Manual de referencia MDS

Manual de referencia MDS
Modular Drive System
Reference Manual
400525-01
Revision A1
February 27, 2002
© Control Techniques Drives, Inc. 2001, 2002
Modular Drive System
Reference Manual
Information furnished by Control Techniques Drives Inc. (Control Techniques) is believed to be
accurate and reliable. However, no responsibility is assumed by Control Techniques for its use.
Control Techniques reserves the right to change the design or operation of the equipment described
herein and any associated motion products without notice. Control Techniques also assumes no
responsibility for any errors that may appear in this document. Information in this document is subject
to change without notice.
P/N 400525-01
Revision: A1
Date: February 27, 2002
© Control Techniques Drives, Inc. 2001, 2002
© Control Techniques Drives, Inc. 2001, 2002
Part Number: 400525-01
Revision: A1
Date: February 2002
Printed in United States of America
Information in this document is subject to change without notice. No part of this document may be
reproduced or transmitted in any form or by any means, electronic or mechanical, for any purpose,
without the express written permission of Control Techniques.
The following are trademarks of Control Techniques and may not be reproduced in any fashion
without written approval of Control Techniques: EMERSON Motion Control,
EMERSON Motion Control PowerTools, AXIMA, “Motion Made Easy.”
Control Techniques is a division of EMERSON Co.
Control Techniques, Inc. is not affiliated with Microsoft Corporation, owner of the Microsoft,
Windows, and Windows NT trademarks.
IBM is a registered trademark of International Business Machines Corporation.
Modbus and Shawmut are registered trademarks of Gould, Inc.
Schaffner is a registered trademark of Schaffner
Data Highway Plus is a trademark of Allen-Bradley
This document has been prepared to conform to the current released version of the product. Because
of our extensive development efforts and our desire to further improve and enhance the product,
inconsistencies may exist between the product and documentation in some instances. Call your
customer support representative if you encounter an inconsistency.
ii
Customer Support
Control Techniques
12005 Technology Drive
Eden Prairie, Minnesota 55344-3620
U.S.A.
Telephone: (952) 995-8000 or (800) 397-3786
It is Control Techniques’ goal to ensure your greatest possible satisfaction with the operation
of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is
why we offer you so many ways to get the support you need. Whether it’s by phone, fax or
modem, you can access Control Techniques support information 24 hours a day, seven days
a week. Our wide range of services include:
FAX
(952) 995-8099
You can FAX questions and comments to Control Techniques. Just send a FAX to the number
listed above.
Website and Email
www.emersonct.com
Website: www.emersonct.com
Email: [email protected]
If you have Internet capabilities, you also have access to technical support using our website.
The website includes technical notes, frequently asked questions, release notes and other
technical documentation. This direct technical support connection lets you request assistance
and exchange software files electronically.
Technical Support
(952) 995-8033 or (800) 397-3786
Email: [email protected]
Control Techniques’ “Motion Made Easy” products are backed by a team of professionals
who will service your installation. Our technical support center in Eden Prairie, Minnesota is
ready to help you solve those occasional problems over the telephone. Our technical support
center is available 24 hours a day for emergency service to help speed any problem solving.
Also, all hardware replacement parts, if needed, are available through our customer service
organization.
When you call, please be at your computer, with your documentation easily available, and be
prepared to provide the following information:
•
Product version number, found by choosing About from the Help menu
•
The type of controller or product you are using
iii
•
Exact wording of any messages that appear on your screen
•
What you were doing when the problem occurred
•
How you tried to solve the problem
Need on-site help? Control Techniques provides service, in most cases, the next day. Just call
Control Techniques’ technical support center when on-site service or maintenance is
required.
Training Services
(952) 995-8000 or (800) 397-3786
Email: [email protected]
Control Techniques maintains a highly trained staff of instructors to familiarize customers
with Control Techniques’ “Motion Made Easy” products and their applications. A number of
courses are offered, many of which can be taught in your plant upon request.
Application Engineering
(952) 995-8000 or (800) 397-3786
Email: [email protected]
An experienced staff of factory application engineers provides complete customer support for
tough or complex applications. Our engineers offer you a broad base of experience and
knowledge of electronic motion control applications.
Customer Service (Sales)
(952) 995-8000 or (800) 397-3786
Email: [email protected]
Authorized Control Techniques distributors may place orders directly with our Customer
Service department. Contact the Customer Service department at this number for the
distributor nearest you.
Document Conventions
Manual conventions have been established to help you learn to use this manual quickly and
easily. As much as possible, these conventions correspond to those found in other Microsoft®
Windows® compatible software documentation.
Menu names and options are printed in bold type: the File menu.
Dialog box names begin with uppercase letters: the Axis Limits dialog box.
Dialog box field names are in quotes: “Field Name.”
Button names are in italic: OK button.
Source code is printed in Courier font: Case ERMS.
iv
In addition, you will find the following typographic conventions throughout this manual.
This
Represents
bold
Characters that you must type exactly as they appear. For example, if you are directed to type
a:setup, you should type all the bold characters exactly as they are printed.
italic
Placeholders for information you must provide. For example, if you are directed to type
filename, you should type the actual name for a file instead of the word shown in italic type.
ALL CAPITALS
Directory names, file names, key names, and acronyms.
SMALL CAPS
Non-printable ASCII control characters.
KEY1+KEY2
example: (Alt+F)
A plus sign (+) between key names means to press and hold down the first key while you press
the second key.
KEY1,KEY2
example: (Alt,F)
A comma (,) between key names means to press and release the keys one after the other.
“Warning” indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
“Caution” indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
“Caution” used without the safety alert symbol indicates a potentially hazardous situation
that, if not avoided, may result in property damage.
Note
For the purpose of this manual and product, “Note” indicates essential information about
the product or the respective part of the manual.
Throughout this manual, the word “drive” refers to an MDS.
Throughout this manual. the word “FM-3” refers to an FM-3, FM-3DN or FM-3PB.
Throughout thie manual the word “FM-4” refers to an FM-4, FM-4DN or FM-4PB.
v
Safety Instructions
General Warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages
used in the product can cause severe electric shock and/or burns and could be lethal. Extreme
care is necessary at all times when working with or adjacent to the product. The installation
must comply with all relevant safety legislation in the country of use.
Qualified Person
For the purpose of this manual and product, a “qualified person” is one who is familiar with
the installation, construction and operation of the equipment and the hazards involved. In
addition, this individual has the following qualifications:
•
Is trained and authorized to energize, de-energize, clear and ground and tag circuits and
equipment in accordance with established safety practices.
•
Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
•
Is trained in rendering first aid.
Reference Materials
The following related reference and installation manuals may be useful with your particular
system.
• PowerTools Software User’s Guide (P/N 400503-01)
• FM-1 Speed Module Reference Manual (P/N 400506-01)
• FM-2 Indexing Module Reference Manual (P/N 400507-01)
• FM-3 Programming Module Reference Manual (P/N 400508-01)
• FM-4 Programming Module Reference Manual (P/N 400509-01)
• FM-3 and FM-4 DeviceNet Module Reference Manual (P/N 400508-03)
• Function Module Installation Manual (400506-03)
• FM-3 and FM-4 Profibus Module Reference Manual (P/N 400508-04)
vi
Underwriters Laboratories Listed
LISTED 768R
IND. CONT. EQ.
The MDS Digital Servo Drives are marked with the “UL Listed” label after passing a rigorous
set of design and testing criteria developed by UL (UL508C). This label indicates that UL
certifies this product to be safe when installed according to the installation guidelines and
used within the product specifications.
The “conditions of acceptability” required by UL are:
•
The drive surrounding air ambient temperature must be 40° C (104° F) or less.
•
MDS surrounding air ambient temperature can be up to 50°C (122° F) with 3% linear
derating for every degree above 40° C (104° F)
•
This product is suitable for use on a circuit capable of delivering not more than 10,000
RMS symmetrical amperes, 480 volts maximum.
•
Motors must incorporate an overload protection device such as an overtemperature
switch.
Drive Overload Protection
The drive output current overload protection is provided by the drive and is not adjustable.
This overload protection is based on maximum continuous output current capacity. It will
allow up to 200 percent of the drive rated current to be delivered for the amount of time
determined by the following chart.
Rated output current (Amps RMS)
Drive Module Model
Continuous
MD-404
4
Peak
8
MD-407
7
14
MD-410
10
20
MD-420
20
40
MD-434
34
68
vii
Drive Output Current vs. Time graph
60
Time (seconds)
50
40
30
20
10
0
100
125
150
175
200
% Drive Rated Current
CE Declaration of Conformity
The MDS Drive and Power Modules are marked with the “Conformite Europeenne Mark”
(CE mark) after passing a rigorous set of design and testing criteria. This label indicates that
this product meets safety and noise immunity and emissions (EMC) standards when installed
according to the installation guidelines and used within the product specifications.
viii
Declaration of Conformity
Manufacturer’s Name:
Control Techniques/Emerson Industrial Automation
Manufacturer’s Address:
12005 Technology Drive
Eden Prairie, MN 55344
USA
Declares that the following products:
Products Description:
Modular Drive System (MDS)
Model Number:
MP-1250/MP-2500/MP-5000
MD-407/MD-410/MD-420/MD-434
Conforms to the following product specification:
Electomagnetic Compatibility (EMC):
EN 55011/1998 w/Amendment A1:1999 Class A Group 1, CISPR 11/1990 Class A Group 1
EN 61800-3, 1996:
IEC 1000-4-2/1995; EN 61000-4-2, 6kV CD
IEC 1000-4-3/1995; EN 61000-4-3, ENV 50140/1993, 80%
AM, 10V/m @ 3 m
IEC 1000-4-4/1995; EN 61000-4-4, 2 kV ALL LINES
EN 61000-4-5, 1kV L-L, 2kV L-G
Supplementary information:
The products herewith comply with the requirements of the Low Voltage Directive (LVD) 73/23/EEC and EMC
Directive 89/336/EEC
This servo drive system is intended to be used with an appropriate motor, electrical protection components, and
other equipment to form a complete end product or system. MDS must only be installed by a professional
assembler who is familiar with safety and electromagnetic compatibility (“EMC”) requirements. The assembler is
responsible for ensuring that the end product or system complies with all the relevant laws in the country where it
is to be used. Refer to the information on EMC standards that the MDS complies with, as well ar the product
manual for installation guidelines.
January 31, 2002
John Wiegers/ Director Enigineering
Date
European Contact:
Sobetra Automation
Langeveldpark Lot 10
P. Dasterleusstraat 2
1600 St. Pieters Leeuw, Belgium
ix
x
Modular Drive System Reference Manual
Safety Considerations
Safety Precautions
This product is intended for professional incorporation into a complete system. If you install
the product incorrectly, it may present a safety hazard. The product and system may use high
voltages and currents, carries a high level of stored electrical energy, or is used to control
mechanical equipment which can cause injury.
You should give close attention to the electrical installation and system design to avoid
hazards either in normal operation or in the event of equipment malfunction. System design,
installation, commissioning and maintenance must be carried out by personnel who have the
necessary training and experience. Read and follow this safety information and the instruction
manual carefully.
Enclosure
This product is intended to be mounted in an enclosure which prevents access except by
trained and authorized personnel, and which prevents the ingress of contamination. This
product is designed for use in an environment classified as pollution degree 2 in accordance
with IEC664-1. This means that only dry, non-conducting contamination is acceptable.
Setup, Commissioning and Maintenance
It is essential that you give careful consideration to changes to drive settings. Depending on
the application, a change could have an impact on safety. You must take appropriate
precautions against inadvertent changes or tampering. Restoring default parameters in certain
applications may cause unpredictable or hazardous operation.
Safety of Machinery
Within the European Union all machinery in which this product is used must comply with
Directive 89/392/EEC, Safety of Machinery.
The product has been designed and tested to a high standard, and failures are very unlikely.
However the level of integrity offered by the product’s control function – for example stop/
start, forward/reverse and maximum speed – is not sufficient for use in safety-critical
applications without additional independent channels of protection. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment, and further
protection provided where needed.
General warning
Failure to follow safe installation guidelines can cause death or serious injury. The
xi
Modular Drive System Reference Manual
voltages used in this unit can cause severe electric shock and/or burns, and could be lethal.
Extreme care is necessary at all times when working with or adjacent to this equipment.
The installation must comply with all relevant safety legislation in the country of use.
AC supply isolation device
The AC supply must be removed from the Power Module backplane using an approved
isolation device or disconnect before any servicing work is performed, removing and/or
installing the Power Module and/or Drive Module(s), other than adjustments to the
settings or parameters specified in the manual. The drive contains capacitors which
remain charged to a potentially lethal voltage after the supply has been removed. Allow
at least 3 minutes after removing the supply before carrying out any work which may
involve contact with electrical connections to the drive.
Grounding (Earthing, equipotential bonding)
The drive must be grounded by a conductor sufficient to carry all possible fault current in
the event of a fault. The ground connections shown in the manual must be followed.
Fuses
Fuses must be provided at the input in accordance with the instructions in the manual.
Isolation of control circuits
The installer must ensure that the external control circuits are isolated from human
contact by at least one layer of insulation rated for use at the applied AC supply voltage.
xii
Modular Drive System Reference Manual
Table of Contents
Safety Considerations
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Setup, Commissioning and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety of Machinery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Introduction
xi
xi
xi
xi
xi
1
Modular Drive System (MDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation
5
MDS Installation Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Basic Installation Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Panel Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
MDS Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Power Module Backplane Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Power Module Assembly Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Drive Module Backplane Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Drive Module Assembly Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Step 1: Power Module Backplane Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Step 2: Drive Module Backplane Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Step 3: Power Module High Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
AC Input Power Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Electrical AC Input Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Step 4: Drive Module High Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Step 5: Power Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Step 6: Drive Module Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Step 7: Power and Drive Module Low Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Logic and Digitial I/O Power Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Power Module I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Drive Module I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Motor Brake Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Command Connector Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Step 8: Power Up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Power up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Drive and Power Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Drive Module Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
xiii
Modular Drive System Reference Manual
Drive Module Backplane Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Operational Overview
73
Operational Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Module Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shunt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Motion Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Functional Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pulse Mode. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Velocity Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Modifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current Foldback. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Brake Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Command Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Module Digital Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options and Accessories
103
MDS Options. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ECI-44 External Connector Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM-2 Indexing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM-3 Programming Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FM-4 Programming Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MS-510-00 and MS-530-00 Shunt Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Quick Start
73
73
73
74
75
75
77
77
77
82
85
86
91
92
94
96
97
103
103
105
105
105
106
109
Offline Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Online Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Setting Up Parameters
125
EZ Setup/Detailed Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Identification Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Configuration Group (EZ Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ConfigurationMD Group (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Load Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Operating Mode Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
xiv
125
125
126
126
127
128
Pulse Mode Interpretation Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Velocity Mode Submode Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Torque Mode Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Positive Direction Group (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Inputs Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Outputs Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Position Tab (Detailed Setup view only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Limits Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Actual Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Velocity Tab (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Limits Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Trigger Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Actual Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Velocity Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Accel/Decel Presets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Torque Tab (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
Actual Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Motor Tab (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Configuration Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Low Pass Filter Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Encoder Output Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Load Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Tuning Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Position Error Integral Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Analog Tab (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Analog Inputs Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Analog Outputs Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
I/O Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Inputs Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Outputs Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Status Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Position Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Velocity Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Torque Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Drive Status Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
ID Group (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Drive Run Time Group (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Fault Log Group (EZ Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
History Tab (Detailed Setup view only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Fault Log Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Fault Counts Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Advanced Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
xv
Modular Drive System Reference Manual
Bus Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Advanced Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Tuning Procedures
165
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PID vs. State-Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining Tuning Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Status, Diagnostics and Troubleshooting
177
Power Module Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Module Diagnostic Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fault Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Diagnostic Analog Output Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Watch Window . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
View Motor Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
User Defined Motors
165
165
166
168
172
177
177
178
182
184
185
186
187
189
Commutation Basics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Specifications
215
MDS Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive and Motor Combination Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Axial/Radial Loading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IP Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MDS Power Module Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MDS Drive Module Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
215
220
221
221
221
222
224
226
229
Glossary
241
Index
247
xvi
Modular Drive System Reference Manual
Introduction
Modular Drive System (MDS)
The Modular Drive System (MDS) is a 480V servo system comprised of a common Power
Module and up to eight Drive Modules. The modular approach provides an optimum solution
for each application. The Power Module provides the AC rectification and provides DC bus
power for up to eight Drive Modules. The common power supply minimizes installation
space and cost because there is only one AC Input, one Contactor, one set of AC fuses and
one AC line Filter per system. Each Power and Drive Module mounts on an innovative
backplane that provides the connection for the DC Bus and Logic Power, this minimzes
installation time. A compact installation is possible because the backplanes mount next to
each other, removing the need for space between each axis. Fuses (included) are mounted
directly on each Drive Module backplane to provide individual protection for each axis.
The Drive Modules can operate as base drives providing Velocity, Torque and Pulse/
Direction operations. For positioning and more advanced applications with more
functionality add a FM module to that axis for control. FM modules give the MDS "snap-on"
functionality for indexing (FM-2), programming (FM-3) and advanced programming (FM4). For applications that require fieldbus, the FM-3 and FM-4 modules can be ordered with
DeviceNet or Profibus options. Regardless of the control needed commissioning and
programming is made easy with our FREE PowerTools FM and PowerTools Pro software.
PowerTools is a Windows® based software that makes extensive use of drag and drop
editing, tabbed and hierarchal views, and on-line help to create a "Motion Made Easy"
experience. Commissioning time is minimized because the tuning of the drives is completed
with system parameters, Inertia mismatch, Friction and Response. The State-Space algorithm
uses the system parameters and motor map (DDF files) to make a robust control system that
is capable of 10:1 inertia mismatch applications out of the box. For higher mismatches, up to
50:1, a simple adjustment to the Inertia and Response parameters will provide the desired
performance. PowerTools has complete diagnostics and status indicators for quick
troubleshooting. System problems can be quickly identified with the status indicators and
I/O on the Power and Drive Modules, along with fault logging stored in the non-volatile
memory, minimizing startup time.
The MDS is able to use Control Techniques motors as well as other manufacturers motors.
Setup with a Control Techniques’ motor is done by selecting the desired motor in
PowerTools. Control Techniques has two lines of motors, MH and Unimotor motors to
provide an optimal solution for each application.
1
Modular Drive System Reference Manual
342 - 528 VAC
3 Phase
Input Power
Mains
Contactor
AC Line
Filter
(Optional)
AC Line
Fuses
FM Module
Connection
MP
MD
MD
MD
RS-232
or
RS-485
Computer or
Operator
Interface Panel
+24 VDC
User
Supply
MLP-002,
MLP-005,
MLP-010
Shunt Resistor
Optional
MH or UNI Motors
Figure 1: Module Drive System Overview
Power Modules are available in three power ratings
Power Module
Continuous Power
Peak Power
MP-1250
12.5 KW
25.0 KW
MP-2500
25.0 KW
50.0 KW
MP-5000
50.0 KW
100.0 KW
Drive modules are available in five current ratings.
Switching Frequency
Power Rating
Drive Module
(At 5 KHz)
5 KHz
10 KHz
Continuous Current
Peak Current
Continuous Current
Peak Current
MD-404
2.6 KW
4 A RMS
8 A RMS
2.8 A RMS
5.6 A RMS
MD-407
4.5 KW
7 A RMS
14 A RMS
5 A RMS
10 A RMS
MD-410
6.5 KW
10 A RMS
20 A RMS
6.5 A RMS
13 A RMS
MD-420
13.0 KW
20 A RMS
40 A RMS
14 A RMS
28 A RMS
MD-434
22.0 KW
34 A RMS
68 A RMS
22 A RMS
44 A RMS
Note
Power ratings in the tables above are for 480 VAC line voltage. For lower input line
voltages de-rate output power proportionally.
2
Introduction
FM Modules
The MDS is designed to accept a line of function modules that further enhance its use in
various applications.
•
FM-2 Indexing Module enables the user to initiate up to 16 different indexes, jogging, and
a single home routine.
•
FM-3, FM-3DN and FM-3PB Programming Modules offer complex motion profiling. A
complex motion profile consists of two or more indexes that are executed in sequence
such that the final velocity of each index except the last is non-zero. Logical instructions
between index statements can provide a powerful tool for altering motion profiles ’on the
fly’. The FM-3 can be order with DeviceNet or Profibus for fieldbus applications.
•
FM-4, FM-4DN adn FM-4PB Programming Modules offer complex motion profiling,
along with multi-tasking user programs. A complex motion profile consists of two or
more indexes that are executed in sequence such that the final velocity of each index
except the last is non-zero. Logical instructions between index statements can provide a
powerful tool for altering motion profiles ’on the fly’. The FM-4 can be order with
DeviceNet or Profibus for fieldbus applications.
The FM Function modules define complex motion by a configuration file that includes setups
and function assignments. For the FM-3 and FM-4 modules, the configuration file also
includes programs. The configuration file is created using PowerTools FM or PowerTools
Pro. The FM-2 module uses PowerTools FM software, and all the FM-3 and FM-4 modules
use PowerTools Pro software. Setup views have the same look and feel as dialog boxes. The
assigning of input and output functions is done through assignments view in the software.
PowerTools software is an easy-to-use Microsoft® Windows® based setup and diagnostics
tool.
FM MODULE CONNECTOR
FM
MP
MD
MD
MD
Programming Module
1
Exp. I/O
Inputs
485+
2
3
4
5
6
485-
7
SHLD
8
Sync.
Output
Outputs 10-30
VDC
Sync.
Input
1
2
3
4
+
-
3
Modular Drive System Reference Manual
4
Modular Drive System Reference Manual
Installation
MDS Installation Overview
Installation of the MDS is completed by following a simple step-by-step process. The MDS
installation begins by mounting the backplanes of the modules to a metal mounting panel
(Steps 1and 2). Next, the high power connections are made to the backplanes (Steps 3 and 4).
Power and Drive Module(s) are mounted to the backplanes (Steps 5, 6, and 7). Once the
modules are secured the low power connections are made. After inspection and test, the
system is complete and can be powered up for commissioning (Step 8).
Step 1: Power Module Backplane Installation, page 19
Step 2: Drive Module Backplane Installation, page 20
Step 3: Power Module Backplane High Power Connections, page 23
• AC Input Power
• Transformer Sizing ( if required)
• External Shunt Connection (if required)
• Line Fusing and Wire Size
Step 4: Drive Module High Power Connections, page 33
• Motor Power Cable
Step 5: Power Module Installation, page 34
Step 6: Drive Module Installation, page 35
Step 7: Power and Drive Module Low Power Connections, page 36
• Logic Power Sizing
• Digital I/O and Logic Power (user supplied)
• AC Interlock
• Digital I/O
• Command Signals
• Motor Brake
• Feedback
• Communications
Step 8: Power Up, page 65
Before starting actual Installation it is recommended that mounting location, cable layout,
environmental and electromagnetic compatibility be considered to insure a proper
installation. Refer to “Basic Installation Notes” on page 6 for Control Techniques
recommended installation guidelines and requirements.
5
Modular Drive System Reference Manual
Basic Installation Notes
You are required to follow all safety precautions during start-up such as providing proper
equipment grounding, correctly fused power and an effective Emergency Stop circuit which
can immediately remove power in the case of a malfunction. See the "Safety Considerations"
section for more information.
Electromagnetic Compatibility (EMC)
Drives are designed to meet the requirements of EMC. Under extreme conditions a drive
might cause or suffer from disturbances due to electromagnetic interaction with other
equipment. It is the responsibility of the installer to ensure that the equipment or system into
which the drive is incorporated complies with the relevant EMC legislation in the country of
use.
The following instructions provide you with installation guidance designed to help you meet
the requirements of the EMC Directive 89/336/EEC.
Adhering to the following guidelines will greatly improve the electromagnetic compatibility
of your system, however, final responsibility for EMC compliance rests with the machine
builder, and Control Techniques cannot guarantee your system will meet tested emission or
immunity requirements.
If you need to meet EMC compliance requirements, EMI/RFI line filters must be used to
control conducted and radiated emissions as well as improve conducted immunity.
Physical location of these filters is very important in achieving these benefits. The filter
output wires should be kept as short as possible (12 inches is suggested) and routed away from
the filter input wires. In addition:
•
Choose an enclosure made of a conductive material such as steel, aluminum or stainless
steel.
•
Devices mounted to the enclosure mounting plate, which depend on their mounting
surfaces for grounding, must have the paint removed from their mounting surfaces and the
mating area on the mounting plate to ensure a good ground. See the, "Achieving Low
Impedance Connections" section for more information.
•
If grounding is required for cable grommets, connectors and/or conduit fittings at
locations where cables are mounted through the enclosure wall, paint must be removed
from the enclosure surface at the contact points.
•
AC line filter input and output wires and cables should be shielded.
Achieving Low Impedance Connections
Noise immunity can be improved and emissions reduced by making sure that all the
components have a low impedance connection to the same ground point. A low impedance
connection is one that conducts high frequency current with very little resistance. Impedance
cannot be accurately measured with a standard ohmmeter, because an ohmmeter measures
6
Installation
DC resistance. For example, a 12 inch long 8 gauge round wire has a significantly higher
impedance than a 12 inch long 12 gauge flat braided conductor. A short wire has less
impedance than a long one.
Low impedance connections can be achieved by bringing large areas of conductive surfaces
into direct contact with each other. In most cases this requires paint removal because a ground
connection through bolt threads is not sufficient. However, component materials should be
conductive, compatible and exhibit good atmospheric corrosion resistance to prevent loss
through corrosion which will hinder the low impedance connection. Enclosure manufacturers
offer corrosion resistant, unpainted mounting plates to help.
Bringing components into direct contact cannot always be achieved. In these situations a
conductor must be relied upon to provide a low impedance path between components.
Remember a flat braided wire has lower impedance than a round wire of a large gauge rating.
A low impedance connection should exist between the following components, but not limited
to:
•
Enclosure and mounting plate
•
Each Power and Drive Module PE grounding tab
•
EMI/RFI AC line filter chassis and mounting plate
•
Other interface equipment chassis and mounting plate
•
Other interface equipment chassis and electrical connectors
•
Enclosure and conduit fittings or electrical connectors
•
Enclosure mounting plate and earth ground
•
Motor frame to conduit fittings, electrical connectors and grounded machine frame
•
Encoder chassis and electrical connector
A good rule to follow when specifying conductors for high frequency applications is to use a
metal strap with a length to width ratio that is less than 3:1.
7
Modular Drive System Reference Manual
Cable to Enclosure Shielding
Shielded motor, feedback, serial communications and external encoder cables were used for
compliance testing and are necessary to meet the EMC requirements. Each cable shield was
grounded at the enclosure wall by the type of grommet shown in the Figure 2.
Figure 2:
Cable Type
Through Wall Shield Grommet
Cable
Model
Shielded Cable Grommet
Kit Part #
Conduit Dimension
Hole Size
Actual Hole Size
Motor Cable, 16 Ga
CMDS
CGS-050
1/2" pipe
7/8"
Motor Cable, 12 Ga
CMMS
CGS-050
1/2" pipe
7/8"
Motor Cable, 8 Ga
CMLS
CGS-100
1" pipe
1 3/4"
Feedback Cable
CFOS
CGS-050
1/2" pipe
7/8"
Flex Motor Cable, 16 Ga
CMDF
CGS-050
1/2" pipe
7/8"
Flex Motor Cable, 12 Ga
CMMF
CGS-075
3/4" pipe
1 1/16"
CFCF, CFOF
CGS-063
3/4" pipe
1 1/16"
ENCO
CGS-038
1/2" pipe
7/8"
user supplied
user supplied
user supplied
user supplied
Flex Feedback Cable
External Encoder
AC Power
8
Installation
AC Line Filters
The AC line filters are necessary to comply with CE emission standards. The MDS was tested
with the filters presented in the table below and recommended by Control Techniques*.
