Heatsink E 1 No Heatsink E 1 No Heatsink 20 20 2 4 6 8 10 12 14 16 18 20 2 4 6 8 10 12 14 16 18 20 Continuous Output Current Adc Continuous Output Current Adc The various cooling configura
37. an RS232 serial link with simple ASCII format commands Mains input voltage to the amplifier can range from 100 to 240 Vac single or three phase and 47 to 63 Hz This allows Xenus the ability to work in the widest possible range of industrial settings Several models are available with peak current ratings of 18 to 40 amps Model Continuous Peak Vac Encoder Resolver Current Current XSL 230 18 XSL 230 18 R 6A 18A XSL 230 36 XSL 230 36 R 12A 36A bo XSL 230 40 XSL 230 40 R 20A 40A A separate 24 Vdc logic supply powers the internal logic and control circuits These are isolated from the high voltage power supply and inverter stage that connect to the mains This simplifies system design by allowing the mains to be completely disconnected from the amplifier for safety reasons but allows the logic side of the amplifier to stay powered This allows the amplifier to retain position information and maintain communication through the digital I O or over the serial or CAN ports when disconnected from the mains 12 Copley Controls Corp Xenus XSL User Guide Introduction 1 2 CME 2 Amplifier commissioning is fast and simple using Copley Controls CME 2 software CME 2 communicates with Xenus via an RS 232 link and all of the operations needed to configure the amplifier are accessible through CME 2 The multi drop feature allows CME 2 to a single RS 232 serial connection to one amplifier as a
38. axes set the CAN node address of the serially connected amplifier gateway to zero 0 Assign each additional amplifier in the chain a unique CAN node address value between 1 and 127 For more information on CAN node address assignment see CAN Addressing p 31 and CAN Interface p 104 Use 120 Ohms termination on the first and last amplifier TERMINATION MUST BE 120 Ohm USED ON FIRST AND LAST Terminator NODE Serial A PC PLC or HMI g SER CK Serial Cable Kit for ASCII Control COM port 9pin D sub RJ11 for RS 232 Copley Amplifier with ASCII RS 232 CAN Network Cable UTP CAT 5E Gigabit Ethernet RJ45 RJ45 CAN Port ADDRESSES MUST BE 120 Ohm SET BEFORE POWER UP Terminator OR RESET 184 Copley Controls Corp APPENDIX G SERVOTUBE MOTOR SETUP This chapter describes the special subset of steps involved in setting up an amplifier to drive a Copley Controls ServoTube motor Before performing the steps in this chapter the reader should have performed a set of steps detailed in the beginning of Quick Setup with CME 2 p 77 jumping to this chapter as instructed See the jump point at Basic Setup p 84 At the end of this chapter the reader will be instructed to return to the proper location in Quick Setup with CME 2 The return point is Current Loop p 110 Contents of this chapter include G 1
39. been exceeded Amplifier is reset and re enabled Latched by default Copley Controls Corp 37 Operational Theory Xenus XSL User Guide 2 11 Position and Velocity Errors 2 11 1 Error Handling Methods In position mode any difference between the limited position output of the trajectory generator and the actual motor position is a position error The amplifier s position loop uses complementary methods for handling position errors following error fault following error warning and a position tracking window Likewise in velocity or position mode any difference between the limited velocity command and actual velocity is a velocity error The amplifier s velocity loop uses a velocity tracking window method to handle velocity errors There is no velocity error fault 2 11 2 Following Error Faults When the position error reaches the programmed fault threshold the amplifier immediately faults The following error fault can be disabled For detailed information see Following Error Fault Details p 39 2 11 3 Following Error Warnings When the position error reaches the programmed warning threshold the amplifier immediately sets the following error warning bit in the status word This bit can be read over the CAN network It can also be used to activate a digital output 2 11 4 Position and Velocity Tracking Windows When the position error exceeds the programmed tracking window value a status word
40. been disabled In velocity mode amplifier is using the Fast Stop Ramp described in Velocity Loop Limits p 22 In position mode the amplifier is using the Abort Deceleration rate described in Trajectory Limits p 24 The output remains active until the amplifier is re enabled Motor Brake Activated Motor brake activated See Brake Operation p 33 for more information PWM Outputs Disabled The amplifier s PWM outputs are disabled Home Switch is Active Axis has contacted the home limit switch Not Settled The motor is moving or it has not yet settled after a move The amplifier is settled when it comes within the position tracking window and stays there for the tracking time at the end of a move Once settled it remains settled until a new move is started 46 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 15 Regen Resistor Theory 2 15 1 Regeneration When a load is accelerated electrical energy is converted into mechanical energy During deceleration the conversion is reversed This is called regeneration Some of this regenerated energy is lost to friction in the mechanical system More of this energy is converted to heat due to I R losses in the motor windings cabling and drive electronics The remainder of the energy is added to the electrical energy already stored in the internal capacitor bank of the amplifier The result of this energy being added is an i
41. bit is set The bit is not reset until the position error remains within the tracking window for the programmed tracking time A similar method is used to handle velocity errors For detailed information see Tracking Window Details p 40 38 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 11 5 Following Error Fault Details Position Error Reaches Fault Level As described earlier position error is the difference between the limited position output of the trajectory generator and the actual position When position error reaches the programmed Following Error Fault level the amplifier faults unless the following error fault is disabled As with a warning a status bit is set In addition the fault is recorded in the error log Additional responses and considerations depend on whether the fault is non latched or latched as described below Amplifier Response to Non Latched Following Error Fault When a non latched following error fault occurs the amplifier drops into velocity mode and applies the Fast Stop Ramp deceleration rate to bring the motor to a halt The amplifier PWM output stage remains enabled and the amplifier holds the velocity at zero using the velocity loop Resuming Operations After a Non Latched Following Error Fault The clearing of a non latched following error depends on the amplifier s mode of operation Issuing a new trajectory command over the CAN or serial bus will clear the fault and return the
42. calculated profile in real time as additional position commands are received The output of the generator is an instantaneous position command limited position In addition values for the instantaneous profile velocity and acceleration are generated These signals along with the actual position feedback are processed by the position loop to generate a velocity command When using digital or analog command inputs the trajectory generator can be disabled by setting the Max Accel limit to zero Note that when using the CAN bus serial bus or CVM Control Program setting Max Accel to zero prevents motion The following diagram summarizes the position loop Position Loop Velocity Feed Forw ard Vff Profile Velocity Target Position Trajectory i i Generator OMS GEBIBITUGIRT Acceleration Feed Forw ard Aff Mile ae rae Limited Position Position Proportional Gain Pp Limits e Max velocity e Max accel Max decel e Abort decel Feedback O from motor encoder or resolver Od from optional position encoder on load Trajectory Limits In position mode the trajectory generator applies the following user set limits to generate the motion profile Limiter Description Maximum Velocity Limits the maximum speed of the profile Maximum Acceleration Limits the maximum acceleration rate of the profile Maximum Deceleration Limits the maximum decele
43. ea m m y A O NN ON ZWMEPOsition and Velocity Errors oc ert DH eve A ae a 2 11 1 Error Handling Methods 2 11 2 Following Error Faults ae 2 11 3 Following Error Warnings 2 11 4 Position and Velocity Tracking Windows 2 11 5 Following Error Fault Details E is b ua si 2 11 6 Tracking Window Deltalils 3 252 o ferr eee pdt LO Roe petita bead Pedo Ge Acasa tee ud 2 12 Communication 5 3 fi rior A e YU YEARS EC ee ves o dc T e det C n ETUR Ai 2 12 1 Communication Interfaces 2 12 2 CME 2 and CAN Operation 2 13 Inputs ie 2 13 1 Digital Inputs 2 13 2 Input Filters NS M e ot ais is Ne 2 13 3 D bounce TIME O em arcade OE een St ea teen sx den ane edu Dre reve con du A 2 13 4 Configure for Pull Up Pull Down Resistors by Groups Programmable Input Functions sssuusse 2 14 2 14 2 Standard Programmable Output Functions Copley Controls Corp 3 Table of Contents Xenus XSL User Guide 2 14 3 Custom Output FUN CUONS lt a are den Eae EE A ee eso 45 219 Regen ResistOr T DIGOF y att tarot A Edi 47 2 15 1 Regeneration v Ne E MS us x xe 2 15 2 Regen ResistoF oerte EHE eod eu cb std ee ie tates tL ino ear ee ob eoe ve e aod Dae eee ote ee eas 2 15 3 Regen Circuit Components RRE setis ennenss sinet ennt tenis sre 2 15 4
44. ege Ye dba d 18 2 3 Commutation Modes ys 2 4 Feedback 2 5 Operating Modes 2 6 CANopen Operation 2 7 LIME Wii dario our ee p Dresd ye de Ia ae tem boss 2 8 Brake Operation 2 9 Status Indicators 2 10 Protection a 2 11 Position and Velocity EITOIS root trn ornetur ern hn nen entera o cacesvooushexsanaiiusiedeaaudedanaidisdeusnecusichs oxsvaitnasdsnesadedeee 38 rupes 41 2 13 Inputs 2 14 Outputs sis 2 15 Regen Resistor THEO D 47 Copley Controls Corp 15 Operational Theory Xenus XSL User Guide 2 1 Amplifier Internal Power Power distribution within Xenus is divided into three sections 24 Vdc logic signal and high voltage Each is isolated from the other 2 1 1 Logic Signal Power An internal DC DC converter operates from the 24 Vdc Logic Supply input and creates the required logic signal operating voltages the isolated voltages required for the high voltage control circuits and a 5 Vdc supply for powering the motor encoder and Hall circuits All the digital and analog inputs digital outputs with the exception of OUT4 Hall and encoder inputs are referenced to the same signal common OUTA is controlled through an opto isolator and is referenced to the 24 Vdc return The CAN interface is also optically isolated Deriving internal operating
45. from Web Optional 5 2 2 1 Choose or create a folder where you will download the software installation file 5222 In an internet browser navigate to http Awww copleycontrols com Motion Downloads index html 5 2 2 3 Under Software Releases click on CME 2 5 2 2 4 When prompted save the CME2 zip file to the folder chosen or created in Step 5 2 2 1 The folder should now contain a file named CME2 zip 5 2 25 Extract the contents of the zip file to the same location The folder should now contain the files CME2 zip and Setup exe 5 2 2 6 If desired delete CME2 zip to save disk space 5 2 3 Installing CME 2 Software 5 2 3 1 If installing from a CD insert the CD Copley Controls part number CME2 Normally inserting the CD causes the installation script to launch and a CME 2 Installation screen appears If so skip to Step 5 2 3 3 5 2 3 2 If the software installation file was downloaded from the Copley Controls website navigate to the folder chosen or created in Step 5 2 2 1 and then double click on Setup exe OR if you inserted the CD and the CME 2 nstallation screen did not appear navigate to the root directory of the installation CD and then double click on Setup exe 52 33 Respond to the prompts on the CME 2 Installation screens to complete the installation We recommend accepting all default installation values Copley Controls Corp 79 Quick Setup with CME 2 Xenus XSL User Guide 5 2 4 Serial Port Setup
46. gains appropriate to the operating mode as described below Modes Gains Description For More Information 7 Pp Position loop proportional gain a mode Aff Acceleration feed forward Trajectory Limits p 24 Vff Velocity feed forward Position or Vp Velocity loop proportional gain rcd mode Vi Velocity loop integral gain Velocity Loop Gains p 23 Cp Current loop proportional gain All modes Current Loop Gains p 21 Ci Current loop integral gain Copley Controls Corp 139 Using CME 2 Xenus XSL User Guide Trajectory Limits Tab In position mode the Trajectory Limits tab can be used to set trajectory limits Position Params vetocity Params Maximum Velocity 3000 rpm Maximum Acceleration 800 rps Maximum Jerk 100 rps For more information on the velocity and acceleration limits see Trajectory Limits p 24 For more information on the Maximum Jerk setting see Test S Curve Profile p 118 and Maximum Jerk p 118 Position Loop Parameters In position mode the Position Params tab can be used to set position loop parameters Settings Gains Trajectory Limits Velocity Params Position Tracking Window 10 counts Actual Position 619309 counts Set Zero Position Time 10ms _SetzZer0Positon Following Error 4000 counts Disable Following Error Fault Set Zero Position sets the amplifier s actual position count to zero F
47. given a value to which it will attempt to control For example the velocity loop receives a velocity command that is the desired motor speed Limits Limits are set on each loop to protect the motor and or mechanical system Feedback The nature of servo control loops is that they receive feedback from the device they are controlling For example the position loop uses the actual motor position as feedback Gains These are constant values that are used in the mathematical equation of the servo loop The values of these gains can be adjusted during amplifier setup to improve the loop performance Adjusting these values is often referred to as tuning the loop Output The loop generates a control signal This signal can be used as the command signal to another control loop or the input to a power amplifier Copley Controls Corp 19 Operational Theory Xenus XSL User Guide 2 5 2 Current Mode and Current Loop Current Loop Diagram As shown below the front end of the current loop is a limiting stage The limiting stage accepts a current command applies limits and passes a limited current command to the summing junction The summing junction takes the commanded current subtracts the actual current represented by the feedback signal and produces an error signal This error signal is then processed using the integral and proportional gains to produce a command This command is then applied to the amplifier s power s
48. selected will use transitions of the Hall switches to determine motor Velocity velocity ServoTube Setup Configures amplifier for ServoTube operation See ServoTube Motor Setup p 185 84 Copley Controls Corp Xenus XSL User Guide 5 4 1 4 5 4 1 5 5 4 1 6 Quick Setup with CME 2 Enter basic System options described below Setting Description Operating Choose the mode of operation See Operating Modes p 19 Mode e Current e Velocity e Position Loop Input Choose the command input source See Input Command Types p 25 e Analog command e PWM command current and velocity mode only e Function generator e CVM Control Program e Digital Input position mode only e CAN position mode only See CANopen Operation p 30 Enter Feedback Options described below Setting Description Motor Select type and source of motor feedback Encoder e None No motor feedback e Primary Incremental ncremental encoder on J8 e Secondary Incremental Incremental encoder on J7 e Analog Analog encoder on J8 e Low Frequency Analog Copley ServoTube motor on J8 e Resolver Resolver version only Resolver on J7 Position Select type and source of Position load feedback Encoder e Primary Incremental Incremental encoder on J8 e Secondary Incremental Incremental encoder on J7 e Analog Analog encoder on J8 Position Select the type of Posit
49. the RMS value of the output current and thus operates the same way regardless of the output current frequency and wave shape PT current limit 16 14 hb AA commanded 124 L 9 e 4 actual amp 10 S 8 a 6 4 2 0 0 1 2 3 4 5 6 7 Time S A PT Accumulator 120 100 lt 80 3 60 PT Setpoint o FT Accumulator c 40 o E 20 0 0 1 2 3 4 5 6 7 Time S B At time 0 plot diagram A shows that the actual output current follows the commanded current Note that the current is higher than the continuous current limit setting of 6 A Under this condition the T Accumulator Variable begins increasing from its initial value of zero Initially the output current linearly increases from 6 A up to 12 A over the course of 1 2 seconds During this same period the I T Accumulator Variable increases in a non linear fashion because of its dependence on the square of the current At about 1 6 seconds the IT Accumulator Variable reaches a values equal to the I T setpoint At this time the amplifier limits the output current to the continuous current limit even though the commanded current remains at 12 A The I T Accumulator Variable value remains constant during 164 Copley Controls Corp Xenus XSL User Guide T Time Limit Algorithm the next 2 seconds since the difference between the actual output current and the continuous current li
50. the motor before it must be reduced to the continuous limit or generate a fault For more details see I T Time Limit Algorithm p 161 Note Although the current limits set by the user may exceed the amplifier s internal limits the amplifier operates using both sets of limits in parallel and therefore will not exceed its own internal limits regardless of the values programmed Ramp Rate of change in current command Used to limit jog moves initiated from the Control Panel Jog function in current mode and in advanced Indexer Program functions 20 Copley Controls Corp Xenus XSL User Guide Current Loop Gains Operational Theory The current loop uses these gains Gain Description Cp Current loop proportional The current error the difference between the actual and the limited commanded current is multiplied by this value The primary effect of this gain is to increase bandwidth or decrease the step response time as the gain is increased Ci Current loop integral The integral of the current error is multiplied by this value Integral gain reduces the current error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the current error value over time Current Loop Output The output of the current loop is a command that sets the duty cycle of the PWM output stage of the amplifier
51. the trigger event on the screen Value is not configurable for Immediate Function Generator or Move Start trigger types e Left for optimal viewing of events following the trigger e Middle for optimal viewing of events preceding and following the trigger e Right for optimal viewing of events preceding the trigger Level Sets the trigger level The Level is expressed in units appropriate to the channel selected Auto Trigger The Auto Trigger option automatically sets the trigger type to Function Generator or Move Start depending on which generator is being used Note that Auto Trigger is automatically set check in box when Auto Setup is set Trace Time and Sample Rate Trace Time sets the length of the recorded trace Sample Rate is the rate at which the signals are sampled The rate depends on the trace time the number of channels selected and which variables are being traced Single Trace Single Trace puts the scope in a single trace mode of operation In this mode the trigger is not re armed after a trace until the user presses the Record button Single Trace is automatically set by the generators in certain cases Copley Controls Corp 137 Using CME 2 Xenus XSL User Guide Scope Display Options The user can set the line style and other scope screen preferences Right click on the scope screen to display the menus as shown below KE Oscilloscope Trace Status Waiting for trigger position dela
52. this value The primary effect of this gain is to decrease following error during acceleration and deceleration Gain Multiplier The output of the position loop is multiplied by this value before being passed to the velocity loop Position Loop Feedback Xenus supports two position feedback configurations e Single sensor Position loop feedback comes from the encoder or resolver on the motor e Dual sensor Position loop feedback comes from the encoder attached to the load Note that in either case velocity loop feedback comes from the motor encoder or resolver For more information see Feedback p 18 Position Loop Output The output of the position loop is a velocity command used as the input to the velocity loop 2 5 5 Input Command Types The amplifier can be controlled by a variety of external sources analog voltage or digital inputs CAN network or over an RS 232 serial connection using ASCII commands The amplifier can also function as a stand alone motion controller running an internal CVM program or using its internal function generator 2 5 6 Analog Command Input Overview The amplifier can be driven by an analog voltage signal through the analog command input The amplifier converts the signal to a current velocity or position command as appropriate for current velocity or position mode operation respectively The analog input signal is conditioned by the scaling dead band and offset settings Scaling
53. voltages from a separate source enables the amplifier to stay on line when the mains have been disconnected for emergency stop or operator intervention conditions This allows CAN bus and serial communications to remain active so that the amplifier can be monitored by the control system while the mains power is removed 2 1 2 High Voltage Mains power drives the high voltage section It is rectified and capacitor filtered to produce the DC bus the DC link power that drives the PWM inverter where it is converted into the voltages that drive a three phase brushless or DC brush motor An internal solid state switch together with an external power resistor provides dissipation during regeneration when the mechanical energy of the motor is converted back into electrical energy This prevents charging the internal capacitors to an overvoltage condition 16 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 1 3 Power and Grounding Diagram SHIELD AMPLIFIER pro CHASSIS REGEN GROUND Za J1 DC BUSS MAINS DC BUSS FRAME o y CASE SAFETY CT 24 Vdc GROUND i aa etwork b Es CONTROL LL H SYSTEM U CONTROL LOGIC CONTROL SIGNAL GROUND Copley Controls Corp 17 Operational Theory Xenus XSL User Guide 2 2 Synchronizing PWM Switching Frequency In some situations such as when sampling small analog signals it is desirable to synchron
54. 0 660BY XSL NT CANopen Network Terminator For cable color codes see Control and Feedback Cable Color Codes p 196 Heatsink Kit Low Profile Model Qty Description 1 Heatsink low profile XSL HL 1 Heatsink thermal material 1 Heatsink hardware mounting kit Heatsink Kit Standard Model Qty Description 1 Heatsink standard XSL HS 1 Heatsink thermal material 1 Heatsink hardware mounting kit Regen Resistor Assemblies Model Description XSL RA 01 Regen Resistor Assembly for use with XSL 230 18 XSL RA 02 Regen Resistor Assembly for use with XSL 230 36 and XSL 230 40 Edge Filter Model Description XSL FA 01 Xenus Edge Filter XSL FA 01 Edge Filter Connector Kit Model Qty Ref Description Mfr Model No 1 J1 Plug 5 position 5 0 mm female Wago 721 105 026 047 XSL FK 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 2 Insertion Extraction Tool Wago 231 131 H 3 Order Example Order 1 XSL 230 18 amplifier with standard heatsink fitted at the factory Connector Kit CME 2 CD and serial cable kit Qty Item Description 1 XSL 230 18 HS Xenus Servoamplifier with standard heatsink installed 1 XSL CK Connector Kit with solder cup connectors 1 CME2 CME 2 CD 1 SER CK Serial Cable Kit for connecting the PC to the amplifier Copley Controls Corp 19
55. 2 2 Select homing options described below Option Description Software limits Positive Position of user defined travel limits that take effect after homing operation Software limits Negative Software limits Disable Disables the use of software limits by setting both limits to zero Method Homing method See Homing Method Descriptions in Copley Indexer Program User s Guide Direction of Motion Initial direction of motion for the homing method Positive or Negative Fast Velocity The velocity used to find a limit or home switch Also used when moving to an offset position Slow Velocity The velocity used to find a switch edge index pulse or hard stop Accel Decel The acceleration and deceleration rate used during homing Offset The axis will execute a move specified by this distance after the reference is found The actual position will be reset to 0 at this new position and it will now be considered home Current Limit A hard stop home is reached when the amplifier outputs the homing Current Limit continuously for the amount of time specified in the Delay Time Current Delay Time Actual Current Shows actual current being applied to windings 6 10 23 Click Home to begin the homing sequence 6 40 24 To stop the homing sequence before it is completed click Stop 6 10 2 5 Click OK to save the homing move settings to the amplifier s flash memory and close the screen 6 10
56. 2 3 158 On the Main screen click Configure Regen emet to open the Regen Resistor screen Regen Resistor X C XSL RA 01 C XSL RA 02 Configure OK Cancel Select Custom Resistor and then click Configure to open the Custom Regen Configuration screen C Custom Resistor Custom Regen Configuration 4 Step 1 Resistance IH 9 SATE TREY 200 y Enter the resistance in Ohms Penh Poe 0000 The minimum value is 15 Q The maximum value is 3000 Q mime at Peak Power 1000 ms Cancel Enter a Resistance within the range described on the screen Click Next for Step 2 Custom Regen Configuration E Step 2 Resistance 150 Continuous Power Hg wy Enter the continuous power rating in Watts AME ez w The minimum value is 200W The maximum value is 4250W Time at Peak Power D ums lt Prev Cancel Copley Controls Corp Xenus XSL User Guide Regen Resistor Sizing and Configuration A 2 2 4 Enter a Continuous Power within the range described Click Next for Step 3 Custom Regen Configuration E xl Step 3 Resistance 1500 P O IU E 2 Enterthe peak power rating in Watts The minimum value is 200V Peak Power 450 Ww 0 The maximum value is 1000044 Time at Peak Power A 2 2 5 Enter a Peak Power within the range described Click Next for Step 4 Custom Regen Configuration B xi Step 4 Psistance Enter the peak power duration in millisecond
57. 20 Fault Levels Amp Over Temperature gt 80 C DC Bus Under Voltage lt 60 Vdc DC Bus Over Voltage gt 400 Vdc Encoder Power lt 4 25 Vdc Copley Controls Corp 55 Specifications 3 21 Power Dissipation Xenus XSL User Guide Model XSL 230 18 XSL 230 36 XSL 230 40 Output Power Mains Voltage XSL 230 18 R XSL 230 36 R XSL 230 40 R Maximum 120 Vac 30 W 55 W 92 W Continuous 240 Vac 40 W 75W 120 W Power Dissipation 120 100 E 80 8 2 60 230 VAC b 120 VAC 40 z o a 20 0 0 5 10 15 20 Continuous Output Current A 3 22 Thermal Impedance See Thermal Considerations p 169 3 23 Mechanical and Environmental Size 7 55 in 191 8 mm X 5 57 in 141 5 mm X 2 57 in 65 3 mm Weight Without Heat Sink With Heat Sink XSL HL With Heat Sink XSL HS 3 0 Ib 1 36 kg 4 3 lb 1 95 kg 4 8 lb 2 20 kg Ambient Tempe rature Storage Operating 40 to 85 C 0 to 55 C Humidity 0 to 95 non condensing Contaminants Pollution degree 2 Environment IEC68 2 1990 Cover Material Meets U L Spec 94 V 0 Flammability Rating Cooling Heat sink and or forced air cooling required for continuous power output 56 Copley Controls Corp Xenus XSL User Guide Specifications 3 24 Dimensions 7 55 191 7 1 5 38 1 4 8 x 0 1
58. 5 Ordering Guide and Accessories H 4 Control and Feedback Cable Color Codes H 4 1 Wire Description Nomenclature Xenus XSL User Guide Most wires are solid color with a stripe of an alternate color shown below as solid stripe For instance Black Orange is a black wire with an orange stripe H 4 2 Control Cable XSL CC 10 The molded connector mates with amplifier J7 and has flying lead terminators with colors shown in the table below Note the color changes affecting pins 1 and 2 between XSL FC 10 Revision B and Revision C Signal Pin Color Pair Color Pin Signal Body Stripe Body Stripe Shield 1 Rev A amp B White Tan 1a 8a White Violet 14 OUT2 Rev C Brown Signal Ground 2 Rev A amp B Tan White 1b 8b Violet White 15 OUT3 Rev C Orange Enable IN1 3 White Brown 2a 9a White Gray 16 Encoder A In Out GP Input IN2 4 Brown White 2b 9b Gray White 17 Encoder A In Out GP Input IN3 5 White Pink 3a 10a Tan Brown 18 Encoder B In Out GP Input IN4 6 Pink White 3b 10b Brown Tan 19 Encoder B In Out HS Input IN6 7 White Orange 4a 11a Tan Pink 20 Encoder X In Out HS Input IN7 8 Orange White 4b 11b Pink Tan 21 Encoder X In Out HS Input IN8 9 White Yellow 5a 12a Tan Orange 22 5 Vdc 400 mA HS Input IN9 10 Yellow White 5b 12b Orange Tan 23 Signal Ground HS Input IN10 11 White Green 6a 13a Tan Yellow 24 Analog R