Power Module Model
Schaffner Part #
Control Techniques
Model #
MP-1250
*
*MFL-020-00
MP-2500
*
*MLF-035-00
MP-5000
FS6717-65-34
MLF-065-00
Rating
65A, 480V, 3 Phase
* Consult factory for availability of the MLF-020-00 and MLF-035-00. The filter
recommended for the MP-5000 can be used for smaller Power Modules.
Toroids
In applications using long cables additional measures to reduce EMI might be necessary, such
as toroids on the motor cable. Based on Control Techniques compliance test results, the
following guidelines should be used.
Total System Current
< 25A
> 25A
Switching Frequency
Maximum Motor Cable Length
(without toroids)
5 kHz
125 Ft
10 kHz
50 Ft
5 kHz
75 Ft
10 kHz
75 Ft
Control Techniques recommends using Rasmi toroids in applications with motor cables
longer than in table above.
Motor Cable Model
Rasmi Toroid Part#
CT Model #
CMDS, CMDF
OC/2
MPF-OC2-00
CMMS, CMMF
OC/2
MPF-OC2-00
CMLS
OC/3
MPF-OC3-00
9
Modular Drive System Reference Manual
NEMA Enclosure
This wall must have
good continuity to
enclosure ground.
Through wall
shield grommets
Note: EMC testing was done with
surface paint removed from
the mounting panel area for
drive contact.
.
AC in
Bonded to mounting plate
and enclosure wall
PE Connection on
Drive Module
3-phase
filter
External Encoder
Loop R,S,T wires through toroid.
DO NOT loop PE wire through
toroid. More loops through toroid
helps reduce conducted emissions
PTB-16-23
CFCS Cable
CFOCS
Cable
Motor Power Cable routing should
be at least 12 inches away from
AC Input wiring or AC Line Filter.
CMDS, CMMS
OR CMLS Cable
Motor
Figure 3:
AC Filter and Cable Connections for MDS Series
Environmental Considerations
If the product will be subjected to atmospheric contaminants such as moisture, oils,
conductive dust, chemical contaminants and metallic particles, it must be mounted in a metal
NEMA type 12 enclosure.
If the ambient temperature inside the enclosure will exceed 40° C (104° F), you must consider
forced air cooling.
10
Installation
Note
It is necessary to maintain the MDS surrounding air ambient temperature at 40° C (104°
F) [50°C (122ºF) with derating of 3% per degree above 40° C].
The amount of cooling depends on the size of the enclosure, the thermal transfer of the
enclosure to the ambient air and the amount of power being dissipated inside the enclosure.
Consult your enclosure manufacturer for assistance with determining cooling requirements.
Wiring Notes
•
To avoid problems associated with EMI (electromagnetic interference), you should route
high power lines (AC input power and motor power) away from low power lines (encoder
feedback, serial communications, etc.).
•
If a neutral wire (not the same as Earth Ground), is supplied from the building distribution
panel it should never be bonded with PE wire in the enclosure.
•
You should consider future troubleshooting and repair when installing all wiring. All
wiring should be either color coded and/or tagged with industrial wire tabs.
•
As a general rule, the minimum cable bend radius is ten times the cable outer diameter.
•
All wiring and cables, stationary and moving, must be protected from abrasion.
•
Ground wires should not be shared with other equipment.
•
Ensure that metal to metal contact is made between the enclosure ground lug and the metal
enclosure, not simply through the mounting bolt and threads.
•
All inductive coils must be suppressed with appropriate devices, such as diodes or
resistor/capacitor (RC) networks.
•
All motor and feedback cables must have a continuous shield from the drive to the motor
(grounded at both ends).
•
Included with every Power and Drive Module is a Cable Strain Relief Bracket. It is a good
wiring practice to use the Strain Relief Bracket especially for heavy cables.
•
If using Toroids as motor power cable filter, mount them as close to the drive as possible.
Best results are obtained when the R, S, T wires are looped through the toroid 4 times.
•
Do Not route the motor PE wire through the toroid.
•
Keep all motor power cables at least 12 inches away from Incoming AC line on the input
side of the filter.
11
Modular Drive System Reference Manual
Panel Layout
High Power Cable Routing Only
Low
Power
Cable
Routing
Only
Wire Tie
Holddowns
High Power Cable Routing Only
Figure 4:
12
Recommended Layout
Installation
MDS Overview
The system must be back mounted vertically on a metal mounting panel such as a NEMA
enclosure. Additional space is necessary above and below the system for wiring and cable
connections. A MDS system is comprised of one Power Module and up to eight Drive
Modules. The Power Module is always the left most mounted module with the Drive Modules
mounted to the right. The Drive Modules are to be mounted from largest (highest current
rating) next to the Power Module to smallest (lowest current rating). Each module mounts to
an associated backplane which is mounted to a metal surface.For mounting dimensions refer
to Pages 14 - 18.
Backplane Installation Page 19
Drive Module
Installation - Page 35
Power Module Installation Page 34
Figure 5:
Modular Drive System
13
Modular Drive System Reference Manual
Power Module Backplane Dimensions
2.75
[69.85]
3.50
[88.90]
1.375
[34.925]
1.375
[34.925]
0.60 [15.24]
0.60 [15.24]
2.64
[67.04]
2.81 [71.37]
10.25
[260.35]
14.25
16.06
[361.95] [407.92]
2.64
[67.04]
2.81 [71.37]
10.25
[260.35]
14.25
16.06
[361.95] [407.92]
1.375
[34.925]
1.375
[34.925]
MP-1250 and MP-2500
Figure 6:
14
Power Module Backplane Dimensions
MP-5000
Installation
Power Module Assembly Dimensions
Power Module Model
DIM “A”
MP-1250 & MP-2500
2.75 [69.85]
MP-5000
3.50 [88.90]
16.06 [407.92]
9.00 [228.60]
14.25 [361.96]
Figure 7:
DIM “A”
Power Module Dimensions - MP-5000 Shown
15
Modular Drive System Reference Manual
Drive Module Backplane Dimensions
1.375
[34.925]
0.60
[15.24]
2.75
[69.85]
2.64
[67.056]
10.25
[260.35]
16.90
14.25
[361.95] [429.25]
2.81
[71.37]
MD-404, MD-407 and MD-410
Figure 8:
16
Drive Module Backplane Dimensions
Installation
1.375
[34.925]
0.60
[15.24]
2.75
[69.85]
3.50
[88.90]
7.0 [177.8]
1.375
[34.925]
0.60
[15.24]
2.64
[67.056]
2.64
[67.056]
14.25
16.90
[361.95] [429.25]
10.25
[260.35]
2.81
[71.37]
14.23
16.90
[361.442] [429.25]
10.25
[260.35]
2.81
[71.37]
MD-420
Figure 9:
MD-434
Drive Module Backplane Dimensions
17
Modular Drive System Reference Manual
Drive Module Assembly Dimensions
DIM "A"
Drive Module Model
MD-404
MD-407
MD-410
MD-420
MD-434
DIM "A"
2.75 [69.85]
2.75 [69.85]
2.75 [69.85]
3.50 [88.90]
5.49 [139.50]
14.25 [361.95]
9.00 [228.60]
14.25 [361.95]
Figure 10:
18
Drive Module Dimensions - MD-420 Shown
Installation
Step 1: Power Module Backplane Installation
Mount the Power Module in the left most position using #10 panhead screws. The optional
Cable Strain Relief bracket must be installed before tightening the screws holding the
backplane to the metal mounting panel. To install the Optional Cable Strain Relief bracket
simply slide the bracket behind the backplane, aligning the slot of the bracket with the screw
holding the backplane to the metal mounting panel. Push on the bracket until it stops. Secure
the Optional Cable Strain Relief bracket with a #10 panhead screw and tighten the backplane
screws.
Optional Cable
Strain Relief
Backplane
Figure 11:
Secure with
#10
panhead screw
MP-5000 Power Module Backplane shown with Optional Cable Strain Relief
Bracket Mounting
19
Modular Drive System Reference Manual
Step 2: Drive Module Backplane Installation
Note
Starting from the Power Module, the Drive Modules must be installed from largest
(highest current rating) to smallest (lowest current rating), with the largest size attached
to the Power Module.
Alignment
Tab
Snap
Tab
Slots
Bus bars
Bus
Screws
Logic connector
Snap
Tab
Slots
Alignment
Tab
MP-5000
Backplane
Figure 12:
20
MD-434
Backplane
Assembling the Drive Module Backplane to the Power Module Backplane.
Installation
1. Loosen the DC Bus screws on the Power Module backplane.
2. Align the DC Bus bars with the DC Bus screws, the Logic connector with the Power
Module board and all the tabs on the Drive Module backplane with the slots in the Power
Module backplane.
3. Push the Drive Module backplane firmly into the Power Module backplane until the
Bus bars are under the DC Bus screws and the backplanes snap together. The Power
Module backplane board is plugged into the Drive Module backplane Logic connector
and the tabs are secure in the slots. Backplane side walls of both modules are in contact
with each other.
4. Torque the bus screws to 8-10 in.lbs.
Secure with #10
panhead screw.
Torque Bus screws
to 8-10 lb-in.
Secure with #10
panhead screw.
Torque to 12 lb-in.
minimum.
Secure with #10
panhead screw.
Secure with #10
panhead screw.
Figure 13:
Securing the Drive Module backplane to the Power Module backplane.
5. To install the Optional Cable Strain Relief bracket, slide the bracket behind the
backplane, aligning the slot with the backplane screw, push until it stops then secure with
a #10 panhead screw.
21
Modular Drive System Reference Manual
6. Secure the Drive Module backplane to enclosure mounting panel with #10 panhead
screws.
The paint must be removed from behind each PE Ground Tab to ensure proper ground
connection.
7. Secure the Power and Drive Module PE ground tabs with #10 panhead screws, torque
to 12 in.lb.
8. Continue adding Drive Modules, largest to smallest, by repeating step 1 through step 7.
The Power Module and Drive Module backplanes can be assembled as described above,
where one backplane is assembled and secured to the enclosure at a time. Another method is
to assemble all the backplanes together (Steps 1-4) and then secure them to the enclosure
mounting panel.
Figure 14:
22
Installing the Optional Cable Strain Relief Bracket
Installation
Step 3: Power Module High Power Connections
System Grounding
To insure a safe and quiet electrical installation, good system grounding is imperative. The
figure below is an overview of the recommended system grounding. For more information on
achieving an electrically quiet installation refer to “Basic Installation Notes” on page 6.
Enclosure Wall
Ground
Mains Contactor
L1
L2
L3
Single Point Ground
3 Phase
Line
Power
Ground connection rail and enclosure panel should
have a low impedance connection. Paint must be
removed from panel mounting surface.
AC Line Fuses
DC
Power Supply
+
+24 VDC
User
Supply
Control
Voltage
Transformer
PE
PE
PE
PE
PE
Secure to panel with
#10 screw.
Paint must be removed
from mounting surface
to assure these tabs are
connected to the
single point
ground.
AC Filter
+ N
Shunt Module
MS-500-XX-00
Optional
MP
MD
MD
MD
Paint
must be
removed
at least
from
behind
the
mounting
tab
PE
MH or UNI Motors
Figure 15:
System Grounding Overview
23
Modular Drive System Reference Manual
PE is not distributed through the backplanes. A separate PE connection is required for
each Power and Drive Module.
Fixed Protective Earth (PE) connections are mandatory for human safety and proper
operation. These connections must not be fused or interrupted by any means. Failure to
follow proper PE wiring can cause death or serious injury.
AC Input Power Connection
The following examples show AC Input power connections for three phase drives. These
examples are shown for reference only. Local electrical codes should be consulted before
installation.
If the continuous power required by the system is greater than 35 KW an AC Line Reactor
needs to be installed. Minimum requirements for the Line Reactor is 250 mH and 80A
continuous. Control Techniques offers a Line Reactor, MLR02580-00. See the CT-MMEPOWER-CD for drawings.
The maximum voltage applied to the Power Module AC Input terminals must not exceed
528VAC phase to phase and phase to PE ground. This can be accomplished by
referencing the AC supply to earth ground.
AC Supplies NOT Requiring Transformers
If the distribution transformer is configured as shown in the figures below, the AC power
supply can be connected directly to the amplifier terminals.
24
Installation
DISTRIBUTION PANEL
L3
L2
SECONDARY
To Fusing and
Power Module
342 to 528 VAC
L1
PE
EARTH
GROUND
Figure 16:
(Protective Earth)
Earth Grounded WYE Distribution Transformer
DISTRIBUTION PANEL
L3
SECONDARY
L2
342 to 528 VAC
L1
To Fusing and
Power Module
PE
EARTH
GROUND
Figure 17:
(Protective Earth)
Earth Grounded Delta Distribution Transformer
AC Supplies Requiring Transformers
If the distribution transformer is configured as shown in the figures below, an isolation
transformer is required. For sizing of isolation transformer See “Transformer Sizing” on
page 27.
If an isolation transformer is used between the power distribution point and the Power
Module, the isolation transformer secondary must be grounded for safety reasons as shown
in the figures below.
25
Modular Drive System Reference Manual
DISTRIBUTION PANEL
3 O ISOLATION TRANSFORMER
L3
L2
342 to 528 VAC
To Fusing and
Power Module
L1
PE
EARTH
GROUND
Figure 18:
(Protective Earth)
Three Phase Delta (with mid-phase GND) Distribution to a Three-Phase
WYE/WYE Isolation Transformer
D IS T R IB U T IO N P A N E L
3 O IS O L A T IO N T R A N S F O R M E R
L3
L2
3 4 2 to 5 2 4 V A C
T o F u sin g a n d
P o w e r M o d u le
L1
PE
EAR TH
GRO UND
Figure 19:
(P ro te ctiv e E a rth)
Three Phase WYE (ungrounded) Distribution to a Three-Phase Delta/WYE
Isolation Transformer
DISTRIBUTION PANEL
3O ISOLATION TRANSFORMER
L3
L2
342 to 528 VAC
L1
EARTH
GROUND
Figure 20:
26
To Fusing and
Power Module
PE
(Protective Earth)
Three Phase Delta Distribution to a Three Phase Delta/Delta Isolation
Transformer
Installation
Transformer Sizing
If your application requires a transformer, use the following table for sizing the KVA rating.
The values in the table are based on “worst case” power usage and can be considered a
conservative recommendation. You can down-size the values only if the maximum power
usage is less than the transformer continuous power rating. Other factors that may influence
the required KVA rating are high transformer ambient temperatures (>40° C or >104° F) and
MDS operation near the maximum speeds.
Power Module
Suggested KVA Rating
MP-1250
25
MP-2500
50
MP-5000
100
Transformer output voltage drop may become a limiting factor at motor speeds and loads near
maximum ratings. Typically, higher KVA transformers have lower voltage drop due to lower
impedance.
Line Fusing and Wire Size
You must incorporate over current protection for the AC Input power with the minimum
rating shown here. Refer to the table below for recommended fuses and wiring of other
uqeivalent fast blow fuses.
Power Module Model
External AC Line Fuse
Recommended Minimum
AC/PE Line Wire Gauge
MP-1250
KTK-R 20A, JKS 20A or JJS 20A
16 GA
MP-2500
JKS 40A or JJS 40 A
10 GA
MP-5000
JJS 70A
4 GA
The MDS has an internal relay that is required to be wired into the control logic of the
installation. The AC Interlock relay contact should be wired in series with the coil of the
Mains contactor. The relay contact is rated at +24VDC at 5A. To protect the Modules the
AC Interlock will open during a High AC Input or Shunt Fault Condition.
27
Modular Drive System Reference Manual
Electrical AC Input Power Connections
Torque:
5 - 8 LB IN.
Figure 21:
L1 L2 L3 PE
Power Module AC Power Wiring Diagram
Do Not apply power to the backplanes before the modules are attached. The backplanes
have exposed high voltage conductors.
28
Installation
External Shunt Electrical Installation
Shunt Wire Size
Power Module Model
Recommended Minimum Shunt Wire Gauge
MP-1250
16 GA
MP-2500
16 GA
MP-5000
16 GA
Shunt Resistor Connection
Connect the Shunt Resistor to B+ and Shunt terminals on the Shunt connector.
Shunt Output
Torque:
5 - 8 LB IN.
Figure 22:
Power Module Shunt Wiring Diagram
Access to Bus- (B-) is given for measurement purposes only (i.e. oscilloscope or voltage
meter). Do Not make any connections to B-.
Shunt connections are at main voltage potential. Components connected must be rated for
the voltage and selected for safety.
29
Modular Drive System Reference Manual
Logic Power
+24VDC
M
Shunt
Thermal Switch
(if available)
AC Mains
Contactor
Coil
AC Mains
Contactor
Single Point
Ground
Fuse Required
See Note below
Thermal Switch
Shunt
Output
External
Shunt
Resistor
Figure 23:
Power Module Shunt Wiring
Note
For proper fuse size refer to table below. Fast blow semiconductor fused rated 700 VDC
or higher are recommended (such as Shawmut A70Q). If using Control Techniques’
shunt, MS-510-00 or MS-530-00 , refer to Figure 24 for proper connections.
30
Power Module
Shunt Output Fuse Size
External Shunt Minimum
Resistance (Ohms)
MP-1250
4A
30
MP-2500
8A
30
MP-5000
16A
9
Installation
Logic Power
+24VDC
M
Shunt
AC Interlock
AC Mains
Contactor
Coil
AC Mains
Contactor
Single Point
Ground
MS-5XX-00
Thermal Switch
Internal
Control
Circuitry
Shunt
Output
+24 24 RTN
Figure 24:
Power Module Shunt to Control Techniques’ MS-5XX-00 Wiring Diagram.
Figure 24 shows the high power connections only. For a complete wiring diagram to a MS5XX-00 see the Option and Accessories section in this manual.
31
Modular Drive System Reference Manual
+
AC INTERLOCK
B+
Figure 25:
SHUNT
24 VDC
The MS-5XX-00 Connections
The MS-5XX-00 has integral control circuitry for protection of the shunt resistor. In order to
protect the installation the shunt interlock must be placed in series with the AC Mains
Contactor.
32
Installation
Step 4: Drive Module High Power Connections
Motor Power Cable Wiring to the Drive Module
The Motors are equipped with up to three male MS (Military Standard) connectors, one for
motor power connections, one for encoder connections and one for the brake (if so equipped).
Motor power connections from the Drive Module to the motor can be made with cables which
have a female MS style connector on the motor end and four individual wires and shield that
connect to the motor power connector on the bottom of the Drive Module.
Motor Model
Standard Cable Model#
MH or HT 3" frame
CMDS
Flex Cable Model # Wire Gauge
CMDF
16
MH 4" and 6" frame
CMMS
CMMF
12
MH 8" frame
CMLS
N/A
8
Note
The motor ground wire and shields must be run all the way back to the amplifier terminal
and must not be connected to any other conductor, shield of ground.
Drive Module Motor
Connections
Motor Power Cable Model Color Code
CMDS, CMMS,and
CMLS
CMDF and CMMF
PE
Green/Yellow
Green/Yellow
T
Blue
Red 3
S
Black
Red 2
R
Brown
Red 1
PE T S R
Torque:
5 - 8 LB IN.
Figure 26:
Drive Module Motor Power Wiring Diagram
33
Modular Drive System Reference Manual
Step 5: Power Module Installation
After all the backplanes are secured with AC Input Power and Motor Power cable connections
made, the Power Module must be installed into the backplane.
Make sure all power is off before installing any of the modules.
Orient the Power Module so the top of the module is up and the alignment bars in the Module
aligns with the alignment tabs in the backplane. The sheet metal of the Power Module will
be on the outside of the alignment tabs.
Improper alignment of the module can cause damage to the module or the backplane.
Firmly press the Power Module into the backplane to insure good backplane connection.
When the Module is completely seated to the backplane, torque the top and bottom retaining
screws to 6 - 8 LB IN.
Retaining Screw
Alignment Tab
Alignment Bars
Alignment Tab
Retaining Screw
Figure 27:
34
Power Module Assembly Diagram
Installation
Step 6: Drive Module Installation
After the Power Module is installed to its backplane the Drive Modules can be installed to
their respective backplanes.
Make sure all power is off before installing any of the modules.
Orient the Drive Module so the top of the module is up and the alignment bars in the Module
aligns with the alignment tabs in the backplane. The sheet metal of the Drive Module will be
on the outside of the alignment tabs.
Improper alignment of the module can cause damage to the module or the backplane.
Firmly press the Drive Module into the backplane to insure good backplane connection.
When the Module is completely seated to the backplane, torque the top and bottom retaining
screws to 6 - 8 LB IN.
Retaining Screw
Alignment Tab
Alignment Bars
Alignment Tab
Retaining Screw
Figure 28:
Drive Module Assembly Diagram
35
Modular Drive System Reference Manual
Step 7: Power and Drive Module Low Power Connections
Logic and Digitial I/O Power Sizing
The MDS requires a user supplied logic power supply, 24 VDC +/- 10%, to power the internal
logic of the Power Module and Drive Modules. Use the table below to determine the current
requirements of the application.
Module
Model Number
RMS Current (A)
MP-1250
Power Module
MP-2500
0.30
MP-5000
MD-404
MD-407
Drive Module
MD-410
0.60/Module
MD-420
MD-434
0.80/Module
FM Module
All
0.40/FM Module
Synchronization
Feedback Encoder
*
0.07/Encoder
* Control Techniques supplies external master synchronization feedback encoders (Model#
SCSLD-XXX) or user supplied synchronization feedback encoders can be used. The current
required to power the synchronization feedback encoder can not exceed 250 mA @ 5 VDC/
Axis.
The user supply connected to the Power Module provides power for the internal logic of the
MDS. The Logic Power is carried through the backplane from the Power Module to the Drive
Modules.
A user supply is also required for the Digital I/O power on the Power Module, Drive Modules,
and FM Modules. The user supply for Logic Power and Digital I/O Power can be the same
supply if desired. However, the input tolerances for Logic Power and Digital I/O are different
and may require that the I/O and Logic Power supply be separated. Reference the following
Figures for connections.
36
Installation
Logic and Digitial I/O Power Connections
In Figures 29 and 30 the MDS is being powered by one power supply. The supply needs to
be wired into the Power Module Logic Power Input and Digital I/O Input. Each Drive Module
and FM module also require Digital I/O power. The Power Module’s Logic Power Input
range is +24VDC +/-10%. The Digital I/O power for all the modules is +10 to 30 VDC. For
applications that require Digital I/O power outside the Logic Power Input range refer to
Figure 31 and 32.
Programming Module
1
2
8
485+
485SHLD
Sync.
Output
Outputs 10-30
VDC
+
-
Sync.
Input
Sync.
Output
Outputs 10-30
VDC
Sync.
Input
1
2
3
4
Sync.
Output
5
6
7
4
5
6
485-
7
SHLD
8
Outputs 10-30
VDC
Sync.
Input
SHLD
3
1
2
3
4
+
-
1
2
Exp. I/O
485+
485-
1
2
3
4
Inputs
Exp. I/O
AC Interlock
Inputs
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
Programming Module
Inputs
Exp. I/O
Programming Module
485+
3
4
5
6
7
8
1
2
3
4
+
-
Power Module Status
Logic Power
System Ready
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
+
-
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
+24 VDC
User Logic
and I/O
Supply
(+24 VDC +/-10%)
+
+24VDC
24V rtn
Single
Point
Ground
Figure 29:
One Power Supply for the Logic and I/O Power Wiring Diagram.
37
Modular Drive System Reference Manual
Drive Module 1
J6
Drive Module 2 . . . . . . . . . . Drive Module 8
10-30
VDC
+ -
J6
10-30
VDC
+ -
J6
10-30
VDC
+ -
Power Module
Logic
Power
+24VDC
24V rtn
PE
I/O 10-30 VDC
+
-
+24 VDC
Function Module 1
24 RTN
Function Module 2 . . . . . . . . Function Module 8
PE Ground
Figure 30:
One Power Supply for the Logic and I/O Power Wiring Diagram.
Drive Module 1
J6
10-30
VDC
+ -
Drive Module 2 . . . . . . . . . . Drive Module 8
J6
10-30
VDC
+ -
J6
10-30
VDC
+ -
Power Module
Logic
Power
+24VDC
24V rtn
PE
I/O 10-30 VDC
+
-
+24 VDC
Function Module 1
24 RTN
Function Module 2 . . . . . . . . Function Module 8
PE Ground
+10-30 VDC
10-30 RTN
Figure 31:
38
Separate Power Supplies for the Logic and I/O Power Wiring Diagram
Installation
In Figures 31 and 32 the MDS Logic and I/O power are separated for applications that have
Digital I/O power (+10 to 30VDC) that is out of the Logic Power Range (+24VDC +/-10 %).
Programming Module
1
2
Sync.
Output
1
2
Sync.
Input
Sync.
Output
+
-
485+
485SHLD
Ou tputs 10-30
VDC
Exp . I/O
Sync.
Output
Ou tputs 10-30
VDC
Sync.
Input
7
8
3
4
5
6
7
8
Outputs 10-30
VDC
Sync.
Input
4
5
6
4
SHLD
1
2
3
4
+
-
1
2
3
Inputs
Exp. I/O
In puts
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
485SHLD
3
485-
Programming Module
1
485+
Inputs
Exp. I/O
Programming Module
485+
2
3
4
5
6
7
8
1
2
3
4
+
-
Power Module Status
Logic Power
System Ready
Shunt Active
AC Interlock
Shunt Fault
Over Temp
High VAC Input
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
A C Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
+
-
+24 VDC
User Logic
Supply
+
+24VDC
24V rtn
(+24 VDC +/-10%)
+ VDC
User I/O
Supply
V rtn
(+10 to 30 VDC )
Single
Point
Ground
Figure 32:
Separate Power Supplies for the Logic and I/O Power Wiring Diagram.
39
Modular Drive System Reference Manual
Power Module I/O Connections
Status I/O,
Logic Power
and I/O
Power, See
Page 43
Status Indicators,
See Page 41
Status I/O, Logic
Power and I/O Power,
See Page 43
ISO View
Figure 33:
Bottom View
Power Module Operation and Features
The function of the Power Module is to rectify the AC input and provide the DC bus for the
Drive Modules. The Power Module has an integral soft-start circuit to limit the in-rush current
when powering up the system. Once the DC bus is charged the Power Module passes a logic
signal (System Ready) to the Drive Modules across the backplane allowing the Drive
Modules to draw power from the bus. For deceleration of loads that generate more energy
than the DC Bus capacitance can store, the Power Module has an integral shunt transistor that
can be connected to an external shunt resistor through the shunt connector on the bottom of
the backplane.
The Power Module has a built in processor providing system soft-start control, shunt control
and basic self-protection and diagnostic functions such as:
•
40
Excessive AC input voltage
Installation
•
Loss of AC input voltage phase (single phase operation)
•
Over temperature of the rectifier bridge and shunt transistor
•
Improper shunt circuit operation or wiring error
Six diagnostic display LEDs controlled by the microprocessor are located on the Power
Module front panel as well as the I/O connector with 4 digital outputs, 2 digital inputs, and
AC Interlock Relay contacts. The function of these signals can be found on the following
pages.