59. 60 Le 3 00 76 2 1 00 25 4 LOW PROFILE 0 88 22 4 HEATSINK OPTION HL 6 75 ig 8 eese s 2 sis 3 9 xu Dus adi 3 STANDARD HEATSINK OPTION HS 1 99 50 5 MI Copley Controls Corp 57 Specifications Xenus XSL User Guide 58 Copley Controls Corp CHAPTER 4 WIRING This chapter describes the wiring of amplifier and motor connections Contents include Title 4 1 General Wiring Instructions viii A nine te o iaa 4 2 AC Mains J1 4 3 Motor J2 5 incen 4 4 Regen Resistor J3 Optional 245 Logic SUPPIY Brake JA o Ue Li oret M Es Lu ER et 4 6 RS 232 Serial Commwunications 5 db Re RE saa cud 66 4 7 CAN BUS JG mere Control J7 4 8 Motor Feedback J8 Copley Controls Corp 59 Wiring Xenus XSL User Guide 4 1 General Wiring Instructions 4 1 1 Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code NEC or its national equivalent and all prevailing local codes DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death DANGER Risk of electric shock High voltage circuits on J1 J2 and J3 are connected to mains power Failure to heed this warning can cause equipment damage injury or death
60. Analog Command Input Channels 1 Type Differential non isolated Measurement Range 10 Vdc Maximum Voltage Differential 10 Vdc Input to Ground 10 Vdc Input Impedance 66 ko Resolution 12 Bit Bandwidth 7 kHz Scan Time 67 uSec Function Current velocity or position command 3 8 Digital Inputs Channels 12 7 general purpose 5 high speed Type 74HC14 Schmitt trigger w RC filter 10 kQ resistor programmable as pull up or pull down to internal 5 Vdc Input Voltage Range General Purpose 0 V 28 Vdc High speed O V 12 Vdc Logic Low Input Voltage lt 1 35 Vdc Logic High Input Voltage gt 3 65 Vdc Scan Time 333 uSec RC Filter Time Constant General Purpose 330 uSec High speed 100 nSec Debounce Type Digital Time Programmable 0 10 000 mSec Function IN1 enable IN2 IN12 programmable 3 9 Digital Outputs Channels 3 Type Current sinking MOSFET non isolated 1 KQ pullup to internal 5 Vdc through diode Maximum Voltage 40 Vdc Maximum Sink Current 1A Low Level Output Resistance lt 0 2 Q Function Programmable 52 Copley Controls Corp Xenus XSL User Guide Specifications 3 10 Brake Output Channels 1 Type Current sinking MOSFET optically isolated from control logic ground Referenced to 24 Vdc logic supply Internal fly back diode to 24 Vdc Maximum Sink Current 1A
61. Auto Tune CME 2 provides an Auto Tune feature which automatically determines optimal Cp and Ci values for the motor For more information see Auto Tune Current Loop p 149 Copley Controls Corp 21 Operational Theory Xenus XSL User Guide 2 5 3 Velocity Mode and Velocity Loop Velocity Loop Diagram As shown below the velocity loop limiting stage accepts a velocity command applies limits and passes a limited velocity command to the input filter The filter then passes a velocity command to the summing junction The summing junction subtracts the actual velocity represented by the feedback signal and produces an error signal The velocity loop feedback signal is always from the motor feedback device even when an additional encoder is attached to the load The error signal is then processed using the integral and proportional gains to produce a current command Programmable digital filters are provided on both the input and output command signals Velocity Loop Velocity Integral Gain Vi Velocity Limited y integ Vi ee Command Velocity Limiter Velocit Da Velocity Proportional Gain Vp 2 Filter a Limits e Velocity Acceleration Feedback Derived Velocity e Deceleration e Emergency Stop Deceleration Not used w hen velocity loop is controlled by position loop See Velocity Loop Limits for details Inputs In velocity mode the velocity command comes from one of the follo
62. Connecting for Serial Control Xenus XSL User Guide F 1 Single Axis and Multi Drop An amplifier s RS 232 serial bus can be used by CME 2 for amplifier commissioning The serial bus can also be used by an external control application HMI PLC PC etc for setup and direct serial control of the amplifier The control application can issue commands in ASCII format For experimentation and simple setup and control a telnet device such as the standard Microsoft Windows HyperTerminal can also be used to send commands in ASCII format For more information see Copley Controls ASCII RS 232 User Guide The serially connected amplifier can also be used as a multi drop gateway for access to other amplifiers linked in a series of CAN bus connections Instructions for hooking up a single axis connection and a multi drop network appear below F 1 2 Single Axis Connections For RS 232 serial bus control of a single axis set the CAN node address of that axis to zero 0 Note that if the CAN node address is switched to zero after power up the amplifier must be reset or power cycled to make the new address setting take effect seal Copley Amplifier PC PLC or HM COM port SER CK Serial Cable Kit Sa CAN 9pin D sub with ASCII for ASCII Control for RS 232 ADDR X RS 232 0 ADDRESS MUST BE SET TO ZERO BEFORE POWER UP OR RESET F 1 3 Multi Drop Network Connections For RS 232 serial bus control of multiple
63. Controls Corp CHAPTER 3 SPECIFICATIONS This chapter describes the amplifier specifications Contents include Title Page 3 1 Agency Approved 50 9 2 POW T INPUT C 50 3 3 Power Output 50 3 4 Control Loops 2x51 3 5 Regen Circuit Output 51 3 6 Digital Command Input zirraren iior a dd e ED Abadia vith Tadic Fo HERR tee A daw 51 3 72 Analog Command M a o1 cuca M 52 3 8 Digital Inputs 3 9 Digital Outputs 3 10 Brake Output sh 8 11 Encoder Power Supply OUIDUt ee oen ees grein ere ea aa 53 3 12 Primary and Secondary Encoder Inputs 82 tenir i onte A euet nei ERU Ru ete iris 53 3 13 Analog Encoder Inputs 53 3 14 Hall Switch Inputs 54 3 15 Resolver Interface 54 3107 EGON CUS PCR 54 311 Serial Ina ERTEILEN 54 3 18 CAN Interface 55 3 19 Status Indicators 55 3 20 Fault Levels 55 AI xe B DISSIPALOM s 24e P 56 3 22 Thermal Imp dance rre eror rrr eren eet rir tt t e RR he ri lesa v che e ERR tsar Ee ea IEA EE EL o ER Yx d ERE ER ERRR E ere once 56 3 23 Mechanical and Environmental 56 cB me
64. Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 2 4 4 5 2 4 5 5 2 4 6 5 2 4 7 Click Next to save the choices and open the Configure Serial Ports screen or click Cancel to close the screen without saving changes kc Communications Wizard ENS x Configure the selected ports 1 Highlight a port in the Selected Devices list 2 Choose a Baud Rate for that port 3 Repeat for each selected port Click Next to save the choices and open the Serial Ports Settings Review screen or click Cancel to close the screen without saving changes Communications Wizard Review the settings To make a change click Back To accept the settings click Finish To close without saving changes click Cancel Copley Controls Corp 81 Quick Setup with CME 2 Xenus XSL User Guide 5 5 Prerequisites 5 3 1 Hardware and Equipment 5 3 1 1 5 3 1 2 5 3 1 3 5 3 1 4 82 Verify that 24 Vdc power is OFF and AC power is OFF Verify wiring and connections Ensure the following connections are wired according to the guidelines in Wiring p 59 1 J8 FDBCK motor signals J2 U V W Earth motor power J7 CNTRL control signals J4 24 Vdc BRAKE required 24 Vdc power OFF J5 RS 232 PC serial link J1 L1 L2 L3 Earth line power power OFF O a A o N Secure the motor 1 Make sure motor is securely fastened 2 Make sure that no load is connected to the motor Apply 24
65. D Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply ground 5 TxD Transmit data output to computer 6 N C No connection RS 232 Serial Communications Wiring Diagram 66 Copley Controls Corp Xenus XSL User Guide 4 7 CAN Bus J6 Mating Connector 8 position modular connector RJ 45 style Copley Controls provides the following assemblies e Prefabricated 10 foot cable PN XSL NC 10 e Prefabricated 1 foot cable PN XSL NC 01 e Terminator Plug PN XSL NT A diagram of the female connector is shown below Pin Description Pin Signal Function 1 CAN H CAN H bus line dominant high 2 CAN L CAN L bus line dominant low 3 CAN Gnd Ground 0 V V 4 No connection 5 Pass though to second connector no internal connection 6 CAN SHLD Pass though to second connector no internal connection 7 CAN Gnd Ground 0 V V 8 CAN V Pass through to second connector no internal connection Table applies to both CAN connectors CAN Bus Wiring Diagram Amplifier J5 J5 1 Y J5 2 CAN Gnd CAN Network Opto isolation J5 3 J5 4 J5 5 J5 6 e J5 7 J5 8 J6 Copley Controls Corp ee J6 2 CAN Network CAN Gnd 31J6 3 7 J6 4 J6 5 J6 6 Note 1 If this is the last amplifier on the network jd use Copley Terminator Plug PN STP NT ET toterminate the bus
66. E TR eA rao dec 1 6 Choosing an Amplifier from a List of Amplifiers 6 1 7 Renaming an Amplifier 6 2 Manage Amplifier and Motor Data IA A 6 2 2 Disk Storage ni kx ve a dis des E 6 2 3 Data Management Tools nenne nhnenn sehn nnt teneis tsi snhthneti isis inne trtss sisi s nh tenens ndis enn tenti senes 6 2 4 Quick Copy Setup Procedure orte tr niet torpe tf n eines rng ako bn ae CE VY Fe ETE E Cana een E NER E lan state ronge 6 3 Downloading Firmware ooooooocccccccncnoconccccncnananancnnccnnnnns 6 3 1 Acquiring Firmware from Web Site Optional 6 3 2 Downloading Firmware to Amplifier 6 4 Control Panel 6 4 1 Control Panel Overview E T i T he dd 6 4 2 Status Indicators and Messages re e eaves ae PU aeta A SA SA DET 6 4 4 Control Functions 6 4 5 Jog Mode 6 5 Scope Tool 6 5 1 Scope Tool Overview 6 5 2 Function Generator and Profile Tabs wet we ie m m p 6 5 3 Sc pe Settings tatin e e adt me HR hr WR P Tene Ue eder 06 5 4 Scope Tool Controls z 51 dte HE ue e n ied ud dto ei as fe FER CE eee nl que 6 5 5 Control Loop Parameters in the Scope Tool 6 5 6 Scope Files onore mt 6 6 Error Log and Communications Log 6 6 1 Error Log ts 6 6 2 Communications Log A E Ve ES ds 22 E 6 7 CME 2 Virtual Aplica 6 7 72 Virtual Amplifier OVOrvIgW 2i ncn entero editore tiva SF e
67. EDI IEEE Copley Controls Corp 77 Quick Setup with CME 2 Xenus XSL User Guide 5 1 Warnings DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death DANGER Make connections with power OFF Do not make connections to motor or drive with power applied Failure to heed this warning can cause equipment damage injury or death DANGER Spinning motor with power off may damage amplifier Do not spin motors with power off Voltages generated by a motor can damage an amplifier Failure to heed this warning can cause equipment damage WARNING 78 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 2 CME 2 Installation and Serial Port Setup 5 2 1 Requirements Computer and Operating System Minimal hardware requirements e CPU Minimum 166 MHZ Recommended minimum 266 MHZ e RAM Minimum 64 MB Recommended minimum 128 MB e Atleast one standard RS 232 serial port or a USB port with a USB to RS 232 adapter e Atleast one serial communication cable Available from Copley Controls Copley Controls cable part number SER CK Operating Systems Supported Windows 95 98 ME NT 2000 XP Using the minimum requirements will allow CME 2 to run but performance will be significantly reduced Software Copley Controls CME 2 software Version 4 0 or higher 5 2 2 Downloading Software
68. Failure to heed this warning can cause equipment damage injury or death Clearing Latched Faults A latched fault is cleared only after the fault has been corrected and at least one of the following actions has been taken e power cycle the 24 Vdc to the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel al and press Clear Faults or Reset e clear the fault over the CANopen network or serial bus Example Non Latched vs Latched Faults For example the amplifier temperature reaches the fault temperature level and the amplifier reports the fault and disables the PWM output Then the amplifier temperature is brought back into operating range If the Amplifier Over Temperature fault is not latched the fault is automatically cleared and the amplifier s PWM outputs are enabled If the fault is latched the fault remains active and the amplifier s PWM outputs remain disabled until the faults are specifically cleared as described above 36 Copley Controls Corp Xenus XSL User Guide Fault Descriptions Operational Theory The set of possible faults is described below For details on limits and ranges see Fault Levels p 55 Fault Description Fault Occurs When Fault is Corrected When Amplifier Over Temperature Amplifier s internal power module temperature exceeds specified temperature Power mo
69. G 2 2 6 6221 6 2 2 8 Make sure that no load is connected to the motor On the Main screen choose Tools Manual Phase to open the Manual Phase window Manual Phase E x Monitor T Configuration Halls No Faults Motor Phase Angle Black Invert Input Hall Angle in Red T Analog Hall Analog Halls 120 60 Hall Offset 0 deg Sine 292 6 mv Cosine 544 mV 180 0 Motor Feedback Hall Angle 28 deg 240 Y 300 IV Invert Input Motor Phase Angle 274 deg Motor Motor Feedback F Invert Output 1434 counts Actual Current Lt 001A Y 002A W 003A Control Increment Rate 90 elec degis Current 0 28 Fa eats FOROR Move Motor ES Fwd Restore Defaults OK C Enable Disable Cancel Enable the amplifier by selecting To control the current vector rotation use Rev or Fwd to command reverse or forward motion NOTE Some motors have bearings stiction so helping the motor with mechanical force is acceptable Motors with no friction may need friction added to steady motion If the motor cannot keep up with the rate of vector rotation then reduce the ncrement Rate or increase the Current Verify that pressing forward button moves motor forward If it does not toggle the Motor Invert Output box setting Verify actual position count agrees with direction of rotation increasing counts in forward direction and decreasing count
70. HASE Procedure sian iacr an nahiei ritan a eiet rete aale 5 10 3 Guidelines for Choosing Auto Phase Current and Increment Rate Values 5 10 4 Trouble Shoot Motor Direction Setup n ds S p 5 10 5 Trouble Shoot Motor Wiring SetUp lcs dee neces hi te entire tite ede e t eade et Lo eere ee ada 5 10 6 Trouble Shoot Halls Wiring Setup sienne 5 10 7 Other Problems ius 5 11 Current Loop 5 11 1 Current Loop Settings 5 11 2 Manually Tune Current Loop 5 12 Velocity Loop B ds e xe de Ae s 5 12 11 Velocity Loop Settings wesine o c rege t En i e erae s ed E ai xe E vana ead OO etn 5 12 2 Manually Tune the Velocity LOOp vis iiec coectetuer noe epe e decada keen dee dy dada 5 13 Position Loop Fi 5 13 1 Position Loop Settings 5 13 2 Manually Tune the Position Loop 5 13 3 Test S Curve Profile 5 14 Completion Steps des i zh Lus e d i P E e EEG A OM PM 5 14 25 Steps or eris rct ex cux i ED eu oe rx re ce Deu io aden ve Pp a eoe Dd xa et Ed ethene 6 Using CME 2 6 1 CME 2 Overview 6 1 1 Main Screen Overview 6 1 2 Tool Bar Overview 6 1 3 Main Menu Overview X ee m xe js 6 1 4 Functional Diagraimi 2 scsi ysis 1 reinen cial 6 1 5 6 1 6 CAN Information and Status Bar rore eet che rer rep e idee n teen dea Dea aea Ea E
71. Jog Mode 6 5 Scope Tool 6 5 1 Scope Tool Overview sisi 6 5 2 Function Generator and Profile Tabs cerit rette ia a nn e rara rana no qun Deacon late dt 6 5 3 Scope Settings sssss 6 5 4 Scope Tool Controls 6 5 5 Control Loop Parameters in the Scope Tool se 6 36 SCODE ICS ota a te LL D MAI MU MIR UM 6 6 Error Log and Communications Log 6 6 1 Error Log nnn 6 6 2 Communications Log 6 7 CME 2 Virtual Amplifier 6 7 1 Virtual Amplifier Overview 6 7 2 Virtual Amplifier Creation 6 8 Manual Phasing 6 8 1 Manual Phase Objectives 6 8 2 Manual Phase Instructions Standard Non Resolver Xenus nenne 6 8 3 Manual Phase Instructions Resolver R Xenus ss 147 6 8 4 Troubleshooting Manual Phase With Halls and Encoder 148 68 5 Verify Motor Pole Gouittis e a Ei 148 6 9 Auto Tune Curretnit EOD 2 reti caras Pap din dee dr dirt YU Spese RD addere AE cuu dad 149 0 9 1 Auto Tune ODJectiVe cone cente dee ean e A eee enr eraat AAA na raide ten teste 149 69 2 Auto Tune nstEUCtioris 5 reote rre icone vars AO 149 LOS LI sorore iere LE E E 152 HEXHeT ur
72. L 230 18 or XSL 230 36 amplifiers the XSL FA 01 operates below maximum temperature values and thus requires no cooling fan When used with XSL 40 amplifiers running continuous currents greater than 12 Adc the XSL FA 01 should be cooled with an external fan The fan should have a flow rate of at least 110 CFM The filter has been tested using the Comair Rotron MD24B2 24 Vdc powered fan Fan Mounting Guidelines Most of the filter s heat is transferred to ambient air rather than through the heat plate Thus it is very important to mount the filter and fan in such a way that the fan can blow up through the filter s cover slots Mount the filter on edge and mount the fan below it so that it blows up through the cover slots There is no heatsink option for the XSL FA 01 edge filter Copley Controls Corp 175 Xenus Filter Xenus XSL User Guide E 4 XSL FA 01 Edge Filter Dimensions The following diagram shows the mounting dimensions of the XSL FA 01 Edge Filter ies 255 ES 64 8 i i LA ar 1 i rs i E opono ipe ogo o ogo J 1 1 1 EA M ey GU E m 1
73. LowPass Type 2 Pole Butterworth y 0 1 2 3 Agjust the filter settings described below Filter Description Class Type Low Pass The single pole low pass filter is the simplest filter The value entered in the Cut off Single Pole Frequency field provides the 3 db point The filter will attenuate at 20 db decade past the cut off frequency reducing excitation of high frequency resonance Low Pass The Butterworth filter is a maximally flat low pass filter This second order two pole 2 Pole Butterworth filter has a damping ratio of 0 707 and produces no peaking in the Bode plot The value entered in the Cut off Frequency field provides the 3 db point The filter attenuates at 40 db decade past the cut off frequency The phase lag at lower frequencies is greater than the phase lag of other second order filters that exhibit more peaking Custom Bi Quad The Bi Quadratic filter has two quadratic terms one in the numerator and one in the denominator The numerator affects the filter s two zeros and the denominator affects the filter s two poles Many filter classes and types can be expressed in the Bi Quad form by entering the coefficients The coefficients can be calculated using any commercially available math software package and entered as floating point numbers However due to the fixed point representation the numbers may be rounded Copley Controls Corp 167 Velocity Loop Filters Xenus XSL User G
74. ML Recv 16 38 33 991 COMI Send 16 38 33 991 COMl Recv 4 V Enable Logging IV Enable Event Status Logging F a On the Main screen choose Tools Communications Log to open the Communications Log screen Kd Communications Log Get Latched Event Status 00 f6 01 Oc OCA Get Latched Event Status 00 9a 02 00 32 Get Event Status 00 7 01 Oc 00 a0 Get Event Status 00 88 02 00 20 00 fO C Get Sticky Event Status 00 fb 01 Oc 00 Get Sticky Event Status 00 88 02 00 20 Get Fault Latch 00 3 01 Oc 00 a4 Get Fault Latch 00 58 02 00 00 00 00 OC Get CAN network status 00 54 01 Oc 0l C Get CAN network status 00 5d 01 00 04 C Get Trajectory Status 00 9e 01 Oc 00 cs Get Trajectory Status 00 Sb 01 00 00 OC Get Latched Event Status 00 6 01 Oc OC Get Latched Event Status 00 9a 02 udi all Clear cose Select the logging options described below Anl xl Option Description Enable Logging When checked logging is enabled and all communications with the exception of status messages are recorded in the log Enable Event Status Logging When checked status messages are included in the log Filter Get Variable Cmds When checked Get Variable commands are not added to the log When prompted enter a File name Then click Save to save the log file and close the window or click Cancel to close the window without saving the log file Copley Controls Corp To clear the log contents fr
75. Output state controlled by CVM or CAN program Copley Controls Corp 95 Quick Setup with CME 2 5 8 3 Custom Digital Outputs 5 8 3 1 Click Configure Custom Custom E Configuration xl T Latched Fault JT Amplifier Over Temperature Latch Output Motor Phasing Error ce 7 Feedback Error Motor Over Temperature F Under Voltage F Over Voltage T Short Circuit Detected Current Output Limited T Voltage Output Limited ba 4 E me m 5 8 3 2 If needed to deselect all events on the list click Clear Xenus XSL User Guide to open Custom Output Configuration 5 8 3 3 Choose any number of events from the list Selected events are OR ed together so any event activates the output 5 8 3 4 To optionally latch the selected events select Latch Output FE For more information on latching see Non Latched and Latched Custom Outputs p 45 5835 Click OK to save changes to volatile memory and close the Custom Output Configuration screen OR click Cancel to close the screen without saving changes 5 8 4 Save Input Output Changes 5 8 4 1 On the nput Output screen click Close 5 8 4 2 On the Main screen click Save to Flash sal 96 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 8 5 Fault Latching 5 8 5 1 Click Configure Faults E to open the Fault Configuration screen xi Latch Fault v Short circuit detected Amplifi
76. Pole 4000 Restore Default Interpolated Resolution 128 um Normally used with ServoTube Pole Pitch is the distance between poles in a poll pair as entered in the Magnetic Pole Pair Length field on the Motor tab The interpolated resolution is the dividend of Pole Pitch Counts per pole value expressed in um Optionally modify the resolution by changing the Counts Pole value Click Restore Default to restore default Counts Pole 5 6 3 3 If using a brake then proceed to Brake Stop Optional p 91 Else proceed to Calculate p 92 90 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 7 Brake Stop Optional 5 7 1 Overview Many control systems employ a brake to hold the axis when the amplifier is disabled For more information see Brake Operation p 33 5 7 2 Procedure 5 7 2 1 Click the Brake Stop tab x Motor Encoder Brake Stop Enable Input Brake Stop delay time H Speed t NI Brake Stop activation velocity Brake Ouptput a EE ie PAM delay Power Section 1 Brake Stop response time i la Brake Stop delay time ol mSec Brake Stop activation velocity rpm PWM delay brake stop response time 0 mSec Ji ss E 4 d catcutate ok Eel 5 7 2 2 Enter the following options Option Description Brake Stop Delay Range of accepted values O to 10 000 mSec Time Brake Activation Range of accepted values 0 to 100 000 rpm
77. SL User Guide Operational Theory 2 14 3 Custom Output Functions Any of the amplifier s digital outputs can be set up in a custom configuration to respond to a combination of events including faults warnings and status indications The output goes active when one or more of the selected events take place Non Latched and Latched Custom Outputs Like an amplifier fault a custom configured output can be non latched or latched If a non latched custom configured digital output goes active it goes inactive as soon as the last of the selected events is cleared If a latched output goes active it remains active until at least one of the following actions has been taken e power cycle the 24 Vdc to the amplifier e cycle disable and then enable an enable input that is configured as Enables with Clear Faults or Enables with Reset e access the CME 2 Control Panel al and press Clear Faults or Reset e clear faults over the CANopen network Latching an output does not eliminate the risk of unexpected motion with non latched faults Associating a fault with a latched custom configured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without operator intervention In this case motion may re start unexpectedly DANGER For more information see Clearing Non Latched Faults p 36 Failure to heed this warning can cause equipment damage injury or death Custom Output F
78. Update period After each sample the updated value of the IT Accumulator Variable is compared with the I T setpoint If the IT Accumulator Variable value is greater than the lT Setpoint value then the amplifier limits the output current to the Continuous Current Limit When current limiting is active the output current will be equal to the Continuous Current Limit if the commanded current is greater than the Continuous Current Limit If instead the commanded current is less than or equal to the Continuous Current Limit the output current will be equal to the commanded current 162 Copley Controls Corp Xenus XSL User Guide T Time Limit Algorithm B 1 3 T Current Limit Algorithm Application Example IT Example Parameters Operation of the IT current limit algorithm is best understood through an example For this example a motor with the following characteristics is used e Peak Current Limit 12 A e l T Time Limit 1 S e Continuous Current Limit 6 A From this information the I T setpoint is T setpoint 12 A 6 A 1 S 108 A S See the example plot diagrams on the next page Copley Controls Corp 163 IT Time Limit Algorithm Xenus XSL User Guide IT Example Plot Diagrams The plots that follow show the response of an amplifier configured w PT setpoint 108 A S toa given current command For this example DC output currents are shown in order to simplify the waveforms The algorithm essentially calculates
79. Vdc to the amplifier s J4 connection Do NOT apply AC voltage to the amplifier at this point Risk of unexpected or uncontrolled motion with CME 2 in CAN mode CME 2 can be used while the amplifier is under CAN control However some extreme changes made with CME 2 could cause unexpected or uncontrolled motion Failure to heed this warning can cause equipment damage injury or death DANGER Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 3 2 Starting CME 2 and Choosing an Amplifier NOTE To immediately software disable the amplifier at any time while running CME 2 press function key F12 Also digital input 1 IN1 should be configured as a hardware disable and may be used to disable the amplifier 5 3 2 1 Verify CME 2 installation and serial port configuration 5 3 2 2 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop CME 2 4 0Beta2 XSL 230 40 Xenus 1 lol xj File Amplifier Tools Help ER E Ay gs D E nal ud sd al Copley Neighborhood CAN Network Address 1 State Pre operational EEB Virtual Amplifier um eeu Sine Commutation Rotary Motor If you have selected an amplifier that has not been set up the Basic Setup screen appears 5 32 9 If necessary click the appropriate or amplifier in the Copley Neighborhood tree acme 2 LES XSL 230 4 File Amplifier Tools He al ELI E E Copley Neighborhood WD Virtual Am
80. WITH CME 2 This chapter describes the general procedure for configuring and tuning an amplifier with a motor To copy setup data from an existing Copley Controls axis file ccx skip to Quick Copy Setup Procedure p 128 Step Page A A UD 78 5 2 CME 2 Installation and Serial Port Setup 79 5 2 1 Requirements 5 etre nens s 79 5 2 2 Downloading Software from Web Optional s 79 5 2 3 Installing CME 2 Software 79 5 2 4 Serial Port Setup 80 5 3 Prerequisites eee 82 5 3 1 Hardware and AR retten etre nhan rer ta eaaa TENAN NDEN EXE FE anne TRATANA FER ENSE EFE RAN EK Frase acaso 82 5 3 2 Starting CME 2 and Choosing an Amplifier enr 83 5 4 Basic Setup seen 5 4 1 Basic Setup Screen zs 5 5 Motor SOL iue cate tiende o pde AA eden decla dec ds dia deduce dpa necp yas nag 50 1 Motor Data 1e LEP C 5 5 2 Rotary Motor 5 5 3 Linear Motor ss 5 6 F edback SOtUp ve maca AAA ERA AO 5 6 A m M MH M 5 6 2 Rotary Motor Feedback Setup Options 5 6 3 Linear Motor Feedback Setup Options xus 5 T Brake Stop Optional iecit aceite A cate cL dT tte de E Elsa pase une ei epa a D 1 1 VOI VIG Ws O MM ad NO 5 7 2 Procedure 5 7 3 Calculate 5 8 Amplifier Co
81. Xenus XSL User Guide Copley controis Corp P N 95 00286 000 Revision 7 June 2008 Xenus XSL User Guide This page for notes TABLE OF CONTENTS About This Manual ONO 8 Overview and us e nte e aye oats REP EO Dt t de eh een ee A ota CP va ANA 8 Related Documentations 5 ei NT aa aAA un ene Pa Rr etat tee ane td tee een te BR ete HE besos one beoe cae Me dea ERES SIE PR e KP CE 8 Comments Copyrights Docurment Validibyx a e o c a a AM me P pe sec AI A dece aM cte m 8 Product Warnings Revision History 2 m e ate B zi d 1 Introduction oerein ie oirre aodai da Cm cane ds fe a de Pra PRSE T K X DIE as ace ADAE an Win KD SEEN RECON HRK IRE RR sage st sente ere danse eB HOS enean aoa ELTE PRETI O NN 1 2 CME 2 at hi is i m oe des de 1 3 CMO OM tee ite Nee O ES o de renom tre 2 Operational Theory onini nein eicit ens e ina 2 1 Amplifier Internal Power 2 1 1 Logic Signal Power Las 2 1 2 High Voltage 2 1 3 Power and Grounding Diagram 2 2 Synchronizing PWM Switching Frequency AN zu ex a tee ig 3 2 9 COMMUTATION MOJES M 2 4 Feedback t s A NO 2 4 1 Encoder and Resolver Support 2 4 2 Secondary Encoder Interface 2 5 Operating Modes 2 5 1 Modes and Control Loops 2 5 2 Current Mode and Current Loop ve me aa ka uni 2 5 3 Velocity M