Power Module Status Indicators (LEDs)
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
Figure 34:
+
-
Power Module Status Indicator location
Logic Power
The Logic Power status indicator (green) is illuminated when the +24VDC logic Power is
correctly supplied to the Power Module. If the status indicator is not illuminated verify that
the user supply is providing between +21.6 VDC and +26.4 VDC.
System Ready
The System Ready status indicator (green) is illuminated when the system power-up sequence
is properly completed. See “Power up Sequence” on page 66.
The System Ready status indicator will blink if one of the AC Input Phases is lost. The system
will remain functional in single phase condition. However, it’s strongly undesirable to run the
system in single phase mode that can cause severe over heating of the power module
components.
41
Modular Drive System Reference Manual
If AC power is on and the System Ready status indicator is not illuminated, one of the
following has occurred: Shunt fault, Over-temperature or High VAC Input. These faults are
described below.
Shunt Fault
The Shunt Fault status indicator (red) will be illuminated in the case of shunt resistor wiring
error or a short circuit condition.
Over Temp
The Over Temp status indicator (red) will be illuminated if continuous RMS power rating of
the Power Module is exceeded creating an over temperature condition. The Power Module
needs to be shut down to allow for cooling before the Over Temp condition is not present.
This fault may also occur if ambient temperature exceeds 40oC.
High VAC Input
The High VAC Input status indicator (red) will be illuminated if the AC input Voltage
exceeds 528 VAC.
Shunt Active
The Shunt Active status indicator (green) will be illuminated when the Shunt Transistor is on.
The Shunt Transistor will turn on under two conditions:
42
•
The Bus voltage exceeds 830 VDC due to regenerative energy during motor deceleration.
Shunt Transistor turn off level is 780 VDC.
•
The External Shunt Control Input is active in case of emergency stop.
Installation
Power Module I/O
A highspeed diode
(such as a 1N4000) is
required for inductive
loads such as a relay,
solenoid or contactor.
I/O Supply
+10 to 30 VDC
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
System Ready
2.8 k
Shunt Active
Shunt Fault
Over Temp
High VAC Input
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Load
Load
Load
Load
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
Ext Shunt Control
Fault Reset
Logic +24VDC
24V rtn
Power
PE
I/O 10-30 VDC
Load
AC Interlock
Power Module Status
Logic Power
Load
+
-
+
-
Torque to
4 - 6 lb in.
V rtn
+ VDC
Single point
PE ground.
I/O Supply
(+10 to 30 VDC)
Figure 35:
Power Module I/O Wiring Diagram
System Ready
The System Ready output is active (high) when the Power Module has completed the powerup sequence properly.
(See Figure 38) Once this signal is active the Drive Module can be
enabled. The System Ready output remains high during normal system operation and turns
low in case of system fault.
If AC power is on and System Ready output is low, one of the following has occurred:
Shunt fault,
Over-temperature fault or
High VAC Input. These faults are described
below.
Shunt Fault
The Shunt Fault output
short circuit condition.
will be active (high) in the case of shunt resistor wiring error or a
43
Modular Drive System Reference Manual
Over Temp
The Over Temp fault will be active (high) if continuous RMS power rating of the Power
Module is exceeded creating an over temperature condition.
High VAC Input
The High VAC output will be active (high) if the AC input Voltage exceeds 528 VAC.
Drive Module Fault
The Drive Module Fault output will be active (high) if at least one of the Drive Modules is in
over current or short circuit condition. In this case a ’Z’ fault will be displayed on the Drive
Module display indicator. The System Ready signal will not be affected by the status of this
signal.
Shunt Active
The Shunt Active Output will be active (high) when the Shunt Transistor is on. The Shunt
Transistor will turn on under two conditions:
•
The Bus voltage exceeds 830 VDC due to regenerative energy during motor deceleration.
Shunt Transistor turn off level is 780 VDC.
•
The External Shunt Control Input is active in case of emergency stop.
AC Interlock
The AC Interlock relay contacts are closed if +24 VDC Logic Power is supplied to the
system. This relay is intended to remove AC power from the system (contacts are open)
when one of the faults below occur:
44
•
High VAC Input
•
Shunt Fault
or
Installation
AC Interlock Connections
The MDS has an internal relay that is required to be wired into the control logic of the
installation. The AC Interlock relay contact should be wired in series with the coil of the
Mains contactor. The relay contact is rated at +24VDC at 5A. To protect the Modules the
AC Interlock will open during a High AC Input or Shunt Fault Condition.
Ground
L1
3 Phase
Line
Power
L2
L3
M
AC Mains
Contactor
AC Line
Fuses
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
+24 VDC
User Supply
(+24 VDC +/- 10%)
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
24V RTN
+ 24VDC
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
Logic
Power
+24VDC
+
-
AC Mains
Contactor Coil
M
AC Mains
Contactor
Figure 36:
AC Interlock wiring with +24VDC Mains Contactor Coil
45
Modular Drive System Reference Manual
Ground
L1
3 Phase
Line
Power
L2
L3
M
AC Mains
Contactor
AC Line
Fuses
Power Module Status
Logic Power
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
+24 VDC
User Supply
(+24 VDC +/- 10%)
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
24V RTN
+ 24VDC
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
I/O 10-30 VDC
+
-
Logic
Power
+24VDC
CR
120/240
VAC
Control
Voltage
M
AC Mains
Contactor Coil
Figure 37:
AC Interlock with 120/240VAC Mains Contactor
Ext Shunt Control
The External Shunt Control Input (active high) gives the user control of the shunt transistor
in case of an emergency stop. When this input is active the shunt transistor will turn on and
bleed the bus down through an external shut resistor.
This Input is disabled when AC Power is supplied to the system.
46
Installation
Fault Reset
The Faults Reset Input (active high) allows the user to reset any of three faults without
removing +24 VDC Logic Power from the system.
Figure 38:
Power Module Logic Timing Diagram
Logic Power
The Logic Power is necessary for all internal logic operation of the Power and Drive Modules.
The Logic Power input is +24 VDC +/- 10 %. See “Logic and Digitial I/O Power
Connections” on page 37 for wiring diagrams.
PE (SHIELD)
The PE connection is a convenient place to connect I/O cable shield. It is the same electrical
point as all other PE connections of the MDS. See “System Grounding” on page 23.
47
Modular Drive System Reference Manual
I/O
The I/O supply input is used to power the user side of the Power Module I/O. The I/O supply
supports +10 to 30 VDC input. See “Logic and Digitial I/O Power Connections” on page 37
for wiring diagrams.
Drive Module I/O Connections
FM Module Connection See Page vi
Analog Output Test
Points - See Page 182
Reset Button
I/O Connector See Page 49
Motor
Feedback
Connector See Page 61
Serial Connector See Page 62
Command Connector See Page 52
Diagnostic Display
- See Page 177
Iso View
Figure 39:
Bottom View
Drive Module Operations and Features
The Drive Module draws power from the DC Bus and controls the current flow to the motor.
Each Drive Module is configured using PowerTools FM or PowerTools PRO. The Drive
Module contains a diagnostic display that provides visible feedback to the current status of
the Drive Module. The Drive Module has connections for Digital I/O, Analog I/O, Encoder
Feedback, Sync Encoder and the ability to connect FM modules for more functionality.
48
Installation
Input/Output Connector Wiring
Drive Modules are equipped with five optically isolated input lines (one is dedicated to a drive
enable function) and three optically isolated output lines. They are designed to operate from
a +10 to 30 VDC source. All inputs and outputs are configured as sourcing.
Each output is capable of providing 150mA and must be protected from over current
conditions by a user supplied fuse.
Highly inductive loads such as relays must be suppressed with a diode.
Front View
A highspeed diode
(such as a 1N5819) is
required for inductive
loads such as a relay,
solenoid or contactor.
I/O Supply
+10 to 30 VDC
OUTPUT
1 2 3
Load
INPUT
2 3 4
Load
1
2.8 k
Load
Drive
Enable
10-30
VDC
RESET
SERIAL
COMMAND
+ -
DRIVE
ENABLE
J6
10-30
VDC
INPUT
1
2 3
J4
1 Amp Fuse
J5
OUTPUT
4 1 2 3
J6
Single point
PE ground.
Figure 40:
- +
24 VDC
MDS Drive Module Input/Output Wiring Diagram
The I/O connector is a 10-pin removable terminal block. It is recommended that #18 to 24
AWG stranded wire be used and torque to 4 - 5 lb.-in.
49
Modular Drive System Reference Manual
Front View
Internal to Drive Module
Input #4
Input #3
Input #2
Input #1
Drive Enable Input
Output #3
Output #2
Output #1
I/O Common I/O Common I/O Supply +
I/O Supply +
4
3
2
1
16
17
2.8 k
18
19
31
32
33
34
GND
3
J5
1
2
OUTPUT
RESET
3
4
J5
2
1 2 3
J4
OUTPUT
4 1 2 3
1
+ -
DRIVE
ENABLE
J6
INPUT
INPUT
SERIAL
COMMAND
10-30
VDC
J6
Figure 41:
10-30
VDC
+ --
DRIVE
ENABLE
MDS Drive Module I/O Connector to Command Connector Internal
Connections
Note
If loads are applied to the same output signal on both Command Connector and I/O
Connector, the sum total current loading must be limited to 150 mA per output signal.
Motor Brake Wiring
HT and MH motors equipped with brakes have a separate three-pin MS style connector for
brake power. The brake power cable (model CBMS-XXX) has an MS style connector on the
motor end and three wire leads on the Drive Module end (see Figures 42 and 43). For
Unimotors equipped with brakes the brake wiring is contained in the motor power cable.
You must provide a DC power supply rated at +24 VDC with a 2 amp minimum current
capacity for the brake. If you use this voltage source to power other accessories such as I/O
or more than one brake, you must increase its current capability.
50
Installation
Front View
CBMS-XXX Cable
Black A2
SERIAL
J4
10-30
VDC
Customer
Supplied Drive
Enable Contact
INPUT
1 2
3
OUTPUT
4 1 2 3
Drive
Enable
14
10-30
VDC
+ -
DRIVE
ENABLE
J6
C
B
A
K1
1
J5
INPUT
2 3 4
RESET
COMMAND
Motor Brake
Connection
OUTPUT
1 2 3
A1
2 Amp Fuse
1 Amp Fuse
11
Relay:
Model: BRM-1
Red +
J6
- +
Single point
PE ground.
Figure 42:
Internal
to Brake
Motor
Motor
P/N PT06A-8-3SSR
Motor Brake Connector
(HT and MH Motors Only)
Connected to
Single point PE ground
24 VDC
MDS Drive Module Brake Wiring Diagram using the I/O Connector
51
Modular Drive System Reference Manual
Front View
CBMS-XXX Cable
Black A2
A1
RESET
Output #3
SERIAL
COMMAND
+ -
DRIVE
ENABLE
J6
10-30
VDC
INPUT
1
2 3
J4
J5
OUTPUT
4 1 2 3
Drive Enable
I/O Common
I/O Common
I/O Supply
I/O Supply
17
16
32
31
34
33
Customer
Supplied Drive
Enable Contact
A
14
2 Amp
Fuse
J5
- +
Figure 43:
C
B
K1
1 Amp
Fuse
Single point
PE ground.
Motor Brake
Connection
11
Relay:
Model: BRM-1
Red +
Internal
To Motor
Brake
Motor
P/N PT06A-8-3SSR
Motor Brake Connector
(Ht and MH Motors Only)
Connected to
Single point PE ground
24 VDC
MDS Drive Module Brake Wiring Diagram using the Command Connector
Command Connector Wiring
All command and digital I/O signals are available using the 44-pin Command Connector (J5).
If you are interfacing your MDS to an AXIMA 2000 or 4000 multi-axis controller, simply
connect the 44-pin connector of your AX4-CEN-XXX cable to the Drive Module and the 25pin connector to the AXIMA multi-axis controller.
If you are interfacing your MDS to an AXIMA Classic or any other motion controller, you
may use either the CDRO-XXX or CMDO-XXX cables or the optional External Connection
Interface (ECI-44) which provides a convenient screw terminal connection strip. Connect one
end of the CMDX command cable to your Drive Module and the other end to the ECI-44.
52
Installation
Shield
Connected to
Connector Shell
Command Connector
(RED/BRN)
1
(BRN/RED)
(BLK/BLU)
(BLU/BLK)
(WHT/ORG)
2
3
4
6
(ORG/WHT)
(PRP/BLU)
21
8
(BLU/PRP)
(RED/BLU)
9
11
(BLU/RED)
(BLK/GRN)
12
16
(GRN/BLK)
(BLK/BRN)
17
18
19
(BRN/BLK)
(PRP/ORG)
(ORG/PRP)
(BLK/RED)
(RED/BLK)
(PRP/GRN)
(GRN/PRP)
(YEL/BLU)
(BLU/YEL)
(YEL/BRN)
23
24
25
39
27
41
34
32
33
31
37
38
40
(BRN/YEL)
(PRP/BRN)
(BRN/PRP)
(PRP/GRY)
26
14
15
43
44
(GRY/PRP)
(WHT/BLU)
(BLU/WHT)
(WHT/GRN)
(GRN/WHT)
(WHT/RED)
29
28
(RED/WHT)
(GRY/YEL)
(YEL/GRY)
36
20
35
7
10
13
5
22
30
= Twisted Pair
Figure 44:
42
PE
Input #1
Input #2
Input #3
Input #4
10 Ohm
RS 485+
RS 485Encoder Output Channel
Encoder Output Channel
Encoder Supply +5 Volts
Encoder Common
Drive Enable Input
Output #3
Output #2
Output #1
Encoder Output Channel
Encoder Output Channel
Pulse Input Z
A
A/
- Output. 200 mA
B
B/
Pulse Input Z/
Pulse Input A
Pulse Input A/
I/O Supply +
I/O Common I/O Supply +
I/O Common Encoder Output Channel Z
Encoder Output Channel Z/
Pulse Input B/
Pulse Input B
- Analog Command In
+ Analog Command In
Diagnostics Output Channel 1
Diagnostics Output Channel 2
Diagnostic Output Common
+15 Out (Test Only)
Pulse In B Single-ended
Pulse In A Single-ended
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Command Connector (J5) Pinout and CMDO-XXX Wire Colors
For information about Command Connector pinout and CMDO-XXX cable wire colors, see
the "Specifications" section.
Function
Pin Numbers
Electrical Characteristics
Inputs and Drive Enable
1, 2, 3, 4, 16
10-30 V (“On”) 0-3 V (“Off”) optically isolated
Outputs
17, 18, 19
10-30 VDC sourcing 150 mA
I/O Supply
33, 34
10 - 30 VDC @ 1 Amp maximum
I/O Common
31, 32
I/O return
Pulse Inputs Differential
25, 26, 27, 39, 40, 41
5 V, 200 mV differential, 60 mV hysteresis, RS-422 compatible
53
Modular Drive System Reference Manual
Function
Pulse Inputs Single Ended
Pin Numbers
20, 36
Electrical Characteristics
TTL, 330 ohm pull-ups to internal 5 V, 1.5 V = low, 3.5 V = high
Encoder Supply Output +5 V
11
+5 V (200mA) output self-resetting fused internally
Encoder Common 0 V
12
0.0 V, 10 ohms away from PE
Encoder Out
8, 9, 23, 24, 37, 38
Differential line driver output (RS 422)
Analog In
14, 15
± 10 VDC differential command
Diagnostic Output
43, 44
± 10 VDC 10 mA maximum. Analog diagnostic output, ref. to pin
29
Diagnostic Output Common
29
0.0 V, 10 ohms away from PE
0 ohms away from Encoder Common 0V (pin 12)
RS 485 ±
6, 21
Same signals as the Serial Connector
+15 out
28
10 mA supply. ref. pin 29 (for test purposes only.)
Command Cables
The CMDO, CMDX and CDRO cables are all cables that plug into the Command Connector.
The CMDO and CMDX cables both use the same straight connector style, same color code
and carry the full complement of signals available from the Command Connector. The
difference is the CMDO cable has a male connector on one end with open wires on the other
while the CMDX cable has male connectors on both ends.
For information about CMDO-XXX and CMDX-XXX (18 pair cable) cable wire colors see
the "Specifications" section.
Note
Some CMDO and CMDX cables may have White/Yellow and Yellow/White wires in
place of the White/Orange and Orange/White shown in the figure above (pins 6 and 21).
The CDRO cable includes only the most commonly used signals to reduce the cable outer
dimension and has a connector at only one end. The 45 degree connector design used on the
CDRO cable also reduces the enclosure spacing requirement below the Drive Module.
For information about the CDRO-XXX (13 pair) cable wire colors, see the "Specifications"
section.
54
Installation
- Analog In
Command Connector
+ Analog In
Analog Command Wiring
(Internal)
10 Ohm
Logic
Common
PE
15 14
Single Point
Panel Ground
External
Controller
VDC
CW Rotation
+ Command = CW
With positive direction = CW
Controller Logic
Common
Single Point
Panel Ground
Figure 45:
Analog Command, Differential Wiring Diagram
Drive
Command Connector
Figure 46:
Analog Command, Single Ended Wiring Diagram
55
Modular Drive System Reference Manual
Encoder Output Signal Wiring
The encoder outputs meet RS-422 line driver specifications and can drive up to ten RS-422
signal receivers.
The default encoder output scaling is set to output the actual motor encoder resolutions. The
standard MH and HT motors have 2048 lines per revolution. With PowerTools this resolution
is adjustable in one line per revolution increments up to the density of the encoder in the
motor.
Figure 47:
Command Connector (J5) Encoder Output Wiring
B Leads A = (+) Rotation
A
B
Z
CW Rotation
+ Command = CW
With positive direction = CW
Figure 48:
56
Direction Convention Diagram
Installation
Pulse Mode Wiring, Differential Inputs
Figure 49:
Pulse Mode, Differential Output to Differential Input
250 ns Minimum
250 ns Minimum
Motion occurs
on falling edge
Shield connected
to connector shell
( A/ ) Pulse
10 Ohm
CW
CCW
( B ) Direction
A
A/ B
B/
PE
27 41 26 40
Single Point
Panel Ground
+ 5 OUT
R1
R2
Drive
R3
Pulse
Resistor Value
Direction
R4
Single Point
PE Ground
Figure 50:
Twisted Pair
R1, R2
1K Ohm Maximum
240 Ohm Minimum
R3
1K Ohm Maximum
240 Ohm Minimum
R4
½ R3
120 Ohm Minimum
Pulse Mode, Single Ended Output to Differential Input
57
Modular Drive System Reference Manual
Pulse Mode Wiring, Single Ended Inputs
+5
Logic
Power
Pulse
A/
Direct
B
Sinking
Outputs (typ)
Common isolated
from other sources
Figure 51:
Pulse Mode, Single Ended Output to Single Ended Input (twisted pair cable)
+5
Logic
Power
Pulse
A/
Direct
B
Sinking
Outputs (typ)
Common isolated
from other sources
Figure 52:
58
Pulse Mode, Single Ended Output to Single Ended Input (non-twisted pair
cable)
Installation
+5
Logic
Power
CW Pulse
CCW Pulse
Sinking
Outputs (typ)
CW Pulse
CCW Pulse
Common isolated
from other sources
Figure 53:
Pulse/Pulse Mode, Single Ended Output to Single Ended Input (non-twisted
pair cable)
Figure 54:
Master/Slave Encoder Connections
Note
Encoder outputs meet RS-422 driver specifications and can drive up to 10 RS-422 signal
receivers. Each differential pulse input is an RS-422 line receivers. The default encoder
59
Modular Drive System Reference Manual
output resolution is 2048 lines per motor revolution. This resolution is adjustable in one
line per revolution increments with PowerTools software. The range is between 200 and
the actual motor encoder density.
60
Installation
Motor Feedback Wiring
Encoder feedback connections are made with the CFCS cable. This cable has an MS style
connector on the motor end and a 26-pin high density “D” connector on the Drive Module
end. For more information about all feedback cables see the "Specifications" section.
For A, A, B, B and Z, Z pairs, the CFCS cable uses low capacitance (~10 pf/ft) wire to get a
characteristic impedance of 120 ohms. This impedance match is important to minimize signal
loss and ringing.
Figure 55:
Motor Feedback Connector Pinout
The MDS drive can accept differential or single ended commutation signals: U, V, and W. It
the commutation signals are single-ended connect the appropriate signals to U, V, and W. The
compliment signals U\, V\ and W\ do not need to be grounded for operation. The signals are
pulled to ground internally.
61
Modular Drive System Reference Manual
Serial Communications
Serial communications with the MDS is provided through the female DB-9 connector located
on the front of the Drive Module. The serial interface is either three wire non-isolated RS232C or two wire non-isolated RS-485. RS-485 is also available through the 44-pin
Command Connector.
The MDS serial port on the drive contains connection for RS-232 and RS-485 in the same
9-pin connector. With this dual communications support a 9[pin to 9-pin straight through
cable can not be used. The Control Techniques’ TIA-XXX cable is recommended.
When connecting the serial port of your PC to the serial port of the Drive Module, verify
that your PC’s ground is the same as the MDS PE ground. Failure to do so can result in
damage to your PC and/or your Drive Module.
Note
Communication errors can usually be avoided by powering the computer or host device
off of a convenience outlet that is mounted in the enclosure and whose neutral and ground
are wired to the same single ended point ground that the MDSs and controllers are using.
This is sometimes beneficial even with battery powered computers.
Modbus Communications
The Drive Module’s serial communication protocol is Modbus RTU slave with a 32 bit data
extension. The Modbus protocol is available on most operator interface panels and PLC’s.
Serial Communications Specifications
Max baud rate
19.2k
Start bit
1
Stop bit
2
Parity
none
Data
8
Motion Interface panels are supplied with a Modbus master communications driver.
62
Installation
Multi-Drop Communications
The RS-485 option (pins 4 and 9) is provided for multi-drop configurations of up to 32 Drive
Modules. A multi-drop serial cable, is available, which allows you to easily connect two or
more MDS Drive Modules.
Grounded to enclosure ground with screw.
TIA-XXX
Serial Cable
Term-T
Note:
The terminating resistor packs, Term-H
and Term-T, should be installed on the first
(Term-H) and last (Term-T) MDS Drive Modules
in the string if the total cable length is over
50 feet.
*If the user device (PC, Operator Interface, PLC, etc)
is communicating RS-485, the Term-H or equivalent
terminating resistor (120 Ohm) must be placed at
the user device and not on the first MDS module.
Figure 56:
Term-H*
DDS-XXX
Serial Cables
MDS Multi-Drop Wiring Diagram, RS-232 to RS-485 communications
63
Modular Drive System Reference Manual
TIA Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RX (232)
TX (232)
Ground
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
7
8
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
9
120
Ohm
Computer
Computer Serial
Port
Drive Serial Port
0V
+5
Drive Serial Port
1
2
3
4
5
6
576
Ohm
485 +
120
Ohm
7
8
485 -
9
576
Ohm
Drive Serial Port
TERM-H
TERM-T
TIA Cable
DDS Cable
DDS Cable
Top View of Multi-drop Cabling
Figure 57:
Multi-Drop Wiring Pinout with RS-232 Communications to PC
User Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RS-485 +
RS-485 -
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
1
2
3
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
120
Ohm
User Device
User Device
Port
Drive Serial Port
Drive Serial Port
0V
+5
120
Ohm
485 -
576
Ohm
Drive Serial Port
TERM-H
User Cable
576
Ohm
485 +
TERM-T
DDS Cable
DDS Cable
Top View of Multi-drop Cabling
Figure 58:
64
Multi-Drop Wiring Pinout with RS-485 Communications to User Device
Installation
Step 8: Power Up Sequence
Verify that all Power and Drive Modules are installed and secured to their respective
backplanes.
Powering up and running the system without all Modules installed to their backplanes in
NOT SAFE and could result in serious injury or death.
Verify proper wiring of Incoming VAC and Motor Power. Verify that the AC Interlock Relay
is correctly wired to protect the system. Verify that the Logic Power supply and/or I/O Power
supply are wired properly. After installation use the following flow chart to verify the correct
Power Up sequence.
65
Modular Drive System Reference Manual
Power up Sequence
Turn on 24VDC Logic Power Supply
Ÿ
Ÿ
Logic Power Status
Indicator ON
AC Disconnect Relay
Closed
Check +24VDC Supply
Connector to Power
Module
NO
YES
"u" or "d"
Displayed on all
Drive Modules
Status Display
NO
Make sure
Drive Modules with
no display are
properly seated
To verify that
backplanes are
connected properly the
+24VDC bus can be
measured on the last
Drive Module Backplane
YES
Turn on AC Input Power
(342 to 528 VAC)
After Soft Start has been completed
(approx. 2 seconds)
Ÿ
Ÿ
YES
System Ready Status Indicator ON
The "." decimal on all Drive Module
Status Displays are ON
Startup sequence has been
completed properly. System is
ready for operatoin
NO
Ÿ System Ready status Indicator ON
Ÿ "." The decimal point is OFF
Verify that the Drive Module is
seated properly and the Drive
Module fuse is not blown.
See Power and Fuse Replacement
section.
Figure 59:
66
Ÿ System Ready status Indicator OFF
Ÿ "." The decimal point is OFF
To next
page
Power Up Sequence Flow Chart - Part 1
Ÿ System Ready status Indicator OFF
Ÿ "." The decimal point is ON
Power Module does not function
properly
Installation
From
previous
page
Power Module
Faults?
No
Drive module(s) do
not fuction
properly and need
to be replaced
Yes
Over Temp
High VAC Input
Shunt Fault
Power Module
exceeded it's max
temperature and
needs cool down
time.
AC Input line
voltage exceeded
528 VAC
Shunt transistor
failed, due to short
in wiring or module
If none of these conditions have been found it means the Power Module does not function properly
Figure 60:
Power Up Sequence Flow Chart - Part 2
67
Modular Drive System Reference Manual
The MDS is able to handle short drops (glitch) on the AC Input Power without interruption
to system operation. If the DC Bus voltage drop is greater than 250 VDC the System Ready
Signal will go Low (not Active). If AC Input Power is applied before the DC Bus voltage
drops to 60VDC the Power Module will re-enter Soft Start and the Ready Signal will go High
(Active) when the Soft Start is complete. If the DC Bus voltage drops below 60VDC the
system will need to be reset for the Modules to power-up.
+24 VDC
VAC
Short AC Drop
Bus Voltage
Medium AC Drop
Large AC Drop
250 VDC
Drive Module
“u” Fault
60 VDC
Ready Signal
and I/O
Sof-Start Relay
AC Disconnect Relay
Figure 61:
AC Glitch Handling Diagram
Motor Mounting
Motors should be mounted firmly to a metal mounting surface to ensure maximum heat
transfer for maximum power output. The mounting surface should be bonded to the single
point ground.
For motor dimensions, weights and mounting specifications, see the "Specifications" section.
68
Installation
Drive and Power Module Removal
DO NOT remove Power or Drive Modules until at least 3 minutes after AC Power has
been removed from the system.
1.
Unplug all I/O and/or cable connections to the Power and Drive Modules.
2.
Loosen the Retaining Screws of the module being removed
3.
Grasp the top and bottom Integrated Removal Tab of the module.
4.
Pull the module from the backplane.
Integrated
Removal Tab
Integrated
Removal Tab
Retaining Screw
Retaining Screw
Pull Drive or
Power Module
off the backplane
Retaining Screw
Retaining Screw
Integrated
Removal Tab
Figure 62:
Integrated
Removal Tab
Power and Drive Module Removal Diagram
69
Modular Drive System Reference Manual
Drive Module Fuse Replacement
Fuse
locations
Figure 63:
Fuse Location in a Drive Module Backplane - MP-2500/MD-434 Shown
The Drive Module backplane is equipped with two over current protection fuses with the
ratings shown here. Control Techniques recommends fuse type: SHAWMUT® A70QS.
70
Drive Module
Fuse Rating
MD-404
10 A
MD-407
16 A
MD-410
20 A
MD-420
32 A
MD-434
50 A
Installation
Drive Module Backplane Disassembly
These instructions are to remove a Drive Module backplane from another Module backplane.
Shown in the figure below is a Power and Drive Module Backplane assembly.
PE Ground Tab
Snap Tab
Remove the #10
panhead screw.
Insert
screwdriver
here.
Loosen the
Bus screws.
Remove the #10
panhead screw.
Logic Connector
Insert
screwdriver
here.
Snap Tab
Remove the #10
panhead screw.
Optional Cable Strain Relief
Figure 64:
Drive Module Backplane Disassembly Diagram
DO NOT remove Power or Drive Modules until at least 3 minutes after AC Power has
been remove from the system.
71
Modular Drive System Reference Manual
72
1.
Remove the Drive Module and the Power Module from their backplanes. For details see
“Drive and Power Module Removal” on page 69.
2.
Remove the PE ground tab screw and if applicable the Optional Cable Strain Relief screw
of the backplane being removed.
3.
Remove the screws that secure the backplane to the metal mounting panel. If applicable
the Optional Cable Strain Relief can be removed now.
4.
Loosen the Bus screws.
5.
Insert a flat tipped screwdriver into the slot between backplanes as shown in Fig 64. Push
on the screwdriver with enough force to depress the snap tab, at the same time carefully
pull the backplane away from the other backplane. The backplanes only need to be
separated far enough so the snap tab is unlocked from the other backplane.
6.
Insert the screwdriver in the slot on the other end of the backplane and depress the snap
tab, carefully pull the backplane away, unplugging the Logic connector from the other
backplane.
Modular Drive System Reference Manual
Operational Overview
Operational Overview
The Modular Drive System consists of one Power Module and up to eight Drive Modules
connected to the Power Module. The Power Module converts the AC Input Power into a DC
Bus that is passed across the backplane. The Power Module contains Soft start Circuitry,
Shunt Transistor and Digital I/O. The Digital I/O of the Power Module is pre-defined and
there is no software configuration for it.
The Drive Modules are powered by the DC Bus created by the Power Module. The Drive
Module contains Digital I/O, Analog I/O, Encoder Signals, Communication Signals, Pulse
Direction Inputs and Status display. The Status display is for the individual drive axis. The
Drive Module I/O can be configured using PowerTools FM software. PowerTools FM is a
Wndows® based software used for setup and diagnostic tool.
Power Module
Power Module Inputs and Outputs
Logic Power
The Logic Power status indicator (green) is illuminated when the +24VDC, +/- 10% Logic
Power is correctly supplied to the Power Module.
System Ready
The System Ready status indicator (green) is illuminated when the system power-up sequence
is properly completed.
The System Ready status indicator will blink if one of the AC Input Phases is lost. The system
will remain functional in single phase condition.
If AC power is on and the System Ready status indicator is not illuminated, one of the
following has occurred: Shunt fault, Over-temperature or High VAC Input. These faults are
described below.
Shunt Fault
The Shunt Fault status indicator (red) will be illuminated in the case of shunt resistor wiring
error or a short circuit condition.
73
Modular Drive System Reference Manual
Over Temp
The Over Temp status indicator (red) will be illuminated if continuous RMS power rating or
the Power Module is exceeded creating an over temperature condition.
High VAC Input
The High VAC Input status indicator (red) will be illuminated if the AC input Voltage
exceeds 528 VAC.
Shunt Active
The Shunt Active status indicator (green) will be illuminated when the Shunt Transistor is on.
The Shunt Transistor will turn on under two conditions:
•
The Bus voltage exceeds 830 VDC due to regenerative energy during motor deceleration.
Shunt Transistor turn off level is 780 VDC.
•
The External Shunt Control Input is active in case of emergency stop.
Shunt Operation
The MDS Power Module has a internal shunt transistor with 15A capacity that can be
connected to an external shunt resistor to dissipate regenerative energy generated during
deceleration of a load.
The MDS Power and Drive Modules rely on the bus capacitors to absorb normal levels of
regenerative energy.
Power Module Model
External Shunt Minimum
Resistance (Ohms)
MP-1250
30
MP-2500
30
MP-5000
9
External Shunt Operation
The connection for an external shunt resistor is between Bus+ (B+) and Shunt Out located
on the Power Module.
74
Operational Overview
Access to Bus- (B-) is given for measurement purposes only i.e. oscilloscope or voltage
meter. Do Not make any connections to B-.
You should mount the external shunt resistor so that the heat it generates does not affect the
drive.
Drive Module
User Interface
The MDS system is setup using PowerTools FM software.
PowerTools FM Software
PowerTools FM software is an easy to use Windows-based setup and diagnostics tool.
PowerTools FM software provides you with the ability to create, edit and maintain your Drive
Module’s setup. You can download or upload your setup data to or from a Drive Module and
save it to a file on your PC or print it for review or permanent storage.
PowerTools FM software provides two setup views of the Drive Module, EZ Setup and
Detailed Setup. EZ Setup view is intended to be used by most PowerTools FM software users
and provides access to all commonly used drive parameters. Detailed Setup view is available
for more advanced drive users who need access to all setup options and diagnostic
information.
75
Modular Drive System Reference Manual
76
Figure 65:
PowerTools FM Window, EZ Setup View
Figure 66:
PowerTools FM Window, Detailed Setup View
Operational Overview
How Motion Works
Below is a list of details related to motion in a Drive Module.
•
The Stop input function overrides motion in all operating modes including Pulse and
Torque mode. It shifts the mode to Velocity mode and decelerates the axis according to
the Stop deceleration ramp.
•
The Travel Limits work in all operating modes including; Pulse, Velocity and Torque
modes.
•
When a Travel Limit has been activated in a particular direction, uninhibited motion is
allowed in the opposite direction.
•
The Positive Direction parameter affects all motion by specifying which direction the
motor shaft will rotate (CW or CCW) when the command position is increasing.
•
When changing modes with Torque Mode Enable input function, no ramping occurs
between the two different commands.
•
When using Summation mode, the properties of both summed modes are honored.
Functional Overview
The Drive Module is a digital servo drive that provides three basic modes of operation: Pulse,
Velocity and Torque. The Operating Mode selection defines the basic operation of the Drive
Module.
External control capability is provided through the use of input and output functions. On the
power module these functions are pre-defined and on the Drive Module these functions may
be assigned to any input or output line which may be controlled by external devices, such as
a PLC or multi-axis controller, to affect the Drive Module operation.
Drive parameters can be modified using PowerTools FM software or an FM-P. All drive
parameters have a pre-assigned Modbus address which allows you to access them using a
Modbus interface.
Pulse Mode
In Pulse mode, the Drive Module will receive pulses which are used to control the position
and velocity of the motor.
There are three pulse interpretations associated with Pulse mode: Pulse/Pulse, Pulse/
Direction and Pulse/Quadrature. These selections determine how the input pulses are
interpreted by the Drive Module.
Note
High Performance Gains check box in PowerTools FM software is typically enabled when
Pulse mode is used (the default is enabled).
77
Modular Drive System Reference Manual
Pulse Source Selection
The Drive Module provides two types of pulse input circuits which allows you to choose the
appropriate input type to match the device generating the position pulses. The selection is
done by wiring to the desired input pins of the Command Connector and setting the Pulse
Source selection in the Setup tab. The Differential setting (default) is perfect for most
encoders or upstream Drive Modules. The Single Ended setting is a good match for any open
collector driver that requires an external pull up resistor making it ideal for most stepper
controllers, PLC stepper cards and PC computer parallel printer ports.
The two hardware input circuits are included in the Drive Module and are accessible through
the Drive Module command connector. The differential input circuit is RS-422 compatible
making it inherently noise immune while being able to accept pulse rates of up to 2 Mhz per
channel. The single ended inputs use high noise immunity circuitry and have internal pull-up
resistors to the Drive Module’s 5 Volt logic supply so external pull-ups and biasing circuitry
is not required. When proper installation techniques are followed as shown below, the
differential input setup will provide a more robust and noise immune system than a single
ended input setup.
Differential input is recommended under any of the following conditions:
•
Pulse width < 2 µs
•
Pulse frequency > 250 kHz
•
Pulse command cable length > 25 feet
•
Noisy electrical environments
Differential input circuit specifications:
Input frequency maximum
Input device:
Input impedance
Maximum voltage applied to input pins (A, A/) or (B, B/ )
2 Mhz
AM26C32
12 Kohms each input
Single Ended (referenced to 0V drive logic)
+/-10V
Differential (referenced to mating differential input)
+/-10V
Maximum common mode voltage
Minimum differential voltage required
Input voltage hysteresis
ECI-44 Terminal
78
Command
Connector Pin #
+/-7 V
200 mV
60 mV
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
Sync Enc In “A”
27
Pulse
Pulse +
A
Sync Enc In “A/”
41
Pulse/
Pulse +/
A/
Sync Enc In “B”
26
Direction
Pulse -
B
Sync Enc In “B/”
40
Direction/
Pulse -/
B/
Operational Overview
Single ended input circuit specifications:
Single ended input specifications:
1 MHz maximum input frequency
Internal 330 ohm pull-up to 5 Volt (non-isolated)
1.5 Volt low level
3.5 Volt high level
Output driver requirements:
15 mA sinking (open collector)
5 Volt capacity
Signal common connected to Drive Logic 0V (Sync Encoder Common 0V)
ECI-44 terminal
Command
Connector Pin #
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
NC2
20
Pulse /
Pulse CW /
A
NC1
36
Direction
Pulse CCW /
B
Pulse / :
Commands motion on the falling edge (active edge).
Direction:
(active).
Positive (+) motion when high (inactive) and Negative (-) motion when low
Pulse CW / :
Commands positive (+) motion on the falling edge (active edge) of a pulse.
Pulse CCW /:
Commands negative (-) motion on the falling edge (active edge) of a pulse.
A and B :
Encoder Quadrature signal interpretation. When B leads A Positive (+)
motion commands will be generated, When A leads B, negative (-) motion
commands will be generated.
Note
Actual motor rotation direction will depend on pulse ratio polarity and setting of the
Positive Direction bit.
Pulse/Direction Interpretation
In Pulse/Direction interpretation, pulses are received on the A channel and the direction is
received on the B channel. If the B is high, pulses received on the A are interpreted as positive
changes to the Pulse Position Input. If the B is low, pulses received on the A are interpreted
as negative changes to the Pulse Position Input.
79
Modular Drive System Reference Manual
Figure 67:
Pulse/Direction Signals, Differential Inputs
Pulse/Quadrature Interpretation
In Pulse/Quadrature interpretation, a full quadrature encoder signal is used as the command.
When B leads A encoder counts are received they are interpreted as positive changes to the
Pulse Position Input. When A leads B encoder counts are received they are interpreted as
negative changes to the Pulse Position Input. All edges of A and B are counted, therefore one
revolution of a 2048 line encoder will produce an 8192 count change on the Pulse Position
Input.
80
Figure 68:
Pulse/Quadrature Signals, + Command
Figure 69:
Pulse/Quadrature Signals, – Command
Operational Overview
Pulse/Pulse Interpretation
In Pulse/Pulse interpretation, pulses received on the A channel are interpreted as positive
changes to the Pulse Position Input. Pulses received on the B channel are interpreted as
negative changes to the Pulse Position Input.
Figure 70:
Pulse/Pulse Signals, Differential Inputs
Pulse Mode Parameters
The Pulse Position Input parameter shows the total pulse count received by the Drive Module
since the last power-up.
The Pulse Position Input, Position Command, Position Feedback Encoder and Position
Feedback are initialized to zero on power-up. Only Position Feedback Encoder can be preloaded serially with a value after power-up.
The Pulse Mode Ratio parameter includes a numerator which represents motor revolutions,
and a denominator which represents master pulses. The Pulse Ratio Revolutions is allowed
to be negative which reverses all Pulse mode motion.
The Pulse Position Input is multiplied by the Pulse Mode Ratio to produce the Position
Command.
Following Error/Following Error Limit
The Following Error is the algebraic difference between the Position Command and the
Position Feedback. It is positive when the Position Command is greater than the Position
Feedback. All accumulated Following Error will be cleared when the Drive Module is
disabled.
The Following Error Limit is functional in Pulse mode only. A Following Error Limit can be
set using PowerTools FM or a FM-P. This limit is in motor revolutions and has a range of
.001 to 10.000 revolutions. The Following Error Limit can be enabled or disabled.
Pulse Mode Following Error
In Pulse Mode, the range of the Following Error is ±2863.3 revolutions. If the Following
Error Limit is not enabled and the Following Error exceeds 2863.3 revolutions, the displayed
value is limited to this maximum value and will not rollover.
81
Modular Drive System Reference Manual
If the Following Error Limit Enable is enabled, the absolute value of the Following Error will
be compared to the Following Error Limit. If the limit is exceeded, a fault will be generated.
If the Following Error Limit Enable is disabled, the Following Error Limit is not used.
Velocity Mode Following Error
In Velocity mode, the maximum Following Error possible varies based on the gain and torque
limit settings. When the Actual Torque Command reaches the maximum possible level, the
following error will stop increasing and any additional position error will be dropped. In
Velocity mode, when the following error exceeds the Following Error Limit parameter there
is no action.
Encoder Feedback and Position Feedback
Encoder Feedback (Position Feedback Encoder) and Position Feedback are two separate
parameters which indicate the same physical motor position. Encoder Feedback is the
position change since power up in motor encoder counts and Position Feedback is the total
position change since power up in motor revolutions. The Position Direction parameter
setting will change which direction the motor rotates when the position feedback and position
command are counting up. In the default setting the position counts up when the motor shaft
rotates clockwise (when viewed from the shaft end).
The Encoder Feedback (Position Feedback Encoder) parameter can be pre-loaded serially by
setting the Position Feedback Encoder Modbus parameter.
Velocity Mode
Three submodes are associated with Velocity mode: Analog, Presets and Summation.
Analog Submode
The Analog Input receives an analog voltage which is converted to the Velocity Command
Analog parameter using the Full Scale Velocity, Analog Input Full Scale, and Analog Input
Zero Offset parameters. The equation for this conversion is:
VCA =
((AI - AZO) FSV)
AFS
Where:
VCA = Velocity Command Analog (RPM)
AI = Analog Input (volts)
AZO = Analog Input Zero Offset (volts)
FSV = Full Scale Velocity (RPM)
AFS = Analog Input Full Scale (volts)
82
Operational Overview
The Velocity Command is always equal to the Velocity Command Analog in Analog
Velocity mode. The Velocity Command is the command received by the velocity closed loop
control.
Analog Accel/Decel Limit
This feature in the Analog submode allows you to limit the accel and decel rate when using
the analog input for velocity control. This makes it very simple to use the drive in high
performance, variable speed, start-stop applications such as Clutch-Brake replacements
without requiring a sophisticated controller to control the acceleration ramps. In applications
which do not require the drive to limit the ramps such as when using an external position
controller, the parameter can be set to “0” (its default value). If the Analog Accel/Decel Limit
parameter value is changed during a ramp, the new ramp limit is imposed within the next
servo loop update.
The Analog Accel/Decel Limit parameter is accessed on the Velocity tab. Its range is 0.0 to
32700.0 ms/kRPM.
Presets Submode
Presets submode provides up to eight digital Velocity Presets and associated Accel/Decel
Presets. At any time only one Velocity Preset can be selected. They are selected using the
Velocity Preset Line #1, Line #2 and Line #3 input functions (see table below).
Velocity Preset Line #3
Velocity Preset Line #2
Velocity Preset Line #1
Selected Velocity and Accel
/ Decel Preset #
0
0
0
0
0
0
1
1
0
1
0
2
0
1
1
3
1
0
0
4
1
0
1
5
1
1
0
6
1
1
1
7
*
(0) = Inactive input function, (1) = Active input function
When one of the Velocity Presets is selected, the Target Velocity is set equal to the Velocity
Preset value and the accel/decel ramp rate is set to the Accel/Decel value associated with that
velocity.
If the Velocity Command Preset is not equal to the Target Velocity, an acceleration (or
deceleration) ramp is in progress. In this state, the Velocity Command Preset will be increased
(or decreased) based upon the acceleration (or deceleration) ramp rate of the selected velocity
preset. During the acceleration/deceleration ramp, the At Velocity output function is inactive.
If the Velocity Command Preset is equal to the Target Velocity, all ramping is complete, the
Velocity Command Preset is constant and the At Velocity output function is active.
83
Modular Drive System Reference Manual
The Velocity Command is always equal to the Velocity Command Preset in Presets
submode.
Figure 71:
Velocity vs. Time Diagram using Preset Velocities
Summation Submode
In Summation submode the Velocity Command is the result of the sum of the Velocity
Command Analog and the Velocity Command Preset values.:
VC = AC + PC
Where:
VC = Velocity Command
AC = Velocity Command Analog
PC = Velocity Command Preset
Example 1:
Use of Velocity Presets in a phase advance/retard application. Velocity Preset #0 is set to 0
RPM, Velocity Preset #1 is set to +5 RPM, and Velocity Preset #2 is set to -5 RPM. The
Analog Input is the command source for a web application where a phase adjustment may be
useful. Without interrupting the operation, you may select either Velocity Preset #1 or #2 to
speed up or slow down the motor thereby advancing or retarding the phase between the motor
and the web material.
84
Operational Overview
Example 2:
Use the Velocity Command Analog as a trim adjustment to the digital Velocity Presets.
Velocity Preset #2 is selected with Analog Input at 0, so the Velocity Command Preset and
Velocity Command are equal (set to match a conveyor speed). You can use the Analog Input
(Velocity Command Analog) as a fine adjust for the Velocity Command to exactly match the
conveyor speed.
Figure 72:
Summation Mode Block Diagram
Figure 73:
Velocity vs. Time Diagram, Summation Mode
.
Torque Mode
In Torque mode both the position and velocity loops are disabled and only the torque loop is
enabled.
Note
Velocity related faults and velocity related input and output functions are still enabled
(including Stop and Travel Limits).
85
Modular Drive System Reference Manual
In Torque mode the Drive Module receives an Analog Input which is scaled to the Analog
Torque Command by the Full Scale Torque, Analog Input Full Scale, and Analog Input Zero
Offset parameters. The equation is:
TC =
((AI - AZO) FST)
AFS
Where:
TC = Torque Command
AI = Analog Input (volts)
AZO = Analog Input Zero Offset (volts)
FST = Full Scale Torque (%)
AFS = Analog Full Scale (volts)
Drive Modifiers
This section describes functions that can modify the operation of the drive.
Stop
The Stop input function, when activated, will cause motion to stop regardless of motor
direction or the operating mode. The Stop Deceleration Ramp defines the rate of velocity
change to zero speed.
Activating the Stop input function causes the drive to change to Velocity mode. Therefore, if
you are operating in Torque mode, the Drive Module must be tuned to the load to prevent
instability when activating the Stop input function.
For example, if an application is operating in Torque mode at 1000 RPM, and the Stop input
function is activated with a Stop Deceleration Ramp of 500 ms/kRPM, the motor will
decelerate to a stop in 500 ms.
When the Stop input function is deactivated, the previous operating mode is restored
within 400 µs and the Drive Module and motor will respond immediately with no
ramping unless ramping is part of the selected mode.
+/- Travel Limits
The + and - Travel Limit input functions will stop motion in the direction indicated by the
input function using the Travel Limit Deceleration rate. This feature is active in all modes.
When an axis is stopped by a Travel Limit function, it will maintain position until it receives
a command that moves it in the opposite direction of the active Travel Limit.
86
Operational Overview
For example, the + Travel Limit will stop motion only if the motor is moving + but allows motion to move off the limit switch. Conversely, the - Travel Limit will stop motion only if
the motor is moving - but allows + motion to move off the limit switch.
If both input functions are active at the same time, no motion in either direction will be
possible until at least one of the inputs is released.
When either + or - Travel Limit input function is activated, a fault will be logged into the Fault
Log, and the Drive Module will display an “L” on the LED diagnostics display on the front
of the Drive Module. Once the axis is driven off the limit switch, the fault will be cleared and
the “L” will disappear.
If both Travel Limit input functions are activated simultaneously, the Drive Module will
respond as if the Stop input function has been activated and will use the Stop Deceleration
ramp.
Note
The function of the Travel Limits will be effected by the installation of an Function
Module (FM) to the MDS Series. Please refer to the particular FM’s reference manual for
complete description.
Travel Limit Application Notes
Torque Mode
If you are operating in Torque mode, the Drive Module must be tuned to the load to prevent
instability when activating the Travel Limit input functions.
Host Controller Travel Limits
If the host controller decelerates the Drive Module faster than the Travel Limit Deceleration
ramp, the Drive Module allows the controller to maintain full control of the axis during the
deceleration. This results in no following error build up in the controller and easier recovery.
Vertical Loads in Velocity Mode
In applications with horizontal, counterbalanced or un-counterbalanced vertical loads, the
load will held in position when motion is stopped due to a + or - Travel Limit. The position
will be held until the controller commands motion in the opposite direction of the activated
Travel Limit.
Vertical Loads in Torque Mode
In applications with horizontal or counterbalanced vertical loads, the load will held in position
when motion is stopped due to a + or - Travel Limit. The position will be held until the
controller commands motion in the opposite direction of the activated Travel Limit.
87
Modular Drive System Reference Manual
When an axis is stopped by the upper Travel Limit with a vertical load, the controller must
maintain a torque command at a minimum level to hold the load or the load may drop.
In applications with un-counterbalanced vertical loads, you must be careful not to set the
controller’s torque command to zero when the upper Travel limit is activated. Setting the
controllers analog torque command to zero in this situation will command the axis to move
off the limit switch causing the load to drop.
If your controller removes the torque command (zeroes the analog command output) when a
Travel Limit is activated, you have a number of choices to prevent the load from dropping.
All of which require some external logic to determine when the controller can actually take
control again.
•
Activate the opposite Travel Limit input function, then release it when the controller is
operational again.
•
Activate the Stop input function, then release it when the controller is operational again.
•
Apply the axis brake, then release it when the controller is operational again
Pulse Mode
In applications with horizontal, counterbalanced or un-counterbalanced vertical loads, the
load will be held in position when motion is stopped due to a + or - Travel Limit. The position
will be held until the controller commands motion in the opposite direction of the activated
Travel Limit.
When the travel limits are activated, the Drive Module will decelerate at the Travel Limit
Deceleration Ramp and will continue to store all the command pulses received up to ±232
counts. The stored pulses need to be cleared out before the axis will move off the Travel
Limit. This can be done if the controller generates command pulses in the direction opposite
the activated Travel limit. The stored command pulses can also be cleared by activating both
Travel Limit input functions at the same time, activating the Stop input function or disabling
the Drive Module for as little as 5 msec (plus any debounce time).
Torque Limiting
The Torque Command is calculated as shown previously, but its value is limited by the
Torque Limit parameter and the current foldback function (see "Torque Limit" and "Current
Foldback"). The result of this limiting function is Torque Command Actual. This is the
command that drives the Power Stage to generate current in the motor. The Torque Limit
Active output function is active whenever the Torque Command Actual is less than from the
Torque Command. This will be true when motion is stopped due to a Travel Limit input
function.
88
Operational Overview
Torque Limit Function
The Torque Limit Enable input function allows an external controller to limit the Actual
Torque Command to a lower value. The Torque Limit parameter is active only when the
Torque Limit Enable input function is active.
TTL = PMT, PDT, RFL, SFL or PTL (whichever is lower)
Where:
TTL = Total Torque Limit
PMT = Peak motor torque
PDT = Peak Drive Module torque
RFL = RMS foldback limit (80 percent of continuous system torque rating)
SFL = Stall foldback limit (80 percent of Drive Module stall current rating)
PTL = Programmable Torque Limit
Note
The Torque Limit Enable input must be active to use PTL.
If the application requires that the Torque Limit be enabled at all times, the Torque Limit
Enable input function may be setup to be Always Active to avoid the use of an input line.
Velocity Limiting
The Drive Module commanded velocity is limited to 112.5% of the motor’s maximum
operating speed. This limiting has nothing to do with the Line Voltage setting. Depending on
AC supply voltage, it may or may not be possible to get to motor maximum operating speed.
Note
See the "Drive Module/Motor Specifications" section for maximum motor speeds.
Example 1:
If the Motor Type is an HT-320, the maximum motor speed of the HT-320 is 4000 RPM. If
the Line Voltage parameter is set to 230 VAC and the Velocity Limit is equal to 112.5 percent
of 4000 RPM or 4500 RPM.
Overspeed Velocity Parameter
Motor speed is continuously monitored against the Overspeed Velocity parameter whether
the Drive Module is enabled or not and when the motor speed exceeds the limit, or Overspeed
Velocity Limit, a fault is issued. The default value for Overspeed Velocity Limit is 13000
RPM.
89
Modular Drive System Reference Manual
The Drive Module has an internal overspeed velocity limit. This limit is the maximum of the
Overspeed Velocity parameter and 150% of the motor maximum operating speed. For
example, an HT-320 with 4000 RPM maximum speed the internal limit is 6000 RPM.
The Overspeed fault will be activated when either one of these two conditions are met:
1.
When the actual motor speed exceeds the Overspeed Velocity Limit parameter.
2.
If the combination of command pulse frequency and Pulse Ratio can generate a motor
command speed in excess of the fixed limit of 13000 RPM. In Pulse mode operation and
any Summation mode which uses Pulse mode, the input pulse command frequency is
monitored and this calculation is made. For example: with a Pulse Ratio of 10 pulses per
motor revolution, the first pulse received will cause an Overspeed fault even before there
is any motor motion.
In Motion Velocity
The In Motion Velocity parameter defaults to a value of 10 RPM. If the motor Velocity
Feedback is above the In Motion Velocity value, the In + Motion or In - Motion output
function is active. When the motor velocity falls below one half of the In Motion Velocity,
the In + Motion or In - Motion output function is inactive.
The maximum value for In Motion Velocity is 100 RPM and is intended to be used to indicate
“in motion” not “at speed”.
Note
The In Motion Velocity detect is monitored every 400 µs so machine jitter and torque
ripple could cause flicker in this signal if the commanded velocity is near the In Motion
Velocity parameter value.
Motor Direction Polarity
The direction that the motor turns with a positive command can be changed with the Positive
Direction parameter. This can be accessed with PowerTools FM in the EZ Setup tab or
Detailed Setup tab. The positive direction by default causes the motor to turn CW as viewed
looking at the shaft.
Note
CW and CCW rotation is determined by viewing the motor from the shaft end.
90
Operational Overview
CW Rotation (+)
Figure 74:
Clockwise Motor Rotation
Positive direction is defined as the command which causes the internal position counter to
count "Up". They are:
•
A positive analog velocity or torque command (i.e., a higher voltage on the (+)
differential input than on the (-) input).
•
A positive direction (+) pulse command.
•
A positive preset velocity or torque command.