82. a motor data file 1 Click Motor Feedback Memes to open the Motor Feedback screen 2 On the Motor Feedback screen click Restore Motor Data from Disk Lal When prompted navigate to the folder containing the file then click on the file name and then click Open 3 Proceed to Calculate p 92 OR to return to the Main screen without restoring motor data click Cancel 86 Copley Controls Corp Xenus XSL User Guide 5 5 2 Rotary Motor 5 5 2 1 5 5 2 2 Quick Setup with CME 2 Click Motor Feedback Meere to open the Motor Feedback Rotary Motor screen Motor Feedback Rotary Motor xi Motor Feedback Braketstop Manufacturer Model Number Motor Inertia 0 11976 Kg cm Number of Poles 4 Peak Torque 1 9546 Nm bd Continuous Torque 0 6553 Nm hz Velocity Limit 6000 rpm Copley Units 34 ICBL341FE 001 Metric C English Torque Constant 0 1401 Nm A y Back emf Constant 14 67 vKrpm Y Resistance 2 27 ohms Inductance 523 mH call al a ai D cacuicte ox cancel Enter the rotary options described below Option Description Manufacturer Motor manufacturer s name Saved for reference in the motor data file Model Number Motor model number Saved for reference in the motor data file Units Selects whether the parameters entered in this screen are in Metric or English units Motor Inertia The ro
83. ack Setup G 1 3 Calculating ServoTube Initial Values G 1 4 Setting Up the Motor Over Temperature Input G 1 5 Other ServoTube I O and Fault Latching Setup Steps G 2 ServoTube Auto Phase and Manual Phase iii G 2 1 ServoTube Auto Phase G 2 2 ServoTube Manual Phase G 3 Special ServoTube Setup Completion H Ordering Guide and Accessories H 1 Amplifier Model Numbers x e 2 zs re sak s H 2 Accessory Model N mbers 5 1 ha rnt dd ne deuda ds e cure ta SEV doves alia CR ERA EE a aan x Rao duae H 3 Order Exaniple dd betes H 4 Control and Feedback Cable Color Codes iii 6 Copley Controls Corp Xenus XSL User Guide Table Of Contents H 4 1 Wire Description Nomenclature ree eee cae e e pr ade eR 196 H42 Control Cabe XSE CG 10 dcc metre cad bras RPM er deed amate e Peur eite E o ERU Etage 196 H 4 3 Feedback XSL FC 10 H 5sRegen Resistor Specifications ineo e e e edic ao ie du eta H 5 1 XTL RA 03 XTL RA 04 Specifications H 5 2 XTL RA 03 XTL RA 04 Dimensions H 5 3 XSL RA 01 02 Discontinued Specifications H 5 4 XSL RA 01 02 Discontinued Dimensions Copley Controls Corp 7 ABOUT THIS MANUAL Overview and Scope This manual describes the operation and installation of the Xenus amplifier manufactured by Copley Controls Corporation Related Documentation Users of the CANopen features should also read these Cop
84. and diagnostics purposes without using an external control source Function Generator Profile Function Generator Profile Move Type E Je nt ouni ME Relative f Trap Absolute C SCurve Function EX e a Amplitude 047 A Distance 2000 counts Period 10 ms Reverse and Repeat Start Stop Start Stop The Start button starts the function or profile generator The Stop button stops the generator and aborts any profiles in progress Function Generator Tab Option Description Apply To Control loop to which the Excitation will be applied Current available in all modes Velocity available in velocity or position mode or Position available in position mode only Excitation Excitation motion function that will be applied to the control loop selected in the Apply To list box The choices vary with the control loop selected Selected Control Loop Excitations Available Current Sine Wave Square Wave Step Forward Step Forward and Reverse and Impulse Velocity Sine Wave Square Wave Step Forward Step Forward and Reverse Position Sine Wave Square Wave Amplitude Amplitude of the command Units vary depending on the value chosen in the Apply To field Frequency Sine Wave and Square Wave only Frequency of input command cycle Period Step Forward Step Forward and Reverse and Impulse only Duration of each input pulse Profile Tab Option Description Move R
85. and Common Mode Filtering oes 2 T p zi E 1 2 Description and Functional DiagraM ooooonooccccnnccnccooooncncconnnannncnnncnnnnnnnnnnnn rn nan n nn nn rre nnn nnnnnnrh rs sed nnne nntl nsn dh nre rnnn nsns nenne E 1 3 PWMLOUtpULPIOL a oct cce eee De e Pos uo e sande lost reed eg E 2 XSL FA 01 Edge Filter Specifications i ie mM Lis ie d us E 3 T hermaliGorisideratioris se x sooner er de dada deu dau eva Du edades vu d tilde enr A pe den ane E4 XSL FA 01 Edge Filter Dimensions see oi D en ten oio are ente en esp den ann RE pav ena CERE Eng edens E 5 XSL FA 01 Edge Filter Wiring E 5 2 Electrical Codes and Warnings ES ie dal hn ws K E 5 2 Connector Locations nissan near b peace A i AE A A wanton deo ape 5 3 CADDIE NOTES in me OA E 5 4 Input J1 From Amplifier zs des E E E ET E E 5 5 Output J2 To Motor uc Aa did E 5 6 Diagram Edge Filter Wiring with Brushless Motor E 5 7 Diagram Edge Filter Wiring with Brush Motor E 6 XSL FA 01 Edge Filter Ordering sud T bis the fe ie F Connecting for Serial Control irent ien ici iia FAT Single Axis and MultizDEOp s 72 23 AN F 1 2 Single Axis Connections zs s DN m AS rr F 1 3 Multi Drop Network Connections is eeteeaaaaeeeeeeegeeaaeeeeeeeseeeaaeeeseeseeeaeeeeeeeeeeeaea G ServoTube Motor Setup ii G 1 ServoTube Setup and Configuration G 1 1 ServoTube Basic Setup Screen Options G 1 2 ServoTube Motor Feedb
86. ase Current and Increment Rate values using the guidelines in Guidelines for Choosing Auto Phase Current and Increment Rate Values p 109 If desired results are not obtained proceed to Manual Phasing p 145 Copley Controls Corp Xenus XSL User Guide Xenus XSL User Guide Quick Setup with CME 2 5 10 3 Guidelines for Choosing Auto Phase Current and Increment Rate Values Here are some considerations in choosing Auto Phase Current and Increment Rate values e If friction is high then more current may be required to move the load e High static friction may require more current to overcome stiction e Transition from static friction to dynamic friction and back may produce jerky motion e A faster rate will operate in the dynamic friction range e A slower rate will operate in the static friction range e If the friction is low as in the case of air bearings low frequency oscillations may occur thus less current and slower rates may be required If oscillations persist then friction may need to be temporarily added 5 10 4 Trouble Shoot Motor Direction Setup If motor direction setup step failed 5 10 4 1 Check Encoder or resolver power and signals 5 10 4 2 Verify that the encoder is differential Contact factory if encoder is single ended 5 10 4 3 Check shielding for proper grounding 5 10 5 Trouble Shoot Motor Wiring Setup If motor wiring setup step failed 5 10 5 1 Verify that amplifier is disabled 5 10 5 2
87. aults A custom output can be configured to go active in response to any of the amplifier faults described in Fault Descriptions p 37 Example Custom Output Fault Handling vs Overall Fault Handling A fault on an output is separate from a fault on the amplifier For instance suppose e OUT3 has a Custom configuration Only the Under Voltage fault condition is selected and the output is latched e Under Voltage is not latched on the Configure Faults screen An under voltage condition occurs and the amplifier goes into fault condition output stages are disabled and faults are reported At the same time OUT3 goes active The under voltage condition is corrected and e The amplifier fault is cleared Output stages are enabled e OUT3 remains active Copley Controls Corp 45 Operational Theory Xenus XSL User Guide Custom Output Warning Functions A custom output can be configured to go active when the amplifier issues any of the following warnings Event Description Current Output Limited The current output is being limited by the T algorithm or a latched current fault has occurred See Limits p 20 Voltage Output Limited Current loop is commanding the full bus voltage in an attempt to control current Commonly occurs when the motor is running as fast as the available bus voltage will allow Positive Limit Switch Active Axis has contacted positive limit switch Negative Limit Switch Ac
88. by the bus capacitors in joules C Bus capacitance in farads Viegen Voltage at which the regen circuit turns on in volts Vimains Mains voltage applied to the amplifier in volts AC A 1 7 Calculate Energy to be Dissipated for Each Deceleration For each deceleration where the energy exceeds the amplifier s capacity use the following formula to calculate the energy that must be dissipated by the regen resistor E regen E retumed Eamp Where Eregen Energy that must be dissipated in the regen resistor in joules Eretumea Energy delivered back to the amplifier from the motor in joules Eamp Energy that the amplifier will absorb in joules A 1 8 Calculate Pulse Power of Each Deceleration that Exceeds Amplifier Capacity For each deceleration where energy must be dissipated by the regen resistor use the following formula to calculate the pulse power that will be dissipated by the regen resistor Poulse E regen T decel Where Pouse Pulse power in watts Eregen Energy that must be dissipated in the regen resistor in joules Tec Time of the deceleration in seconds A 1 9 Calculate Resistance Needed to Dissipate the Pulse Power Using the maximum pulse power from the previous calculation calculate the resistance value of the regen resistor required to dissipate the maximum pulse power For related amplifier specifications see Regen Circuit Output p 51 R Vis Pulse max Where R Resistance in ohms
89. cally sets the scope settings and sets a standard move into the profile generator Changing any of the preset settings de selects the Auto Set Up feature 138 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 5 4 Scope Tool Controls The basic controls for the Scope Tool are shown below Record Stop Trace Clear Close Descriptions follow Button Description Record Begins recording a trace Stop Trace Stops recording a trace Clear Clears the trace from the screen and trace data from buffer Close Closes the scope tool 6 5 5 Control Loop Parameters in the Scope Tool The Scope tool provides convenient access to all of the control loop parameters that might be used in tuning and diagnosing an amplifier The user can adjust these parameters and see the results immediately on the scope Control loop parameters are accessed through a set of tabs shown below Settings Gains Trajectory Limits Position Params Velocity Params Pp 5000 E Vp 7500 E Cp 750 E Aff 0 Vi 1400 E Ci 83 E Vf 16384 E Note that the parameters represented on these tabs can also be accessed through the screens used to configure the control loops and the digital position input Changing a value in the Scope tool automatically updates the value on the other screens where it appears and vice versa Control loop parameter tab descriptions follow Gains Tab The Gains tab provides access to all of the
90. cel Help a b 1 Select Create new amplifier 2 When prompted highlight the virtual amplifier template filename ccv that represents the type of virtual amplifier you wish to create 3 Click Open to open the file and the Basic Setup screen Motor and amplifier values may now be viewed entered and adjusted on the appropriate CME 2 software screens 6 7 24 Alternately open an existing amplifier file 1 Select Open existing amplifier file 2 When prompted highlight the name of the file you wish to open 3 Click Open Motor and amplifier values may now be viewed entered and adjusted on the appropriate CME 2 software screens 144 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 8 Manual Phasing 6 8 1 Manual Phase Objectives The CME 2 Manual Phase tool lets the user phase a brushless motor monitor signals check configuration wiring and control a microstepping current vector The manual phase procedure is followed by a manual phase troubleshooting procedure 6 8 2 Manual Phase Instructions Standard Non Resolver Xenus 6 8 2 1 Make sure that no load is connected to the motor 6 8 2 2 On the Main screen choose Tools Manual Phase to open the Manual Phase window Manual Phase xj rContiguration Monitor Halls gt No Faults Motor Phase Angle Invert Input amp Hall State m m rw Hall Wiring Wuv x r Hall States 120 60 Hall Offset deg u v w Ecc da EE E Wis amo E p Mot
91. click the S Curve button Adjust the following options Set values that represent a typical move under normal operation Trajectory Limits Tab Maximum Velocity Maximum speed of the profile Maximum Acceleration Deceleration Maximum acceleration deceleration of the profile The deceleration is set to be the same as acceleration Maximum Jerk The value of jerk set during the calculate procedure produces an S Curve whose maximum slope is equal to the trajectory profile slope This value will produce a maximum acceleration that is not more than the initial default value of acceleration Small values will produce less jerking but will take longer to complete move Large values will produce more jerking and a more trapezoidal profile but will complete the move faster Profile Tab Distance Increase the move distance to produce a complete trajectory profile Use an acceptable value the does not exceed mechanical limits of the system Move Relative Type S Curve Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 14 Completion Steps 5 14 1 Objective Save the work and perform additional testing with load and under normal control source 5 14 2 Steps 5 14 2 1 5 14 2 2 5 14 2 3 5 14 2 4 5 14 2 5 5 14 2 6 5 14 2 7 5 14 2 8 5 14 2 9 On the Main screen click Save to Flash sal Remove AC power from connector J1 Attach load Reconnect AC power to connecto
92. cted and must never be grounded Failure to heed this warning can cause equipment damage 177 Xenus Filter E 5 2 Connector Locations Edge Filter J1 connects to Xenus J2 Edge Filter J2 connects to the motor 178 Xenus 5 RS232 J5 L3 N FROM AMPLIFIER Xenus XSL User Guide Copley Controls Corp Xenus XSL User Guide Xenus Filter E 5 3 Cable Notes 1 Keep the Edge Filter J1 to Xenus J2 cable as short as possible A typical length is 7 inches 2 To reduce noise twisted shielded cable must be used and the signal cables should not be bundled in the same conduit E 5 4 Input J1 From Amplifier Mating Connector Description Euro style 5 position 5 0 mm pluggable female terminal block Manufacturer PN Wago 721 105 026 047 Wire Size 22 12 AWG Recommended Wire 12 AWG 600 V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in connector kit XSL FK Pin Description Pin Signal Function 1 Ground Chassis ground and cable shield 2 Phase W Phase W input from amplifier 3 Phase V Phase V input from amplifier use for DC motor connection 4 Phase U Phase U input from amplifier use for DC motor connection 5 No connection E 5 5 Output J2 To Motor Mating Connector Description Euro style 4 position 5 0 mm pluggable female te
93. ction Generator PWM Command or Analog Command Theory Input Command Types p 25 Programming instructions Basic Setup Screen p 84 Control Loops Each opens a control loop configuration screen Theory Operating Modes p 19 Programming instructions Current Loop p 110 Velocity Loop p 113 and Position Loop p 115 Motor Feedback Opens the Motor Feedback screen Theory Feedback p 18 Programming instructions Motor Setup p 86 Home Configure and test homing Home Function p 152 Configure Regen Opens Regen Resistor screen Theory Regen Resistor Theory p 18 Programming instructions Regen Resistor p 98 Configure Faults Opens Fault Configuration screen Theory Faults p 36 Programming instructions Fault Latching p 97 124 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 1 5 CAN Information and Status Bar The Main screen displays the basic CAN information shown below CAN Network Address 1 State Pre operational The Address field shows the amplifier s present CAN address This value is updated on 24 Vdc power up or reset only for more information see CAN Addressing p 31 When the Position Loop Input is set to CAN the State field shows the state of the amplifiers CANopen state machine for more information see Copley Control s CANopen Programmer s Manual The status bar describes the present commutation m
94. ctory Limits described below Option Description Max Velocity Maximum trajectory velocity Max value may depend upon the back EMF and the Max feedback count Min 0 Default 0 25 x motor velocity limit Max Accel Maximum trajectory acceleration Max value may depend upon the load inertia and peak current Min 0 Default 0 5 x velocity loop Accel Limit value Max Decel Maximum trajectory deceleration Max value may depend upon the load inertia and peak current Min 0 Default 0 5 x velocity loop Accel Limit value Abort Decel Deceleration rate used by the trajectory generator when motion is aborted Min 0 Default 0 5 x velocity loop Accel Limit value 5 9 1 5 Click Close 5 9 1 6 On the Main screen click Save to Flash sl 5 9 1 7 Proceed to Auto Phase p 105 100 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 9 2 PWM Input For more information see PWM Input p 27 5 9 2 1 Click PWM Command mem to open the PWM Command screen lola Configuration Scaling 3000 rpm at100 duty cycle PYM Input Type 50 Duty Cycle C 100 Duty Cycle Options E Invert PWM input Allow 10096 output Invert Sign input 5 9 2 2 Set the input options described below Option Description Scaling Current mode output current at 10096 duty cycle Range 0 to 10 000 000 A Default Peak Current value Velocity mode output velocity at 10096 duty
95. cycle Range 0 to 100 000 rpm mm sec Default Maximum Velocity value PWM Input One wire 50 or two wire 100 with direction Type Options Invert PWM input Inverts the PWM logic Allow 10096 output Overrides the 10096 command safety measure See Failsafe Protection from 0 or 100 Duty Cycle Commands p 27 Invert Sign Input In 10096 duty cycle mode inverts the polarity of the directional input 5 9 2 3 Click Close 5 9 2 4 On the Main screen click Save to Flash sal 5 9 2 5 Proceed to Auto Phase p 105 Copley Controls Corp 101 Quick Setup with CME 2 Xenus XSL User Guide 5 9 3 Digital Position Input For more information see Digital Input p 28 5 9 3 1 5 9 3 2 5 9 3 3 102 Click Digital Position Inputs ta poston pao to open the Digital Position Input screen Configuration tab IEi xil Configuration Trajectory Limits Control input Increment position on Pulse end Direction Rising Edge C Pulse Up Pulse Down C Falling Edge C Quadrature Stepping Resolution 1 Input Pulses 1 Output Counts Invert Command Set the options described below Option Description Control Input Pulse and Direction One input takes a series of pulses as motion step commands and another input takes a high or low signal as a direction command Pulse Up Pulse Down One input takes each pulse as a positive step command and another takes each pulse as a negative st
96. d Motor Data Files At any time the user can save certain data from volatile and flash memory to a file on disk From the Main screen the user can save all user entered data represented on all screens the data described as Flash only and Flash and Volatile on p 126 This data is saved in a Copley Controls amplifier data file with a ccx filename extension From the Motor Feedback screen the user can save all data represented on the Motor Feedback screen This data is saved in a Copley Controls motor data file with a ccm filename extension A ccx file can be restored to return the amplifier to a previous state or to copy settings from one amplifier to another as described in Quick Copy Setup Procedure p 128 This procedure can be performed via a direct RS 232 serial connection or on node amplifiers via the serial connection gateway amplifier 126 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 2 3 Data Management Tools Amplifier Data Management Tools Operations performed using the amplifier data management tools at the top of the Main screen shown below affect amplifier settings including motor feedback data CVM Control Program data is not saved by these operations I GACME 2 4 0Beta2 XSL 230 40 Xenus 1 File Amplifier Tools Help 3 a uwuBa a Amplifier Data Management Tools The amplifier data management tools are described below Icon Name Description ll Sav
97. de Operational Theory 2 9 3 CAN Interface Status Indicator Operation The amplifier status indicator color blink codes comply with CAN Indicator Specification 303 3 as described below Note that green and red codes are often interlaced each indicating a different set of conditions The green codes indicate the CANopen state machine mode of operation pre operational operational or stopped The red codes indicate the status of the physical bus warning or error conditions CANopen State Machine Mode of Operation Indicator State Diagram Blinking green Pre operational 200 ms off ms Steady green Operational green off I Single flash green Stopped 1 second green off 4 200 ms Physical Bus Status Single flash red Warning Limit 1 second Reached red off 200 ms Double flash red Error Control Event 1 second red off f 200 200 ms ms Triple flash red Sync Error 1 second red off 200 ms ms ms Steady red Bus Off red off In addition the CAN status indicator is turned off when the CAN node ID selector CAN ADDR is set to 0 A setting of 0 which is invalid shuts down most operations on the CAN interface and the light is shut off to indicate this status Copley Controls Corp 35 Operational Theory Xenus XSL User Guide 2 10 Protection 2 10 1 Faults Overview Xenus detects and responds to a set of conditions regarded as faults such as amp
98. der B Input 8 Encoder X Input 9 Encoder X Input 10 Signal Ground Signal and 5 Vdc ground 11 Digital Hall U Standard Xenus Motor Hall switch inputs 12 Digital Hall V Resolver Xenus Resolver outputs OR Resolver R1 Output 13 Digital Hall W OR Resolver R2 Output 14 Digital Input IN5 Motor over temperature switch Standard speed Pull up pull down May be programmed to other group 2 functions 15 Signal Ground Signal and 5 Vdc ground 16 Encoder Sin In OR Resolver S3 Input 17 Encoder Sin In OR Standard Xenus Analog encoder inputs Resolver S1 Input Resolver Xenus Resolver inputs 18 Encoder Cos In Resolver S2 Input 19 Encoder Cos In Resolver S4 Input 20 Signal Ground Signal and 5 Vdc ground Copley Controls Corp Wiring 73 Wiring Xenus XSL User Guide Incremental Encoder Wiring Diagram pre Sete ult ucc ctore EE Typical Circuit 5 Vda Incremental Encoder To Encoder Encoder Power g 1 Frame Gnd Case Ground Hall Switch Wiring Diagram Amplifier Case Ground 74 Copley Controls Corp Xenus XSL User Guide Wiring Analog Encoder Wiring Diagram Analog Encoder Ground Resolver O Case Ground Motor Over Temperature Wiring Diagram 5 Vdc 4 99 KO pull up pull down Motor Over Temperature V Switch Case Ground Copley Controls Corp 75 Wiring Xenus XSL User Guide 76 Copley Controls Corp CHAPTER 5 Quick SETUP
99. drop gateway There are several basic methods for setting the CAN address as described below These method can be used in any combination producing a CAN address equal to the sum of the settings Addressing Method Description Use switch If the address number lt 15 CAN address can be set using the CAN ADDR switch only Use inputs Use the amplifiers programmable digital inputs user selects how many 1 7 and which inputs are used Use programmed value Program address into flash only For more information on CAN addressing see CAN Interface p 104 For more information on CAN communications see Communication p 41 For more information on CANopen operations see the following Copley Controls documents e CANopen Programmer s Manual e CML Reference Manual e Copley Motion Objects Programmer s Guide Copley Controls Corp 31 Operational Theory Xenus XSL User Guide 2 7 Limit Switches 2 7 1 Use Digital Inputs to Connect Limit Switches Limit switches help protect the motion system from unintended travel to the mechanical limits Any of the digital inputs 2 12 can be can be programmed as positive or negative limit switch inputs With the amplifier operating as a CAN node an input can also be programmed as a home limit Switch for CANopen homing operations 2 7 2 Diagram Sample Placement of Limit Switches The following diagram shows these limit switches in use on a sample motion stage Mechanical
100. ductive loads Secondary Encoder Interface Diagram Amplifier Typical Circuit LG ons 26032 AAA ia Position Motion Controller Copley Controls Corp 71 Wiring 4 8 Motor Feedback J8 Mating Connector Xenus XSL User Guide Description Manufacturer PN Wire Size 20 Position 050 Mini D Ribbon MDR Connector 3M 10120 3000 VE 24 30 AWG standard Molex 54306 2019 rugged 20 position 050 mini D Connector molded Plug assembly 28 AWG Insulation Displacement IDC style Molex 52316 2011 Boot cover Molex 52370 2010 Back shell 3M 10320 52F0 008 standard Molex 54331 0201 rugged Standard solder style connector included in Connector Kit PN XSL CK 10 foot cable assembly included in Connector Kit PN XSL CA uses molded IDC style connector NOTE For color codes see Control and Feedback Cable Color Codes p 196 Pin connections are shown here J8 72 10 1 oje fo 20 11 Copley Controls Corp Xenus XSL User Guide J8 Pin Description Pin Signal Function Frame Ground Cable shield connection 2 Signal Ground Signal and 5 Vdc ground 3 5 Vde Encoder and or Halls 5 Vdc power supply output Total load current on J7 22 and J8 3 not to exceed 400 mA 4 Encoder A Input 5 Encoder A Input 6 Encoder B Input Primary incremental encoder inputs 7 Enco
101. dule temperature falls below specified temperature Motor Phasing Error Encoder based phase angle does not agree with Hall switch states This fault can occur only with brushless motors set up using sinusoidal commutation It does not occur with resolver feedback or with Halls correction turned off Encoder based phase angle agrees with Hall switch states See Troubleshooting Manual Phase With Halls and Encoder p 148 Feedback error Over current condition detected on output of the internal 5 Vdc supply used to power the feedback Resolver or analog encoder not connected or levels out of tolerance Encoder power returns to specified voltage range Feedback signals stay within specified levels Motor Over Temperature Motor over temperature switch changes state to indicate an over temperature condition Temperature switch changes back to normal operating state Under Voltage DC bus voltage falls below specified DC bus voltage returns to specified voltage limit voltage range Over Voltage DC bus voltage exceeds specified DC bus voltage returns to specified voltage limit voltage range Following Error User set following error threshold exceeded See Position and Velocity Errors p 38 Short Circuit Detected Output to output output to ground internal PWM bridge fault Short circuit has been removed Over Current Latched Output current I 2T limit has
102. e C Disable Move Motor Rev 4 Microstep motor in Forward direction at increment rate Restore Defaults OK Cancel Note Motors motor manufacturers typically align the resolve in 30 degree increments typically by applying current through a pair of motor power wires Copley Controls Corp 147 Using CME 2 Xenus XSL User Guide 6 8 4 Troubleshooting Manual Phase With Halls and Encoder To perform trapezoidal commutation after power up or reset the amplifier must receive good Hall signals After the first Hall transition is detected then sinusoidal commutation can be performed In sinusoidal commutation the amplifier uses the encoder for commutation while monitoring the Halls to verify proper phase If the error between the encoder count and Hall transition is too large then the Hall phase correction will not be performed and a phase fault will be triggered Here are the most common causes of phase fault problems Test for them in the order presented 6 8 4 1 Problem Wrong data 1 Verify a rotary motor s pole count See Verify Motor Pole Count p 148 2 Verify the encoder line count OR a linear motor s magnetic pair length and the encoder resolution 6 8 4 2 Problem Bad wiring of encoders If the Halls produce good trapezoidal commutation but a phase fault is persistent in sinusoidal commutation mode the encoder is highly suspect 1 Verify the differential encoder signals Verify proper twisted shielded cable wit
103. e Used for calculating the initial current loop tuning values Range see Power Output p 50 Copley Controls Corp 87 Quick Setup with CME 2 5 5 3 Linear Motor 5 5 3 1 5 5 3 2 88 Xenus XSL User Guide Click Motor Feedback to open the Motor Feedback Linear Motor screen Motor Feedback Linear Motor 1 xj Motor Feedback Brake Stop Manufacturer Model Number Mass 000 fkg y Peak Force 0 0001 JN pa Continuous Force 0 0001 JN hd Velocity Limit 0 1 mmiSec m Units gt a Metric English Force Constant 0 001 amp X Back emf Constant 0 01 Vim sec y Resistance 0 01 ohms Inductance 0 01 mH Magnetic Pole Pair Length 0 04 mm cal al L al E coicuete ox Cancel Enter the linear motor options shown below Option Description Manufacturer Motor maker s name Saved in motor data file Choose from list or enter manually Model Number Motor model number Saved in the motor data file Choose from list or enter manually Units Selects whether the parameters entered in this screen are in Metric or English units Mass The mass of the motor Used for calculating initial velocity loop tuning values Range 0001 Kg to 100 000 Kg Default 0001 Kg Peak Force The peak force that the motor can produce Peak Force divided by Force Constant motor s peak current limit Range 0 00001 to 1 000 N Defau
104. e Angle 62 deg Test Complete Halls have been configured Motor Actual Position 1053 counts Back r Cancel G 2 1 9 Click Start to begin the Analog Hall wiring setup The message area displays the messages Microstepping Test Complete Motor has been properly phased During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate The field produced should push on the permanent magnet s magnetic field causing the motor to move As the motor moves the Analog Hall lines are decoded for proper commutation If the step fails see Trouble Shoot Halls Wiring Setup p 109 G 2 1 10 Click Finish to close the screen and save values to flash memory OR to close the screen without saving changes click Cancel G 2 1 11 If the Auto Phase algorithm does not produce desired results try adjusting the Auto Phase Current and Increment Rate values using the guidelines in Guidelines for Choosing Auto Phase Current and Increment Rate Values p 109 G 2 1 12 If desired results are not obtained proceed to Manual Phasing p 145 190 Copley Controls Corp Xenus XSL User Guide ServoTube Motor Setup Choosing ServoTube Auto Phase Current and Increment Rate Values Here are some considerations in choosing Auto Phase Current and Increment Rate values e If friction is high then more current may be required to move the load e High static friction may require more current t
105. e amplifier data to flash Saves contents of amplifier s volatile RAM to permanent flash memory Restore amplifier data from flash Restores contents amplifier s permanent flash memory to amplifier s volatile RAM Manage Amplifier and Motor Data p 126 Copley Controls Corp Xenus XSL User Guide 6 1 3 Main Menu Overview The CME 2 Main Menu choices are described below Using CME 2 Menu Selection Description For More Information File Exit Closes CME 2 Prompts for data saving decision Amplifier Basic Setup Opens Basic Setup screen Basic Setup p 84 Control Panel Opens Control Panel Control Panel p 131 Auto Phase Opens Auto Phase tool Auto Phase p 105 Scope Opens Scope Scope Tool p 134 Error Log Opens Error Log Error Log p 142 Amplifier Displays basic amplifier properties Properties CAN Configuration Opens CAN Configuration screen Rename Prompts for new amplifier name Renaming an Amplifier p 125 Tools Communications Starts sequence of prompts to set up Serial Port Setup p 80 Wizard serial port Communications Opens Communications Log Communications Log p 143 Log Download Starts sequence of prompts to download Downloading Firmware p 129 Firmware new firmware image from disk to amplifier Manual Phase Opens Manual Phase tool Manual Phasing p 145 View Scope Files Opens Trace Viewer window Scope
106. e amplifier Saves save all user entered data represented on all screens from volatile and flash data to disk memory to a disk file with a ccx filename extension al Restore amplifier data from disk Restores amplifier and motor data from a ccx file to the amplifier s volatile and flash memory Note that only certain data is saved to flash by this operation the data described as Flash only on p 126 To assure that all data including the data described as Flash and Volatile is stored in flash use the Save amplifier data to flash tool 4 Save amplifier data to flash Saves contents of the amplifier s volatile memory to the amplifier s flash memory E Restore amplifier data from flash Restores contents the amplifier s flash memory to amplifier s volatile RAM To use a data management tool click the icon and respond to prompts Motor Data Management Tools Operations performed using the data management tools at the bottom of the Motor Feedback screen shown below affect only user entered data that is represented on the Motor Feedback screen Motor Feedback Data Management Tools The motor data management tools are described below Icon Name Description sal Save motor data to disk Saves only motor feedback data from flash memory to a disk file with a ccm filename extension Amplifier data that is not represented on the Motor Feedback screen is not saved in this file
107. e following formulas P motor 3 4 Rwinding F Kt Where Pmotor Power dissipated in the motor in watts Rwinaing Line to line resistance of the motor F Force needed to decelerate the motor Nm for rotary applications N for linear applications Kt Torque constant for the motor Nm Amp for rotary applications N Amp for linear applications E motor P motor Taecel Where Emotor Energy dissipated in the motor in joules Tuecel Time of deceleration in seconds A 1 5 Determine the Amount of Energy Returned to the Amplifier Calculate the amount of energy that will be returned to the amplifier for each deceleration using the following formula E returned Edec 7 E motor Where Eretumea Energy returned to the amplifier in joules Ege Energy returned by the deceleration in joules E motor Energy dissipated by the motor in joules Copley Controls Corp 155 Regen Resistor Sizing and Configuration Xenus XSL User Guide A 1 6 Determine if Energy Returned Exceeds Amplifier Capacity Compare the amount of energy returned to the amplifier in each deceleration with the amplifier s energy absorption capacity For related amplifier specifications see Regen Circuit Output p 51 For mains voltages not listed in the specification table use the following formula to determine the energy that can be absorbed by the amplifier W capacity 2 C Viegen E 1 414 Vmains Where Weapacity The energy that can be absorbed
108. e likely to be called for when tuning a linear motor with an encoder resolution finer than a micrometer Velocity Loop Command and Output Filters The velocity loop contains two programmable digital filters The input filter should be used to reduce the effects of a noisy velocity command signal The output filter can be used to reduce the excitation of any resonance in the motion system Two filter classes can be programmed the Low Pass and the Custom Bi Quadratic The Low Pass filter class includes the Single Pole and the Two Pole Butterworth filter types The Custom Bi Quadratic filter allows advanced users to define their own filters incorporating two poles and two zeros For more information see Velocity Loop Filters p 167 Velocity Loop Outputs The output of the velocity loop is a current command used as the input to the current loop Copley Controls Corp 23 Operational Theory Xenus XSL User Guide 2 5 4 Position Mode and Position Loop Position Loop Diagram The amplifier receives position commands from the digital or analog command inputs over the CAN interface or serial bus or from the CVM Control Program When using the digital or analog inputs the amplifier s internal trajectory generator calculates a trapezoidal motion profile based on the trajectory limit parameters When using the CAN bus serial bus or CVM Control Program a trapezoidal or S curve profile can be programmed The trajectory generator updates the
109. e might be reduced i e slow correction to disturbances or transients 2 If the amplifier is set up to run in position mode under analog input command and the analog command signal produces too much noise at the motor after tuning the Velocity Loop Command Filter may be used to reduce the noise further See Velocity Loop Filters p 167 5 13 2 6 Tune to multiple sets of profiles representing typical moves that might be executed in the application Starting with Set up a trapezoidal profile repeat the process as needed Copley Controls Corp 117 Quick Setup with CME 2 5 13 3 Test S Curve Profile NOTE Skip this step unless the amplifier will perform CANopen S Curve profile moves Xenus XSL User Guide Jerk is the rate of change of acceleration S Curve moves reduce jerk to provide a smooth profile To tune the level of jerk run an S Curve profile and adjust velocity acceleration deceleration and jerk levels until the desired profile is obtained a amp Oscilloscope MEEI 1200 Trace Status Ready 0 1 02 03 04 05 06 07 08 09 Time seconds 10 a 12 13 Function Generator Profile Move Relative C Absolute Distance 40000 counts Maximum Weceleration 375 Type Maximum Velocity 1125 C Trap 5 Curve Maximum Acceleration 376 Maximum Jerk 15000 Settings Gains Trajectory Limits Position Params Velocity Params 5 13 3 1 5 13 3 2 118 On the Profile tab
110. e software will now micro step the motor in 20 e the positive direciton Make sure the motor is 450 3D free to move Press Start when ready 180 0 Auto Phase Current 0 47 A 210 330 240 org 900 Increment Rate 90 elec deg sec Actual Position 0 counts Ready Back Mext gt Cancel Copley Controls Corp 189 ServoTube Motor Setup Xenus XSL User Guide G 2 1 7 Click Start to begin the motor wiring setup The software displays messages Configuring Initial Settings Microstepping Test Complete Motor Wiring has been configured During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate The field produced should push on the permanent magnet s magnetic field causing the motor to move If the step fails see Trouble Shoot Motor Wiring Setup p 109 NOTE If incorrect values were entered for inductance and resistance the calculated Cp and Ci values may produce current loop oscillation evidenced by an audible high frequency squeal during auto phasing G 2 1 8 Click Next to display the Analog Hall Wiring Setup screen ENS x Analog Hall Setup Hall angle in red Commanded Position your motor in center of its range motor phase angle in black The software will now micro step the motor Make sure the motor is free to move Press Start when ready 120 7 Auto Phase Current 14 180 0 Start Stop 240 300 Hall Offset 150 deg Hall Phas
111. eat to temperatures that could cause injury If higher settings are required contact Copley Controls customer support WARNING Failure to heed this warning can cause equipment damage or injury H 5 2 XTL RA 03 XTL RA 04 Dimensions The diagram below shows XTL RA 03 and XTL RA 04 mounting dimensions in mm 4 3 hole 225 2 OA 10 60 0 5 265 2 COPLEY CONTROLS CORP MODEL XTL RA 03 PART 32 00100 000 REV A RoHS COMPLIANT 198 Copley Controls Corp Xenus XSL User Guide H 5 3 XSL RA 01 02 Discontinued Specifications Ordering Guide and Accessories Copley Controls no longer distributes XSL RA regen resistors Resistors with model numbers XSL RA 01 and XSL RA 02 have been replaced by models XTL RA 03 and XTL RA 04 Model Resistance Continuous Power Peak Power For Use With XSL RA 01 30 ohms 167 W 5 kW XSL 230 18 XSL 230 18 R XSL RA 02 15 ohms 200 W 10 kW XSL 230 36 XSL 230 36 R XSL 230 40 XSL 230 40 R H 5 4 XSL RA 01 02 Discontinued Dimensions B 9 25 AR FS SR Ri C 2 9 3 S 4 12
112. echanical and Environmental 3 24 Dimensions 4 1 General Wiring Instructions 4 1 1 Electrical Codes and Warnings xs ies EN T vas sss 4 12 Grounding GONSiGerations 5 1 don eee REA PME et a eR ended Ea e Guat Ea dents 4 13 Connector Locations cimas C s one te 4 2 AC Mains J1 zc i i T ss m 2 9 MOTO 2 6 cr aa a ec a rd te do ott tore Ai ie ar Lo T 4 4 Regen Resistor J9 Optional 1 tn cir prt ci 4 5 Logic Supply Brake J4 4 6 RS 232 Serial Communications J5 E i ae us E A AT GAN BUS JE i uf Bee i ea bett te A d n de da AAEE CONTON PE A A oce A loa ee 4 8 Motor Feedback J8 oe He a E zs a T 5 Quick Setup With CME H ns 5 1 Warning incon neat En el NE lel Neath Heer bb Ese d Du vete det e e Hub eb A SEED o RAA ARE AE 5 2 CME 2 Installation and Serial Port Setup a 5 2 1 Requirements ocoooocccccccnccccnncnccnoncnanannncnnnnn 5 2 2 Downloading Software from Web Optional 5 2 3 Installing CME 2 Software 5 2 4 Serial Port Setup ave z Es m as ae 5 9 Preredquisiles zo a mer A NR 5 3 1 Hardware and Equipment 5 esnaera tite le D Een nent tre nn tn Dra aaaea 5 3 2 Starting CME 2 and Choosing an Amplifier 5 4 Basic Setup ncnanannnncnnn
113. ed by the Motor ssssssssssseeeneemeeeeeenenmnte eren A 1 5 Determine the Amount of Energy Returned to the Amplifier x A 1 6 Determine if Energy Returned Exceeds Amplifier Capacity BT Ad m ES T A 1 7 Calculate Energy to be Dissipated for Each Deceleration tenn nnnnn nnt A 1 8 Calculate Pulse Power of Each Deceleration that Exceeds Amplifier Capacity A 1 9 Calculate Resistance Needed to Dissipate the Pulse Power s ET A 1 10 Calculate Continuous Power to be Dissipated ss AT T4 SClSCHEUSES is ot nine ANN A 2 Configuring a Custom Regen Resistor A 2 1 Regen Configuration Objective and Warning du zs T us i m A 2 2 Regen Configuration Instructions sise B TTime Limit Algorithm laca ali B 1 T Algorithm B 1 1 IT Overview B 1 2 I T Formulas and Algorithm Obperatloh 7 ie lidad B 1 3 T Current Limit Algorithm Application Example C Velocity Loop Filters sisi C 1 Advanced Velocity Loop Filter C 1 1 Filter Overview C 1 2 Filter Instructions and Details E ses ES nm D LIEB ngpmciu t H D 1 Operating Temperature and Cooling Configurations sise D 1 2 Heatsink and Fan Configurations D 2 Heatsink Mounting Instructions E Xenus Filter x E 17 QVeIVIBW 6 uicti recep tei ko ern Ced rae e E 1 1 Differential
114. ee Digital Inputs 1 5 Digital Inputs 6 12 Digital Outputs OUT1 Fault Active High El lo e Red light output is active a Grey light output is not active OUT2 Fault Active Low y Hi OUT3 Not Configured Hi OUT4 Brake Active High v Lo Hi Indicates current state of output Restore Defaults Close 5 8 22 Choose any of the following functions for any output OUT4 is recommended for brake function Output Function Description For More Information Not Configured No function assigned Output remains high Fault Active High Output goes high when at least one fault is detected Faults p 36 Fault Active Low Output goes low when at least one fault is detected Brake Active High Output goes high to activate the brake Brake Operation p 33 Brake Active Low Output goes low to activate the brake PWM Sync Output OUT1 only Custom Active High The PWM synchronization output PWM Sync Input p 43 and PWM Sync Output p 44 The output goes high when one or more of the triggering events are detected To set the triggering events see Custom Digital Outputs p 96 The output goes low when one or more of the triggering events are detected To set the triggering events see Custom Digital Outputs p 96 Custom Active Low Program Control High Output state controlled by CVM or CAN program Program Control Low
115. ef In GP Input IN11 12 Green White 6b 13b Yellow Tan 25 Analog Ref In OUT1 13 White Blue 7 7b Blue White 26 IN12 GP Input 196 Copley Controls Corp Xenus XSL User Guide H 4 3 Feedback XSL FC 10 The molded connector mates with amplifier J8 and has flying lead terminators with colors shown in the tables below Ordering Guide and Accessories Note the color changes affecting pins 1 and 11 between XSL FC 10 Revision B and Revision C Standard Version Encoder Feedback Signal Pin Color Pair Color Pin Signal Body Stripe Body Stripe Frame Ground 1 Rev A amp B White Tan 1a 1b Rev A amp B Tan White 11 Digital Hall U Rev C Brown Rev C Orange Signal Ground 2 White Brown 2a 7a White Blue 12 Digital Hall V 5 Vdc 400 mA 3 Brown White 2b 7b Blue White 13 Digital Hall W Encoder A Input 4 White Pink 3a 8a White Violet 14 IN5 Temp Sensor Encoder A Input 5 Pink White 3b 8b Violet White 15 Signal Ground Encoder B Input 6 White Orange 4a 9a White Gray 16 Encoder Sin Input Encoder B Input Orange White 4b 9b Gray White 17 Encoder Sin Input Encoder X Input 8 White Yellow 5a 10a Tan Brown 18 Encoder Cos Input Encoder X Input 9 Yellow White 5b 10b Brown Tan 19 Encoder Cos Input Signal Ground 10 White Green 6a 6b Green White 20 Signal Ground Resolver Version Signal Pi
116. egen Resistor Fusing Recommended Fuses Regen Resistor Fuse type XSL RA 01 Cooper Bussman KLM 8 or equivalent XSL RA 02 Cooper Bussman KLM 12 or equivalent User Supplied See Regen Resistor Sizing and Configuration p 153 64 Copley Controls Corp Xenus XSL User Guide Wiring 4 5 Logic Supply Brake J4 Mating Connector Description Euro style 3 position 5 0 mm pluggable female terminal block Manufacturer PN Wago Standard 721 103 026 047 Right Angle 722 203 026 000 Wire Size 22 14 AWG Recommended Wire 18 AWG Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 RTN 24 Vdc return 2 Brake Return or low side of motor brake 3 24 Vdc 24 Vdc Logic power supply Logic Supply Brake Wiring Diagram Amplifier Isolated Logic Power Supply 24 Vdc Power Supply Required Copley Controls Corp 65 Wiring Xenus XSL User Guide 4 6 RS 232 Serial Communications J5 Mating Connector 6 position modular connector RJ 11 style Copley Controls provides a prefabricated cable and modular to 9 pin sub D adapter in RS 232 Serial Cable Kit PN SER CK A diagram of the female connector is shown below L1 r 00 1 2 3 4 5 6 Pin Description Pin Signal Function 1 N C No connection 2 Rx
117. elative Moves axis a specified distance from the starting position Absolute Moves axis to a specific position Type Trap or S Curve Distance Distance for Relative move Position Target position for Absolute move Reverse Relative move only When checked will continuously generate forward and reverse moves of the and distance specified until Stop is pressed Repeat Copley Controls Corp 135 Using CME 2 6 5 3 Scope Settings The settings accessible from the screen and tabs shown below affect the operation of the scope Settings Gains Trajectory Limits Position Params Velocity Params chan Disabled Chan 4 Disabled Trace Time ss gt Sample Rate 7mS zuo DUE UN Chan 2 Actual current Auto Setup Auto Trigger Single Trace Channel Trace Variable Options Chan 1 4 To choose which trace variable to display in a scope channel click the channel button such as x Category Trace Variable Disabled Commanded current Current Actual current Velocity Position Acceleration Voltage x Cancel The categories and variables are listed below 21 Then choose a category and then a trace variable X enus XSL User Guide Category Trace Variable Category Trace Variable Disabled Channel disabled no Position Commanded Position associated variable Limited Position Actual Position Following Error Current Comma
118. elmage ri 2 oA E My Recent D Desktop My Documents z pE My Computer a My Network File name Accelnet 4 32 cff Open Files of type Firmware Image Files cff Cancel Click Open to begin the download Or click Cancel to close the screen without downloading new firmware message window displays a series of progress messages Writing new firmware image When the message window closes the firmware download is complete Copley Controls Corp Xenus XSL User Guide Using CME 2 6 4 Control Panel 6 4 1 Control Panel Overview To access the control panel click the Control Panel icon al on the Main screen Each of the features labeled below is described in the following sections Monitor real time amplifier values i control Panel ol xl r Status rMonitor Motor Output Active Hardware Enable Enabled Software Enable Enabled actua Current gt ME A Status indicators J POS Limit Not Active NEG Limit Not Active actua motor velocity y E ro Dispi i 3 Motor Phase OK isplay error log p gt Error Log CAN Network actual Postion x Actual Posit d nt CVM Control Program Not Running cano MESE roin Home Not Referenced Message box Control Move Control functions Y gt C Disable Amplifier Reset C Jog Mode Clear Faults Set Zero Position Deceleration Move NEG
119. encoder input e Provide an emulated digital encoder output based on the analog encoder or resolver input e Provide a second digital encoder input to be used in the dual encoder position mode In this mode an encoder attached to the load provides position loop feedback and the motor encoder or resolver provides velocity loop feedback 18 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 5 Operating Modes 2 5 1 Modes and Control Loops Nesting of Control Loops and Modes Copley Controls amplifiers use up to three nested control loops current velocity and position to control a motor in three associated operating modes Control Loops Illustration In position mode the amplifier uses all three loops As shown below the position loop drives the nested velocity loop which drives the nested current loop Limits Target Position Velocity Limited Current Limited PWM Position Command Command Velocity Command Current Command Trajectory Position ci loci Current Motor Generator Loop imite Loop Sensors Actual Position Derived Velocity Actual Current In velocity mode the velocity loop drives the current loop In current mode the current loop is driven directly by external or internal current commands Basic Attributes of All Control Loops These loops and servo control loops in general share several common attributes Loop Attribute Description Command input Every loop is
120. eneral purpose and HS high speed Input reference functions such as Pulse and Direction Pulse Up Pulse Down and Quadrature A B are wired to inputs having the HS filters and inputs with the GP filters are used for general purpose logic functions limit switches and the motor temperature sensor 2 13 3 Debounce Time To prevent undesired multiple triggering caused by switch bounce upon switch closures each input can be programmed with a debounce time The programmed time specifies how long an input must remain stable at a new state before the amplifier recognizes the state 2 13 4 Configure for Pull Up Pull Down Resistors by Groups Pre defined groups of inputs can be programmed to have either an internal pull up or pull down resistor See J7 Pin Description p 69 for groupings 2 13 5 Programmable Input Functions Enable Input Functions IN1 can only be programmed to one of the enable functions described below Function Description AMP Enable When the input is low amplifier enables PWM output stage Amplifier LO Enables with clear faults clears faults on the low to high transition of the input When input is high the amplifier disables the PWM output stage AMP Enable When the input is high amplifier enables PWM output stage Amplifier HI Enables with clear faults clears faults on the high to low transition of the input When input is low the amplifier disables the PWM output stage AMP Enable When the input is l
121. ep command Quadrature A B quadrature commands from a master encoder via two inputs provide velocity and direction commands Increment position Rising Edge Increment position on the rising edge of the input pulse on Falling Edge Increment position on the falling edge of the input pulse Stepping Input Pulses Number of Input Pulses required to produce output counts Resolution Range 1 to 32 767 Default 1 Output Counts Number of Output Counts per given number of input pulses Range 1 to 32 767 Default 1 Invert Command When checked inverts commanded direction Click the Trajectory Limits tab Kd Analog Command 15 xl Configuration Trajectory Limits Profile Commanded Profile Position Acceleration Limited Position Max Velocity 12500 rpm Max Accel 4167 rps Max Decel e rps Abort Decel 4167 rps Copley Controls Corp Xenus XSL User Guide 5 9 3 4 Enter the options described below Quick Setup with CME 2 Option Description For More Information Max Velocity Maximum trajectory velocity Max value may depend upon the back EMF and the Max feedback count Min 0 Default 0 25 x motor velocity limit Max Accel Maximum trajectory acceleration Max value may depend upon the load inertia and peak current Min 0 Default 0 5 x velocity loop Accel Limit value Max Decel Maximum trajectory deceleration Max value may
122. er over temperature Motor over temperature Over voltage Under Voltage Feedback error Motor phasing error F Following error Optional Faults Over Current latched Restore Defaults Cancel Help 5852 To make a fault condition latching click to put a check mark next to the fault description Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against DANGER Unexpected motion Failure to heed this warning can cause equipment damage injury or death For more information on faults see Faults p 36 5 8 5 3 To restore factory defaults if needed click Restore Defaults 5 8 5 4 Click OK to save fault configuration settings to volatile memory and close the Fault Configuration screen OR click Cancel to restore to previous values and close the screen 5 8 5 5 On the Main screen click Save to Flash sal Copley Controls Corp 97 Quick Setup with CME 2 Xenus XSL User Guide 5 8 6 Regen Resistor For more information on the external regen resistor see Regen Resistor Theory p 47 and Regen Resistor Sizing and Configuration p 153 5 8 6 1 5 8 6 2 5 8 6 3 Click Configu
123. falling edge of the signal Stepping resolution can be programmed for electronic gearing 28 Copley Controls Corp Xenus XSL User Guide Operational Theory Count Up Count Down Format In the count up count down format one input takes each pulse as a positive step command and another takes each pulse as a negative step command as shown below Up Input JUuUUL n Velocity Command The amplifier can be set to increment position on the rising or falling edge of the signal Stepping resolution can be programmed for electronic gearing Quadrature Format In quadrature format A B quadrature commands from a master encoder via two inputs provide velocity and direction commands as shown below A Input Jill TUL B Input Jf EJ LF LI Le Velocity Command The ratio can be programmed for electronic gearing 2 5 9 CVM Program The Copley Virtual Machine CVM is a software program that runs motion control programs on supported Copley Controls amplifiers When a CVM program is running the amplifier receives input commands from the CVM program For more information see the Copley Indexer Program User s Guide Copley Controls Corp 29 Operational Theory Xenus XSL User Guide 2 6 CANopen Operation 2 6 1 CAN Network and CANopen Profiles for Motion In position mode the amplifier can take instruction over a two wire Controller Area Network CAN CAN specifies the data link and physical connection layers of a fast reliab
124. filter can increase rise time to 500 ns reducing the high frequency noise emissions by the square law The differential filter is designed with 82 uH inductors and a proprietary passive circuit The inductance will provide a total of 164uH in series with the load helping to reduce ripple current This brings low inductance motors into the required range The common mode filter is designed with a 220 uH common mode toroid that works with the cable capacitance to earth ground to remove common mode switching noise Filter 82uHTT u Ans 82uH ET YYYYA 82uH 11 Differential V Case GN Mode x 90 T 4 10 3 pbF 34 Raw PWM Filtered 174 Copley Controls Corp Xenus XSL User Guide Xenus Filter E 2 XSL FA 01 Edge Filter Specifications input Voltage maximum 373 Vdc Current maximum 20 Adc Voltage maximum 373 Vdc Output Current maximum 20 Adc Peak Current Peak Current Time 40 Adc for 1 second Rise Fall Time 500 nS typical Differential Mode Inductance 82 uH per phase 162 uH phase phase nominal Common Mode Inductance 220 UH nominal Nominal Resistance 27 milliohms per leg 54 milliohms phase phase nominal Agency Approvals UL508C EN60204 E 3 Thermal Considerations Cooling Requirements When used with XS
125. gateway to other amplifiers linked together by CAN bus connections Auto phasing of brushless motor Hall sensors and phase wires eliminates wire and try Connections are made once and CME 2 does the rest Encoder or resolver wire swapping to establish the direction of positive motion is also eliminated Motor data can be saved as ccm files Amplifier data is saved as ccx files that contain all amplifier settings plus motor data This makes it possible to quickly set up amplifiers by copying configurations from one amplifier to another 1 3 CMO CML Copley Motion Libraries CML and Copley Motion Objects CMO make CANopen system commissioning fast and simple All network housekeeping is taken care of automatically by a few simple commands linked into your application program CML provides a suite of C libraries allowing a C application program to communicate with and control an amplifier over the CANopen network CMO provides a similar suite of COM objects that can be used by Visual Basic NET LabVIEW or any other program supporting the Microsoft COM object interface Copley Controls Corp 13 Introduction Xenus XSL User Guide 14 Copley Controls Corp CHAPTER 2 OPERATIONAL THEORY This chapter describes the basics of Xenus operation Contents include Title Page 2 1 Amplifier Internal POW e X 16 2 2 Synchronizing PWM Switching Frequency cordc erect tee coupe a ga