Current Foldback
Current foldback is used to protect the motor and Drive Module from overload. There are two
levels of current foldback: RMS Foldback and Stall Foldback.
RMS and Stall Foldback are displayed on the diagnostic display as a "C" and "c" respectively.
RMS Foldback
RMS foldback protects the motor from overheating. The RMS Foldback parameter models
the thermal heating and cooling of the Drive Module and motor based on the commanded
current and the motor velocity. On power-up, the RMS Foldback level is zero and is
continually updated. When the RMS Foldback level reaches 100 percent, current foldback is
activated and the Foldback Active output function is active.
Each Drive Module is designed to deliver up to 300 percent of the motor’s continuous torque
for no less the two seconds when running at 100 RPM or more. If only 150 percent of
continuous torque is required, several seconds of operation before RMS foldback is typical.
During current foldback the Torque Command Actual will be limited to 80 percent
continuous motor torque. Current foldback is cancelled when the RMS Foldback level falls
below 70 percent. This could take several seconds or several minutes depending on the load.
The RMS Foldback value is dependent on both torque and velocity. At low speeds (<20
percent of maximum motor speed) the RMS Foldback will closely follow the Torque
Command Actual. At high speeds (>50 percent of maximum motor speed) the RMS Foldback
will read higher than the Torque Command Actual.
91
Modular Drive System Reference Manual
The time constant for RMS Foldback is 10 seconds. This means that if the load is 150 percent
of continuous, it will take about 10 seconds to reach the foldback trip point.
Figure 75:
RMS Foldback Trip Point (this graph is accurate to ±5 percent)
Stall Foldback
Stall Foldback prevents overheating of the Drive Module. It activates in any mode when the
motor velocity is 100 RPM or less and the Torque Command causes the current to exceed the
stall current threshold for 100 ms or more.
Stall Foldback will also be triggered when the drive sees repeated high currents in one of the
three motor phases. This can occur when a motor is indexed back and forth between two of
its electrical poles.
•
For 4 pole motors this distance is 90° mechanical.
•
For 6 pole motors this distance is 60° mechanical.
•
For 8 pole motors this distance is 45° mechanical.
Once Stall Foldback is activated, the drive current is reduced to 80 percent of the stall current
threshold until the Torque Command Actual is reduced to less than 70 percent of the stall
current threshold for about 200 ms or until the motor velocity exceeds 100 RPM.
Brake Operation
Motor brake operation is controlled by the Brake Release and Brake Control input functions.
These input functions can be used together to control the state of the Brake output function.
The table below shows the relationship between the Brake input and Brake output functions.
92
Operational Overview
Note
No motion should be commanded while the brake is engaged.
Brake
Release
Input
Off
Brake
Control
Input
*
On
On
Off
On
Off
Drive
Module
Power
Stage
Enabled
Disabled
Enabled
Disabled
Enabled
Disabled
Enabled
Disabled
Brake
Output
Off
Off
On
Off
On
On
On
On
Brake*
Eng
Eng
Diseng
Eng
Diseng
Diseng
Diseng
Diseng
Eng=Mechanically Engaged
Diseng=Mechanically Disengaged
Brake Release Input Function
The Brake Release input function will release the brake under all conditions. When this input
function is "On", the Brake output function will be "On" (i.e., release brake). This input
function overrides all other brake control, thus allowing the brake to be released while a fault
is active or the power stage is disabled. See also Brake output function.
Brake Control Input Function
This input function, when active, will engage the brake unless overridden by the Brake
Release input function. This input lets you externally engage the brake while allowing the
Drive Module to also control the brake during fault and disabled conditions.
Brake Output Function
The Brake output function is used to control the motor holding brake. If the Brake output
function is "Off", the brake is mechanically engaged. When the brake is engaged, the
diagnostic display on the front of the Drive Module will display a “b”.
The Drive Module outputs are limited to 150 mA capacity, therefore, a suppressed relay is
required to control motor coil. Control Techniques offers a relay, model BRM-1.
93
Modular Drive System Reference Manual
Analog Command Input
The Analog Command Input can be used as a velocity or torque command. The Drive Module
accepts a ±10 VDC differential analog command on pins 14 and 15 of the Command
Connector and has 14 bits of resolution.
The Analog Inputs Bandwidth, Analog Full Scale and Analog Input Zero Offset parameters
are applied to the Analog Input to generate either an analog velocity or torque command.
These three parameters can be edited using PowerTools FM, a FM-P or serially using
Modbus.
Bandwidth
The value of the parameters sets the Low Pass Filter cutoff frequency applied to the analog
command input. Signals that exceed this frequency are filtered at a rate of 20 dB/decade.
Analog Full Scale
This parameter specifies the full scale voltage for the analog input. When the Drive Module
receives an analog command input equal to the Analog Input Full Scale parameter, the Drive
Module will command either Full Scale Velocity or Full Scale Torque depending on the
operating mode.
Analog Zero Offset
Analog Input Zero Offset is used to null any input voltage that may be present at the Drive
Module when a zero velocity or torque is commanded by a controller. The amount of offset
can be read with PowerTools FM software or a FM-P using the following procedure:
94
1.
Provide the zero velocity command to the analog command input on the command
connector.
2.
Read the Analog Input Value.
3.
Enter the Analog Input Value in the Analog Input Zero Offset.
Operational Overview
Analog Command Wiring
Figure 76:
Analog Command, Differential Wiring Diagram
Drive
Command Connector
Figure 77:
Analog Command, Single-ended Wiring Diagram
95
Modular Drive System Reference Manual
Analog Outputs
The Drive Module has two 8 bit Analog Outputs which may be used for diagnostics,
monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2.
They can be accessed from the Command Connector on the Drive Module or from the
diagnostics output pins located on the front of the Drive Module.
Each Channel provides a programmable Analog Output Source.
Analog Output Source options are:
•
Velocity Command
•
Velocity Feedback
•
Torque Command (equates to Torque Command Actual parameter)
•
Torque Feedback
•
Following Error
Default Analog Output Source:
Channel
Output Source
Offset
Scale
1
Velocity Feedback
0
600 RPM/volt
2
Torque Command
0
30 percent/volt for selected motor
Each channel includes a programmable Analog Output Offset and an Analog Output Scale.
This feature allows you to “zoom in” to a desired range effectively increasing the resolution.
The units for both of these parameters is dependent upon the Analog Output Source selection.
Analog Output Offset units:
•
Velocity Command = RPM
•
Velocity Feedback = RPM
•
Torque Command = Percent of continuous torque for selected motor
•
Torque Feedback = Percent of continuous torque for selected motor
•
Following Error = Revs
Analog Output Scale units:
96
•
Velocity Command = RPM/volt
•
Velocity Feedback = RPM/volt
•
Torque Command = Percent of continuous torque/volt for selected motor
•
Torque Feedback = Percent of continuous torque/volt for selected motor
•
Following Error = Revs/volts
Operational Overview
Example:
You could use the Analog Outputs to accurately measure velocity overshoot. For example, to
measure a target velocity of 2000 RPM at a resolution of ±10 V = ±200 RPM do the
following.
1.
Selected Velocity Feedback for the Analog Output Source
2.
Set the Analog Output Offset to 2000 RPM
3.
Set the Analog Output Scale to 20 RPM/VOLT
This will provide an active range from ±10 Volts to represent 1800 to 2200 RPM. Therefore,
the measured resolution has been increased.
Drive Module Digital Inputs and Outputs
External control capability is provided through the use of input and output functions. These
functions may be assigned to any input or output line. After they are assigned to lines, external
controllers such as a PLC or multi-axis controllers, may be used to affect or monitor the Drive
Module operation.
Drive Modules are equipped with five optically isolated input lines (one dedicated to a Drive
Module Enable function) and three optically isolated output lines. All inputs and outputs are
compatible with sourcing signals (active = + voltage) and are designed to operate from a +10
to 30 VDC. You are responsible for limiting the output current to less than 150 mA for each
digital output.
These input and output lines can be accessed through the removable 10-pin I/O Connector,
and through the 44-pin Command Connector.
Note
See “Input/Output and Drive Module Enable Wiring”.
Input Function Active State
The active state of an input function can be programmed to be “Active Off” or “Active On”
using PowerTools FM. Making an input function “Active On” means that it will be active
when +10 to 30 VDC is applied to the input line it is assigned to and is inactive when no
voltage is applied to the line. Making an input function "Active Off" means that it will be
active when no voltage is applied to the input line and inactive while +10 to 30 VDC is being
applied.
You can also make an input function "Always Active", which means that it is active
regardless of whether or not it is assigned to an input line and, if you assign it to an input line,
97
Modular Drive System Reference Manual
it will be active whether or not voltage is applied to that line. This is useful for testing the
Drive Module operation before I/O wiring is complete.
Input Line Debounce Time
You can program a “Debounce Time” which means the line will need to be active for at least
the debounce time before it is recognized. This feature helps prevent false triggering in
applications with high ambient noise.
Figure 78:
Input Line Diagram
Output Line Active State
The default active state of an output line is "Active On". This means that the output line will
supply a voltage when the result of the OR’ed output function(s) assigned to that output line
is activated by the Drive Module.
Making an output line "Active Off" means that the line will be “Off” (not conducting) when
the result of the OR’ed output function(s) assigned to that output line is active, and will supply
a voltage when the output function is inactive.
Input Functions
Travel Limit + or The + and - Travel Limit input functions will stop motion in the direction indicated by the
input function using the Travel Limit Deceleration rate. This feature is active in all modes.
When an axis is stopped by a Travel Limit function, it will maintain position until it receives
a command that moves it in the opposite direction of the active Travel Limit.
For example, the + Travel Limit will stop motion only if the motor is moving + but allows motion to move off the limit switch. Conversely, the - Travel Limit will stop motion only if
the motor is moving - but allows + motion to move off the limit switch.
If both input functions are active at the same time, no motion in either direction will be
possible until at least one of the inputs is released.
98
Operational Overview
When either + or - Travel Limit input function is activated, a fault will be logged into the Fault
Log, and the Drive Module will display an “L” on the LED diagnostics display on the front
of the Drive Module. Once the axis is driven off the limit switch, the fault will be cleared and
the “L” will disappear.
If both Travel Limit input functions are activated simultaneously, the Drive Module will
respond as if the Stop input function has been activated and will use the Stop Deceleration
ramp.
Stop
The Stop input function, when activated, will cause motion to stop regardless of motor
direction or the operating mode. The Stop Deceleration Ramp defines the rate of velocity
change to zero speed.
Activating the Stop input function causes the Drive Module to change to Velocity mode.
Therefore, if you are operating in Torque mode, the Drive Module must be tuned to the load
to prevent instability when activating the Stop input function.
For example, if an application is operating in Torque mode at 1000 RPM, and the Stop input
function is activated with a Stop Deceleration Ramp of 500 ms/kRPM, the motor will
decelerate to a stop in 500 ms.
When the Stop input function is deactivated, the previous operating mode is restored
within 400 µs and the Drive Module and motor will respond immediately with no
ramping unless ramping is part of the selected mode.
Reset
This input is used to reset fault conditions and is logically OR’ed with the Reset button. A
rising edge pulse is required to reset faults.
Velocity Preset Lines 1, 2 and 3
The Velocity Preset Lines are used to select one of the eight pre-defined velocities using the
binary selection patterns shown below.
If you select a different Preset Velocity, the Drive Module will immediately ramp to the new
velocity using the new acceleration ramp without stopping.
Velocity Preset #3
Velocity Preset Line #2
Velocity Preset Line #1
Selected Velocity and Accel/
Decel Preset #
0
0
0
0
0
0
1
1
0
1
0
2
99
Modular Drive System Reference Manual
*
Velocity Preset #3
Velocity Preset Line #2
Velocity Preset Line #1
Selected Velocity and Accel/
Decel Preset #
0
1
1
3
1
0
0
4
1
0
1
5
1
1
0
6
1
1
1
7
(0) = Inactive input function
(1) = Active input function
Torque Limit Enable
This input function, when active, causes the Torque Command to be limited to the value of
the Torque Limit parameter. The Torque Limit can be made "Always Active" by checking the
Always Active checkbox on the Inputs tab.
Brake Release
This input function will release the brake under all conditions. If this input function is active,
the Brake output function is switched to active (i.e., release brake). This overrides all other
brake control, thus allowing the brake to be released while a fault is active or the power stage
is disabled.
Brake Control
This input function, when active, will engage the brake unless overridden by the Brake
Release input function. This input function lets you externally engage the brake, while
allowing the Drive Module to also control the brake during fault and disabled conditions.
Torque Mode Enable
This input function, when active, causes the Drive Module to change operating mode to
torque mode. When this input function is deactivated the default operating mode is enabled
with no transitional ramping.
Output Functions
Travel Limit + or These outputs are active when the associated Travel Limit input function are active.
100
Operational Overview
Brake
This output function is used to control the motor holding brake. If the Brake output is “Off”,
the brake is mechanically engaged.
Foldback Active
This output function is active when the Drive Module is limiting motor current. If the RMS
Foldback value exceeds 100 percent of the continuous rating, the current foldback algorithm
will limit the current delivered to the motor to 80 percent of the continuous rating.
Drive OK
This output function is active whenever no fault condition exists. Travel Limits and the Drive
Module Enable have no effect on this output function.
In Motion + or These output function is active whenever the motor is turning at a velocity greater than the In
Motion Velocity parameter in the + or - direction respectively. Default value of In Motion
Velocity is 10 RPM. Hysteresis is used to avoid a high frequency toggling of this output
function. This function is deactivated when the motor velocity is less than 1/2 of the In Motion
Velocity parameter.
Power Stage Enabled
This output is active when the Drive Module is OK and enabled. It will go inactive when
anything happens to disable the output power stage.
Fault
This output function is active whenever a Drive Module fault condition exists. The Travel
Limits will also cause this output function to be active.
At Velocity
This output function is active whenever the motor is at the desired velocity (i.e., acceleration
or deceleration is complete). This output is only associated with Velocity Preset Velocities.
Torque Limit Active
This output is active if the Torque Command exceeds the specified Torque Limit value. Refer
to Torque Limiting in the Operating Overview section of this manual.
101
Modular Drive System Reference Manual
Velocity Limiting Active
This output function is active when the Actual Velocity Command is being limited. The
velocity limit is dependent upon the maximum motor speed for the Motor Type selected.
If the Actual Velocity Command exceeds the velocity limit, the command will be limited and
the Velocity Limiting Active output function will be active.
Torque Level 1 and 2 Active
These outputs are active if the Torque Command exceeds the respective Torque level value.
Temperature Current Limit Active
The Temperature Current Limit Active Output will turn on when the measured heatsink
temperature is above 70° C. This output will limit the Drive Module Peak Current available to
170% of Continuous Current. This limitation only happens in the MD-410, MD-420 and MD434 Drive Modules. This Output will stay active until the heatsink has had time to cool down
to 60° C.
102
Modular Drive System Reference Manual
Options and Accessories
MDS Options
ECI-44 External Connector Interface
The ECI-44 allows access to all command and input and output signals. The ECI-44 should
be mounted close to the MDS and away from any high voltage wiring. The ECI-44 comes
complete with the hardware necessary for mounting to most DIN rail mounting tracks.
Figure 79:
Dimensions of ECI-44
Note
Shield connection points are connected to the shell of the 44-pin “D” connector on the
ECI-44.
Use tie wraps to provide a strain relief and a ground connection at the shield connection
points.
If you do not wish to use the DIN rail mounting hardware, the ECI-44 can be disassembled
and the mounting clips removed.
103
Modular Drive System Reference Manual
The ECI-44 wire range is #18 to 24 AWG stranded insulated wire.
Note
Wiring should be done with consideration for future troubleshooting and repair. All
wiring should be either color coded and/or tagged with industrial wire tabs. Low voltage
wiring should be routed away from high voltage wiring.
Figure 80:
104
ECI-44 Signal Connections
Options and Accessories
FM-2 Indexing Module
The FM-2 is a compact and rugged indexing module that attaches to the front of the MDS
drive module. It enables you to initiate up to 16 different indexes, jogging and a single home
routine. It also provides eight digital input lines and four digital output lines in addition to the
four input and three output lines available on the MDS drive module. The FM-2 is setup using
PowerTools FM software. PowerTools FM is an easy-to-use Microsoft® Windows®-based
setup and diagnostics tool.
Note
See the FM-2 Indexing Module Reference Manual, P/N 400507-01, for more information.
FM-3 Programming Module
The FM-3 is a compact and rugged programming module that attaches to the front of the MDS
Dive Module. They provides eight digital input lines and four digital output lines in addition
to the four input and three output lines available on the MDS Drive Module. The FM-3 offers
complex motion profiling, along with multi-tasking user programs. A complex motion profile
consists of two or more indexes that are executes in sequence such that the final velocity of
each index except the last is non-zero. Logical instructions between index statements can
provide a powerful tool for altering motion profiles "on the fly". The FM-3 is setup using
PowerTools PRO software. PowerTools PRO is an easy-to-use Microsoft® Windows®based setup and diagnostics tool.
Note
See the FM-3 Indexing Module Reference Manual, P/N 400508-01, the FM-3/4DN
Programming Module Reference Manual, 400508-03, and the FM-3/4PB Programming
Module Reference Manual, 400508-04, for more information.
FM-4 Programming Module
The FM-4 is a compact and rugged programming module that attaches to the front of the MDS
Drive Module. It provides eight digital input lines and four digital output lines in addition to
the four input and three output lines available on the MDS drive module. The FM-4 offers
complex motion profiling, along with multi-tasking user programs. A complex motion profile
consists of two or more indexes that are executes in sequence such that the final velocity of
each index except the last is non-zero. Logical instructions between index statements can
provide a powerful tool for altering motion profiles "on the fly". The FM-4 is setup using
PowerTools PRO software. PowerTools PRO is an easy-to-use Microsoft® Windows®based setup and diagnostics tool.
Note
See the FM-4 Indexing Module Reference Manual, P/N 400509-01, the FM-3/4DN
Programming Module Reference Manual, 400508-03, and the FM-3/4PB Programming
Module Reference Manual, 400508-04,for more information.
105
Modular Drive System Reference Manual
MS-510-00 and MS-530-00 Shunt Module
Ground
L1
3 Phase
Line
Power
AC Line
Filter
(Optional)
L2
L3
M
AC Mains
Contactor
AC Line
Fuses
System Ready
Shunt Active
Shunt Fault
Over Temp
High VAC Input
Drive Module Fault
AC Interlock
Ext Shunt Control
Fault Reset
Logic +24VDC
Power
24V rtn
PE
+24 VDC
User Supply
(+24 VDC +/- 10%)
I/O 10-30 VDC
+
-
24V RTN
SHUNT
+ 24VDC
B+
M
Figure 81:
MS-5XX-00 Shunt Module Wiring Diagram
The MS-5XX-00 has internal circuitry that will protect the shunt during overload conditions.
The circuitry will open the Shunt Interlock relay that is to be wired in series with the AC
mains contactor. See Figure 81.
106
Options and Accessories
The shunt module requires a user +24 VDC power supply. The current requirement is 250 mA
@ 24 VDC.
Diagnostic LEDs
Logic Power Overload Overtemp -
24VDC
Logic Power
+ -
AC Interlock
J1
Torque to
2-4 inch
Lbs
B+
Figure 82:
From MP
Shunt
MS-5XX-00 Shunt Module Diagnostic LED
The shunt module has three diagnostic LEDs, as follows:
Logic Power
The Logic Power LED will be illiminated when +24 VDC is applied.
Overtemp
The thermal overtemp will be illuminated when the RMS power rating of the resistor is
exceeded. This will cause the shunt relay to open.
Overload
The thermal overload will be illuminated if the continuous power rating of the resistor is
exceeded. This will cause the shunt’s AC Interlock relay to open. An overload condition is
caused be a very high current due to a miswiring or shunt transistor failure.
107
Modular Drive System Reference Manual
108
Modular Drive System Reference Manual
Quick Start
Offline Setup
Note
Generally, online setup is used when editing parameters in a drive. Offline setup editing
is usually only done when not connected to a drive.
EZ Setup View
The EZ Setup view is the default tab that is displayed each time you open the PowerTools
software. This tab allows you to set most of the parameters needed to configure your drive,
with the exception of the digital input and output functions.
Figure 83:
PowerTools Window, EZ Setup View, Offline
You can change the software so that the Detailed Setup tab becomes the default view.
Step 1: Changing the Default View
To select the default setup screen view (EZ Setup or Detailed Setup):
1.
Select “Preferences” from the Options menu.
2.
Select the “General” option from the menu.
3.
Click the “Default to Detailed View” check box to change view to Detailed Setup or
deselect to change view to EZ Setup.
4.
Click the OK button.
109
Modular Drive System Reference Manual
Figure 84:
PowerTools FM Window, Detailed Setup View, Offline
Detailed Setup View
The Detailed Setup view allows you to access many additional parameters and details about
your drive. When you are online with a drive, PowerTools FM will display twelve tabs if you
have selected to view the Advanced tab in the Options/Preferences/General dialog box.
Figure 85:
110
PowerTools FM Window, Detailed Setup View, Online
Quick Start
Step 2: Opening an Offline Configuration Window
To open an offline Configuration Window, click the New icon from the toolbar or select New
from the File menu.
Figure 86:
New Dialog Box
When the Predefined Setup Selection dialog box appears, select the desired predefined setup
and press the OK button. A new Configuration Window will be displayed.
All drive setup parameters are accessible in the tabs of the offline configuration window.
You can now proceed to setup the drive parameters as desired.
Step 3: Entering General Drive Setup Information
The EZ Setup tab contains system data such as drive type, motor type and axis name.
Figure 87:
Offline EZ Setup Tab
Identification Group:
1.
Enter an identifying name in the “Name” box for the drive you are setting up. You can
use up to 24 alpha-numeric characters.
111
Modular Drive System Reference Manual
2.
Enter the “Target Drive Address(es)” to which you wish to download the setup
information. Unless you have changed the Modbus address of your drive, leave this
parameter set to the default value of 1.
You may use commas (,) or spaces ( ) to separate individual drive addresses or you may
use hyphens (-) to include all the drive addresses within a range. For example, if you
wanted to download to drives 1, 3, 4, 5, 6, 7 and 9 you could enter the addresses like this:
1,3-7,9.
Configuration Group:
EZ Setup view, drive type and motor type are available. Detail Setup view, drive type and line
voltage are available. Motor type is selected using the Motor tab.
1.
Click the down arrow of the “Drive Type” list box, then select the drive model for the
drive you are currently setting up.
2.
Click the down arrow of the “Motor Type” list box, then select the motor connected to
the drive you are setting up. PowerTools FM will only display the motor models that are
compatible with the “Drive Type” you selected.
Positive Direction Selections:
In Detail Setup view, click which direction, clockwise (CW) or counterclockwise (CCW), is
to be considered as motion in the positive direction.
Note
CW and CCW rotation is determined by viewing the motor from the shaft end.
CW Rotation (+)
Figure 88:
Clockwise Motor Rotation
Step 4: Selecting an Operating Mode
Depending on the mode you select, PowerTools FM software will display related submodes
and/or additional parameters that pertain to the main operating mode you selected.
Pulse Mode Setup
This procedure assumes that you have connected the proper pulse mode wiring as described
in the "Installation" section of this manual.
112
Quick Start
1.
Select the “Pulse Mode” radio button from the Operating Mode group.
Figure 89:
Operating Mode View
2.
Select one of the Interpretation group radio buttons; “Pulse/Pulse”, “Pulse/Direction” or
“Pulse/Quadrature”.
3.
Select Differential or Single Ended from the Source group.
4.
Enter a “Ratio”. The default is 1 output motor revolution to 8192 input pulse counts. This
can be a signed (+/-) number.
Note
The coarsest ratio possible is 10 input counts per motor revolution. Settings below this
will cause an overspeed fault.
5.
If needed, enable the “Following Error Limit” by checking the “Enable” check box.
6.
Enter a value between 0.0010 and 10.000 revolutions of the motor.
Velocity Mode Setup
The following Velocity mode setup procedures assume that you have connected the proper
analog command wiring as described in the “ Installation” section of this manual.
Velocity Analog Submode Setup
1.
Select the “Velocity Mode” radio button from the Operating Mode group.
2.
Select the “Analog” submode radio button from the Submode group.
Figure 90:
Operating Mode, Velocity Mode Selected
113
Modular Drive System Reference Manual
3.
Enter a “Full Scale Velocity” value. The velocity is equal to the Analog Full Scale
parameter which is defaulted to a 10V analog command.
Velocity Presets Submode Setup
1.
Select the “Velocity Mode” radio button from the Operating Mode group.
2.
Select the “Presets” submode radio button from the Submode group.
Figure 91:
Velocity Submode, Velocity Presets
3.
Select the desired “Velocity Preset” number.
4.
Enter a "Velocity Preset" for each "Preset Number" being used.
5.
Enter an “Accel/Decel Presets” value for each "Preset Number" being used.
6.
Click on the Inputs tab. Assign the “Velocity Preset Line #1” and “Velocity Preset Line
#2” functions to input lines by highlighting the function then selecting one of the “Input
Line Selection” radio buttons or by dragging the highlighted preset to the desired input
lines.
7.
The Velocity Preset Input functions can be made Always Active or Active Off by using
the respective check box.
Velocity Summation Submode Setup
114
1.
Select the “Velocity Mode” radio button from the Operating Mode group.
2.
Select the “Summation” submode radio button from the Submode group.
3.
Select the desired “Velocity Preset” number.
4.
Enter a "Velocity Preset" for each "Preset Number" being used.
5.
Enter an “Accel/Decel Presets” value for each "Preset Number" being used
Quick Start
.
Figure 92:
Velocity Summation Submode
Torque Mode Setup
This procedure assumes that you have connected the proper analog command wiring as
described in the "Installation" section of this manual.
1.
Select the “Torque Mode” radio button from the Operating Mode group.
Figure 93:
2.
Operating Mode, Torque Mode Selected
Enter a “Full Scale Torque” value. This "Full Scale Torque" value corresponds to an
Analog Full Scale parameter, which is defaulted to a 10V analog command.
Torque Limit Setup
This function can be active in any Operating Mode.
1.
Enter a "Torque Limit" value. The "Torque Limit" is the value at which the Torque
Command will be limited when the "Torque Limit Enable" input function is active.
2.
Click on the Inputs tab. Assign the "Torque Limit Enable" input function to an input line
by highlighting the function, then selecting one of the "Input Line Selection" radio
buttons or by dragging the highlighted input function to the desired input line.
Torque Level 1 and 2 Setup
This function can be active in any Operating Mode.
1.
Click on the Outputs tab.
2.
Highlight the “Torque Level 1 Active or Torque Level 2 Active” output function in the
“Output Functions” window.
115
Modular Drive System Reference Manual
3.
Select an Output Line radio button that corresponds to the output line you wish to assign
this function.
4.
In Detailed Setup view, click on the Torque tab.
5.
Enter a value into the Torque Level 1 and/or Torque Level 2. The Torque Levels
correspond to the Analog Full Scale parameter, which is defaulted to a 10V analog
command.
Figure 94:
Torque Tab
Step 5: Entering Load Parameters
In Detailed Setup view select the Motor tab otherwise the EZ Setup tab can be used. The load
on the motor is specified by the Inertia Ratio and Friction parameters. Application
requirements are specified by the Response adjustment. If more accurate tuning is required,
see the “Tuning Procedures” section.