126. h CME 2 p 77 have been performed Prerequisites Basic Setup Motor Setup Amplifier Configuration Command Input Auto Phase 6 9 2 2 Click Current Loop ae to open the Current Loop screen Curren t Loop 5 xl Current Offset Commanded Current Peak Current Limit 1395 a FT Time Limit 1000 ms ES GE 285 nd Continuous Current Limit 468 A Auto Tune Current Loop Offset 0A aene 69 23 Verify that amplifier is hardware enabled 6 9 2 4 Click Auto Tune sto Tune to open the Current Loop Auto Tune screen and start the Auto Tune procedure current Loop Auto Tune E 15 x Auto Tune Current 1 Status Auto Tune in progress Cp 100 GT 0 Start Stop 6 9 2 5 To Change the Auto Tune Current Press Stop enter the new current in the Auto Tune Current field and then press Start Copley Controls Corp 149 Using CME 2 Xenus XSL User Guide 6 9 2 6 Observe the auto tune process and results Auto Tune uses a proprietary algorithm to mimic a standard tuning approach that would be used by a trained technician as described below 1 Sets Cp and Ci to zero and then adjusts Cp and Ci for optimal values ll Auto Tune Current 1 Status Auto Tune in progress CON 25 0 NND 0 Start Stop 2 a we m Auto Tune Current 1 Status Auto Tune finished Cp 2469 Ci 157 Start Stop 3 Displays the results a set of Cp Ci and bandwidt
127. h good grounding Disable the amplifier and move the motor manually to test for phase fault Bb N If phase fault only occurs under command of current make sure the motor power cable is not bundled with the encoder cable 6 8 4 3 Problem Hall signals bad 1 Make sure Halls change states as the motor moves through one electrical cycle 2 Some Hall signals are noisy and require filtering Check with motor manufacturer 3 Some Halls are not properly calibrated to the motor manufacturer s specification 6 8 4 4 Problem Hall transition wrong The location of the Hall transition is not within 30 degrees 1 Adjust Hall offset in smaller increments 2 Verify Hall alignment 3 Make sure motion is smooth 6 8 5 Verify Motor Pole Count Use this procedure if needed to troubleshoot wrong data 6 8 5 1 Apply a current vector at zero Increment Rate to lock motor in position 6 8 5 2 Turn the motor shaft and count the number of distinct locking positions 6 8 5 3 Calculate the number of poles Poles Number of Positions 2 148 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 9 Auto Tune Current Loop 6 9 1 Auto Tune Objective The current loop auto tune algorithm applies a square wave command to the current loop and adjusts current loop proportional gain Cp and current loop integral gain Ci until a desirable waveform is obtained 6 9 2 Auto Tune Instructions 6 9 2 1 Verify that the following steps in Quick Setup wit
128. h value alternatives x Auto Tune has determined new values for Cp and Ci along with a high bandwidth measurement Select desired settings C High Cp 2469 ci 157 Bandwidth 2100 Hz Medium Cp 1481 ci 94 C Low Cp 988 ci 63 C Original EN 1393998 123 Save Cp and Cito Flash C Keep Cp and Ci in RAM only Cancel 150 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 9 2 7 Choose an action based on Auto Tune results 1 Optionally choose which set of values to save High Medium Low or Original The Medium values selected by default are appropriate for most applications 2 Optionally choose how to save Save Cp and Ci to Flash or Keep Cp and Ci in RAM only 3 Click OK to save the values as chosen and close the Auto Tune Results window or click Cancel to close the window without saving any changes Copley Controls Corp 151 Using CME 2 Xenus XSL User Guide 6 10 Home Function 6 10 1 Overview The CME 2 Home function can be used to set and test homing parameters 6 10 2 Homing Functions Settings 6 40 2534 On the CME 2 Main screen click Home CNN to display the Homing screen xl Software limits Positive O counts Negative 0 counts Disable Direction of Motion Positive C Negative Fast Velocity 326 rpm Offset 0 counts Slow Velocity 65 rpm Current Limit 117 A AccelDecet 108 rps Current Delay Time 250 ms Lotual Home stop ok Cancel 6 10
129. hed following error occurs in position mode then the amplifier drops into velocity mode and the Fast Stop Ramp is used For more information see Following Error Fault Details p 39 22 Copley Controls Corp Xenus XSL User Guide Operational Theory Diagram Effects of Limits on Velocity Command The following diagram illustrates the effects of the velocity loop limits Limited Velocity Commanded Velocity Vel Limit I Accel Limit Fr Decel Limit gt Velocity Loop Gains The velocity loop uses these gains Gain Description Vp Velocity loop proportional The velocity error the difference between the actual and the limited commanded velocity is multiplied by this gain The primary effect of this gain is to increase bandwidth or decrease the step response time as the gain is increased Vi Velocity loop integral The integral of the velocity error is multiplied by this value Integral gain reduces the velocity error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral is the accumulated sum of the velocity error value over time Velocity Loop Gains Scalar The Enable Gains Scalar feature increases the resolution of the units used to express Vp and Vi providing more precise tuning This feature is used when tuning results in non scaled Vp or Vi values of 64 or less Such low values ar
130. i 3 59 i i n M FROM e L 3 98 V AMPLIFIER kj A e A 1 101 1 7 d e 3 uo A Nu E y La wu Mg M M XE 3 15 DS JL 80 annamgnnnannn 91 2 W n 3 Ty 1 Y MOTER 1 1 P 1 U I pueri V Ad g v M LU UV S 23 DCCLER CL CCLCE E AL 1 ZA ua nL jar nur rjr nur rjr mar jr irn A Y i 1 I chy 1 L J 1 160 4 1 42 gt 1 50 10 7 55 E pu 762 z S 188 4 8 n l 4 a umi a E a Fi a F j ad A 5 49 139 4 ii ad a X ru F ad EE i 188 c f 4 8 LA 1 176 Copley Controls Corp Xenus XSL User Guide Xenus Filter E 5 XSL FA 01 Edge Filter Wiring This section describes the wiring of the XSL FA 01 Edge Filter E 5 2 Electrical Codes and Warnings Be sure that all wiring complies with the National Electrical Code NEC or its national equivalent and all prevailing local codes DANGER DANGER WARNING Copley Controls Corp DANGER Hazardous voltages Exercise caution when installing Failure to heed this warning can cause equipment damage injury or death Risk of electric shock High voltage circuits on Xenus J1 J2 and J3 and on Filter J1 and J2 are connected to mains power Failure to heed this warning can cause equipment damage injury or death Do not ground mains connected circuits With the exception of the ground pins on Xenus J1 J2 and J3 and on Filter J1 and J2 all of the other circuits on these connectors are mains conne
131. ier is not disabled by a motor over temperature fault G 1 5 Other ServoTube I O and Fault Latching Setup Steps Before proceeding with this chapter perform any other required configuration of the amplifier s digital inputs digital outputs and fault latching Inputs and outputs Digital Inputs p 93 Standard Digital Outputs p 95 Custom Digital Outputs p 96 Save Input Output Changes p 96 Fault latching Fault Latching p 97 188 Copley Controls Corp Xenus XSL User Guide ServoTube Motor Setup G 2 ServoTube Auto Phase and Manual Phase G 2 1 ServoTube Auto Phase NOTE The following steps use a ServoTube motor For short stoke ServoTube motors with less than 2 electrical cycles proceed to G 2 2 ServoTube Manual Phase p 192 G 2 1 1 Verify that the Enable Input is not activated G 2 1 2 Apply power G 2 1 3 Click Auto Phase El to open the Auto Phase Motor Direction Setup screen x Motor Direction Setup Move the motor in the direction that you want to be positive Press Next when done Actual Position 0 counts G 2 1 4 Move the motor in the direction you wish to be considered positive The Actual Position value on the screen should change If it does not change see Trouble Shoot Motor Direction Setup p 109 G 2 1 5 Activate the Enable Input G 2 1 6 Click Next to display the Auto Phase Motor Wiring Setup screen x Motor Wiring Setup Commanded Motor Phase Angle Th
132. ing options as needed Options Description Peak Current Limit Used to limit the peak phase current to the motor Max value depends upon the amplifier model Min value gt continuous limit T Time Limit Sets IT Time Limit in mS For more information see IT Time Limit Algorithm p 161 Continuous Current Limit Used to limit the Phase Current Max Value is Peak Current and depends upon the amplifier model Min value 0 Current Loop Offset Sets current loop offset Leave it set to zero until after tuning For more information see Offset p 20 Cp Current loop proportional gain Range 0 32 767 Ci Current loop integral gain Range 0 32 767 Auto Tune See Auto Tune Current Loop p 149 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 11 2 Manually Tune Current Loop To tune the current loop apply square wave excitation to the current loop and adjust current loop proportional gain Cp and current loop integral gain Ci to obtain a desired waveform E Oscilloscope Ma Ei Trace Status Reading trace data from amplifier 0 000 0 002 0 004 0 008 0 008 0 010 0 012 0 014 0 016 0 018 0 020 0 022 0 024 0 Time seconds Function Generator Prone Apply To c urrent Y Settings Gains Trajectory Limits Position Params velocity Params Chan2 Reta currant Aut Setup Auto Trigger Tider setup
133. ing the power section Enable Input Brake Stop delay time Li Speed H NS Brake Stop activation velocity Brake Ouptput Enable mo PM delay Power Section Brake Stop response time This sequence is not available in the current mode of operation Instead in current mode the amplifier output turns off and the brake output activates immediately when the disable command is received Copley Controls Corp 33 Operational Theory Xenus XSL User Guide 2 9 Status Indicators 2 9 1 Amplifier and CAN Interface Status Indicators The amplifier s status indicator is a bicolor LED labeled STATUS on the amplifier front panel The CAN interface status indicator is a bicolor LED labeled CAN Locations are shown below Xenus Status Indicator CAN Status Indicator 2 9 2 Amplifier Status Indicator Operation Amplifier status indicator color blink codes are described below Color Blink Code Meaning Not illuminated No 24 Vdc power to amplifier Steady green Amplifier is enabled and operational Slow blinking green Amplifier is disabled No faults or warnings are active Fast blinking green A limit switch is active The amplifier is enabled Steady red A non latched fault has occurred Blinking red A latched fault has occurred 20 Fast red blinks on power up or reset Amplifier has reverted to boot mode 34 Copley Controls Corp Xenus XSL User Gui
134. ion load encoder n e Rotary e Linear not available in CME 4 0 Encoder Select source of the encoder output signal Not available if secondary Output encoder input is used Source e Motor Encoder e Position load Encoder For more information see Feedback p 18 and Feedback Setup p 89 Click OK to accept the values and write them to flash memory OR to return to the Main screen without saving changes click Cancel Copley Controls Corp 85 Quick Setup with CME 2 Xenus XSL User Guide 5 5 Motor Setup There are three methods for performing motor setup Choose the appropriate method and perform the steps described Method Step Load motor data from file ccm Motor Data File p 86 Enter rotary motor data Rotary Motor p 87 Enter linear motor data Linear Motor p 88 5 5 1 Motor Data File 5 5 1 1 To download motor data files from the website 1 Inan internet browser navigate to http www copleycontrols com Motion Downloads motorData html 2 Click on the appropriate motor name 3 When prompted save the file to the MotorData folder in the CME 2 installation folder 4 The default installation folder is C Program Files Copley Motion CME 2 MotorData 5 Extract the contents of the zip file to the same location 6 The folder should now contain the new motor data file with a ccm filename extension 7 If desired delete the zip file to save disk space 5 5 1 2 To load motor data from
135. ion Description Pull up 5 V Internally pulls the group of inputs up to internal 5 V Pull down Internally pulls the group of inputs down to signal ground Debounce Sets the input debounce time Time Range of accepted values 0 to 10 000 mSec For more information see Debounce Time p 42 IN1 IN12 Select the function for the input See Digital Input Functions p 94 for input function descriptions Copley Controls Corp 93 Quick Setup with CME 2 5 8 1 3 94 Digital Input Functions Xenus XSL User Guide Input Function Description AMP Enable LO Enables with clear faults A low input will enable the amplifier A low to high transition will clear latched faults and outputs AMP Enable HI Enables with clear faults A high input will enable the amplifier A high to low transition will clear latched faults and outputs AMP Enable LO Enables with reset A low input will enable the amplifier A low to high transition will reset the amplifier AMP Enable HI Enables with reset A high input will enable the amplifier A high to low transition will reset the amplifier AMP Enable A low input will enable the amplifier LO Enables AMP Enable A high input will enable the amplifier HI Enables Not Configured No function assigned to the input NEG Limit HI Inhibits A high input will inhibit motion in negative direction NEG Limit LO Inhibits A lo
136. is a segment of a larger more complex move rather than a single index or profile The amplifier then uses cubic polynomial interpolation to connect the dots so that the motor reaches each point at the specified velocity at the programmed time Homing mode is used to move the axis from an unknown position to a known reference or zero point with respect to the mechanical system The homing mode is configurable to work with a variety of combinations of encoder index home switch and limit switches 30 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 6 3 Architecture As shown below in a CANopen motion control system control loops are closed on the individual amplifiers not across the network A master application coordinates multiple devices using the network to transmit commands and receive status information Each device can transmit to the master or any other device on the network CANopen provides the protocol for mapping device and master internal commands to messages that can be shared across the network Local Control Softw are Application Master Controller Local Control CAN port CANopen Xenus Amplifier VO CAN Network 2 6 4 CAN Addressing A CANopen network can support up to 127 nodes Each node must have a unique and valid seven bit address Node ID in the range of 1 127 Address 0 is reserved and should only be used when the amplifier is serving as a CME 2 serial port multi
137. ition Params Velocity Params Function Profile Generation Trigger Setup Ay To Scope and Function Square wave x J Auto Setup v Auto Trigger control loop settings amplude 097 A crono TENE gt Frequency 100 Hz E Trace Time fi 255 aa SN Sample Rate 2mS Se Stop Sooo se cess oss oes soe ses sess sesssosne9 Record Stop Trace _ Clear Close Here are general procedures for performing basic activities with the scope cope controls L1 To Run a Function Generator Move 1 Click on the Function Generator tab 2 As required adjust Function Generator settings scope tool settings gains limits and parameters as described in the following sections of this chapter 3 Click Start to begin move and trace Click Stop to stop the move O To Run a Profile Move 1 Click on the Profile tab 2 As required adjust Profile settings scope tool settings gains limits and parameters as described in the following sections of this chapter 3 Click Start Click Stop to stop the move O To Monitor Externally Controlled Motion 1 As required adjust scope tool settings 2 Click Record to begin trace Click Stop Trace to stop the trace recording 3 Begin move with external controller 134 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 5 2 Function Generator and Profile Tabs The Function and Profile generators can provide inputs to the different control loops for tuning
138. ize the PWM switching frequency among multiple amplifiers In these cases one amplifier serves as a master for one or more slave amplifiers The PWM sync output of the master sends a signal that is received as a PWM sync input by each slave 2 3 Commutation Modes The amplifier supports three commutation modes to drive brush and brushless motors AC brushless sinusoidal AC brushless trapezoidal and DC brush In most applications sinusoidal commutation is preferred over trapezoidal because it reduces torque ripple and offers the smoothest motion at any velocity or torque In the sinusoidal commutation mode an encoder or a resolver are required for all modes of operation In AC brushless trapezoidal commutation mode the amplifier provides traditional six step commutation When driving a DC brush motor the amplifier operates as a traditional H Bridge amplifier 2 4 Feedback 2 4 1 Encoder and Resolver Support The Xenus amplifier is offered in two versions to support encoder or resolver feedback The encoder version supports digital quadrature or analog sin cos encoders This version normally requires the use of Hall switches for the commutation of brushless motors The resolver version supports standard single speed transmit type resolvers 2 4 2 Secondary Encoder Interface Both versions support a secondary encoder interface This interface can be configured to e Provide a buffered digital encoder output based on the digital
139. k from an incremental motor encoder through the Primary feedback channel J8 Position load encoder feedback comes through the Secondary channel J7 The ratio of motor turns to position encoder turns is 1 to 10 Motor Feedback Rotary Motor xj Motor Feedback ses r Motor Primary Incremental 1000 lines 4000 counts Position Secondary Incremental 1000 lines 4000 counts Ratio Motor Turns 1 Positon Turns 10 call al a ai I cacuicte x conca Copley Controls Corp 89 Quick Setup with CME 2 Xenus XSL User Guide 5 6 2 Rotary Motor Feedback Setup Options 5 6 2 1 Click the Feedback tab 5 6 2 2 As appropriate for each encoder or resolver enter the options described here Feedback Type Options Actions Incremental 1000 lines 4000 counts In the lines field enter the number of encoder lines see encoder or motor data sheet As indicated by the counts field the number of encoder counts per revolution is equal to 4 x the number of lines Analog In Fundamental Lines enter the number of fundamental encoder lines see encoder or motor data sheet As indicated by the Fundamental Ur k n Counts field the number of fundamental encoder counts per revolution is Rect i zi equal to 4 x the number of Fundamental Lines eee x Optionally modify the encoder resolution by changing the Interpolation value The interpolated resolution Interpolated Counts Per Rev is the produc
140. le 4096 Restore Default Interpolated Resolution 125 um al m Y M E o ons Copley Controls Corp 187 ServoTube Motor Setup Xenus XSL User Guide G 1 3 Calculating ServoTube Initial Values G 1 3 1 Click Calculate E eee to calculate and display initial loop gains and limits x Current Loop Cp Gain Current Loop Ci Gain Peak Current Limit Continuous Current Limit FT Time Limit Current Loop Offset Velocity Loop Vp Gain Velocity Loop Vi Gain Velocity Loop Velocity Limit Velocity Loop Accel Decel Fast Stop Velocity Tracking Window Velocity Tracking Time Position Loop Proportional Gain Pp Positon Loop Velocity Feedforward Vff G 1 3 2 Load the values into volatile memory by clicking OK OR to close the screen without saving changes click Cancel G 1 3 3 Click Save to Flash sal G 1 4 Setting Up the Motor Over Temperature Input It is important to program the amplifier to shut down the PWM outputs when a motor over temperature signal is sent over digital input IN5 by the motor temperature sensor G 1 4 1 On the CME 2 Main screen click Input Output to display the nput Output screen G 1 4 2 Verify that the inputs group containing IN5 is pulled up to internal 5 V and the IN5 function is set to Motor Temp HI Disables If the motor temperature sensor is wired to IN5 and the motor temperature is within specified operating range a grey indicator will show that the input is inactive and the amplif
141. le network CANopen is a set of profiles specifications built on a subset of the CAN application layer protocol These profiles specify how various types of devices including motion control devices can use the CAN network in a highly efficient manner Xenus supports the relevant CANopen profiles allowing it to operate in the following modes of operation profile torque profile velocity profile position interpolated position and homing 2 6 2 Supported CANopen Modes In profile torque mode the amplifier is programmed with a torque command When the amplifier is enabled or the torque command is changed the motor torque ramps to the new value at a programmable rate When the amplifier is halted the torque ramps down at the same rate In profile velocity mode the amplifier is programmed with a velocity a direction and acceleration and deceleration rates When the amplifier is enabled the motor accelerates to the set velocity and continues at that speed When the amplifier is halted the velocity decelerates to zero In profile position mode the amplifier is programmed with a velocity a relative distance or absolute position and acceleration and deceleration rates On command a complete motion profile is executed traveling the programmed distance or ending at the programmed position The amplifier supports both trapezoidal and s curve profiles In PVT mode the controller sends a sequence of points to the amplifier each of which
142. leared The contents of this tab are not refreshed automatically as new events occur The contents are refreshed only when the tab is displayed or when Refresh is clicked Frequency Type description and frequency of each fault and warning that has occurred since the log was last cleared The contents are refreshed only when the tab is displayed or when Refresh is clicked CAN Under CAN control only Status of CAN bus Lists warnings and errors Network O To update the contents of the History or Frequency tabs click Refresh Li To clear the log if needed press Clear Log Contents cannot be recovered To save the log to a disk file click the Save to Disk icon ad on the log screen Then navigate to the appropriate folder enter a File Name for the log and click Save O To close the log screen click Close 142 Copley Controls Corp Xenus XSL User Guide 6 6 2 Communications Log Using CME 2 The communications log tracks all communications between CME 2 and the amplifier The log is maintained in the PC s RAM Use the following instructions to manage the tracking and storage of these serial port messages O O 16 38 33 678 COML Send 16 38 33 741 COMl Recv 16 38 33 756 COMI Send 16 38 33 756 COML Recv 16 38 33 772 COML Send 16 38 33 772 COML Recv 16 38 33 772 COMl Send 16 38 33 772 COML Recv 16 38 33 772 COMl Send 16 38 33 772 COML Recv 16 38 33 772 COML Send 16 38 33 787 CO
143. ley Controls documents e CANopen Programmer s Manual e CML Reference Manual e Copley Motion Objects Programmer s Guide Also of related interest e Copley Indexer Program User s Guide describes use of Indexer Program to create motion control sequences e Copley Controls ASCII RS 232 User Guide describes how to send ASCII format commands over an amplifier s serial bus to set up and control one or more amplifiers Information on Copley Controls Software can be found at http www copleycontrols com Motion Products Software index html Comments Copley Controls Corporation welcomes your comments on this manual See http www copleycontrols com for contact information Copyrights No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Copley Controls Corporation Xenus is a registered trademark of Copley Controls Corporation CME 2 is a registered trademark of Copley Controls Corporation Windows 95 98 NT ME 2000 and XP Visual Basic Excel and NET are trademarks or registered trademarks of the Microsoft Corporation LabVIEW is a registered trademark of National Instruments Document Validity We reserve the right to modify our products The information in this document is subject to change without notice and does not represent a commitment by Copley Controls Corporation Copley Controls Corporation assumes no respon
144. lifier by selecting Enable as shown here Control Increment Rate 90 elec deg sec Current O47 A Set Zero Position C Disable Move Motor Rev Fwd 6 8 3 4 To control the current vector rotation command the motor Fwd or Rev NOTE Some motors have bearings stiction so helping the motor with mechanical force is acceptable Motors with no friction may need friction added to steady motion 6 8 3 5 If the motor cannot keep up with the rate of vector rotation then reduce the Increment Rate or increase the Current 6 8 3 6 Verify that Fwd moves motor forward If not toggle Motor Invert Output setting 6 8 3 7 Verify actual position count agrees with direction of rotation increasing counts in forward direction and decreasing counts in reverse direction If it does not toggle the Motor Feedback Invert Input box setting 6 8 3 8 Adjust Resolver Offset configuration as required testing Fwd and Rev to produce alignment of Motor Phase Angle with Resolver Angle as shown here Manual Phase xl Configuration Monitor No Faults Resolver 34 Motor Phase Angle Black Resolver Angle in Red Offset 120 deg Resolver 120 50 Motor Feedback 180 0 Ange 123 deg IV Invert Input 240 300 Motor Phase Angle 123 deg Motor Position 5528 counts Invert Output Actual Current U 098A Vi 045A W 053A Control Increment Rate 90 elec deg s Current 14 Set Zero Position Enabl
145. lifier over temperature and excessive following error When any fault occurs with the exception of a following error the amplifier s PWM output stage is disabled the fault type is recorded in the amplifier s internal error log which can be viewed with CME 2 and the status LED changes to indicate a fault condition exists A digital output can also be programmed to activate on a fault condition The following error fault behaves with slight differences as described in Following Error Fault Details p 39 The amplifiers PWM output stage can be re enabled after the fault condition is corrected and the amplifier faults are cleared The process for clearing faults varies depending on whether the fault is configured as non latched or latched The fault clearing descriptions below apply to all faults except for the following error fault which is described in Following Error Fault Details p 39 Clearing Non Latched Faults The amplifier clears a non latched fault without operator intervention as soon as the fault condition is corrected Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against DANGER unexpected motion
146. lose NOTE During position loop tuning observe any warnings that appear to the left of the trace 5 13 2 1 Perform an auto setup test 1 Click the Scope button B to open the Oscilloscope window 2 Select the Profile tab 3 Onthe Settings tab make sure that Auto Setup is checked Auto Setup automatically sets the following options Profile Tab Move Relative Type Trap Distance 2000 counts Reverse and Not checked repeat Settings Tab Channel 1 Profile velocity green Channel 2 Following error white 4 If the auto setup default profile distance is not appropriate enter an appropriate short distance 5 Click Start The Profile Generator executes a short move NOTES 1 The profile may not reach constant velocity during a short move 2 Ifa following error occurs open the CME 2 Control Panel al and click Clear Faults 116 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 13 2 2 Set up a trapezoidal profile by setting the trajectory limits and distance See table Trajectory Limits Tab Maximum Velocity Maximum Acceleration Set values typical of those expected to be used in the application Maximum Deceleration Profile Tab Distance Set the move distance to produce a complete trajectory profile Be sure that this distance does not exceed mechanical limits of the system Move Relative Type Trap 5 43 23
147. lt 0 00001 N Continuous Force The continuous force that the motor can produce Used with the force constant to calculate continuous current Range 0 00001 to 1 000 N Default 0 00001 N Velocity Limit Maximum speed of the motor Used to calculate the velocity and acceleration limits for the velocity loop Range dependent on encoder resolution Force Constant Relates the motor s input current to force produced Sometimes abbreviated as Kf Range 0 00001 to 1 000 N Amp Default 0 00001 N Amp Back emf Relates the motor s input voltage to speed Sometimes abbreviated as Ke Used for Constant calculating maximum velocity for a given amplifier voltage Range 0 01 to 1 000 V M Sec Default 0 01 V M Sec Resistance Motor resistance line to line Used for calculating the initial current loop tuning values Range 0 01 to 327 O Default 0 01 O Inductance Motor inductance line to line Used for calculating the initial current loop tuning values Range see Power Output p 50 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 6 Feedback Setup 5 6 1 Overview A Xenus amplifier can receive position feedback from sensors on the motor the load or both through the Primary feedback channel J7 the Secondary Feedback channel J8 or both It can also operate in certain modes without encoders or resolvers A dual feedback setup is shown below The amplifier receives feedbac
148. me it is enabled The Homing sequence may be initiated by CAN ASCII serial or CVM Indexer program commands 26 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 5 7 PWM Input Two Formats The amplifier can accept a pulse width modulated signal PWM signal to provide a current command in current mode and a velocity command in velocity mode The PWM input can be programmed for two formats 5096 duty cycle one wire and 10096 duty cycle two wire 50 Duty Cycle Format One Wire The input takes a PWM waveform of fixed frequency and variable duty cycle As shown below a 50 duty cycle produces zero output from the amplifier Increasing the duty cycle toward 100 commands a positive output and decreasing the duty cycle toward zero commands a negative output a _ Decreasing Duty Cycle Increasing Duty Cycle m9 PWM Input 50 96 Duty Cycle Amplifier Output 0 Max The command can be inverted so that increased duty cycle commands negative output and vice versa 100 Duty Cycle Format Two Wire One input takes a PWM waveform of fixed frequency and variable duty cycle and the other input takes a DC level that controls the polarity of the output A 096 duty cycle creates a zero command and a 100 duty cycle creates a maximum command level The command can be inverted so that increasing the duty cycle decreases the output and vice versa 100 100 Duty Cycle
149. med tracking time Velocity Tracking Illustration The following diagram illustrates the use of tracking window and time settings in velocity mode Actual Velocity Limited Velocit Y d Ye X r xTracking Window A Fs x N SS 7 yf 4 S d F J JA LARA Tracking Er Time J gd Tracking Window Output 40 Copley Controls Corp Xenus XSL User Guide Operational Theory 2 12 Communication 2 12 1 Communication Interfaces As described below the amplifier features two communication interfaces each used for different purposes Interface Description RS 232 port The amplifier features a three wire RS 232 port CME 2 software communicates with the amplifier using a binary protocol over this link for commissioning adjustments and diagnostics In addition ASCII commands can be issued over the serial port For RS 232 port specifications see Serial Interface p 54 For RS 232 port wiring instructions see RS 232 Serial Communications J5 p 66 In an RS 232 multi drop configuration a single amplifier with a serial connection to a controller can act as a gateway allowing the controller to access other node amplifiers interconnected by CAN bus connections via the serial connection CME 2 can be used to make adjustments even when the amplifier is being controlled over the CAN interface or by the digital inputs CAN interface When operating as a CAN n
150. mit is zero At approximately 3 5 seconds the commanded current falls below the continuous current limit and once again the output current follows the commanded current Because the actual current is less than the continuous current the IT Accumulator Variable value begins to fall incrementally The I T Accumulator Variable value continues to fall until at approximately 5 0 seconds when the commanded current goes above the continuous current limit again The actual output current follows the current command until the IT Accumulator Variable value reaches the I T setpoint and current limiting is invoked Copley Controls Corp 165 IT Time Limit Algorithm Xenus XSL User Guide This page for notes 166 Copley Controls Corp APPENDIX C VELOCITY LOOP FILTERS C 1 Advanced Velocity Loop Filter C 1 1 Filter Overview CME 2 supports 2 classes of filters the Low Pass and the Custom Bi Quad The Low Pass filter class includes the Single Pole and the Two Pole Butterworth filter types The default filter settings 2 Pole Butterworth with 200 Hz Cut Off Frequency suit the needs of most applications C 1 2 Filter Instructions and Details 6 1 2 1 Click V Loop ES to open the Velocity Loop screen CA22 Click Filter to open the Velocity Loop Output Filter screen kc velocity Loop Output Filter sd x Butterworth Low Pass Filter 3db Cut Off Frequency 200 Hz d 40db_ decade Help Class
151. mm s for linear motor Velocity PWM Delay Range of accepted values O to 10 000 mSec Brake Stop Response Time Copley Controls Corp 91 Quick Setup with CME 2 Xenus XSL User Guide 5 7 3 Calculate The Calculate function uses the motor and encoder values entered to calculate initial loop gains and limits These can be modified later to fine tune the amplifier 5 3 1 5 7 32 5 7 3 3 5 7 3 4 92 Click Calculate T E to calculate and display the settings 3 Current Loop Cp Gain 1539 ni Current Loop Ci Gain 83 Peak Current Limit 13 95 A Continuous Current Limit 4 68 A FT Time Limit 1000 ms Velocity Loop Vp Gain 13312 Velocity Loop Vi Gain 2958 Velocity Loop Velocity Limit 3000 rpm Velocity Loop Accel Decel Fast Stop 1000 rps Velocity Tracking Window 600 rpm Velocity Tracking Time 100 ms Position Loop Proportional Gain Pp 1000 Positon Loop Velocity Feedforward Vif 16384 Position Loop Following Error 4000 Coun msi Cancel Verify the peak current limit continuous current limit and velocity loop velocity limit If one or more of these values seems inappropriate click Cancel and check the following values entered in Motor Setup p 86 Peak Torque or Force Continuous Torque or Force Velocity Limit and Torque or Force Constant Correct them if needed If the Motor Feedback values were correct but the peak current limit continuous current limit
152. n Abort Active LO When the input is low motion stops but the amplifier remains enabled Any position or velocity commands received while the input is active are ignored In position mode upon activation of the input the motor will decelerate at the trajectory abort deceleration rate to zero velocity and then hold current position In velocity mode upon activation of the input the motor will decelerate to zero velocity at the velocity fast stop ramp rate and then hold zero velocity In current mode the input has no effect Hi Res Analog Divide Active HI A high input causes the firmware to divide the level of the analog input signal by 8 Hi Res Analog Divide Active LO A low input causes the firmware to divide the level of the analog input signal by 8 PWM Sync Input Receives the PWM sync output of a master amplifier For more information see Synchronizing PWM Switching Frequency p 18 Only on high speed inputs Copley Controls Corp 43 Operational Theory Xenus XSL User Guide 2 14 Outputs 2 14 1 Digital Outputs The amplifier has four programmable digital outputs Three of the outputs OUT 1 3 are general purpose outputs The fourth OUTA is specifically designed as a brake output but can be programmed to perform any of the functions The general purpose outputs are open drain MOSFETs each with a pull up resistor in series with a diode connected to the amplifier s internal 5 Vdc s
153. n Color Pair Color Pin Signal Body Stripe Body Stripe Frame Ground 1 Rev A amp B White Tan 1a 1b Rev A amp B Tan White 11 No Connect Rev C Brown Rev C Orange Signal Ground 2 White Brown 2a 7a White Blue 12 Resolver R1 Output 5 Vdc 400 mA 3 Brown White 2b 7b Blue White 13 Resolver R2 Output 4 White Pink 3a 8a White Violet 14 IN5 Temp Sensor 5 Pink White 3b 8b Violet White 15 Signal Ground 6 White Orange 4a 9a White Gray 16 Resolver S3 Input No connect 7 Orange White 4b 9b Gray White 17 Resolver S1 Input 8 White Yellow 5a 10a Tan Brown 18 Resolver S2 Input 9 Yellow White 5b 10b Brown Tan 19 Resolver S4 Input Signal Ground 10 White Green 6a 6b Green White 20 Signal Ground Copley Controls Corp 197 Ordering Guide and Accessories Xenus XSL User Guide H 5 Regen Resistor Specifications H 5 1 XTL RA 03 XTL RA 04 Specifications Specifications for Copley s standard regen resistors are described below Model Resistance Default Max Peak Peak For Use With Continuous Power Continuous Power Power Power Time XTL RA 03 30 ohms 65W 400 W 5 kW 1000 ms XSL 230 18 XSL 230 18 R XTL RA 04 15 ohms 65 W 400 W 10 kW 1000 ms XSL 230 36 XSL 230 36 R XSL 230 40 XSL 230 40 R High Temperature Risk Setting Default Continuous Power for a standard Copley regen resistor to a value greater than the default of 65 W may cause the resistor casing to h
154. n e s s n hs 5 41 Basie Setup Na dadas ie dde e aa 5 5 Motor Setup eee eon Deed edet tdi id 5 5 1 Motor Data File oe ES E e m T 5 5 2 Rotary Motor iie Lea de HL nude Re RP ca Ld is eroi Let te Ho ae D eb ete de ta 5 9 9 Bin ear Motorne ratsia moe ree A det Mee AAN 5 6 Feedback Setup 5 6 1 Overview sei E hc 5 6 2 Rotary Motor Feedback Setup Options sise 5 6 3 Linear Motor Feedback Setup Options iii 5 7 Brake Stop Optional 2s se tee is A A O A E Mz recie E ER 5 7 3 Calculate 5 8 Amplifier Configuration E 2 za ois a ET A 5 8 1 Digital Inputs Line en ren nr eed vs id de eas 5 8 2 Standard Digital Outputs o eeepc ee eer eedem dee re deseen tle re eno re ed ene as 4 Copley Controls Corp Xenus XSL User Guide Table Of Contents 5 8 3 Custom Digital DUI Sia 96 5 8 4 Save Input Outp t Charges ere toon is adas 96 5 8 5 Fault Latching ays S as i En E 5 8 6 Regen Resistot ssh HU D ee cbe Obat eie E oda Oa Ier ee e tac Ue ed bote zig A e dais 98 5 9 Gommand Iriput c es seh e ome cU e cL ir seu Meets NAR RAA A Boa Och I Samen Mara me 5 9 1 Analog Input s 5 9 2 PWM Input DN lla EE D i i a ds 5 9 3 Digita Position NPU 2 rice emet eer een ei ER nee E Gaia n eO C TO Deed 594 SCAN Interface ii ete ae A elo eaten eder hb ke aM Reged cheat neta tbe eset doa ia AAA EEEE 5 10 Auto Phase 5 10 1 Auto Phase Warnings and Notes ES as 5 10 2 Auto P
155. n or velocity modes of operation Copley Controls Corp 53 Specifications Xenus XSL User Guide 3 14 Hall Switch Inputs Channels 3 Type 74HC14 Schmitt trigger w RC Filter 10 kQ pull up resistor to internal 5 Vdc Input Voltage Range 0 Vdc 28 Vdc Low Level Input Voltage lt 1 35 Vdc High Level Input Voltage gt 3 65 Vdc Scan Time 67 uSec RC Filter Time Constant 33 uSec Function Commutation of brushless motors in trapezoidal mode Commutation initialization and phase error detection in sinusoidal mode 3 15 Resolver Interface Type Transmit 1 1 to 2 1 transformation ratio Resolution 14 bits equivalent to a 4096 line quadrature encoder Reference Frequency 7 5 kHz Reference Voltage 3 Vrms auto adjustable by amplifier to maximize feedback Reference Max Current 100 mA Max RPM 10 000 Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation Type Transmit 1 1 to 2 1 transformation ratio 3 16 Encoder Outputs Channels 3 Type Differential RS 422 line driver 26C31 Signals A A B B X X Function Programmable Buffered primary incremental encoder Emulated from analog encoder Emulated from resolver Maximum Frequency Buffered Emulated 5 MHz Line 20 Mcount sec 4 5 MHz Line 18 Mcounts sec 3 17 Se
156. navigate from the default ScopeData folder to another folder where you wish to store the file 3 Click Save to save the sco and csv files in the same folder and close the screen or click Cancel to close the screen without saving any files O To view a Trace File with the CME 2 trace viewer 1 Onthe Main screen choose Tools gt Trace Viewer to open the Trace Viewer window kc TS Viewer Trigger Setting Apply To Type Excitation Apply To Amplitude Position Frequency Trace Time kie Open File 2 Click Open File When prompted select the name of the file you wish to open Then click Open to display the file in the Trace Viewer window Copley Controls Corp 141 Using CME 2 Xenus XSL User Guide 6 6 Error Log and Communications Log 6 6 1 Error Log The amplifier tracks faults and warnings in an internal error event log stored in the amplifier s flash memory TET Log L1 To view the log click the Error Log tool on the Main screen OR click Error Log i on the Control Panel Active History Frequency CAN Network Type Description None The log has several sections accessible by clicking on the tabs described below Tab Contents Active Type and description of each active fault and warning The contents of this tab are automatically refreshed as new events occur History Type description and time of occurrence of each fault and most warnings since the log was last c
157. ncrease in the voltage on the capacitor bank 2 15 2 Regen Resistor If too much energy is added to the capacitor bank the voltage will rise to a point where the amplifier s over voltage protection will shut down the amplifier To prevent this a regen circuit shunts some of the energy into an external resistor known as a regen resistor when the voltage rises too high 2 15 3 Regen Circuit Components The amplifier provides an internal transistor that is used in combination with an external resistor Copley Controls supplies compatible resistors When using a resistor acquired from another source be sure it meets the specifications described in Regen Resistor Sizing and Configuration p 153 2 15 4 Regen Circuit Protections The amplifier protects the regen circuit against short circuit and uses T peak current time algorithms to protect both the external resistor and internal transistor 2 15 5 Configurable Custom Resistor The following values can be entered for a custom resistor using CME 2 Option Description Resistance Value Value in ohms of the resistor Continuous Power Continuous power rating of the resistor Peak Power Peak power rating of the resistor Time at Peak Power Time at peak power of resistor For more information see Regen Resistor p 98 and Regen Resistor Sizing and Configuration p 153 Copley Controls Corp 47 Operational Theory 48 Xenus XSL User Guide Copley
158. nd terminals at J2 1 and J3 5 also connect to the amplifier chassis Motor cases can be safety grounded either at the motor by earthing the frame or by a grounding conductor in the motor cable that connects to J2 1 This conductor should be of the same gauge as the other motor phase conductors The case of the regen resistor can also be safety grounded by earthing the case or by a grounding conductor connected to J3 5 Again this conductor should be of the same gauge as the other regen resistor conductors Cable shields because of their smaller wire size must not be used as part of a safety ground system Signal Grounding The amplifier signal ground must be connected to the control system signal ground The amplifier signal ground is not connected to earth ground internal to the amplifier Therefore the control system signal ground can be connected to earth ground without introducing a ground loop Shielding Shields on cables reduce emissions from the amplifier and help protect internal circuits from interference due to external sources of electrical noise The shields shown in the wiring diagrams are also required for CE compliance Cable shields should be tied at both ends to earth or chassis ground The housing and pin 1 of both J7 and J8 are connected to the amplifier s chassis 4 1 3 Connector Locations Connector locations are shown below Xenus y Copley Controls Corp 61 Wiring Xenus XSL User Guide 4 2 AC Mai
159. nd the amplifier in open loop systems CME 2 provides an Offset parameter and a Measure function The Measure function takes 10 readings of the analog input voltage over a period of approximately 200 ms averages the readings and then displays the results The Offset parameter allows the user to enter a corrective offset to be applied to the input voltage The offset can also set up the amplifier for bi directional operation from a uni polar input voltage An example of this would be a 0 to 10 Vdc velocity command that had to control 1000 rpm CCW to 1000 rpm CW Scale would be set to 2000 rpm for a 10 Vdc input and Offset set to 5V After this a O Vdc input command would be interpreted as 5 Vdc which would produce 1000 rpm CCW rotation A 10 Vdc command would be interpreted as 5 Vdc and produce 1000 rpm CW rotation Monitoring the Analog Command Voltage The analog input voltage can be monitored in the CME 2 control panel oscilloscope The voltage displayed in both cases is after both offset and deadband have been applied Analog Command in Position Mode The Xenus Analog Position command operates as a relative motion command When the amplifier is enabled the voltage on the analog input is read Then any change in the command voltage will move the axis a relative distance equal to the change in voltage from its position when enabled To use the analog position command as an absolute position command the amplifier should be homed every ti
160. nded Current Acceleration Profile Acceleration Actual Current Velocity Profile Velocity Voltage Analog Command Commanded Velocity Bus Voltage Limited Velocity Analog sin Input Actual Velocity Analog cos Input Velocity Error 136 Copley Controls Corp Xenus XSL User Guide Using CME 2 Trigger Setup Access the screen by clicking Trigger Setup x Trigger Type Rising Edge y Trigger On Channelt x Position Left af Level Fi counts OK Cancel The settings described below determine what triggers the start of a trace Setting Description Trigger Type Selects trigger type e Immediate Trigger Trace begins as soon as Record is pressed e Rising Edge Trace triggers when after Record is pressed the trigger signal rises though the trigger level setting e Falling Edge Trace triggers when after Record is pressed the trigger signal falls though the trigger level setting e Above Level Trace triggers when the trigger signal is greater than or equal to the trigger level setting e Below Level Trace triggers when the trigger signal is less than or equal to the trigger level setting e Function Generator Trace begins in synchronization with the Function Generator e Move Start position mode only Trace begins in synchronization with the trajectory generator Trigger On Selects which channel will be used as the trigger signal Channel 1 2 3 or 4 Position Selects placement of
161. ne dne re eei sep eese ee Eoo ceo LL yeso se EXE id ERR aes 6 7 2 Virtual Amplifier Creation 6 8 Manual Phasing s 6 8 1 Manual Phase Objectives zs 2 6 8 2 Manual Phase Instructions Standard Non Resolver Xenus 6 8 3 Manual Phase Instructions Resolver R Xenus n xe es e s 6 8 4 Troubleshooting Manual Phase With Halls and Encoder eterne nennt nnne 6 3 5 Verity Motor Pole Count 4 hod ees bleu eee pte ao eere epu ode ois xcii eed Ld ire iba Len R ace Copley Controls Corp 5 Table of Contents Xenus XSL User Guide 6 9 Au to T n Current LOOP tan M M M aee 6 9 1Auto une ODJectiVe cotorra e ond I Pt OR Rae Minis tt Ao amen 6 9 2 Auto Tune Instructions E ES NS e m T p 6 10 HOME FUNCION C td ceden bo cae OONK OVENIEW e dct eda stellen O NT eas DK LU Sit octet ett 6 10 2 Homing Functions Settings A Regen Resistor Sizing and Configuration A 1 Sizing a Regen Resistor A 1 1 Gather Required Information A 1 2 Observe the Properties of Each Deceleration During a Complete Cycle of Operation d ix E A 1 3 Calculate Energy Returned for Each Deceleration sise A 1 4 Determine the Amount of Energy Dissipat
162. ne the minimum peak and continuous current ratings of the fuse For related amplifier specifications see Regen Circuit Output p 51 The peak current is determined by the chosen regen resistor value peak Vregen Rregen Where loea The current though the regen resistor during regeneration in amps Viegen The voltage at which the regen circuit turns on Rregen The resistance value of the chosen regen resistor in ohms The continuous current is determined by the continuous regen power leont Pront Vregen Where lco The minimum continuous current rating the fuse requires in amps Peont The continuous power calculated in the previous step in watts Viegen The voltage at which the regen circuit turns on Copley Controls Corp 157 Regen Resistor Sizing and Configuration Xenus XSL User Guide A 2 Configuring a Custom Regen Resistor A 2 1 Regen Configuration Objective and Warning Configure the amplifier to operate properly with the custom resistor Incorrect values may damage amplifier or external regen resistor For the regen PT algorithms to work correctly the values entered in the following steps must be correct Damage to the external regen resistor may result from incorrect values entered Damage to the amplifier may result if an incorrect resistance value is entered WARNING Failure to heed this warning can cause equipment damage A 2 2 Regen Configuration Instructions A 2 2 1 A 2 2 2 A 2
163. nfiguration 5 8 1 Digital Inputs 5 8 2 Standard Digital Outputs 5 8 3 Custom Digital Outputs 5 8 4 Save Input Output Changes 5 8 5 Fault Latching 5 8 6 Regen Resistor 5 9 Command Input 5 9 1 Analog Input 5 9 2 PWM Input 5 9 3 Digital Position Input 5 9 4 CAN Interface 5 10 Auto Phase seen 5 10 1 Auto Phase Warnings and Notes 5 10 2 Auto Phase Proced re crm sot rotten e dao 5 10 3 Guidelines for Choosing Auto Phase Current and Increment Rate Values ooooocccnnccccincccccnoccccononccnonnccconaaccnann nos 5 10 4 Trouble Shoot Motor Direction Setup sienne 109 5 10 5 Trouble Shoot Motor Wiring SetUp crescent arde eri 109 5 10 6 Trouble Shoot Halls Wiring Setup usine 109 5 10 7 Other Problems 5 11 Current Loop D 1151 CUTE POOP Setting Ste cetero tee rtr cedere dis ne ee auc sistas el an ee ne irse eA Rae aerea 110 5 11 2 Manually Tune Current L OOp 1 ires esterne nee etra eoe daa 111 5 12 Velocity Loop 5 12 1 Velocity Loop Settings 5 12 2 Manually Tune the Velocity LOODp riori canvases crt true buen dead te ko EAR EN cere aX ERES 5 13 POSITION LOO Pies C 5 13 1 Position Loop Settings 5 13 2 Manually Tune the Position Loop 5 13 3 Test S Curve Profile 5 14 Completion Steps 5 14 1 Objective LP
164. ns J1 Mating Connector Description Euro style 4 position 7 5 mm pluggable female terminal block Manufacturer PN Wago Standard 721 204 026 045 Right Angle 732 180 026 000 Wire size 22 12 AWG Recommended Wire 12 AWG 600 V Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 L1 AC power input hot or L1 2 L2 AC power input neutral or L2 3 Protective ground Chassis safety ground 4 L3 AC power input L3 AC Mains Fuse Recommendation Recommended fuse type Class CC 600 Vac rated Ferraz Shawmut ATDR Littelfuse CCMR Bussman LP CC or equivalent AC Mains Wiring Diagram Single Phase L2 Neut 19 47 63 Hz L1 Line 100 240 VAC Filter Concepts SF20L Keep wire length or equivalent as shortas used for CE compliance possible Not to E Notrequired on exceed 1 Meter a neutral line AC Mains Wiring Diagram Three Phase Line Filter 30 47 63 Hz 100 240 VAC Earth Ground Keep wire length as short as Filter Concepts 3F15 gt possible Not to E or equivalent exceed 1 Meter used for CE compliance 62 Copley Controls Corp Xenus XSL User Guide 4 3 Motor J2 Mating Connector Description Euro style 4 position 5 0 mm pluggable female terminal block Manufacturer PN Wago Standard 721 104 026 047
165. ns in progress Using such commands to initiate motion may cause CAN operations to suspend CAN operations may restart unexpectedly when the commanded motion is stopped Failure to heed this warning can cause equipment damage injury or death Latching an output does not eliminate the risk of unexpected motion with non latched faults Associating a fault with a latched custom configured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without operator intervention In this case motion may re start unexpectedly For more information see Clearing Non Latched Faults p 36 Failure to heed this warning can cause equipment damage injury or death Use equipment as described Operate amplifiers within the specifications provided in this manual Failure to heed this warning can cause equipment damage injury or death About this Manual Revision History Xenus XSL User Guide Revision Date DECO Comments 1 0 June 2003 Initial publication 1 1 July 2003 New CAN termination plug requires documentation changes in CAN Interface p 55 and CAN Bus J6 p 67 2 0 April 2005 Support for resolvers and dual feedback configurations and emulated digital encoder output source See Feedback p 18 Copley Virtual Machine CVM and Indexer Program for writing motion control sequences to run on the Xenus See CVM Prog
166. o overcome stiction e Transition from static friction to dynamic friction and back may produce jerky motion e A faster rate will operate in the dynamic friction range e A slower rate will operate in the static friction range Trouble Shoot Motor Direction Setup If motor direction setup step failed e Check feedback power and sin cos signals e Check shielding for proper grounding Trouble Shoot Motor Wiring Setup If motor wiring setup step failed e Verify that amplifier is disabled e Check for mechanical jamming e Check for smooth motion with no mechanical jerking e Check for good connections to the motor power wires e Disconnect motor power wires e Measure for proper motor resistance Trouble Shoot Analog Hall Wiring Setup If Analog Hall wiring setup step failed e Check feedback power and sin cos signals e Check for smooth motion with no mechanical jerking e Check shielding for proper grounding Other Problems If the auto phase procedure fails despite these corrective measures see G 2 2 ServoTube Manual Phase p 192 Copley Controls Corp 191 ServoTube Motor Setup Xenus XSL User Guide G 2 2 ServoTube Manual Phase The CME 2 Manual Phase tool lets the user phase a brushless motor monitor signals check configuration wiring and control a microstepping current vector The manual phase procedure is followed by a manual phase troubleshooting procedure G 2 2 1 6 2 2 2 6223 G 2 2 4 6220
167. ode motor type and amplifier control status as shown below It also includes a reminder that pressing the F12 function key while CME 2 is running disables the amplifier Sinusoidal Commutation Rotary Motor Fi2ToDisable 6 1 6 Choosing an Amplifier from a List of Amplifiers If as shown on left below there is only one serial port set up for communications with an amplifier CME 2 automatically attempts to connect to the amplifier on that port on CME 2 startup If as shown at center below multiple PC serial ports have been set up for communications with multiple amplifiers CME polls all the amplifiers and displays their names in the Copley Neighborhood To choose an amplifier click on the amplifier name If as shown on right below one amplifier serves as a CME 2 multi drop gateway for one or more node amplifiers the node amplifiers are indented under the gateway One amplifier Multiple amplifiers Multi drop cme 2 3 1 XSL 230 4 File Amplifier Tools He E Copley Neighborhood VD Virtual Amplifier acme 2 3 2 Beta 2 Engine File Amplifier Tools He Cople ES Virtual Amplifier MER COMS X Axis EB Coma Y Axis acme 2 4 0 STP 075 07 STI File Amplifier Tools Help Zi Copley Neighborhood VE Virtual Amplifier EES coMt ACP EEB Node 1 ACM VE Node 2 XSL 1 WEB Node 10 XSL 2 VT COMBS Z Axis 6 1 7 Renaming an Amplifier
168. ode the amplifier takes command inputs over a CANopen network CAN communications are described in the next section 2 12 2 CME 2 and CAN Operation When the amplifier is operated as a CAN node CME 2 can be used for programming before and after installation in a CAN network CME 2 can also monitor operations while the amplifier is operating as a CAN node If CME 2 is used to initiate any movement using the Control Panel Jog feature or a scope function the amplifier s CANopen operations are suspended When adjustments are complete CME 2 relinquishes control of the amplifier and returns it to the CAN node state Using CME 2 can affect or suspend CAN operations When operating the amplifier as a CAN node use of CME 2 to change amplifier parameters can affect CAN operations in progress Using CME 2 to initiate motion can cause CAN operations to suspend The operations may restart unexpectedly when the CME 2 move is stopped DANGER Failure to heed this warning can cause equipment damage injury or death Copley Controls Corp 41 Operational Theory Xenus XSL User Guide 2 13 Inputs 2 13 1 Digital Inputs The amplifier has twelve digital inputs IN1 IN12 Eleven of them appear on the control connector IN5 appears on the feedback connector and is intended for the motor over temperature switch although it can be programmed for any function 2 13 2 Input Filters Two types of input RC filters are used GP g
169. ode and Velocity LOP is mei oanrin ina el phot gah bet ere bos had ae ARR ne dede de fecta 2 5 4 Position Mode and Position Loop emere adn etae er te a dee et EE edo rr E e PEE P Ht EE Dade der 2 5 5 Input Command Types i y 2 5 6 Analog Command Input 2 5 7 PWM Input 2 5 8 Digital Input 2 5 9 CVM Program Ne Be e T SA n T Asa for EG Ir Re 2 6 1 CAN Network and CANopen Profiles for Motion ss 30 2 6 2 Supported CANopen Modes iss 2 6 3 Architecture oy ds Bes es T 2 0 CAN AGGESSSING E t SEVA i Les ATE HIS Irc C ARNES 2 7 1 Use Digital Inputs to Connect Limit Switches yas hs bis A d i 2 7 2 Diagram Sample Placement of Limit Switches sise 2 7 3 How the Amplifier Responds to Limit Switch Activation 2 7 4 Using Custom Output to Signal Limit Switch Activation 2 8 Brake Operation ooooccccccccconoccccccccononanncccnnncannnncccncnnnnnan cnc ncnnnannnnns zs ie i 2 8 1 Digit l Output Controls Brake 22 reete Ee en teta t i da dest eld cy exo ea d e cna 2 8 2 Brake Stop Sequences M RAR RRA RR RR RR sinet en nnne nsns nnns 2 9 Status Indicators s se i m T 2 9 1 Amplifier and CAN Interface Status Indicators ss 2 9 2 Amplifier Status Indicator Operation suisses 2 9 3 CAN Interface Status Indicator Operation y 2 10 Protection sis iaa ck er Heer exea si