Note
Also, refer to the Enable High Performance Gains and Feedforward Gains features.
Inertia Ratio
Inertia Ratio specifies the load to rotor inertia ratio and has a range of 0.0 to 50.0. A value of
1.0 specifies that load inertia equals the rotor inertia (1:1 load to motor inertia). The drives
can control up to a 10:1 inertia mismatch with the default Inertia value of 0.0. Inertial Ratio
mismatches of over 50:1 are possible with some minimal additional adjustments.
116
Quick Start
Note
If the exact inertia value is unknown, the value that is entered should be conservative,
because values higher than the actual can cause the motor to oscillate.
Friction
This parameter specifies the viscous friction component of the load and has a range of 0.0 to
100.0. The units are percent continuous torque increase per 100 RPM. This value is used to
tune the velocity and position loops, including feedforward compensation (if enabled). A
typical value would be between 0.0 and 1.0.
Note
If the value is unknown, use a conservative value or a zero value.
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hertz. In general,
it affects how quickly the drive will respond to commands, load disturbances and velocity
corrections. The effect of Response is greatly influenced by the status of the High
Performance Gains. With High Performance Gains enabled, the maximum value
recommended is 100 Hz.
Step 6: Assigning Inputs
Inputs are assigned in the Inputs tab which is divided into two windows. The "Input
Functions" window, on the left side, displays the input functions available, the function
polarity and the always active state. The "Input Lines" window, on the right side, displays the
four input lines, the debounce value and input function assignments.
117
Modular Drive System Reference Manual
Figure 95:
Inputs Tab
To assign an Input Function to an Input line:
1.
Assign an input by highlighting an input function in the "Input Functions" window and
selecting the desired input radio button or by dragging the highlighted input function to
the desired input in the "Input Lines" window.
2.
To unassign an input function from an input line, select the desired input function from
the “Input Functions” window, then select the “Unassigned” radio button or by dragging
the highlighted input assignment back to the "Input Functions" window.
To make an Input Function “Active Off”:
1.
Select the desired input function in the “Input Functions” window
2.
Click the “Active Off” check box. The Active State column in the "Input Functions"
window will automatically update to the current setup.
To make an Input Function “Always Active”:
1.
Select the desired input function in the “Input Functions” window.
2.
Click the “Always Active” check box. The Active State column in the "Input Functions"
window will automatically update to the current setup.
Step 7: Assigning Outputs
Output functions are assigned in the Outputs tab which is divided into two windows. The
“Output Functions” window, on the left side, displays the output functions available. The
118
Quick Start
“Output Lines” window, on the right side, displays the three output lines, the line active state
and the output function assignments.
Figure 96:
Outputs Tab
To assign an Output Function to an Output Line:
1.
Assign an output by highlighting an output function in the "Output Functions" window
and selecting the desired output radio button or by dragging the highlighted output
function to the desired output in the "Output Lines" window.
2.
To unassign an output function from an output line, select the desired output function
from the “Output Functions” window, then select the “Unassigned” radio button or by
dragging the highlighted output assignment back to the "Output Functions" window.
To make an Output Function “Active Off”:
1.
Select the desired output function in the “Output Lines” window.
2.
Click the “Active Off” check box. The Active State column in the "Output Lines"
window will automatically update to the current setup.
Online Setup
If you have previously created a configuration file, go to Step 3. If you do not have one done,
go to Offline Setup Step 1. Do Steps 1 through 9 in the previous section, "Offline Setup",
before establishing communications.
119
Modular Drive System Reference Manual
Note
Generally, online setup is used when editing parameters in a drive. Offline setup editing
is usually only done when not connected to a drive.
Step 1: Establishing Communications with Drive
Now that the basic MDS drive setup parameters are entered, it is time to establish
communications with the Drive Module and download the configuration data. Before
proceeding, be sure to connect the serial communication cable between your PC and the Drive
Module.
The first step in establishing serial communications is to select the Com port and the baud rate
using the procedure below:
1.
Clicking on the Options menu.
2.
Select the "Preferences\Communications" option. The Modbus Setup dialog box will be
displayed.
Figure 97:
3.
Select the “Configure Serial Port” button. The Communications Setup dialog box below
will be displayed.
Figure 98:
4.
120
Modbus Setup Dialog Box
Communications Setup Dialog Box
Select the Com port you will be using on your PC and baud rate.
Quick Start
5.
Click the OK button.
6.
Click the OK button in the Modbus Setup dialog box.
Note
The default baud rate for all drives is 19200.
Step 2: Downloading the Configuration File
When you are ready to download the information in the current Configuration Window, go to
the Setup tab and enter the address(es) of the drive(s) you wish to download to in the “Target
Drive Address(es)” text box.
You may use commas (,) or spaces ( ) to separate individual drive addresses or you may use
hyphens (-) to include all the drive addresses within a range. For example, if you wanted to
download to drives 1, 3, 4, 5, 6, 7 and 9 you could enter the addresses like this: 1,3-7,9.
Note
To download to more than one drive, all drive models and motor models must be the same
and any FM modules attached to the MDS Drive Modules must all be of the same model
and firmware revision.
Click the Download button at the bottom of the Configuration Window (or click the
Download icon in the toolbar).
PowerTools FM will establish communications and transfer all the information in the current
Configuration Window to the drive(s) you select in the Download window.
Note
Downloading will automatically clear an Invalid Configuration fault (“U” fault).
Step 3: Opening an Online Configuration Window
If you are not already online with the drive, use this section to upload a configuration for
online editing.
To open an online Configuration Window, click the Upload icon on the toolbar. PowerTools
FM will display the Scanning dialog box while it scans your PC’s serial ports for any
compatible devices.
Next, the Upload Drive Configuration dialog box is displayed. This dialog box allows you to
select the device(s) you wish to upload into a Configuration Window.
121
Modular Drive System Reference Manual
Figure 99:
Upload Configuration Dialog Box
Selected Drives Radio Button
If you have only one device connected, that device’s address will be displayed in the Selected
drives data box. If you have more than one device connected in a multi-drop configuration,
the Selected drives data box will be empty. You can then select either the All drives radio
button or the Show drives button.
All Drives Radio Button
If you select the All drives radio button, PowerTools FM will open a Configuration Window
for each device connected to your PC.
Show drives . . . Button
The Show drives button will display the Available Devices dialog box. This dialog box
displays a list of the devices that are attached to your system (or network). This includes both
Control Techniques and non-Control Techniques devices. Devices which are not serviceable
by PowerTools FM software will be grayed.
Figure 100:
Available Devices Dialog Box
From this dialog box select the device(s) you wish to upload into a Configuration Window.
You can only select non-grayed items. The list box is updated at regular intervals. Please
122
Quick Start
allow time when connecting and disconnecting devices to the system. Click the OK button to
begin the upload.
Step 4: Operation Verification
After downloading a configuration file to the drive, you may want to verify the operation of
the system using the checklist below.
1.
I/O powered.
2.
Connections installed.
3.
The drive enabled.
4.
The characters “V, T, P or +” displays verified on the drive "LED" status display with
the decimal point "On".
Step 5: Saving the Configuration File
To save the drive setup information, select Save from the File menu. Follow the dialog box
instructions.
Step 6: Printing the Configuration File
To generate a printed copy of all the data in the drive configuration, select Print from the File
menu. If you print while online, the print-out will include several pages of useful online
diagnostic information.
Step 7: Disconnecting Communications
After you successfully download to the drive, you may want to disconnect the serial
communications link between the drive and your PC to clear the serial port or to access some
PowerTools FM options only available when offline.
To disconnect serial communications, click the Disconnect button at the bottom of the
Configuration Window (or select the Disconnect command from the Device menu).
123
Modular Drive System Reference Manual
124
Modular Drive System Reference Manual
Setting Up Parameters
EZ Setup/Detailed Setup Tab
This is the default tab that is displayed each time you open a Configuration Window.
Figure 101:
Default Offline EZ Setup Tab
Identification Group
Name
Enter a 24 character alpha-numeric name for the drive you are currently setting up. Assigning
a unique name for each drive in your system allows you to quickly identify a drive when
downloading, editing and troubleshooting. All keyboard characters are valid.
Target Drive Address(es)
Enter the “Target Drive Address(es)” you wish to download/upload the setup information to/
from.
To download to multiple drives simultaneously, separate the device addresses with commas,
spaces or hyphens. Commas and spaces separate individual addresses. Hyphens indicate to
include all address, between the indicated addresses, (i.e., 1, 3, 7) means download to
addresses 1 and 3 and 7 only. (1 - 7) indicates, download to addresses 1, 2, 3, 4, 5, 6, 7. If you
download to more than one device simultaneously, they must all be the same drive and any
125
Modular Drive System Reference Manual
FM modules attached to MDS Drive Modules must all be of the same model and firmware
revision.
Configuration Group (EZ Setup view only)
Drive Type
Select the drive model for the system you are currently setting up. PowerTools FM software
will only display the motor models that are compatible with the drive you selected and any
User Defined Motors. For User Defined Motors See “User Defined Motors” on page 189.
Motor Type
Select the motor you wish to use. PowerTools FM software will only display the motor
models that are compatible with the drive you selected and any User Defined Motors.
Selecting the wrong motor type can cause poor performance and may even damage the
motor and/or drive.
ConfigurationMD Group (Detailed Setup view only)
Figure 102:
126
Detailed Setup Window for an MDS.
Setting Up Parameters
Drive Type
Select the drive model for the system you are currently setting up. PowerTools FM software
will only display the motor models that are compatible with the drive you selected and any
User Defined Motors. For User Defined Motors See “User Defined Motors” on page 189.
Switching Frequency
This parameter is used to select the Drive Module switching frequency. There are two
switching frequencies, 5 KHz (default) and 10 KHz. When using 10KHz the Drive Module
current rating will be derated.
Load Group
This is found on the EZ Setup tab in EZ Setup view or on the Motor tab in Detailed Setup
view.
Inertia Ratio
Inertia Ratio specifies the load to rotor inertia ratio and has a range of 0.0 to 50.0. If the exact
inertia is unknown, a conservative approximate value should be used. If you enter an inertia
value higher than the actual inertia, the resultant motor response will tend to be more
oscillatory.
Friction
This parameter is characterized in terms of the rate of friction increase per 100 motor RPM.
If estimated, always use a conservative (less than or equal to actual) estimate. If the friction
is completely unknown, a value of zero should be used. A typical value used here is less than
one percent.
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hz. In general, it
affects how quickly the drive will respond to commands, load disturbances and velocity
corrections. A good value to start with (the default) is 50 Hz. The effect of Response in greatly
influenced by High Performance Gain settings. With High performance Gains enabled, the
maximum value recommended is 100 Hz.
127
Modular Drive System Reference Manual
Operating Mode Group
Disabled Radio Button
Selecting this radio button to put the drive in the Disabled Mode. This is equivalent to
removing the Drive Enable input. In Disabled the Drive Module can be configures or
diagnosed and the I/O will function.
Figure 103:
Operating Mode, Disabled Mode Selected
Pulse Mode Radio Button
Selecting this radio button puts your drive into Pulse mode and displays three Interpretations:
Pulse/Pulse, Pulse/Direction and Pulse/Quadrature. In Pulse mode the drive will receive
pulses which are used to control the position and velocity of a move.
Velocity Mode Radio Button
Selecting this radio button puts your drive into Velocity mode which includes three
Submodes: Analog, Presets and Summation.
Torque Mode Radio Button
Selecting this radio button will put your drive in Torque mode and activates the Full Scale
Torque and the Torque Limit data entry boxes. In Torque mode the drive develops torque in
proportion to the voltage received on the Analog Input. The Analog Input is scaled to the
Analog Torque Command by the Full Scale Torque, Analog Input Full Scale and Analog
Input Zero Offset parameters.
Pulse Mode Interpretation Group
Figure 104:
128
Operating Mode, Pulse Mode Selected
Setting Up Parameters
Interpretation Group
Pulse/Pulse Radio Button
Selecting this radio button puts your drive in Pulse/Pulse interpretation. In Pulse/Pulse mode,
pulses received on the A channel are interpreted as positive changes to the Pulse Position
Input, and pulses received on the B channel are interpreted as negative changes to the Pulse
Position Input.
Pulse/Direction Radio Button
Selecting this radio button puts your drive in Pulse/Direction interpretation. In Pulse
Direction mode, pulses are received on the A channel, and the direction is received on the B
channel. If the B is high, pulses received on the A are interpreted as positive changes to the
Pulse Position Input. If the B is low, pulses received on the A are interpreted as negative
changes to the Pulse Position Input.
Pulse/Quadrature Radio Button
Selecting this radio button puts your drive in Pulse/Quadrature interpretation. If Pulse
Quadrature is selected, a full quadrature encoder signal is used as the command. When B
leads A encoder counts received are interpreted positive changes to the Pulse Position Input.
When A leads B encoder counts received are interpreted as negative changes to the Pulse
Position Input. All edges of A and B are counted, therefore one revolution of a 2048 line
encoder will produce a 8192 count change on the Pulse Position Input.
Source Group
The Drive Module is able to accept Differential or Single Ended signals in Pulse Mode. The
hardware connections are on separate pins and thus the Drive Module must be configured to
select the appropriate source.
Differential Radio Button
Selects the differential hardware input of the drive to receive pulses (default) these pulse
inputs are as follows:
ECI-44 Terminal
Command
Connector Pin #
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
Sync Enc In “A”
27
Pulse
Pulse +
A
Sync Enc In “A/”
41
Pulse/
Pulse +/
A/
Sync Enc In “B”
26
Direction
Pulse -
B
Sync Enc In “B/”
40
Direction/
Pulse -/
B/
Differential Inputs are typically needed for pulse rate 7250 kHz or high ambient noise
environments.
129
Modular Drive System Reference Manual
Single Ended Radio Button
Selects the single ended hardware input of the drive to receive pulses (default) these pulse
inputs are as follows:
ECI-44 Terminal
Command
Connector Pin #
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
A or NC2
B or NC1
20
Pulse /
Pulse + /
A
36
Direction
Pulse - /
B
Ratio Formula
Defines the number of command pulses it will take to move the motor the distance specified
in the Pulse Mode Ratio Revolutions. The default value is 1 motor revolution per 8192 counts.
The coarsest ratio possible is 10 input counts per motor revolution. Setting a ratio to fewer
than 10 input counts per motor revolution will cause an Overspeed fault without generating
motion.
Following Error Limit Group
Enable Check Box
Check this box to enable or disable the Following Error Limit. The Following Error is the
algebraic difference between the Position Command and the Position Feedback. It is positive
when the Position Command is greater than the Position Feedback. If the absolute value of
the following error exceeds the value you enter here, the drive will generate a Following Error
fault. All accumulated Following Error will be cleared when the drive is disabled.
Following Error Limit
The Following Error Limit is functional in Pulse mode only. This limit is in motor revolutions
and has a range of .001 to 10.000 revolutions.
Velocity Mode Submode Group
Analog Radio Button
Selecting this radio button puts the drive into Analog submode. In Velocity mode the drive
develops velocity in proportion to the voltage received on the Analog Input. The Analog Input
is scaled to the Analog Velocity Command by the Full Scale Velocity, Analog Input Full
Scale, and Analog Input Zero Offset parameters.
For example:
130
Setting Up Parameters
+5V = 2000 RPM CW
-5V = 2000 RPM CCW
Analog Input Full Scale = 10V
Full Scale Velocity = 4000 RPM
Figure 105:
Operating Mode, Velocity Mode Selected
Full Scale Velocity
This parameter is the maximum motor velocity (in RPM) desired when the drive receives an
analog voltage equal to the Analog Input Full Scale parameter setting.
Note
Full Scale Velocity and Analog Input Full Scale do not set limits. They only set the
proportion of motor speed to Analog Input Voltage.
The Full Scale Velocity and Analog Input Full Scale parameters are used in the Analog or
Summation operating modes.
Default values:
Motor Selection
Full Scale Velocity @ Analog Input Full Scale
HT-320, HT-330
5000 RPM @ 10V
HT-345, HT-355
4000 RPM @ 10V
MH-455, MH-490, MH-4120
3000 RPM @ 10V
MH-8350, MH- 8550, MH-8750
3000 RPM @ 10V
95UWB, 95UMD, 115UMB, 115UMD, 142UMB,
142UMD, 190UMA, 190UMB, 190UMC
3000 RPM @ 10V
Presets Radio Button
Selecting this radio button puts the drive into Presets submode. Presets submode provides up
to eight digital Velocity Presets and associated Accel/Decel Presets. At any time, only one
Velocity Preset can be selected. They are selected using the Velocity Preset 1, the Velocity
Preset 2 and the Velocity Preset 3 input functions.
131
Modular Drive System Reference Manual
Figure 106:
Velocity Presets
Velocity Presets
Enter a value for each of the Velocity Presets you wish to use. The units are RPM and the
range is from ± maximum motor velocity. A positive value will cause CW motion and a
negative value will cause CCW motion. (Motor direction is determined as you face the shaft
end of the motor).
Accel/Decel Presets
Enter an Accel/Decel Presets value for each of the velocity presets you are using. The units
are milliseconds per 1000 RPM and the range is from 0 to 32700.0. Default is 1000 ms/kRPM.
Summation Radio Button
Selecting this radio button puts the drive into Summation submode. Summation Velocity
operating mode is defined as the summation of the Velocity Command Analog and the
Velocity Command Preset to produce the Velocity Command.
Figure 107:
Full Scale Velocity
Velocity Presets
Enter a value for each of the Velocity Presets you wish to use. The units are RPM and the
range is from ± maximum motor velocity. A positive value will cause CW motion and a
negative value will cause CCW motion. (Motor direction is determined as you face the shaft
end of the motor).
132
Setting Up Parameters
Accel/Decel Presets
Enter an Accel/Decel Presets value for each of the Velocity Presets you are using. The units
are milliseconds per 1000 RPM and the range is from 0 to 32700.0. Default is 1000 ms/kRPM.
Full Scale Velocity
This parameter is the motor velocity (in RPM) desired when the drive receives an analog
voltage equal to the Analog Input Full Scale parameter setting.
Note
Full Scale Velocity and Analog Input Full Scale do not set limits. They only set the
proportion of motor speed to Analog Input Voltage.
The Full Scale Velocity and Analog Input Full Scale parameters are used in the Analog or
Summation operating modes.
Default values:
Motor Selection
Full Scale Velocity @ Analog Input Full Scale
HT-320, HT-330
5000 RPM @ 10V
HT-345, HT-355
4000 RPM @ 10V
MH-455, MH-490, MH-4120
3000 RPM @ 10V
MH-8350, MH- 8550, MH-8750
3000 RPM @ 10V
95UWB, 95UMD, 115UMB, 115UMD, 142UMB,
142UMD, 190UMA, 190UMB, 190UMC
3000 RPM @ 10V
Torque Mode Group
Selecting this radio button will put your drive in Torque mode and activates the Full Scale
Torque and the Torque Limit data entry boxes. In Torque mode the drive develops torque in
proportion to the voltage received on the Analog Input. The Analog Input is scaled to the
Analog Torque Command by the Full Scale Torque, Analog Input Full Scale and Analog
Input Zero Offset parameters.
For example:
5V = Motor continuous torque
10V = Motor peak torque (2 times continuous)
+10V = Peak motor torque CW
-10V = Peak motor torque CCW
133
Modular Drive System Reference Manual
Figure 108:
Operating Mode, Torque Mode Selected
Full Scale Torque
This parameter specifies the Torque Command when the Analog Input voltage is equal to the
Analog Full Scale parameter.
Torque Limit
This value is the level which the Torque Command will be limited to when the Torque Limit
input function is active. To make the Torque Limit always active, set the Torque Limit Input
Function to be Always Active.
Peak Torque Available
This displays the maximum torque available from the selected drive and motor combination.
This is calculated by PowerTools FM and is not a drive parameter.
Positive Direction Group (Detailed Setup view only)
Figure 109:
Positive Direction in Detailed Setup View
CW Motor Rotation Radio Button
This defines that the motor will rotate clockwise when given a positive velocity, torque or
position command. CW/CCW is defined when facing the motor output shaft.
CW Rotation (+)
Figure 110:
134
CW Motor Rotation
Setting Up Parameters
CCW Motor Rotation Radio Button
This defines that the motor will rotate counterclockwise when given a positive velocity,
torque or position command. CW/CCW is defined when facing the motor output shaft.
Inputs Tab
This tab is divided into two windows: The “Input Functions” window, on the left side,
displays the input functions available, the function polarity and the always active state. The
“Input Lines” window, on the right side, displays the four input lines, the debounce value and
input function assignments.
Figure 111:
Inputs Tab
Input Functions Window
This window allows you to select the input function you wish to assign to an input line.
Active State
The active state of each input function is displayed next to the output function. See the
"Active Off" check box section on the following page.
Always Active
The setting for Always Active is displayed next to each input function. See "Always Active"
check box section on the following page.
135
Modular Drive System Reference Manual
Input Line Selection List Box
This list box allows you to assign or unassign a highlighted Input Function to an Input Line.
Click on the list box arrow to see the Input lines. Then click on the line numbers to assign the
function. Assigning the input functions can also be accomplished by dragging the Input
Function over and dropping it onto an Input line. To unassign an input function, highlight the
function in the Input Lines window and press the delete key or drag the input function from
the Input Lines window back to the Input Functions window .
Figure 112:
Input Line Selection View
Active Off Check Box
This check box allows you to change the “Active On/Off” state. Select the desired function
in the input functions window, then check or uncheck the “Active Off” checkbox.
Making an input function “Active On” means that it will be active when +10 to 30 VDC is
applied to the input line it’s assigned to and is inactive when no voltage is applied to the line.
Making an input function "Active Off" means that it will be active when no voltage is applied
to the input line and inactive while +10 to 30 VDC is being applied.
Always Active Check Box
This check box is used to make an input function “Always Active”. When you make an input
function always active, it’s active whether assigned to an input line or not. If you make an
input function “Always Active” then assign it to an input line, that function will be active
whether or not voltage is applied to the line it is assigned to.
Input Lines Window
Debounce
The debounce value is displayed next to each input line. See “Debounce” below.
Functions assigned ...
This feature displays the Input Function assigned to each particular Input Line.
Debounce
This feature helps prevent false input triggering in noisy electrical environments. Enter a
“Debounce Time” in milliseconds. The value entered here is the minimum amount of time the
input line will need to be active before it is recognized as a valid input.
136
Setting Up Parameters
Outputs Tab
This tab is divided into two windows: The “Output Functions” window, on the left side,
displays the available output functions. The “Output Lines” window, on the right side,
displays the output lines, the line active state and the output function assignments.
Figure 113:
Outputs Tab
Output Functions Window
This window allows you to select the output function you wish to assign to an output line.
Output Line Selection List Box
This list box allows you to assign or unassign the currently highlighted Output Function to an
Output Line. Click on the list box arrow to see the possible assignment lines. Then click on
one of the line numbers to assign the function. This list box would normally be used when a
mouse is not available to navigate the software. Assigning the input functions can also be
accomplished by dragging the Output Function and dropping it onto an Output line. To
unassign an output function, highlight the function in the Output Lines window and press the
delete key or drag the output function from the Output Lines window back to the Output
Functions Window.
137
Modular Drive System Reference Manual
Output Lines Window
Active State
The setting for “Active State” is displayed next to each output function. See “Active Off”
check box below.
Functions Assigned ...
This feature displays the Output Function assigned to each particular Output Line.
Active Off Check Box
The default active state of an output line is "Active On". This means that the output line will
supply a voltage when the result of the logical OR of the output function(s) assigned to that
output line is active.
Making an output line "Active Off" means that the line will be “Off” (not conducting) when
the result of the logical OR of the output function(s) assigned to that output line is active, and
will supply a voltage when the logical OR of the output function(s) is not active.
138
Setting Up Parameters
Position Tab (Detailed Setup view only)
This tab is only definable in Pulse mode and allows you to enable and define the Following
Error Limit and if you are on line, view actual operating parameters.
Figure 114:
Position Tab
Limits Group
Enable Following Error Limit Check Box
Check this box to enable or disable the Following Error Limit.
Following Error Limit
This parameter only has an effect in Pulse mode. The Following Error is the difference
between the Position Command and the Position Feedback. It is positive when the Position
Command is greater than the Position Feedback. If the absolute value of the following error
exceeds the value you enter here, the drive will generate a Following Error Fault (F). All
accumulated Following Error will be cleared when the drive is disabled.
The Following Error Limit is in motor revolutions and has a range of .001 to 10.000
revolutions.
139
Modular Drive System Reference Manual
Actual Group
Pulse Position Input
This parameter returns the total number of actual pulses received on the pulse input hardware.
This value is active in all operating modes.
Position Command
This is the commanded position generated by either the pulse command or velocity command.
In Pulse Summation mode, it is the sum total position command by both pulse and velocity
commands.
Following Error
The Following Error is the difference between the Position Command and the Position
Feedback. It is positive when the Position Command is greater than the Position Feedback.
Encoder Feedback
The motor position in encoder counts since power-up when the value was set to zero. This is
a signed 32 bit value. The motor position in encoder counts since power-up when the value
was set to zero. This parameter can be rewritten anytime after power-up.
Position Feedback
This is the feedback position of the motor. This parameter displays the motor position in
revolutions and fractions since this parameter was set to zero since power-up.
140
Setting Up Parameters
Velocity Tab (Detailed Setup view only)
This tab allows you to set the drive limits, and if you are online, view the actual operating
velocity feedback parameters.
Figure 115:
Velocity Tab
Limits Group
Stop Deceleration
The value you enter here defines the rate of velocity change to zero speed when a Stop input
function is activated.
The units are ms/kRPM and the range is from 0 to 32700.0. The default is 100 ms/kRPM.
Travel Limit Deceleration
The value you enter here defines the rate of velocity change to zero speed when a Travel Limit
input function is activated.
The units are ms/kRPM and the range is from 1.0 to 5000.0. Default is 100 ms/kRPM.
141
Modular Drive System Reference Manual
Analog Accel/Decel Limit
This parameter determines the maximum accel and decel rate that will be allowed when using
the Analog input in Analog Velocity mode. It does not affect the Stop decel or Travel limit
decel rates.
Overspeed Velocity
This parameter specifies the maximum allowable speed. If the Velocity Feedback exceeds
either the drive’s internal overspeed fault limit or the value of the Overspeed Velocity which
is lower, an Overspeed fault will be generated. The internal overspeed fault limit is equal to
150 percent of the Motor Maximum Operating Speed.
Max Motor Speed
Displays the maximum rated motor speed for the selected motor as defined by the motor
specification file. For the User Defined Motors this is defined in the MOTOR.DDF file.
Trigger Group
In Motion Velocity
This parameter sets the activation point for both the In + Motion and In - Motion output
functions. The output function will deactivate when the motor velocity slows to half of this
value. The default is 10 RPMs.
Actual Group
Preset Command
Preset Velocity Command is based on the velocity preset selected. Units are in RPMs.
Analog Command
Analog command voltage currently being applied to the analog command input on the
command connector. Units are in RPMs.
Velocity Command
The Velocity Command is the actual command received by the velocity loop. Units are in
RPMs.
142
Setting Up Parameters
Velocity Feedback
This parameter is the actual motor velocity feedback in RPMs.
Velocity Presets
Enter a value for each of the Velocity Presets you wish to use. The units are RPM and the
range is from ± maximum motor velocity. A positive value will cause CW motion and a
negative value will cause CCW motion. (Motor direction is determined as you face the shaft
end of the motor).