170. oder ratio Following Error Fault The level in encoder counts at which the Following Error Fault Details following error produces a fault which stops the p 39 servo loop We recommend raising the fault level before tuning the loop Warning The level in encoder counts at which the following error produces a warning without stopping the servo loop Disable Prevents following error from triggering a fault Fault Tracking Tracking Width of the tracking window in counts Tracking Window Details Window p 40 Tracking Position must remain in the tracking window for Time this amount of time to be considered tracking 115 Quick Setup with CME 2 Xenus XSL User Guide 5 13 2 Manually Tune the Position Loop To tune the position loop minimize following error and oscillation by running profiles and adjusting position proportional gain Pp velocity feed forward Vff acceleration feed forward Aff and other settings KE Oscilloscope ME 00 01 02 03 04 05 08 OF 08 09 10 14 12 13 Time seconds Function Generator Profile Settings Gains Trajectory Limits Position Params velocity Params Cran 1 EE 0 nennen v Auto Setup v Auto Trigger Move Type Relative Trap C Absolute C 8 Curve Chan Following error F Single Trace Distance 70000 counts o2 CES SER Trace Time 1 258 y an 4 EC Sample Rate 2mS Record Stop Trace Clear C
171. ol panel provides real time monitoring of up to three separate values Monitor Actual Current y WE counts Actual Velocity Zl on Actual Position y 97239 counts To set up a monitor display box click in the list box and select a variable from the list Disabled disables the display Other options represent the following amplifier values e Actual Current e Commanded Current e Limited Position e Actual Velocity e Commanded Velocity e Analog Command e Actual Position e Commanded Position e Bus Voltage e Velocity Error e Profile Velocity e Temperature Profile Acceleration Following Error Motor Phase Angle 132 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 4 4 Control Functions The Control area of the screen provides functions related to overall amplifier control The screen options are different when the Position Loop Input is CAN as shown on the right Control Control C Software Enable Amplifier C Under CAN Control Disable Amplifier Disable Amplifier Reset Reset C Jog Mode C Jog Mode Clear Faults Set Zero Position Clear Faults Set Zero Position 6 4 4 1 Control the operational state of the amplifier using the radio buttons described below Button Text Description Software Enable Amplifier Amplifier is software enabled when button is selected Under CAN Control Amplifier state is under CAN control when button is selected Disable Amplifier Amplifier is sof
172. om the PC s RAM press Clear NOTE The log is limited to 2000 lines When it reaches that limit CME 2 automatically clears the oldest 1000 lines To save the log contents from the PC s RAM to a disk file click the Save to Disk icon 143 Using CME 2 Xenus XSL User Guide 6 7 CME 2 Virtual Amplifier 6 7 1 Virtual Amplifier Overview A virtual amplifier can be used for training purposes and for creating motor data files off line A new virtual amplifier can be created based on a virtual amplifier template file ccv Each CME 2 installation includes a set of ccv files representing all of the Copley Controls amplifier models Alternately a virtual amplifier can be created based on a saved amplifier file ccx 6 7 2 Virtual Amplifier Creation 6 7 2 1 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop dc pr CME 2 6 7 2 2 Choose Virtual Amplifier from the Copley Neighborhood tree to a display the Open Virtual Amplifier screen b Open Virtual Amplifier x Choose the method you want to use to create the CME 2 V3 1 X9L 230 4 virtual amplifier le PITE LOIR He Create new amplifier file e m A Es E C Open existing amplifier file WEB Virtual Amplifier i WEB 6 7 2 3 To open a virtual amplifier from an existing amplifier file skip to Step 6 7 2 4 now To create a new virtual amplifier file based on a virtual amplifier template file C3 Copley Neighborhood Can
173. oops Specifications Type Current Velocity 100 digital Position Sampling rate time Current 15 kHz 67 us Velocity 3 kHz 333 us Position 3 kHz 333 us Current Loop Small Signal Bandwidth gt 2 kHz Tuning and load impedance dependent Velocity Loop Filter Type Programmable Low Pass 1 Pole Frequency Range Programmable 20 1500 Hz Low Pass Butterworth 2 Poles Bi Quadratic 2 Poles amp 2 Zeros Bus Voltage Compensation Changes in bus or mains voltage do not affect tuning 3 5 Regen Circuit Output Model XSL 230 18 XSL 230 36 XSL 230 40 XSL 230 18 R XSL 230 36 R XSL 230 40 R Continuous Power 2 kW 4 kW Peak Power 5 kW 10 kw Minimum Resistance 30 Q 150 Minimum Resistor Wattage 25 W 50 W Turn On Voltage 390 Vdc Turn Off Voltage 380 Vdc DC Bus Capacitance 1760 uF nominal Regen Energy Absorption Capacity Input Voltage 120 Vac 108 joules 208 Vac 57 joules 240 Vac 32 joules 3 6 Digital Command Input Digital Position Command Pulse and direction Count up count down maximum rate 2 MHz with active driver Quadrature A B encoder maximum rate 2 M line sec 8 M count sec after quadrature Digital Current amp Velocity Command PWM frequency range 1 kHz 100 kHz PWM minimum pulse width 220 nSec Copley Controls Corp 51 Specifications Xenus XSL User Guide 3 7
174. opley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 13 Position Loop Initial position loop proportional gain Pp velocity feed forward Vff and acceleration feed forward Aff values were calculated in a previous step 5 13 1 Position Loop Settings For more information see Position Mode and Position Loop p 24 5 13 11 Copley Controls Corp Click P Loop Etoo to open the Position Loop screen Kd Position Loop Profile Acceleration Profile Velocit Limited Position 101 x Commanded Velocit Actual Position Pp E vit 16384 Atf 0 m GensMutpie 1 10096 Vff 16384 Following Error Tracking Fault 4000 counts Window 1000 counts Warning 2000 counts zn n Me Disable Fault A2A Close Options are described in the following table loop In dual encoder systems the multiplier s initial value is calculated based on the ratio of motor encoder turns to position encoder turns Option Description For More Information Gains Aff Acceleration feed forward Range 0 to 32 767 Trajectory Limits p 24 Vff Velocity feed forward Range 0 to 32 767 100 Vff 16 384 Pp Position loop proportional gain Range 0 to 32 767 Gains The output of the position loop is multiplied by See Rotary Motor Feedback Multiplier this value before being passed to the velocity Setup Options p 90 for information on motor position enc
175. or Feedback Lb bo d 240 300 IV Invert Input i Motor Phase Angle 0 deg rMotc A Motor Feedback 7501 counts T Invert Output Actual Current U 00 A V 0034 M 002A Control Increment Rate 90 elec deg s Current 0 47 A Set Zero Position Enable Disable Move Motor FE Fwd Restore Defaults OK Cancel 6 8 2 3 Enable the amplifier by selecting Enable as shown here Control Increment Rate 90 elec deg sec Current O47 A Set Zero Position C Disable Move Motor Rev Fwd 6 8 24 To control the current vector rotation command the motor forward or reverse using the buttons shown here Move Motor r Fwd NOTE Some motors have bearings stiction so helping the motor with mechanical force is acceptable Motors with no friction may need friction added to steady motion 6 8 2 5 If the motor cannot keep up with the rate of vector rotation then reduce the ncrement Rate or increase the Current 6 8 2 6 Verify that pressing forward button moves motor forward If it does not toggle the Motor Invert Output box setting 6 8 2 7 Verify actual position count agrees with direction of rotation increasing counts in forward direction and decreasing counts in reverse direction If it does not toggle the Encoder Invert Input box setting Copley Controls Corp 145 Using CME 2 Xenus XSL User Guide 6 8 2 8 Monitor the vector rotation through one electrical cycle for proper Hall transitions
176. or more information on the other settings see Position and Velocity Errors p 38 Velocity Loop Parameters In position and velocity modes the Velocity Params tab can be used to set velocity loop parameters Settings Gains Trajectory Limits Position Params Velocity Params Velocity Tracking E 2 Window 600 mm Accel Limit 1000 rps Time 100 mS Decel Limit 1000 rps For information on the Velocity Tracking options see Position and Velocity Errors p 38 For information on the limits see Velocity Loop Limits p 22 140 Copley Controls Corp Xenus XSL User Guide Using CME 2 6 5 6 Scope Files The Scope Tool can save trace data in Copley Controls scope files sco files that can be opened later with the CME 2 Trace Viewer Simultaneously a version of the same trace is stored in a comma separated text file csv that can be opened with a spreadsheet application such as Microsoft Excel or other programs for mathematical analysis The format of the csv file is Column 1 time Column 2 Trace Channel 1 Column 3 Trace Channel 2 if used Column n Trace Channel n if used NOTE By default scope files are saved in the ScopeData folder in the CME 2 installation folder For instance c Program Files Copley Motion CME 2 ScopeData O To save trace data 1 Generate the trace you wish to save 2 Inthe Oscilloscope window click the Save to Disk icon ad When prompted enter a File Name If needed
177. ow amplifier enables PWM output stage Amplifier LO Enables with reset resets on the low to high transition of the input When input is high the amplifier disables the PWM output stage AMP Enable When the input is high amplifier enables PWM output stage Amplifier HI Enables with reset resets on the high to low transition of the input When input is low the amplifier disables the PWM output stage AMP Enable When the input is low amplifier enables PWM output stage LO Enables When input is high the amplifier disables the PWM output stage AMP Enable When the input is high amplifier enables PWM output stage HI Enables When input is low the amplifier disables the PWM output stage Multiple Enable Inputs In addition to IN1 other inputs can be programmed to be additional enables If there is more than one input programmed as an enable then all the inputs must be in the enabled state before the amplifier PWM output stage will be enabled 42 Copley Controls Corp Xenus XSL User Guide Operational Theory General Programmable Input Functions Other inputs depending on the selected mode of operation may also have pre defined functions as described in Mode Dependant Dedicated Inputs p 70 The remaining inputs can be programmed to functions listed below Function Description NEG Limit HI Inhibits When input is high amplifier inhibits motion in negative direction NEG Limit LO Inhibit
178. plifier em m Copley Controls Corp 83 Quick Setup with CME 2 Xenus XSL User Guide 5 4 Basic Setup 5 4 1 Basic Setup Screen To configure an amplifier for use with a Copley Controls ServoTube motor skip now to 5 4 1 1 ServoTube Motor Setup p 185 5 4 1 2 Click the Basic Setup button i to display the Basic Setup screen Basic Setup xj Motor Options System Family s Operating Mode ositio A ESS Eu Position Loop Input can E ype Rotary Linear Commutation Encoder Sinusoidal Trapezoidal Motor Encoder Primary Incremental 7 Hall Type Digital 7 Hall Phase Correction Brake Use back EMF for Velocit Use halls for Velocity ServoTube Setup 5 4 1 3 Enter basic Motor options described below Setting Description Motor Family Select motor family e Brushless e Brush Motor Type Select motor type e Rotary e Linear Commutation Select commutation method e Sinusoidal e Trapezoidal See Commutation Modes p 18 Halls Type Select Hall type e None e Digital e Analog used with Copley Controls ServoTube motors Hall Phase If checked will enable error checking between Hall switches and encoder Correction based phase angle See Fault Descriptions p 37 Brake If checked will enable brake delay times See Brake Operation p 33 and Brake Stop Optional p 91 Use back EMF If selected will use the motors measured back EMF to determine motor for Velocity velocity Use Halls for If
179. ply in position mode Deceleration Limit Maximum deceleration rate Max value may depend upon load inertia amp peak current Min value 1 Does not apply in position mode Tracking Window See Tracking Window Details p 40 Tracking Time Vp Velocity loop proportional gain Range 0 to 32 767 Vi Velocity loop integral gain Range 0 to 32 767 Fast Stop Deceleration rate used by the velocity loop when the amplifier is hardware disabled Ramp Range 0 to 100 000 000 Default velocity loop Decel Limit value For more information see Velocity Loop Limits p 22 Enable Gains Scalar Increases the resolution of the units used to express Vp and Vi providing more precise tuning For more information see Velocity Loop Gains Scalar p 23 Filter See Velocity Loop Filters p 167 Copley Controls Corp 113 Quick Setup with CME 2 Xenus XSL User Guide 5 12 2 Manually Tune the Velocity Loop To tune the velocity loop apply square wave excitation to the velocity loop and adjust velocity loop proportional gain Vp and velocity loop integral gain Vi to obtain a desired waveform Oscilloscope 300 200 0 05 0 10 0 45 020 025 0 30 035 040 0 45 0 50 Time seconds Function Generator Profile ApplyTo velocity y Excitation Square Wave Amplitude Frequency 5 Hz Settings Gains Trajectory Limits Position Params Velocity Params
180. r Model No 1 J1 Plug 4 position 7 5 mm female Wago 721 204 026 045 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 1 J3 Plug 5 position 5 0 mm male Wago 721 605 000 043 XSL CA 1 J4 Plug 3 position 5 0 mm female Wago 721 103 026 047 4 J1 4 Tool wire insertion and extraction Wago 231 131 1 J7 Cable assembly control 10 ft 3 m Copley Controls XSL CC 10 1 J8 Cable assembly feedback 10 ft 3 m Copley Controls XSL FC 10 For cable color codes see Control and Feedback Cable Color Codes p 196 194 Copley Controls Corp Xenus XSL User Guide CANopen Connector Kit Ordering Guide and Accessories Model Qty Ref Description Mfr Model No 1 Sub D 9 position female to RJ 45 adapter XSL NK 1 CANopen Network Cable 10 ft 3 m Kristamicro 60 662BY J6 1 CANopen Network Terminator Individual Cable Assemblies and Related Accessories Model Ref Description Mfr Model No SER CK J5 RS 232 Serial Cable Kit for connecting PC to amplifier XSL CC 10 J7 Control Cable with molded connector and flying leads 10 ft 3 m XSL FC 10 J8 Feedback Cable with molded connector and flying leads 10 ft 3 m XSL CV Sub D 9 position female to RJ 45 adapter PC to CANopen cable adapter XSL NC 10 CANopen Network Cable 10 ft 3 m Kristamicro 60 662BY XSL NC 01 J6 CANopen Network Cable 1 ft 0 3 m Kristamicro 6
181. r J1 Re tune velocity and position loops if applicable On the Main screen click Save to Flash sal On the Main screen click Save to Disk all for backup or duplication Click Control Panel Leal and then click Reset OR Power cycle the amplifier The amplifier tuning procedure is complete Copley Controls Corp 119 Quick Setup with CME 2 Xenus XSL User Guide 120 Copley Controls Corp CHAPTER 6 USING CME 2 This chapter provides an overview of CME 2 software features Contents include Title Me ze 6 1 1 Main Screen Overview 6 1 2 Tool Bar Overview 6 1 3 Main Menu Overview 6 1 4 Functional Diagram 6 1 5 6 1 6 5 CAN Information and Status Bar 1 6 Choosing an Amplifier from a List of Amplifiers 6 1 7 Renaming an Amplifier 6 2 Manage Amplifier and Motor Data 6 2 1 Memory 6 2 2 Disk Storage 6 2 3 Data Management Tools 6 2 4 Quick Copy Setup Procedure 6 3 Downloading Firmware eene 6 3 1 Acquiring Firmware from Web Site Optional 6 3 2 Downloading Firmware to Amplifier 6 4 Control Panel 6 4 1 Control Panel Overview 6 4 2 Status Indicators and Messages 6 4 3 Moriitor FUNCIONS a HS ERN ERES 6 47 Control UM CUS sostener LM teams usse an cd tsar terre ce Die een 6 4 5
182. ram p 29 Xenus filter See Xenus Filter p 173 High res input See General Programmable Input Functions p 43 Velocity loop input filter See Velocity Loop Filters p 167 Position loop Gain Multiplier See Position Mode and Position Loop p 24 Over Current fault See Fault Descriptions p 37 RS 232 multi drop serial control See Connecting for Serial Control p 183 New CAN addressing interface See CAN Interface p 104 New CME 2 homing function for setting up and testing homing moves See Home Function p 152 3 April 2006 12526 Changed drawing in Heatsink Mounting Instructions p 172 to clarify that two sheets of clear plastic carrier should be removed from phase change material and discarded 4 April 2006 14711 Internal version control adjustment 5 January 2008 16585 Add XSL to title to avoid confusion with Xenus XTL document 6 June 2008 17112 Changes to Control and Feedback Cable Color Codes p 196 and Regen Resistor Specifications p 198 7 June 2008 17137 Updated Web page references 10 Copley Controls Corp CHAPTER 1 INTRODUCTION This chapter provides an overview of Copley Controls Xenus amplifier Contents include Title 1 1 Amplifier 1 2 CME 2 1 3 CMO CML Copley Controls Corp 11 Introduction Xenus XSL User Guide 1 1 Amplifier Xenus provides 100 digital control of brushless or brush motors in an off line powered package It can al
183. ration rate of the profile Abort Deceleration Specifies the deceleration rate used by the trajectory generator when motion is aborted Position Loop Inputs From the Trajectory Generator The position loop receives the following inputs from the trajectory generator Input Description Profile Velocity The instantaneous velocity value of the profile Used to calculate the velocity feed forward value Profile Acceleration The instantaneous acceleration deceleration value of the profile Used to calculate the acceleration feed forward value Limited Position The instantaneous commanded position of the profile Used with the actual position feedback to generate a position error 24 Copley Controls Corp Xenus XSL User Guide Operational Theory Position Loop Gains The following gains are used by the position loop to calculate the velocity command Gain Description Pp Position loop proportional The loop calculates the position error as the difference between the actual and limited position values This error in turn is multiplied by the proportional gain value The primary effect of this gain is to reduce the following error Vff Velocity feed forward The value of the profile velocity is multiplied by this value The primary effect of this gain is to decrease following error during constant velocity Aff Acceleration feed forward The value of the profile acceleration is multiplied by
184. re Regen Sette to open the Regen Resistor screen x C KSL RA 01 C XSL RA 02 C Custom Resistor OK Cancel Select a resistor option Option Description None No external regen resistor is used XSL RA 01 Standard regen resistors supplied by Copley Controls XSL RA 02 Custom Resistor User supplied resistor See Regen Resistor Sizing and Configuration p 153 Click OK to save regen settings to flash memory and close the Regen Resistor screen OR click Cancel to restore to previous values and close the screen 5 9 Command Input Choose the appropriate step for the input format Input Format Step Analog Analog Input p 99 PWM PWM Input p 101 Digital Position Digital Position Input p 102 CAN CAN Interface p 104 ASCII Contact Customer Support 98 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 9 1 Analog Input For more information see Analog Command Input p 25 5 9 1 1 Click Analog Command rion emmans to open the mode specific Analog Command screen Current mode Velocity mode Position mode analog Command Acl Kd Analog Command iz x lol xl 7 Configuration Trajectory Limits n m Configuration Dead Band D mv Scaling 3000 RPM 10 S con counts 10v Invert Command Dead Band my Dead Band 0 mv Invert Command Offset Measure 0 mv Offset mv EI Calibrate Auto Offset Offset 0 mv
185. red with the I T setpoint that is calculated from the user entered Peak Current Limit T Time Limit and Continuous Current Limit Whenever the energy delivered to the motor exceeds the I T setpoint the algorithm protects the motor by limiting the output current or generates a fault B 1 2 T Formulas and Algorithm Operation Calculating the IT Setpoint Value The FT setpoint value has units of Amperes seconds A S and is calculated from programmed motor data The setpoint is calculated from the Peak Current Limit the T Time Limit and the Continuous Current Limit as follows PT setpoint Peak Current Limit Continuous Current Limit T Time Limit IT Algorithm Operation During amplifier operation the I T algorithm periodically updates the I T Accumulator Variable at a rate related to the output current Sampling Frequency The value of the I T Accumulator Variable is incrementally increased for output currents greater than the Continuous Current Limit and is incrementally decreased for output currents less than the Continuous Current Limit The IT Accumulator Variable is not allowed to have a value less than zero and is initialized to zero upon reset or 24 Vdc logic supply power cycle Accumulator Increment Formula At each update a new value for the IT Accumulator Variable is calculated as follows l T Accumulator Variable n I T Accumulator Variable n Actual Output Current Continuous Current Limit
186. rial Interface Channels 1 Type RS 232 Signals Rxd Txd Gnd Baud Rate 9 600 to 115 200 defaults to 9600 on power up or reset Data Format N 8 1 Flow Control None Protocol Binary or ASCII format Function Set up control and diagnostics status 54 Copley Controls Corp Xenus XSL User Guide Specifications 3 18 CAN Interface Channels 1 Connectors 2 eight position modular RJ 45 style wired as per CAN Cia DR 303 1 V1 1 One connector for signal input Second connector for daisy chaining to next node Signals CAN H CAN L CAN Gnd CAN 5 Vdc Pass though only Format CAN V2 0b physical layer for high speed connections compliant Protocol Motion Control Device Under DSP 402 of the CANopen DS 301 V4 01 EN 50325 4 Application Layer Supported Modes Profile Current Velocity and Position PVT and Homing Node Address Selection 16 position rotary switch on front panel OR programmable digital inputs OR stored in flash memory OR combination of above Bus Termination External 121 O resistor across CAN H and CAN L when termination plug is installed in second connector Function Real time motion control 3 19 Status Indic ators Amplifier Status Bi Color LED on front panel labeled Status CAN Status Bi Color LED on front panel labeled CAN Conforms to CAN Indicator Specification CiA DR 303 3 3
187. rminal block Manufacturer PN Wago 721 104 026 047 Wire Size 22 12 AWG Recommended Wire 12 AWG 600 V Shielded cable used for CE compliance Wire Insertion Extraction Tool Wago 231 131 Connector and tool are included in connector kit XSL FK Pin Description Pin Signal Function 1 Ground Chassis ground and cable shield 2 Phase W Phase W output to motor 3 Phase V Phase V output to motor use for DC motor connection 4 Phase U Phase U output to motor use for DC motor connection Copley Controls Corp 179 Xenus Filter Xenus XSL User Guide E 5 6 Diagram Edge Filter Wiring with Brushless Motor Brushless E 5 7 Diagram Edge Filter Wiring with Brush Motor Case Ground 180 Copley Controls Corp Xenus XSL User Guide E 6 XSL FA 01 Edge Filter Ordering Filter Model Description XSL FA 01 Xenus Edge Filter Connector Kit Model Qty Ref Description Mfr Model No 1 J1 Plug 5 position 5 0 mm female Wago 721 105 026 047 XSL FK 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 2 Insertion Extraction Tool Wago 231 131 Copley Controls Corp Xenus Filter 181 Xenus Filter Xenus XSL User Guide 182 Copley Controls Corp APPENDIX F CONNECTING FOR SERIAL CONTROL This chapter describes how to connect one or more amplifiers for control via the RS 232 bus on one of the amplifiers Copley Controls Corp 183
188. s Continuous Power p The minimum value is 50 mS Peak Power The maximum value is 5000 mS Cancel A 2 2 6 Click Next for Step 5 Custom Regen Configuration xi Step 5 Time at Peak Power Resistance Custom regen configuration is complete Continuous Power Press Finish to accept the values entered and Peak Po 450 save them to the amplifier s RAM and flash Time at keak Power 50 ME To change any of the values press Prev lt Prev Cancel A 2 2 7 Review the configuration A 2 2 8 Click Finish to save the configuration to volatile and flash memory and close the Screen OR click Prev to modify any values OR click Cancel to close the screen without saving any changes Copley Controls Corp 159 Regen Resistor Sizing and Configuration Xenus XSL User Guide This page for notes 160 Copley Controls Corp APPENDIX B I T TIME LIMIT ALGORITHM The current loop IT limit specifies the maximum amount of time that the peak current can be applied to the motor before it must be reduced to the continuous limit or generate a fault This chapter describes the algorithm used to implement the 1 T limit Copley Controls Corp 161 IT Time Limit Algorithm Xenus XSL User Guide B 1 IT Algorithm B 1 1 PT Overview The IT current limit algorithm continuously monitors the energy being delivered to the motor using the I T Accumulator Variable The value stored in the I T Accumulator Variable is compa
189. s When input is low amplifier inhibits motion in negative direction POS Limit HI Inhibits When input is high amplifier inhibits motion in positive direction POS Limit LO Inhibits When input is low amplifier inhibits motion in positive direction Reset on LO HI Transition Amplifier resets on the low to high transition of the input Reset on HI LO Transition Amplifier resets on the high to low transition of the input Motor Temp HI Disables When the input is high amplifier generates a Motor Over Temperature fault which disables the PWM output stage Motor Temp LO Disables When the input is low amplifier generates a Motor Over Temperature fault which disables the PWM output stage Home Switch Active HI When the input is high the home switch is activated Home Switch Active LO When the input is low the home switch is activated Motion Abort Active HI When the input is high motion stops but the amplifier remains enabled Any position or velocity commands received while the input is active are ignored In position mode upon activation of the input the motor will decelerate at the trajectory abort deceleration rate to zero velocity and then hold current position In velocity mode upon activation of the input the motor will decelerate to zero velocity at the velocity fast stop ramp rate and then hold zero velocity In current mode the input has no effect Motio
190. s in reverse direction If it does not toggle the Encoder Invert Output box setting Monitor the vector rotation through one electrical cycle for proper Analog Hall rotation 1 Verify that the red needle rotates in phase and in the same direction as the black motor phase angle 5 few degrees 2 If the black needle and the red Analog Hall needles do not track in the same direction properly check the invert input analog Hall option swap the amplifier s analog Hall wire configuration 3 If the red indicator transition leads or lags behind the centered needle by more than 5 degrees then try adjusting the Hall Offset in 30 degree increments G 3 Special ServoTube Setup Completion Proceed now to Current Loop p 110 to complete the general amplifier setup procedure 192 Copley Controls Corp APPENDIX H ORDERING GUIDE AND ACCESSORIES This chapter lists part numbers for amplifiers and accessories Contents include H 1 Amplifier Model Numbers H 2 Accessory Model Numbers 194 H 3 Order Example sess 195 H 4 Control and Feedback Cable Color Codes 196 H 4 1 Wire Description Nomenclature 196 H 4 2 Control Cable XSL CC 10 196 H 4 3 Feedback XSL FC 10 197 H 5 Regen Resistor Specifications 198 H 5 1 XTL RA 03 XTL RA 04 Specifications 198 H 5 2 XTL RA 03 XTL RA 04 Dimensions
191. s of the moving load 2 Mass of the motor forcer block if the motor rod is stationary OR Mass of the motor rod if the motor forcer block is stationary A 1 2 Observe the Properties of Each Deceleration During a Complete Cycle of Operation A 1 2 1 For each deceleration during the motion cycle determine 1 Speed at the start of the deceleration 2 Speed at the end of the deceleration 3 Time over which the deceleration takes place 154 Copley Controls Corp Xenus XSL User Guide Regen Resistor Sizing and Configuration A 1 3 Calculate Energy Returned for Each Deceleration Use the following formulas to calculate the energy returned during each deceleration Rotary motor Edec Y Ji o B w2 Where Ege Energy returned by the deceleration in joules Jt Load inertia on the motor shaft plus the motor inertia in kg m w1 Shaft speed at the start of deceleration in radians per second w2 Shaft speed at the end of deceleration in radians per second w 2m RPS Linear motor Egec Ye M Vi V Where Ed Energy returned by the deceleration in joules M Total mass of the load and the moving part of the motor in kg V Velocity at the start of deceleration in meters per second V2 Velocity at the end of deceleration in meters per second A 1 4 Determine the Amount of Energy Dissipated by the Motor Calculate the amount of energy dissipated by the motor due to current flow though the motor winding resistance using th
192. save disk space Copley Controls Corp 129 Using CME 2 Xenus XSL User Guide 6 3 2 Downloading Firmware to Amplifier NOTE Firmware can only be downloaded to an amplifier via a direct serial port connection between the amplifier and the PC CME 2 does not support downloading firmware to a node amplifier via a multi drop gateway amplifier 6 3 2 1 6 3 2 2 6 3 2 3 6 3 2 4 6 3 2 5 130 On the Main screen choose Tools Download Firmware to open the Download Firmware window Download Firmware xi q Do you want to save your data before downloading new firmware No Cancel To download new firmware without saving amplifier and motor data click No and then proceed to Step 6 3 2 4 To save amplifier and motor data for backup purposes before downloading firmware click Yes Save Amplifier Data x v Save Data To Disk v Save Data To Flash Cancel 1 Use check marks to select whether to save to disk flash both or neither 2 Click OK to save data and continue to select a firmware image or click Cancel to continue without saving data 3 If Save Data to Disk was checked use the Save Amplifier Data to Disk screen to browse to the folder where you want to save the ccx file Then enter a name in the Name field Then click Save When the Firmware Images window appears proceed to Step 6 3 2 4 Use the Firmware Images window to locate and select a firmware image file x Look in la Firmwar
193. sibility for any errors that may appear in this document Copley Controls Corp 8 Xenus XSL User Guide About this Manual Product Warnings Observe all relevant state regional and local safety regulations when installing and using this product For safety and to assure compliance with documented system data only Copley Controls Corporation should perform repairs to amplifiers DANGER DANGER DANGER DANGER DANGER DANGER Copley Controls Corp DANGER Hazardous voltages Exercise caution when installing and adjusting Failure to heed this warning can cause equipment damage injury or death Risk of electric shock High voltage circuits on J1 J2 and J3 are connected to mains power Failure to heed this warning can cause equipment damage injury or death Risk of unexpected motion with non latched faults After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warning can cause equipment damage injury or death Using CME 2 or serial commands may affect or suspend CAN operations When operating the amplifier as a CAN node the use of CME 2 or ASCII serial commands may affect CAN operatio
194. so control a Copley Controls ServoTube motor see ServoTube Setup p 84 Xenus can operate from single or three phase mains with a continuous power output of up to 4 kW Xenus is offered in two versions to support three types of feedback devices The standard version supports digital quadrature or analog sin cos encoders The R version supports brushless resolvers Both versions can emulate a digital quadrature encoder output from the analog encoder or resolver respectively Xenus can operate in several basic ways e As a traditional motor amplifier accepting current velocity or position commands from an external controller In current and velocity modes it can accept 10 Vdc analog digital 50 PWM or PWM polarity inputs In position mode inputs can be incremental position commands from step motor controllers in Pulse and Direction or Count Up Count Down format as well as A B quadrature commands from a master encoder Pulse to position ratio is programmable for electronic gearing e Asa node on a CANopen network CANopen compliance allows the amplifier to take instruction from a master application over a CAN network to perform torque velocity and position profiling interpolated motion and homing operations Multiple drives can be tightly synchronized for high performance coordinated motion e As a stand alone controller running Copley Virtual Machine CVM control programs such as the Indexer Program It can also be controlled directly over
195. t Hold Torque Pos to apply positive torque to the motor hold down Torque Neg to apply mode negative torque to the motor Release the button to stop movement Velocity Hold Jog Pos to command a forward velocity hold down Jog Neg to command a negative mode velocity Release the button to command zero velocity Position Hold Move Pos to generate a forward move profile hold Move Neg to generate a negative mode move profile Release the button to stop movement NOTE Position mode jog is accomplished by continuously updating the commanded position If a following error develops with Following Error Fault is disabled motion will not stop on button release Instead it stops when actual position commanded position Copley Controls Corp 133 Using CME 2 Xenus XSL User Guide 6 5 Scope Tool 6 5 1 Scope Tool Overview The CME 2 Scope Tool can be used to tune the amplifier monitor amplifier performance while in normal operation and to perform diagnostics The Scope s Function Generator and Profile Generator can be used to drive the motor without using an external control source The Auto Set Up feature automatically sets all the scope parameters for the most commonly used tuning scenarios Click the Scope tool I to access the tool and open the Oscilloscope window CG Oscilloscope Trace Status Ready Scope Screen Function Generator Profile Settings Gains Trajectory Limits Pos
196. t of Fundamental Counts value and the Interpolation value Resolver Optionally modify the feedback resolution by changing the value in Resolver 4000 CountsPerRev Counts Per Rev Default 16384 5 6 2 3 If two feedback devices are installed verify that the values of Motor Turns to Position Turns correctly represent the ratio of motor encoder turns to position encoder turns Ratio Motor Turns 1 Positon Turns 10 5 6 24 If using a brake then proceed to Brake Stop Optional p 91 Else proceed to Calculate p 92 5 6 3 Linear Motor Feedback Setup Options 5 6 3 1 Click the Feedback tab 5 6 3 2 As appropriate for each encoder installed enter the options described below Feedback Type Options Actions Incremental Encoder Resolution 1 Cmn Cnm um Choose units mm nm um and then enter the Encoder Resolution see encoder or motor data sheet Analog Fundamental Pitch um um Fundamental bissl si 1 Resolution Interpolation 1 e Interpolated Resolution 1 um Enter the Fundamental Pitch distance between encoder lines see encoder or motor data sheet As indicated by the Fundamental Resolution field every unit of fundamental pitch produces four encoder counts The interpolated resolution is the dividend of Fundamental Counts value Interpolation value Optionally modify the resolution by changing the Interpolation value Low Frequency Analog Pole Pitch 512 mm Counts
197. tage Current Loop Current Integral Gain Ci Ey Command ES me j Current Command Current Limiter Limited Current Current Proportional Gain Cp l Current Offset gt FRS Limits Feedback Actual Current e Peak Current e Continuous Current e Peak Current Limit Time Current Loop Inputs e The amplifiers analog or PWM inputs e A CANopen network via the amplifier s CAN interface e A Copley Virtual Motion CVM control program e The amplifiers internal function generator In velocity or position modes the current command is generated by the velocity loop Offset The current loop offset is intended for use in applications where there is a constant force applied to or required of the servomotor and the system must control this force Typical applications would be a vertical axis holding against gravity or web tensioning This offset value is summed with the current command before the limiting stage Limits The current command is limited based on the following parameters Limiter Description Peak Current Limit Maximum current that can be generated by the amplifier for a short duration of time This value cannot exceed the peak current rating of the amplifier Continuous Current Maximum current that can be constantly generated by the amplifier Limit PT Time Limit Maximum amount of time that the peak current can be applied to
198. the motor terminals and the results are saved to flash memory The actual wire configuration should NEVER change e Brushless motors require two electrical cycles for auto phasing Phasing accomplishes several objectives e Checks the encoder or resolver and establishes proper commutation e Checks the motor power wires for proper connection and establishes proper phasing e Checks the Hall switches and establishes proper commutation Copley Controls Corp 105 Quick Setup with CME 2 Xenus XSL User Guide 5 10 2 Auto Phase Procedure NOTE The following steps use a brushless rotary motor The screens and sequences vary for other motor types 5 10 2 1 Verify that the Enable Input is not activated 5 10 2 2 Apply AC power 5 10 2 3 Click Auto Phase El to open the Auto Phase Motor Direction Setup screen x Motor Direction Setup Move the motor in the direction that you want to be positive Press Nextwhen done Actual Position 0 counts 5 00 24 Move the motor in the direction you wish to be considered positive The Actual Position value on the screen should change If it does not change see Trouble Shoot Motor Direction Setup p 109 5 10 2 5 Activate the Enable Input 5 10 2 6 Click Next to display the Auto Phase Motor Wiring Setup screen fauto phase x Motor Wiring Setup Commanded Motor Phase Angle The software will now micro step the motor in 40 9 e the positive direciton Make sure the motor is o A free
199. tions are shown on the following page 170 Copley Controls Corp Xenus XSL User Guide Thermal Considerations D 1 2 Heatsink and Fan Configurations No Heatsink No Fan With Fan Low Profile Heatsink No Fan Standard Heatsink No Fan With Fan Select a 4 25 inch square fan that supplies forced air at a minimum rate of 300 linear feet per minute Copley Controls Corp 171 Thermal Considerations Xenus XSL User Guide D 2 Heatsink Mounting Instructions Phase change material PSM is used in place of thermal grease This material comes in sheet form and changes from solid to liquid form as the amplifier warms up This forms an excellent thermal path from amplifier heatplate to heatsink for optimum heat transfer 9 2 7 D 2 2 D 2 3 D 2 4 172 Remove the transparent plastic carrier sheets from both sides of the phase change material Phase Change Material Transparent Carrier Discard Place the phase change material on the amplifier taking care to center the phase change material holes over the heatsink mounting holes Mount the heatsink onto the amplifier taking care to see that the holes in the heatsink phase change material and amplifier all line up Torque the 226 32 mounting screws to 8 10 Ib in 0 91 13 Nm 6 32 Mounting Screws Heatsink Phase Change Material Xenus Amplifier NOTE The drawing shows the standard heatsink kit XSL HS but the mounting instruc
200. tions given are valid for the low profile heatsink kit XSL HL as well Copley Controls Corp APPENDIX E XENUS FILTER This chapter provides an overview of the Model XSL FA 01 edge filter The contents of this chapter include Title E OVBIVIBW ctetu LL MEM a ee E D ee E 2 XSL FA 01 Edge Filter Specifications E 3 Thermal Considerations E 4 XSL FA 01 Edge Filter Dimensions E 5 XSL FA 01 Edge Filter Wiring E 6 XSL FA 01 Edge Filter Ordering Copley Controls Corp 173 Xenus Filter Xenus XSL User Guide E 1 Overview The XSL FA 01 edge filter can be used to minimize noise on the output of any Xenus amplifier E 1 1 Differential and Common Mode Filtering Most noise is capacitively coupled from the motor power cable to neighboring cables To minimize this noise the XSL FA 01 edge filter uses both differential edge filtering and common mode filtering Differential edge filtering reduces the high frequency component of the PWM signal thus producing a signal with less energy that can be coupled during transmission Common mode filtering reduces the unnecessary common mode noise generated by PWM signals E 1 2 Description and Functional Diagram The differential filter increases the rise time by at least a factor of 3 substantially reducing noise in the system Copley Controls amplifiers typically have a 150 ns rise time high frequency component in the MHz range Thus the edge
201. tive Axis has contacted negative limit switch Positive Software Limit Actual position has exceeded the positive software limit setting See Home Function p 152 Negative Software Limit Actual position has exceeded the negative software limit setting See Home Function p 152 Following Warning Following error has reached programmed warning limit See Following Error Fault Details p 39 Velocity Limit Reached The velocity command from analog input PWM input or position loop has exceeded the velocity limit that was set as described in Velocity Loop Limits p 22 Acceleration Limit reached In velocity mode motor has reached an acceleration or deceleration limit that was set as described in Velocity Loop Limits p 22 Velocity Outside of Tracking Window Difference between target and actual velocity has exceeded the window See Tracking Window Details p 40 Position Outside of Tracking Window The following error has exceeded the programmed value See Tracking Window Details p 40 Custom Output Status Functions A custom output can be configured to go active to indicate the following conditions Event Description Amplifier Disabled by Hardware Amplifier enable input s is not active Amplifier Disabled by Software Amplifier is disabled by a software command Attempting to Stop Motor The amplifier while in velocity or position mode has
202. to move Press Start when ready 180 0 Auto Phase Current D47 A 210 330 240 779 900 Increment Rate 90 elec deg sec Actual Position 0 counts Ready Back Next Cancel 106 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 100 277 Click Start to begin the motor wiring setup The software displays messages Configuring Initial Settings Microstepping Test Complete Motor Wiring has been configured During microstepping a current vector is applied to the motor windings and microstepped through an electrical cycle at a set rate The field produced should push on the permanent magnet s magnetic field causing the motor to move If the step fails see Trouble Shoot Motor Wiring Setup p 109 NOTE If incorrect values were entered for inductance and resistance the calculated Cp and Ci values may produce current loop oscillation evidenced by an audible high frequency squeal during auto phasing 5 10 2 8 For a R version of Xenus with a resolver skip to 5 10 2 11 5 40 29 Fora standard version Xenus click Next to display the Halls Wiring Setup screen x Hall Wiring Setup Commanded Motor Phase Angle amp Hall State The software will now micro step the motor Make sure the motor is free to move El E Press Start when ready 120 60 Miss o B 124 Auto Phase Current 240 300 Increment Rate 80 elec degisec E E Stop Hall Offset 0 deg Ready Cancel 5 10 2 10 Click
203. tor inertia of the motor Used for calculating initial velocity loop tuning values Range 0 00001 to 1 000 kg cm Default 0 00001 kg cm Number of Brushless only The number of magnetic poles in the motor Required for correct Poles commutation of the motor If the number of poles is not known refer to Verify Motor Pole Count p 148 Range 2 to 200 Default 4 Peak Torque The peak torque that the motor can produce Peak Torque divided by torque constant motor s peak current limit Range 0 001 to 1 000 Nm Default 0 0001 Nm Continuous The continuous torque that the motor can produce Used with the torque constant to Torque calculate continuous current Range 0 001 to 1 000 Nm Default 0 0001 Nm Velocity Limit Maximum speed of the motor Used to calculate the velocity and acceleration limits for the velocity loop Range dependent on encoder resolution Torque Relates the motor s input current to torque produced Sometimes abbreviated as Kt Constant Range 0 001 to 1 000 Nm Amp Default 0 001 Nm Amp Back emf Relates the motor s input voltage to speed Sometimes abbreviated as Ke Used for Constant calculating the maximum velocity for a given amplifier bus voltage Range 0 01 to 1 000 V Krpm Default 0 01 V Krpm Resistance Motor resistance line to line Used for calculating the initial current loop tuning values Range 0 01 to 327 O Default 0 01 O Inductance Motor inductance line to lin
204. trols Corp Xenus XSL User Guide Operational Theory 2 8 Brake Operation 2 8 1 Digital Output Controls Brake Many control systems employ a brake to hold the axis when the amplifier is disabled Digital output 4 OUTA4 is designed specifically for a brake output Other outputs can be used for brake control but OUT4 is recommended Unlike the other outputs OUTA is optically isolated from the control signals and has an internal fly back diode connected to the 24 Vdc input By eliminating the need to connect into the amplifier control connector having the brake output on the 24 Vdc power connector simplifies wiring when the brake wires are in the power cable of the motor For more information see Brake Output p 53 and Logic Supply Brake J4 p 65 2 8 2 Brake Stop Sequences Disabling the amplifier by a hardware or software command starts the following sequence of events e The motor begins to decelerate at Abort Deceleration rate in position mode or Fast Stop Ramp rate in velocity mode At the same time the Brake Stop Delay Time count begins This allows the amplifier to slow the motor before applying the brake e When the motor slows to Brake Stop Activation Velocity OR the Brake Stop Delay Time expires the brake output activates and PWM Delay Brake Stop Response Time count begins e When response time has passed the amplifier s output stages are disabled This delay ensures the brake has time to lock in before disabl
205. tware disabled when button is selected Jog Mode See Jog Mode p 133 6 4 4 2 To reset the amplifier click Reset To clear all amplifier faults click Clear Faults To set the amplifiers actual position counter to zero click Set Zero Position Risk of unexpected or uncontrolled motion Using the CME 2 Set Zero Position function while the amplifier is operating under CANopen control could cause unexpected or uncontrolled motion Failure to heed this warning can cause equipment damage WARNING 6 4 5 Jog Mode Jog mode provides a simple means for generating forward or reverse commands 6 4 5 1 To put the amplifier in jog mode select the Jog Mode radio button Then set up a jog move by setting the following mode specific options Mode Option Description Current Torque Current applied to the motor Limited by current loop Continuous Current Warning Unloaded motors may depending on torque setting ramp up in speed very quickly Current Ramp Sets the rate at which the current will increase and decrease Velocity Jog Speed Velocity of the jog move Limited by velocity loop Vel Limit Position Velocity Velocity of the jog move Limited by velocity loop Vel Limit Acceleration Acceleration rate of the jog move Limited by Trajectory Limits Max Accel Deceleration Deceleration rate of the jog move Limited by Trajectory Limits Max Decel 6 4 5 2 Command the move Curren
206. ues from these sources 5 9 4 5 For each source selected perform the additional steps described below Source Steps Comments Use Switch Verify the S1 switch setting Assigns values for Bit 0 Bit 3 of CAN address Use Inputs Enter the Number of inputs Choose the input that will represent each CAN address bit Use Enter the Programmed value Programmed Value 5 9 4 6 Click OK to close the screen and save the changes to flash OR click Cancel to close the screen without saving the changes NOTE CAN address and bit rate are changed only after 24 Vdc power up or reset 104 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 10 Auto Phase 5 10 1 Auto Phase Warnings and Notes Warnings Motor Motion Applying AC power to the amplifier may result in motor motion Be sure that motor motion will not cause injury Failure to heed this warning can result in equipment damage injury or death Danger High Voltage Applying AC power to the amplifier applies high voltage to the amplifier motor connections and cabling Protect personnel against electrical shock Failure to heed this warning can result in equipment damage injury or death Danger Notes e Do not connect a load to the motor before performing Auto Phase procedure e Always connect the motor using the same configuration e Wire properly and consistently e Connections are actually changed within the DSP not at
207. uide This page for notes 168 Copley Controls Corp APPENDIX D THERMAL CONSIDERATIONS This chapter describes operating temperature characteristics heatsink options and heatsink mounting instructions Contents include D 1 Operating Temperature and Cooling Configurations D 1 2 Heatsink and Fan Configurations ooooncccnncnnnnccnnccnonnnnoncnoncconnn corn conocia eene D2 Heatsink Mounting Instr ctlons cuoc Added iia Copley Controls Corp 169 Thermal Considerations Xenus XSL User Guide D 1 Operating Temperature and Cooling Configurations The following charts show the maximum allowable ambient temperature of Xenus amplifiers for a variety of operating conditions and cooling configurations The cooling options are for Xenus amplifiers with no heatsink with the low profile heatsink and with the standard heatsink all with and without forced air cooling The operating conditions considered cover a range of continuous output currents at both 120 Vac and 240 Vac mains voltages Model XSL 230 18 XSL 230 18 R Mains 120 Vac Mains 120 Vac Mains 240 Vac 60 i 60 2 2 Low Profile 3 3 All other B CERE UR fee A Heatsink heatsink fan 1 e 3 o 50 gt 50 combinations 3 1 No Heatsink 3 2 enable operation at o o o 2 40 All other 40 De heatsink fan 2 Low Profile E combinations Heatsink 9 30 enable 2 30 a
208. up 4 13 OUT1 14 OUT2 General purpose programmable outputs 15 OUT3 16 Encoder A 17 Encoder A 18 Encoder B Programmable secondary encoder input output 19 Encoder B 20 Encoder X 21 Encoder X 22 5 Vdc Encoder 5 Vdc power supply output Total load current on J7 22 and J8 3 not to exceed 400 mA 23 Signal Ground Signal ground reference for inputs and outputs 24 Ref Input Analog command positive input 25 Ref Input Analog command negative input 26 IN12 Programmable Standard Group 4 Copley Controls Corp Wiring 69 Wiring Xenus XSL User Guide Mode Dependant Dedicated Inputs These inputs are dedicated to specific functions depending on operating mode Mode Input Function All IN1 Enable Current amp Velocity IN9 PWM Input PWM 50 Current amp Velocity IN9 PWM Input PWM 100 IN10 Direction Input Position IN9 Pulse Input Pulse amp Direction IN10 Direction Input Position IN9 Count Up Up Down IN10 Count Down Position IN9 Channel A Quadrature IN10 Channel B Digital Inputs Wiring Diagram Motion Controller Typical Circuit 5Vdc 10 KQ pull up pull down Standard input R KO C 0 033uf High speed input R 1KO C 100 pf 70 Copley Controls Corp Xenus XSL User Guide Wiring Digital Outputs Wiring Diagram Typical Output Loads Typical Circuit Motion Controller External Power Supply Flyoack diode required for in
209. upply This design allows the outputs to be directly connected to optically isolated PLC inputs that reference a voltage higher than 5 Vdc typically 24 Vdc The diode prevents current flow between the 24 Vdc supply and the internal 5 Vdc supply though the pull up resistor This current if allowed to flow could turn on the PLC input giving a false indication of the amplifiers true output state The general purpose outputs require an external fly back diode to be installed across any inductive loads such as relays that are connected to them The brake output OUT4 is described in Brake Operation p 33 2 14 2 Standard Programmable Output Functions Each digital output can be programmed to perform one of the following standard functions Function Description Fault Active High Low The output is high low when a fault is active Brake Active High Low The output high low when brake is active PWM Sync Output Only available on OUT1 Sends the PWM sync input of a slave amplifier See Synchronizing PWM Switching Frequency p 18 Custom Active High Low The output is high low when at least one of the events selected on the Custom Output Configuration form occurs For more information see Custom Output Functions p 45 Program Control Active High The state of the output is controlled by the CAN controller or the CVM control Low program 44 Copley Controls Corp Xenus X
210. w input will inhibit motion in negative direction POS Limit HI Inhibits A high input will inhibit motion in positive direction POS Limit LO Inhibits A low input will inhibit motion in positive direction Reset on LO HI Transition A low to high transition of the input will reset the amplifier Reset on HI LO Transition A high to low transition of the input will reset the amplifier Motor Temp HI Disables A high input will generate a Motor Over Temperature fault Motor Temp LO Disables A low input will generate a Motor Over Temperature fault Home Switch Active HI A high input indicates the home switch is activated Home Switch Active LO A low input indicates the home switch is activated Motion Abort Active HII A high input will stop motion leaving amplifier enabled Motion Abort Active LO A low input will stop motion leaving amplifier enabled Hi Res Analog Divide Active HI A high input causes the firmware to divide the level of the analog input signal by 8 Hi Res Analog Divide Active LO A low input causes the firmware to divide the level of the analog input signal by 8 PWM Sync Input PWM synchronization input see PWM Sync Input p 43 and PWM Sync Output p 44 Copley Controls Corp Xenus XSL User Guide Quick Setup with CME 2 5 8 2 Standard Digital Outputs 5 8 2 1 Click the Digital Outputs tab of the Input Output screen P
211. wing e The amplifier s analog or PWM inputs e A CANopen network via the amplifiers CAN interface e A Copley Virtual Motion CVM control program e The amplifier s internal function generator In position mode the velocity command is generated by the position loop Velocity Loop Limits The velocity command is limited based on the following set of parameters designed to protect the motor and or the mechanical system Limiter Description Velocity Limit Sets the maximum velocity command input to the velocity loop Acceleration Limit Limits the maximum acceleration rate of the commanded velocity input to the velocity loop This limit is used in velocity mode only In position mode the trajectory generator handles acceleration limiting Deceleration Limit Limits the maximum deceleration rate of the commanded velocity input to the velocity loop This limit is used in velocity mode only In position mode the trajectory generator handles deceleration limiting Fast Stop Ramp Specifies the deceleration rate used by the velocity loop when the amplifier is hardware disabled Fast stop ramp is not used when amplifier is software disabled If the brake output is active the fast stop ramp is used to decelerate the motor before applying the brake Note that Fast Stop Ramp is used only in velocity mode In position mode the trajectory generator handles controlled stopping of the motor There is one exception if a non latc
212. y to expire 101 x 0 1 0 2 03 04 Preferences gt plus connected plus 0 5 06 0 7 08 09 10 Es 1e Time seconds The Scope display options are described below Menu Option Description Line Style line A line connects the plotted data points plus The Scope plots data points as plus signs with no connecting line connected plus Data points are plotted as plus signs and are connected with a line Preferences anti aliasing When anti aliasing is checked the Scope smoothes out any screen related jaggedness in the displayed trace Use of this feature may slow down the refreshing of traces on slow computers grid When checked a grid is displayed on the scope screen Auto Scale and Zoom The Scope automatically scales the display axes to optimally display all channels To zoom in one area of a trace hold the left mouse button and drag a box around the area of interest Release the button and the display zooms in on the selected area To restore the normal display left click anywhere on the trace image Normal display is also restored automatically when the next trigger event occurs Auto Setup With Auto Set Up selected if the function generator tab is active CME 2 automatically sets the Scope settings and the function generator s amplitude and frequency period to best suit the function generator s Apply To and Excitation mode settings If the Profile tab is active CME 2 automati

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