Accel/Decel Presets
Enter an Accel/Decel Presets value for each of the velocity presets you are using. The units
are milliseconds per 1000 RPM and the range is from 0 to 32700.0. Default is 1000 ms/kRPM.
Torque Tab (Detailed Setup view only)
This tab allows you to edit the Torque Limit and view the following torque parameters. These
parameters are continuously updated when you are online with the drive.
Figure 116:
Torque Tab
143
Modular Drive System Reference Manual
Note
The Torque Limit value takes effect only when the Torque Limit Enable input function is
active.
Actual Group
Torque Command
This parameter returns the torque command value before it is limited. The Torque Command
may be limited by either the Torque Limit (if the Torque Limit Enable input function is
active) or current foldback.
Torque Limit
This value is the level which the Torque Command will be limited to when the Torque Limit
input function is active. To make the Torque Limit always active, set the Torque Limit Input
Function to be "Always Active".
Peak Torque Available
This displays the maximum torque available from the selected drive and motor combination.
This is calculated by PowerTools FM and is not a drive parameter.
Actual Torque Command
Displays the Torque command after all limiting. This command is used by the current loop to
generate motor torque.
Foldback RMS
This parameter accurately models the thermal heating and cooling of the drive and motor.
When it reaches 100 percent, current foldback will be activated.
Torque Level 1 and 2
This parameter sets the activation level for the appropriate Torque Level output function.
Motor Tab (Detailed Setup view only)
This tab allows you to select the motor to be used with the current drive (only when offline
with the drive). Standard or user-defined motors (available in the MOTOR.DDF file) are
allowed selections. The drive selected will affect the standard motor options but the user-
144
Setting Up Parameters
defined motors are always available. All other parameters on the Motor tab are related to the
load on the motor and application requirements.
Note
If you are online with the drive, the Motor Type will be grayed.
All parameters on the Motor tab are related to the load on the motor and application
requirements.
The load on the motor is specified by two parameters: Inertia Ratio and Friction. Typical
application requirements are specified by the response adjustment and Feedforward Gains.
Position Error Integral is provided to compensate for systems with high friction or vertical
loads. A Low Pass Filter is provided to filter machine resonance that are present is some
applications.
Figure 117:
Motor Tab
Configuration Group
Motor Type
Select the motor you wish to use. PowerTools FM software will only display the motor
models that are compatible with the drive you selected and any user defined motors.
145
Modular Drive System Reference Manual
Selecting the wrong motor type can cause poor performance and may even damage the
motor and/or drive.
Low Pass Filter Group
Low Pass Filter Enable Checkbox
This enables a low pass filter applied to the output of the velocity command before the torque
compensator. The low pass filter is only active in Pulse and Velocity modes, not Torque
Modes.
Low Pass Frequency
This parameter defines the low pass filter cut-off frequency signals exceeding this frequency
will be filtered at a rate of 40 db. per decade.
Encoder Output Group
Encoder Scaling Check Box
This check box enables the Encoder Scaling feature. When not enabled, the encoder output
density is the same as the motor encoder density.
Encoder Scaling
This feature allows you to change the drive encoder output resolution in increments of one
line per revolution up to the density of the encoder in the motor. If the Encoder Scaling
parameter is set to a value higher than the motor encoder density, the drive encoder output
density will equal that of the motor encoder.
Load Group
Inertia Ratio
Inertia Ratio specifies the load to rotor inertia ratio and has a range of 0.0 to 50.0. If the exact
inertia is unknown, a conservative approximate value should be used. If you enter an inertia
value higher than the actual inertia, the resultant motor response will tend to be more
oscillatory.
146
Setting Up Parameters
Friction
This parameter is characterized in terms of the rate of friction increase per 100 motor RPM.
If estimated, always use a conservative (less than or equal to actual) estimate. If the friction
is completely unknown, a value of zero should be used. A typical value used here is less than
one percent.
Tuning Group
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hz. In general, it
affects how quickly the drive will respond to commands, load disturbances and velocity
corrections. A good value to start with (the default) is 50 Hz. The affect of response is greatly
affected by High Performance Gains. With High Performance Gains the maximum value
recommended is 100 Hz.
Position Error Integral Group
Position Error Integral Check Box
The Position Error Integral is a control term, which can be used to compensate for the
continuous torque required to hold a vertical load against gravity. It is also useful in Pulse
mode applications to minimize following error.
Time Constant
The user configures this control term using the “Position Error Integral Time Constant”
parameter. This parameter determines how quickly the drive will correct for in-position
following error. The time constant is in milliseconds and defines how long it will take to
decrease the following error to 37 percent of the original value. In certain circumstances the
value actually used by the drive will be greater than the value specified here.
Min. Time Constant = 1000/Response
For example, with “Response” set to 50, the minimum time constant value is 1000/50 = 20
msec.
Enable High Performance Gains Check Box
Enabling the High Performance Gains increases closed loop stiffness which can be beneficial
in open loop velocity applications and Pulse mode. When enabled, they make the system less
forgiving in applications where the actual inertia varies or the coupling between the motor and
the load has excessive windup or backlash.
147
Modular Drive System Reference Manual
Note
When using an external position controller in Velocity mode, High Performance Gains
should not be enabled.
Enable Feedforwards Check Box
When feedforwards are enabled, the accuracy of the Inertia and Friction are very important.
If the Inertia is larger than the actual inertia, the result could be a significant overshoot during
ramping. If the Inertia is smaller than the actual inertia, following error during ramping will
be reduced but not eliminated. If the Friction is greater than the actual friction, it may result
in velocity error or instability. If the Friction is less than the actual friction, velocity error will
be reduced by not eliminated.
Analog Tab (Detailed Setup view only)
This tab displays the setup and feedback data for the Analog Input and the two diagnostic
Analog Outputs.
Figure 118:
148
Analog Tab
Setting Up Parameters
Analog Inputs Group
Bandwidth
This sets the low-pass filter cut off frequency applied to the analog command input. Signals
exceeding this frequency will be filtered at a rate 20 db. per decade.
Analog Full Scale
This parameter specifies the voltage required to command Full Scale Velocity or Full Scale
Torque. It is used in Velocity Analog and Torque Analog operating modes.
Analog Zero Offset
This parameter is used to null any voltage present at the drive when a zero velocity or torque
command is provided by a controller. The amount of offset can be measured by the Analog
Input parameter when a zero velocity or torque command is supplied.
Analog Input
The analog voltage signal that is received on pins 14 and 15 of the Command Connector and
is used to generate the Analog Velocity Command or the Analog Torque Command
depending on the Actual Operating Mode.
For example:
+10 VDC = Maximum motor CW velocity or maximum CW torque.
-10 VDC = Maximum motor CCW velocity or maximum CCW torque.
Analog Outputs Group
Source
Select the signal that you wish to use as the source for Analog Output Channel #1 and Channel
#2. There are five options: Velocity Feedback, Velocity Command, Torque Feedback, Torque
Command and Following Error. The scaling and offset are affected by the source parameter
selected. The units of the scaling and offset are adjusted according to the source parameter.
Offset and Scale
Each analog diagnostic output channel includes a programmable Analog Output Offset and
an Analog Output Scale. These features allows you to “zoom in” to a desired range effectively
increasing the resolution. The units for both of these parameters is dependent upon the Analog
Output Source selection.
149
Modular Drive System Reference Manual
Feedback
This is a display of the real time status of the two analog outputs in volts. It is only available
when you are online.
150
Setting Up Parameters
I/O Status Tab
This tab displays the status of the input and output functions in real time and is only available
when you are online with a drive. This tab is divided into two windows, the "Inputs" window
and the "Outputs" window.
Figure 119:
I/O Status Tab
Inputs Group
Inputs Lines Window
This feature shows the various input lines and whether they are active. The line is active if the
circle next to the line is green or lit-up.
Active State
The active state is shown for each input line.
Forced
The forced state is shown for each input line.
151
Modular Drive System Reference Manual
Forced On and Forced Off
You can force an input line to a level by using the "Forced On" and "Forced Off" check boxes.
When you force an input line “On” or “Off”, all the functions assigned to that line will be
affected.
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
Sort By Function/Line Button
Click on this button to change how the "Inputs" window is sorted (i.e., by functions or lines).
The window can be sorted by either function or line. The functions and lines are arranged in
a hierarchy. If the window is sorted by lines, then each line is displayed and any functions
assigned to a particular line are grouped below the line.
Expand/Collapse Button
This button expands or collapses the hierarchy of the "Inputs" window. An expanded view
shows the relationship between functions and lines. A collapsed view shows only lines or
functions.
Figure 120:
Collapsed and Expanded Views
If the function or line is currently active, the "LED" to the left of the function or line name
will be green.
152
Setting Up Parameters
Note
When a function or line is active, the state of the "LED" associated with the function or
line is dependent on how the "Always Active", "Forced On or Off" and "Active Off"
controls are used.
Outputs Group
Outputs Lines Window
This feature shows the various output lines and whether they are active. The line is active if
the circle next to the line is green or lit-up.
Active State
The active state is displayed for each output line.
Forced
The forced state is displayed for each output line.
Forced On and Forced Off
You can force an output line to a level by using the "Forced On" and "Forced Off" check
boxes. When you force an output line “On” or “Off”, the output functions are not affected.
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
Sort By Function/Line Button
Click on this button to change how the "Outputs" window is sorted (i.e., by functions or lines).
Each window can be sorted by either function or line. The functions and lines are arranged in
a hierarchy. If the window is sorted by lines, then each line is displayed and any functions
assigned to a particular line are grouped below the line.
Expand/Collapse Button
This button expands or collapses the hierarchy of the "Outputs" window. An expanded view
shows the relationship between functions and lines. A collapsed view shows only lines or
functions.
153
Modular Drive System Reference Manual
Figure 121:
Collapsed and Expanded Views
If the function or line is currently active, the "LED" to the left of the function or line name
will be green.
Note
When a function or line is active, the state of the "LED" associated with the function or
line is dependent on how the "Always Active", "Forced On or Off" and "Active Off"
controls are used.
154
Setting Up Parameters
Status Tab
This tab displays the drive status in real time and is only available when you are on-line with
a drive. The information in this tab is divided into six categories: Position, Velocity, Torque,
Drive Status, I.D. and Drive Run Time.
Figure 122:
Status Tab
Note
The information in this tab is for diagnostics purposes only and cannot be changed from
within this tab.
Position Group
Pulse Position Input
This parameter returns the total number of actual pulses received on the pulse input hardware.
This value is active in all operating modes.
Position Command
This is set to zero when the Absolute Position Valid output function is activated.
155
Modular Drive System Reference Manual
Following Error
The Following Error is the difference between the Position Command and the Position
Feedback. It is positive when the Position Command is greater than the Position Feedback.
Encoder Feedback
The motor position in encoder counts since power up when the value was set to zero. This is
a signed 32 bit value. This parameter can be preloaded using the serial interface.
Position Feedback
This parameter is the motor position since power-up. This value is automatically reset to zero
at power-up.
Velocity Group
Preset Command
Preset Velocity command based on the velocity preset selected.
Analog Command
Analog command voltage currently being applied to the analog command input on the
command connector.
Velocity Command
The Velocity Command is the actual command received by the velocity loop.
Velocity Feedback
This parameter is the actual feedback motor velocity in RPMs.
Torque Group
Torque Command
This parameter returns the torque command value before it is limited. The torque command
may be limited by either the Torque Limit (if the Torque Limit Enable input function is
active) or current foldback.
156
Setting Up Parameters
Actual Command
Displays the Torque command after all limiting. This command is used by the current loop to
generate Motor Torque.
Drive Status Group
Foldback RMS
This parameter accurately models the RMS loading of the drive and motor. When it reaches
100 percent, current foldback will be activated.
Heatsink Temperature
This parameter displays the temperature of the Drive Module heatsink in degrees Fahrenheit.
This parameter models the thermal utilization of the heatsink by the power stage. It
determines the amount of thermal capacity available for the Regen Shunt Resistor. A display
of 10 percent heatsink capacity remaining for use by the shunt resistor. When this value
reaches 100 percent or higher, no capacity is left for the shunt resistor and a shunt resistor and
a shunt fault will occur as soon as the shunt is activated.
Segment Display
Character currently being displayed by the status display on the front of the drive.
Actual Operating Mode
This parameter returns the actual (or current) operating mode or state of the drive. This is
determined by the Operating Mode Default, Alternate Operating Mode, Input Functions
which override the operating mode, fault conditions, function modules or disabling the drive.
Bus Voltage
Displays the actual measured voltage on the DC power bus.
ID Group (Detailed Setup view only)
Firmware Revision
Displays the revision of the firmware in the drive you are currently online with.
157
Modular Drive System Reference Manual
Serial Number
Displays the serial number of the drive with which you are currently online.
Drive Run Time Group (Detailed Setup view only)
Total Power Up Time
Total amount of time displayed in hours the drive has been powered-up since leaving the
factory.
Power Up Count
Number of times the drive has been powered-up since leaving the factory.
Power Up Time
Amount of time displayed in hours the drive has been powered-up since last power up.
View Active Faults Button
Pushing this button displays the Active Drive Faults dialog box. From this dialog box you can
reset any resettable active fault by clicking the Reset Faults button.
Figure 123:
158
Active Drive Faults Dialog Box
Setting Up Parameters
Fault Log Group (EZ Setup view only)
Figure 124:
Fault Log View
Fault Log Window
This window displays the last ten drive faults with time stamps. The first fault is the most
recent fault. The information in this window is read only and cannot be edited or cleared.
Power up
This feature indicates during which power-up that the fault occurred.
Time (days hrs:min)
This feature indicates the time into the power-up that the fault occurred. The time is displayed
in days, hours and minutes).
159
Modular Drive System Reference Manual
History Tab (Detailed Setup view only)
This tab displays a complete fault history including a "Fault Log" window and a "Fault
Count" window.
Figure 125:
History Tab
Note
The "Fault Log" and "Fault Counts" cannot be cleared.
Fault Log Group
Fault Log Window
This window displays the last ten drive faults with time stamps. The first fault is the most
recent fault. The information in this window is read only and cannot be edited or cleared.
Power up
This feature indicates during which power-up that the fault occurred.
Time (days hrs:min)
This feature indicates the time into the power-up that the fault occurred. The time is displayed
in days, hours and minutes).
160
Setting Up Parameters
Fault Counts Group
Fault Counts Window
The "Fault Counts" window displays all the faults that can occur and the number of times
those faults happened since the drive was originally powered-up. The information in this
window cannot be edited or cleared.
# of Occurrences
The "# of Occurrences" column displays the number of times each fault has occurred since
the drive was originally powered up.
161
Modular Drive System Reference Manual
Advanced Tab
This tab is reserved for very infrequently used parameters that sometimes need to be adjusted
to solve certain application problems. This tab is not normally visible and it is only rarely
necessary. If any parameter in this tab is not at default, then it will automatically be enabled
when starting PowerTools FM.
All the setups here are effective for all modes used and for both the (Main) Default Operating
Mode and the Alternate Operating Mode.
Figure 126:
Advanced tad View
Bus Voltage
Low DC Bus Enable
This parameter’s default setting is enabled. When enabled, the drive will detect a low DC bus
at 60 VDC and will log a Low DC Bus Fault if a power down is not completed after the low
DC bus is detected. Setting this to disabled will disable the Low DC Bus Voltage Fault. This
will allow the drive to operate at a DC bus voltage below 60 VDC as long as the logic power
is supplied by the A.P.S. (Alternate Power Supply).
162
Setting Up Parameters
Advanced Settings
Encoder State Fault Enable
This parameter’s default setting is enabled. When enabled, the drive will detect encoder state
faults. Refer to Fault Codes in the Diagnostic and Troubleshooting section of this manual. The
drive will not detect Encoder State faults when the fault is disabled. Disabling encoder faults
is necessary for some types of program able encoders where the state transitions are not
always deterministic.
163
Modular Drive System Reference Manual
164
Modular Drive System Reference Manual
Tuning Procedures
Overview
The drive uses closed loop controllers to control the position and velocity of the attached
motor. These position and velocity controllers and the associated tuning parameters are in
effect when the drive is in velocity or pulse mode and have no effect when the drive is in
Torque mode.
Classic closed loop controllers are tuned using proportional, integral and derivative (PID)
gains which require skilled “tweaking” to optimize. The drive uses a revolutionary tuning
approach utilizing state-space algorithms. Using this method a drive can control the motor
more accurately and with more robustness than the older PID algorithms.
The drive’s default settings are designed to work in applications with up to a 10:1 load to
motor inertia mismatch. Most applications can operate with this default setting.
Some applications may have performance requirements which are not attainable with the
factory settings. For these applications a set of measurable parameters can be specified which
will set up the internal control functions to optimize the drive performance. The parameters
include Inertia Ratio, Friction, Response and Line Voltage. All the values needed for
optimization are “real world” values that can be determined by calculation or some method
of dynamic measurement.
PID vs. State-Space
The power of the state-space control algorithm is that there is no guessing and no “fine
tuning” as needed with PID methods. PID methods work well in controlled situations but tend
to be difficult to setup in applications where all the effects of the system are not compensated
for in the PID loop. The results are that the system response is compromised to avoid
instability.
The drive state-space control algorithm uses a number of internally calculated gains that
represent the wide variety of effects present in a servo system. This method gives a more
accurate representation of the system and maximizes the performance by minimizing the
compromises.
You need only to setup the system and enter three parameters to describe the load and the
application needs. Once the entries are made the tuning is complete - no guessing and no
“tweaking”. The drive uses these entries plus motor and amplifier information to set up the
internal digital gain values. These values are used in the control loops to accurately set up a
stable, repeatable and highly responsive system.
165
Modular Drive System Reference Manual
Tuning Procedure
Once the initial setup has been completed, you can run the system to determine if the level of
tuning is adequate for the application. There are basically four levels of tuning for a drive.
•
•
•
•
No Tuning
Basic Level
Intermediate Level
Fully Optimized Level
Each level is slightly more involved than the previous one requiring you to enter more
information. If your system needs optimization, we recommend that you start with the Basic
Level, then determine if further tuning is needed based on axis performance.
The setup procedures explained here assume that you are using Control Techniques’
PowerTools software or an FM-P.
Initial settings
Pulse Mode (with or without a position controller)
Velocity Mode (without a position controller)
If you are using the drive in Pulse mode with or without a position controller or as an open
loop velocity drive only, set the drive tuning parameters as follows:
•
•
•
•
•
Inertia Ratio = 0
Friction = 0
Response = 50
High Performance Gains = Enabled
Feedforwards = Disabled
Velocity Mode (with a position controller)
If you are using the drive in Velocity mode with a position controller, set the drive tuning
parameters as follows:
•
•
•
•
•
Inertia Ratio = 0
Friction = 0
Response = 100
High Performance Gains = Enabled
Feedforwards = Disabled
Torque Mode (with or without a closed loop position controller)
If you are using the drive in Torque mode, without Stop inputs or Travel Limit inputs, no
tuning is required.
If you are operating in Torque mode and you are using the Stop or Travel Limit inputs, you
must setup the drive as if it were running in Velocity mode without a position controller. This
is because the drive will automatically shift into Velocity mode when either of these functions
is activated and will use the gain setups when decelerating and holding position.
166
Tuning Procedures
This unique feature offers an extra level of safety because the drive can override the position
controller and bring the axis to a safe stop if the controller loses the ability to control the axis.
Tuning steps
If your Inertia Ratio is greater than 10 times the motor inertia go directly to the Intermediate
Level tuning.
No Tuning
No tuning will be required in most applications where the load inertia is 10 times the motor
inertia or less.
Basic Level
Adjust Response to obtain the best performance.
Intermediate Level
1.
Calculate or estimate the load inertia. It is always better to estimate low.
2.
Disable the drive.
3.
Enter the inertia value calculated into the Inertia Ratio parameter.
4.
Leave all other tuning parameters at the initial values.
5.
Enable the drive and run the system.
6.
Adjust Response to obtain the best performance.
Fully Optimized Level
1.
Determine the actual system parameters.
2.
Disable the drive.
3.
Enter the parameters.
4.
Enable the drive and run the system.
5.
Adjust Response to obtain the best performance.
General Tuning Hints
The Response is normally the final adjustment when tuning. For best performance the
Response should be lower with a higher inertia mismatch (>10:1) and higher with a lower
inertia mismatch.
167
Modular Drive System Reference Manual
If your system has some torsional compliance, such as with a jaw type coupling with a rubber
spider, or if there is a long drive shaft, the Response should be decreased. The highest
recommended Response with High Performance Gains enabled is 100 Hz.
Feedforwards can be enabled if the performance requirements are very demanding. However
when using them, make sure the Inertia Ratio and Friction values are an accurate
representation of the load. Otherwise, the system performance will actually be degraded or
stability will suffer. Enabling the Feedforward makes the system less tolerant of inertia or
friction variations during operation.
Tuning Parameters
Inertia Ratio
Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50.0. A value
of 1.0 specifies that load inertia equals the motor inertia (1:1 load to motor inertia). The drives
can control up to a 10:1 inertia mismatch with the default Inertia Ratio value of 0.0. Inertial
mismatches of over 50:1 are possible if response is reduced.
The Inertia Ratio value is used to set the internal gains in the velocity and position loops,
including feedforward compensation if enabled.
To calculate the Inertia Ratio value, divide the load inertia reflected to the motor by the motor
inertia of the motor. Include the motor brake as a load where applicable. The resulting value
should be entered as the Inertia Ratio parameter.
IR=
RLI
MI
Where:
IR = Inertia Ratio
RLI = Reflected Load Inertia (lb-in-sec2)
MI = Motor Inertia (lb-in- sec2)
If the exact inertia is unknown, a conservative approximate value should be used. If you enter
an inertia value higher than the actual inertia, the resultant motor response will tend to be
more oscillatory.
If you enter an inertia value lower than the actual inertia, but is between 10 and 90 percent of
the actual, the drive will tend to be more sluggish than optimum but will usually operate
satisfactorily. If the value you enter is less than 10 percent of the actual inertia, the drive will
have a low frequency oscillation at speed.
168
Tuning Procedures
Friction
This parameter is characterized in terms of the rate of friction increase per 100 motor RPM.
The range is 0.00 to 100.00 in units of percent continuous torque of the specified motor/drive
combination. The Friction value can either be estimated or measured.
If estimated, always use a conservative (less than or equal to actual) estimate. If the friction
is completely unknown, a value of zero should be used. A typical value used here would be
less than one percent.
If the value entered is higher than the actual, system oscillation is likely. If the value entered
is lower than the actual a more sluggish response is likely but generally results in good
operation.
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hz. In general, it
affects how quickly the drive will respond to commands, load disturbances and velocity
corrections. The effect of Response is greatly influenced by the status of the High
Performance Gains.
With High Performance Gains disabled, the actual command bandwidth of the drive system
will be equal to the Response value. In this case the load disturbance correction bandwidth is
fixed at approximately 5 Hz. Increasing the Response value will reduce the drive’s response
time to velocity command changes but will not affect the response to load or speed
disturbances.
When High Performance Gains are enabled, the actual response bandwidth is three to four
times the Response value. In this case, it affects both the velocity command and the load
disturbance correction bandwidth. Increasing the Response when the High Performance
Gains are enabled will increase loop stiffness. With High Performance gains enabled, the
maximum Response level recommended is approximately 100 Hz.
If the Inertia Ratio and Friction values are exactly correct and the High Performance Gains
are enabled, changing the Response will not affect the damping (percent of overshoot and
number of ringout cycles) to velocity command changes or load disturbance corrections but
will affect their cycle frequency. The response level should be decreased as the load to motor
inertia ratio increases or if High Performance Gains are enabled.
High Performance Gains
Enabling High Performance Gains fundamentally affects the closed loop operation of the
drive and greatly modifies the effect of the Response parameter. High Performance Gains are
most beneficial when the Inertia Ratio and Friction parameters are accurate.
High Performance Gains, when enabled, make the system less forgiving in applications where
the actual inertia varies or the coupling between the motor and the load has excessive windup
or backlash.
169
Modular Drive System Reference Manual
Note
When using an external position controller, some applications will benefit in rare
instances by disabling High Performance Gains.
Position Error Integral
Position Error Integral is a control term that is effective only in Pulse mode which serves to
minimize following error especially at constant speed. This minimizes phase error between
master and slave when running in a line shaft or gearing application. It also helps maintain
accurate command execution during steady state or low frequency torque disturbances
(typically less than 10 Hz) or when holding a non-counterbalanced vertical load in position.
The adjustment parameter is Position Error Integral Time Constant which is available in the
Motor and Tuning Tabs of PowerTools. This parameter determines how quickly the drive will
attempt to eliminate the following error. The time constant is in milliseconds and defines how
long it will take to decrease the following error by 63%. (3 time constants will reduce the
following error by 96 %). The range for this parameter is 5 to 500 milliseconds. In certain
circumstances the value actually used by the drive will be greater than the value specified in
the Power Tools because the minimum allowed time constant value is a function of the
‘Response’ parameter. The formula is Min. Time Constant = 1000/Response. For example
with ‘Response’ set to 50, the minimum time constant value is 1000/50 = 20 msec. A higher
time constant value will minimize instability with more compliant loads such as long drive
shafts, or spring loads. A lower time constant setting will increase the response and will
stiffen the system.
Feedforwards
Feedforward gains are essentially open loop gains that generate torque commands based on
the commanded velocity, accel/decel and the known load parameters (Inertia Ratio and
Friction). Using the feedforwards reduces velocity error during steady state and reduces
overshoot during ramping. This is because the Feedforwards do not wait for error to build up
to generate current commands.
Feedforwards should be disabled unless the absolute maximum performance is required from
the system. Using them reduces the forgiveness of the servo loop and can create instability if
the actual inertia and/or friction of the machine varies greatly during operation or if the Inertia
Ratio or Friction parameters are not correct.
The internal feedforward velocity and acceleration gains are calculated by using the Inertia
Ratio and Friction parameters. The feedforward acceleration gain is calculated from the
Inertia Ratio parameter and the feedforward velocity gain is calculated from the Friction
parameter.
When Feedforwards are enabled, the accuracy of the Inertia Ratio and Friction parameters is
very important. If the Inertia Ratio parameter is larger than the actual inertia, the result would
be a significant velocity overshoot during ramping. If the Inertia parameter is smaller than the
actual inertia, velocity error during ramping will be reduced but not eliminated. If the Friction
170
Tuning Procedures
parameter is greater than the actual friction, it may result in velocity error or instability. If the
Friction parameter is less than the actual friction, velocity error will be reduced by not
eliminated.
Feedforwards can be enabled in any operating mode, however, there are certain modes in
which they do not function. These modes are described in table below.
Operating Mode
Feedforward Parameters Active
Accel FF
*
Vel FF
Analog Velocity
No
Yes
Preset Velocity
Yes
Yes
Pulse/Position
No
Yes
Summation
Yes
Yes
EN revision B6 or later.
Low Pass Filter Enable and Frequency
The drive provides a low pass filter which may be used to reduce machine resonance due to
mechanical coupling or other flexible load components. The low pass filter filters the torque
command generated by the velocity loop. It is not active in Torque mode.
The low pass filter’s frequency must be at least 2.5 times greater than the actual velocity loop
bandwidth. If there is no noticeable mechanical resonance effecting the system, the system is
better off without the low pass filter. If the system has a mechanical resonance effecting the
performance, the low pass filter can diminish the effects of the resonance and allow the tuning
response parameter to be increased.
The low pass filter may improve system performance when there is an inertia mismatch
between the load and the motor inertia causing compliance in the effective load shaft. For
example, if an EN-214/MG-490 drive motor combination is driving a 16-inch long ne-inch
steel shaft with a 40:1 inertia mismatch, the highest the tuning can be set to is 1 hertz. If the
low pass filter is enabled at a frequency of 70 hertz, the system’s tuning response may be set
to 15 hertz.
171
Modular Drive System Reference Manual
Determining Tuning Parameter Values
For optimum performance you will need to enter the actual system parameters into the drive.
This section discusses the methods which will most accurately determine those parameters.
Note
If you have an application which exerts a constant unidirectional loading throughout the
travel such as in a vertical axis, the inertia tests must be performed in both directions to
cancel out the unidirectional loading effect.
Initial Test Settings
When running the tests outlined in this section, the motor and drive must be operational so
you will need to enter starting values.
If your application has less than a 10:1 inertia mismatch, the default parameter settings will
be acceptable. If the inertial mismatch is greater than 10:1, use the following table for initial
parameter settings.
Parameter
Setting
Friction
0.00
Inertia Ratio
1/3 to 1/2 Actual
Response
500/Inertia Ratio
High Performance Gains
Disabled
Feedforwards
Disabled
Line voltage
Actual Applied
Determining Friction
This parameter represents friction that increases proportionally as motor velocity increases.
The viscous friction of your system can be determined by reading the percent of continuous
torque required to operate the loaded motor at two different speeds.
Consider the following before determining the Friction:
172
•
The most consistent readings can usually be obtained at motor speeds higher than 500
RPM but lower test speeds can be used if necessary.
•
If your application has travel limits, it may be helpful to use an external position controller
to prevent the axis from exceeding the machine limits. Set up a trapezoidal profile as
shown.
•
In the procedure below, the Torque Command and Velocity Feedback parameters can be
measured using the drive’s analog outputs, PowerTools software.
•
With vertical loads the test readings must be taken while traveling in the same direction.
Tuning Procedures
•
An oscilloscope may be needed for systems with limited travel moves to measure the
rapidly changing torque and velocity signals.
•
If your system’s friction changes with operating temperature, perform this procedure at
normal operating temperature.
Procedure for Determining Friction:
1.
Run the motor at the low test speed (at least 500 RPM).
2.
While at speed, note the Torque Command Actual value (TCL).
Note
If the friction loading of your system varies when operating at constant speed, due to a
load or spring load that changes as the motor rotates, use the lowest value measured.
3.
Repeat Step 1 using a velocity at least two times the low speed.
4.
While at speed, note the Torque Command Actual value (TCH).
5.
Use the following formula to calculate the friction:
FV = (100)
(TCH - TCL)
RPMH - RPML
Where:
TCH = Torque Command Limited value at higher speed
TCL = Torque Command Limited at lower speed
RPMH = Higher RPM (velocity)
RPML = Lower RPM (velocity)
FV = Friction value
The figure below shows the relationship of Torque Command to the Velocity Feedback.
There is increased torque during the Accel ramp (Ta), constant torque (Tc) during the
constant velocity portion of the ramp and decreased torque (Td) during the decel ramp.
Figure 127:
Trapezoidal Velocity Waveform with Torque Waveform
173
Modular Drive System Reference Manual
Determining Inertia Ratio
Actual system Inertia Ratio is determined by accelerating and decelerating the load with a
known ramp while measuring the torque required.
Consider the following before determining the inertia:
•
If your application allows a great deal of motor motion without interference, it is
recommended that you use a Preset Velocity to produce accurate acceleration ramps.
•
If your application has a very limited range of motion, it is recommended that you use a
position controller to produce the acceleration ramps and to prevent exceeding the axis
range of motion.
•
The accel and decel ramp should be aggressive enough to require at least 20 percent of
continuous motor torque. The higher the torque used during the ramp, the more accurate
the final result will be.
•
With ramps that take less than 1/2 second to accelerate, read the Diagnostic Analog
Outputs with an oscilloscope to measure the Torque Feedback.
•
With ramps that take 1/2 second or longer to accelerate, read the Torque Command
parameter on the Motor tab of PowerTools or with the Watch Window.
•
To best determine the inertia, use both acceleration and deceleration torque values. The
difference allows you to drop the constant friction out of the final calculation.
•
If your application exerts a constant “unidirectional loading” throughout the travel such
as in a vertical axis, the inertia test profiles must be performed in both directions to cancel
out the unidirectional loading effect.
•
The Torque Command Limited and Velocity Feedback parameters can be measured using
the drive’s Analog Outputs, or PowerTools software.
An oscilloscope will be needed for systems with limited travel moves and rapidly changing
signals of torque and velocity.
Inertia Measurement Procedure:
Note
The test profile will need to be run a number of times in order to get a good sample of data.
174
1.
Enable the drives and run the test profiles.
2.
Note the Torque Command Limited value during acceleration and deceleration.
3.
Use the appropriate formula below to calculate the inertia.
Tuning Procedures
For horizontal loads or counterbalanced vertical loads use the following formula:
IR =
(R · Vm (Ta + Td))
-1
2000
Where:
IR = Inertia Ratio
R = ramp in ms/kRPM
Ta = (unsigned) percent continuous torque required during acceleration ramping (0 - 300)
Td = (unsigned) percent continuous torque required during deceleration ramping (0 - 300)
Vm = motor constant value from Table 18 below
For un-counter balanced vertical loads use the following formula:
IR =
(R · Vm (Tau + Tdu + Tad + Tdd))
-1
4000
Where:
IR = Inertia Ratio
R = ramp in ms/kRPM
Vm = motor constant value from the table below
Tau = (unsigned) percent continuous torque required during acceleration ramping while
moving up (against the constant force)
Tdu = (unsigned) percent continuous torque required during deceleration ramping while
moving up (against the constant force)
Tad = (unsigned) percent continuous torque required during acceleration ramping while
moving down (aided by the constant force)
Tdd = (unsigned) percent continuous torque required during deceleration ramping while
moving down (aided by the constant force)
Ramp Units Conversion
If you are using an external position controller to generate motion you may need to convert
the ramp units as desired below.
Many position controllers define acceleration in units per sec2. The formulas above use ms/
kRPM. Make sure you make this conversion when entering the information into the formula.
Conversion Formula:
MPK =
6
10
(RPSS · 60)
Where:
175
Modular Drive System Reference Manual
MPK = accel ramp in ms/kRPM
RPSS = accel ramp in revolutions per second2
Motor
Drive
MH-316
MH-340
RPM /volt Scaled Velocity
Command Output (default)
3.07
30
600
3.07
30
600
1.74
30
600
MH-455
1.95
30
600
1.51
30
600
MD-407
MH-455
1.95
30
600
1.51
30
600
MH-6120
1.07
30
600
MH-6120
1.07
30
600
MH-490
MH-6200
MD-410
1.19
30
600
MH-6300
1.04
30
600
MH-6200
1.19
30
600
MH-6300
1.04
30
600
0.65
30
600
0.54
30
600
MH-8500
MH-8750
176
Percent Continuous/volt
Scaled Torque Command
Output (default)
MH-455
MH-590
MD-404
Vm
MD-420
MD-434
Modular Drive System Reference Manual
Status, Diagnostics and
Troubleshooting
Power Module Status Indicators
The Power Module status indicators on the front of the Power Module shows system and
Power Module status. When the condition is met the indicators will be illuminated.
Status Function
Logic Power
Condition
The +24VDC Logic Power is correctly supplied to the Power Module.
Everything in the Power Module is properly connected:
System Ready
• +24VDC Logic Power
• AC Input has all three phases
• No Power Module Faults
and soft start is completed.
The System Ready indicator will blink in the condition that one of the AC input phases is
lost. The system will continue to operate in this condition.
The shunt transistor is on. The shunt transistor will turn on under two conditions;
Shunt Active
•
The Bus voltage exceeds 830 VDC
•
The External shunt control input is active.
Fault Function
Condiltion
Shunt Fault
Shunt resistor is shorted or wired incorrectly,
Over Temp
The Power Module RMS power is exceeded creating an over temperature condition in
the Power Module or ambient temperature is higher than 40oC.
High VAC Input
The AC Input voltage exceeds 528 VAC.
Drive Module Diagnostic Display
The diagnostic display on the front of the Drive Module shows Drive Module status and fault
codes. When a fault condition occurs, the Drive Module will display the fault code, overriding
the status code. The decimal point is “On” when the Drive Module is enabled and the Stop
input is not active. This indicates that the Drive Module is ready to run and will respond to
motion commands. Commands will not cause motion unless the decimal point is “On”.
Display Indication
Status
Brake Engaged (Output "Off")
Description
Motor brake is mechanically engaged. This character
will only appear if the Brake output function is
assigned to an output line.
See Brake Operation section for detailed description of
Brake Output function.
177
Modular Drive System Reference Manual
Display Indication
Status
Description
Disabled
Power Stage is disabled.
Position
Pulse mode operation.
Velocity
Velocity mode operation.
Torque
Torque mode operation.
Summation
Summation mode operation.
RMS Foldback
Motor torque is limited to 80 percent.
Stall Foldback
Drive output current is limited to 80 percent of drive
stall current.
Ready to Run
Drive enabled, no Stop input.
Fault Codes
A number of diagnostic and fault detection circuits are incorporated to protect the Drive
Module. Some faults, like High DC bus and Motor Over Temperature, can be reset with the
Reset button on the front of the Drive Module or the Reset input function. Other faults, such
as encoder faults, can only be reset by cycling logic power “Off” (wait until the status display
turns “Off”), then power “On”.
The drive accurately tracks motor position during fault conditions. For example, if there is a
"Low DC Bus" fault where the power stage is disabled, the drive will continue to track the
motor’s position provided the logic power is not interrupted.
178
Status, Diagnostics and Troubleshooting
The +/- Travel Limit faults are automatically cleared when the fault condition is removed.
The table below lists all the fault codes in priority order from highest to lowest. This means
that if two faults are active, only the higher priority fault will be displayed.
Display
Fault
Action to Reset
Bridge Disabled
Power Up Test
Cycle Logic Power
Yes
NVM Invalid
Reset Button or Input Line
Yes
Drive Overtemp
Allow Drive to cool down,
Cycle Logic Power
Yes
Reset Button or Input Line
Yes
Power Module
Cycle Logic Power
Yes
High DC Bus
Reset Button or Input Line
Yes
Low DC Bus
Reset Button or Input Line
Yes
Encoder State
Cycle Logic Power
Yes
Encoder Hardware
Cycle Logic Power
Yes
Motor Overtemp
Allow Motor to cool down,
Reset Button or Input Line
Yes
Invalid Configuration
179
Modular Drive System Reference Manual
Display
Fault
Action to Reset
Bridge Disabled
Overspeed
Reset Button or Input Line
Yes
Following Error
(Pulse mode only)
Reset Button or Input Line
Yes
Travel Limit +/-
Auto
No
All "On"
Normally "On" for one
second during power-up
Yes
Fault Descriptions
Power Up Test
This fault indicates that the power-up self-test has failed. This fault cannot be reset with the
reset command or reset button.
NVM Invalid
At power-up the drive tests the integrity of the non-volatile memory. This fault is generated
if the contents of the non-volatile memory are invalid.
Invalid Configuration
A function module was attached to the drive on its previous power-up. To clear, press and
hold the Reset button for 10 seconds.
Drive Overtemp
Indicates the drive IGBT temperature has reached its limit.
Power Module
This fault indicates either IGBT module failure or over current/short circuit condition as a
result of phase to phase or phase to ground short in the motor or cable.
180
Status, Diagnostics and Troubleshooting
High DC Bus
This fault will occur whenever the voltage on the DC bus exceeds the High DC Bus threshold.
The most likely cause of this fault would be an open external shunt fuse, a high AC line
condition or an application that requires an external shunt (e.g., a large load with rapid
deceleration).
High DC Bus Threshold
MDS
880 VDC
Low DC Bus
This fault will occur whenever the voltage on the DC bus drops below the Low DC Bus
threshold. The most likely cause of this fault is a reduction (or loss) of AC power. A 50 ms
debounce time is used with this fault to avoid faults caused by intermittent power disruption.
With and Epsilon drive, the low DC bus monitoring can be disabled with PowerTools
software in the Advanced tab.
Low DC Bus Threshold
MDS
60 VDC
Encoder State
Certain encoder states and state transitions are invalid and will cause the drive to report an
encoder state fault. This is usually the result of noisy encoder feedback caused by poor
shielding. For some types of custom motors it may be necessary to disable this fault. Refer to
the Advanced Tab section of Setting Up Parameters for more information.
Encoder Hardware
If any pair of complementary encoder lines are in the same state, an encoder line fault is
generated. The most likely cause is a missing or bad encoder connection.
Motor Overtemp
This fault is generated when the motor thermal switch is open due to motor over-temperature
or incorrect wiring.
Overspeed
This fault occurs in one of two circumstances:
181
Modular Drive System Reference Manual
1.
When the actual motor speed exceeds the Overspeed Velocity Limit parameter or 150%
of motor maximum operating speed. This parameter can be accessed with PowerTools
software.
2.
If the combination of command pulse frequency and Pulse Ratio can generate a motor
command speed in excess of the fixed limit of 13000 RPM, an Overspeed Fault will be
activated. In Pulse mode operation and any Summation mode which uses Pulse mode,
the input pulse command frequency is monitored and this calculation is made. For
example, with a Pulse Ratio of 10 pulses per motor revolution, the first pulse received
will cause an Overspeed fault even before there is any motor motion.
Following Error
This fault is generated when the following error exceeds the following error limit (default
following error limit is .2 revs). With PowerTools you can change the Following Error Limit
value or disable in the Position tab. The Following Error Limit is functional in Pulse mode
only.
Travel Limit +/This fault is caused when either the + or - Travel Limit input function is active.
All "On"
This is a normal condition during power up of the drive. It will last for less than 1 second. If
this display persists, call Control Techniques for service advice.
Normally, All "On" for less than one second during power-up. All segments dimly lit when
power is "Off" is normal when an external signal is applied to the encoder inputs (motor or
master) or serial port from an externally powered device. The signals applied to the inputs
cannot exceed 5.5V level required to drive logic common or drive damage will occur.
Diagnostic Analog Output Test Points
The drive has two 8-bit real-time Analog Outputs which may be used for diagnostics,
monitoring or control purposes. These outputs are referred to as Channel 1 and Channel 2.
They can be accessed from the Command Connector on the drive or from the Diagnostics
Analog Output Pins located on the front of the drive.
Each Channel provides a programmable Analog Output Source.
Analog Output Source options are:
182
•
Velocity Command
•
Velocity Feedback
Status, Diagnostics and Troubleshooting
•
Torque Command (equates to Torque Command Actual parameter)
•
Torque Feedback
•
Following Error
Default Analog Output Source:
•
Channel 1 = Velocity Feedback
•
Channel 2 = Torque Command
Channel
Output Source
Offset
Scale
1
Velocity Feedback
0
600 RPM/volt
2
Torque Command
0
30 percent/volt for selected
motor
Channel #2
Analog GND
Channel #1
RESET
SERIAL
J4
COMMAND
10-30
VDC
+ -
DRIV E
ENABLE
J6
INPUT
1 2
3
J5
OUTPUT
4 1
2
3
RESET
SERIAL
COMMAND
MDS Drive Module
Figure 128:
Diagnostic Analog Output Test Points
The DGNE cable was designed to be used with either an oscilloscope or a meter. The wires
are different lengths to avoid shorting to each other. However, if signals do get shorted to
GND, the drive will not be damaged because the circuitry is protected.
183
Modular Drive System Reference Manual
D/A
Black
(GND)
D/A
Yellow
Blue
10 Ohm
2
10 Ohm
2
GND
DGNE Cable
DGNE Cable
Figure 129:
GND 1
1
Pin #'s
44
29
43
Command Connector
Diagnostic Cable (DGNE) Diagram
Drive Faults
The Active Drive Faults dialog box is automatically displayed whenever a fault occurs. There
are two options in this dialog box: Reset Faults and Ignore Faults.
Figure 130:
Active Drive Faults Detected Dialog Box
Resetting Faults
Some drive faults are automatically reset when the fault condition is cleared. Other faults
require drive power to be cycled or the drive to be “rebooted”. If you wish to continue
working in the PowerTools FM software without resetting the fault, click the Ignore Fault
button.
184
Status, Diagnostics and Troubleshooting
To reset faults that can be reset with the Reset Faults button, simply click the Reset Faults
button in the Drive Faults Detected dialog box or push the Reset button on the front of the
drive where the fault occurred.
Viewing Active Drive Faults
To view all active drive faults, select the View Faults command from the Device menu or by
clicking on the View Faults icon on the toolbar. The dialog box displayed is the same as
Active Drive Faults Detected dialog box described above.
Rebooting the Drive
To reboot the drive, cycle power or select the Reboot Drive command from the Device menu.
This command reboots the drive attached to the active Configuration Window.
Watch Window
This feature allows you to customize a window to monitor drive parameters which you select
from a complete list of drive parameters. From this window you can watch the parameters you
selected in real time. This feature is only available when you are online with the drive.
Note
You cannot change the values of the parameters while they are being displayed in the
Watch Window. The parameter in the setup screens will look like they have been changed
when they actually have not. To update a parameter, delete it from the Watch Window
selection.
Note
It is normal to have the Watch Window show up with the three motor parameters already
selected if the motor parameters window has been accessed previously. If you do not need
to view them, simply push the Clear All button and select the parameters you wish to
view.
Figure 131:
Watch Window
The Watch Window is accessed by selecting Watch Drive Parameters from the Tools menu
or by clicking on the Watch Window icon on the toolbar.
185
Modular Drive System Reference Manual
The Watch Window will automatically appear as soon as you select a parameter from the
Select Drive Parameters dialog box. After you have selected the parameters you wish to
watch, click the Close button. The Select Drive Parameters dialog box will close and the
Watch Window will remain open.
Figure 132:
Select Drive Parameters Dialog Box
Group
This list box enables you to view the complete list of parameters or just a group of parameters
you are interested in. The groups include: Analog In, Analog Out, Communication, Digital
Inputs, Execution, Fault Counts, Fault Log, ID, Input Functions, Motor, Output Functions,
Position, Setup, Status, Torque, Tuning, User Defined Motor, and Velocity.
Clear All Button
This button is used to clear all the parameter selections that were previously selected.
Save Selections Button
This button saves the parameter selections. This enables you to restore the same list of
parameters for use in future online sessions.
Restore Selections Button
This button restores the parameter selections previously saved. This enables you to restore the
list of parameters you created in a previous online session.
View Motor Parameters
When online with the drive this feature allows you to display a pre-defined Watch Window
to monitor three motor parameters. These parameters are normally used when testing the
setup of a User Defined Motor for commutation accuracy.
186
Status, Diagnostics and Troubleshooting
Figure 133:
View Motor Parameters Window
The View Motor Parameters window is accessed by selecting View Motor Parameters from
the Tools menu.
Error Messages
PowerTools will pop-up an error message box to alert you to any errors it encounters. These
message boxes will describe the error and offer a possible solution.
The table below list the of common problems you might encounter when working with
PowerTools software along with the error message displayed, the most likely cause and
solution.
Problem/Message
Cause
Solution
Time-out while waiting for device response.
The attempted operation has been cancelled.
(see fault: No device selected)
Loss of serial communications.
Check the serial connection to the device and
try operation again.
The attached device(s) do not have valid
revisions, or do not have matching revisions.
Attempting to broadcast to drive without
matching firmware revisions.
Program each drive individually.
Unable to communicate with device [Address
x]
The device that you are attempting to
communicate with is no longer available.
Check all connections and verify that you are
using the correct baud rate then try again.
The specified drive type (name) does not
match the actual drive type (name). Please
make necessary corrections.
The drive type you selected in the “Drive
Type” list box does not match the drive you
are downloading to.
Change the drive type selected in the “Drive
Type” list box to match the drive you are
downloading to.
Non-Control Techniques device attached
(address). When trying to program more than
one drive, only EMC drives of the same type
can be attached to the network.
This error is caused When you attempting to
perform an upload or download to multiple
drives and one or more of the drives are not
the same type.
Disconnect the device(s) that has been
specified and try the operation again or
program each device individually.
You have changed a parameter which will
not take affect until the drive has been
rebooted. Before you reboot the drive, you
will need to save your setup to NVM. Do you
wish to save your setup to drive NVM now?
See message.
Yes/No.
(Operation Name) The attempted operation
has been cancelled.
Communication error.
Retry operation. Check connection to drive.
Invalid entry. The entry exceeds the precision
allowed by this field. The finest resolution
this field accepts is (value).
Entered a value out of range.
Enter a value within the range of that field.
The status bar displays information on the
currently selected object or action.
The device was disconnected during the
upload. The upload was not complete.
Connection to the device was lost (a time-out
occurred).
Check the connection to the device and try
again.
The device was disconnected during the
download. The download was not complete.
Connection to the device was lost (a time-out
occurred).
Check the connection to the device and try
again.
187
Modular Drive System Reference Manual
Problem/Message
Cause
Solution
No device selected.
No device selected during flash upgrade.
Select device(s) from list box.
The drive at address is use.
188
Close any other windows that are using the
same addresses and try again.
Modular Drive System Reference Manual
User Defined Motors
Drives can be configured to operate with brushless DC (synchronous permanent magnet)
motors not manufactured by Control Techniques. This feature is very useful for users who are
retrofitting drives on existing systems or who have special motor requirements.
Commutation Basics
To properly commutate the motor, the drive must know the electrical angle (the angle
between the motor magnetic field and stator coils; R, S and T). At power-up, the drive
determines the starting electrical angle from the U, V and W commutation tracks. After this
is determined, the U, V and W commutation tracks are ignored and the commutation is
entirely based on the A and B incremental channels. The number of U, V and W cycles must
match the number of poles in the motor but they do not have to be aligned with the motor
poles in any particular way.
The U, V and W tracks have a fairly coarse resolution, therefore, on power-up, the
commutation accuracy is limited to ±30 electrical degrees from optimum. When the Z
channel is seen by the drive, the commutation angle is gradually shifted to the optimum
position as defined by the Motor Encoder Marker Angle parameter. This shift is accomplished
in about one second whether the motor is rotating or not.
Tools Required:
•
Oscilloscope dual trace 5 Mhz bandwidth minimum.
•
AC/DC voltmeter, 20 VDC and 200 VAC minimum.
•
Drill motor (reversible) or some means of spinning the motor.
•
Coupling method between the drill motor and the test motor.
•
5 VDC power supply to power the motor encoder.
•
Motor power cable (CMDS or CMMS).
•
Motor feedback cable (CFCO).
•
Terminal strip (18 position suggested) to conveniently connect the motor power and
encoder wires during testing.
•
Method to securely hold the motor during operation (a vise or large C-clamp).
Procedure
The steps required to assemble a servo system consisting of a drive, and a non-Control
Techniques motor are listed below:
189
Modular Drive System Reference Manual
1.
Determine if your motor is compatible with the drive by verifying its characteristics.
There are a number of restrictions such as encoder line density and motor pole count that
must be considered. Most of these parameters are commonly found on a motor data sheet
and some may have to be determined by testing.
It is important that the encoder used have a repeatable Z channel angle with reference to
one of the commutation channels. This is especially the case if you will be using the same
encoder on several motors and you wish to use the same setup file on them all. Otherwise
you will need to generate a motor file for each individual motor/encoder.
2.
Design and assemble the cabling and interface circuitry required to connect the motor
and drive. Motor and feedback cables must be properly shielded and grounded.
3.
Determine the encoder alignment. In order to commutate a motor correctly the angular
relationship of the encoder commutation tracks and the marker pulse with respect to the
R, S and T windings in the stator must be known.
4.
Enter the motor/encoder data into the MOTOR.DDF file. This data is then read by the
PowerTools software when setting up the drive.
5.
Test your system to verify that the servo system is working correctly.
Step 1: Motor Wiring
The first step is to wire the motor terminals to the drive. Control Techniques designates the
motor terminals as R, S and T.
Use the following procedure to establish the R, S and T mapping:
1.
Assume the motor terminals of the non-Control Techniques motor are designated A, B
and C. If they are not marked, name the terminals randomly. The next steps will
determine their working designations.
2.
You can select any of the three motor terminals and call it R. In this procedure we will
choose terminal A.
The rotation of the motor will generate dangerous voltages and currents on the motor
phase leads. Make sure the wires and connections are properly insulated.
190
3.
Connect the scope to read VCA and VBA. VCA and VBA are measured by putting the
probe ground clips on A and the scope probes on C and B.
4.
Rotate the motor CCW (i.e., rotate the shaft counter-clockwise as you face the shaft end
of the motor).
User Defined Motors
Figure 134:
5.
CCW Rotation of the Motor
Look at the phase-to-phase voltages VCA and VBA. There are two possibilities. If VCA
leads VBA, then assign B to S and C to T. If VBA leads VCA, then assign B to T and C
to S. These relationships are summarized in the figure below.
191
Modular Drive System Reference Manual
Figure 135:
Phase Plot Used to Determining Stator Wiring
Note
For the remainder of this procedure we will refer to the motor terminals using the Control
Techniques designations R, S and T.
Step 2: Motor Feedback Wiring
This step describes how to wire the feedback signals to the drive. There are two parts to this
step: electrical interfacing and logical interfacing.
192
User Defined Motors
Encoder Electrical Interfacing
Each of the encoder signals is received by a differential receiver to minimize the noise
susceptibility and to increase frequency bandwidth. This requires two wires for each logical
signal. (i.e., signal A requires channel A and A/, etc.).
For optimum performance these signals should be generated by an encoder with a line driver
output. Encoders which supply only single ended output signals will require some interfacing
circuitry.
Figure 136:
User Defined Motor Differential Feedback Connections
Note
The maximum current available out of the drive encoder +5 volt supply connection is 250
mA.
193
Modular Drive System Reference Manual
Figure 137:
User Defined Motor Single Ended Feedback Connections
Thermal Switch Interfacing
The drive provides a facility to monitor the motor thermal sensor and shut the drive down in
the event of a motor overtemp condition. This must be connected properly in order to enable
the protection. If your motor does not have a thermal sensor, the sensor input pin needs to be
connected to GND (connect pin 9 to pin 18). The thermal sensor requirements are as follows:
•
If a thermistor is used, it must be a PTC (positive temperature coefficient) or it must
increase in resistance as the temperature increases. The cold resistance should be 500
ohms or less. A motor fault will occur when the thermistor resistance reaches
approximately 1.0 kOhm.
•
Switch Operation: open circuit on temperature rise
•
Voltage rating min: 10 VDC
•
Current capacity min: 1 mA
Encoder Logical Interfacing
The encoder is expected to provide six logical signals: A, B, Z, U, V and W. Each of these
signals is received at the drive by a differential receiver circuit. For example, the A logical
signal is received as channels A and /A.
Signals A and B provide incremental motor position in quadrature format. Z is a once per
revolution marker pulse. U, V and W are commutation tracks.
194
User Defined Motors
There are two steps in interfacing the encoder signals:
1.
Determine whether your encoder has all the required signals to operate with a drive.
Some encoders, for example, do not provide a marker pulse or the marker pulse may not
have a fixed phase relationship to the commutation tracks.
2.
Determine the mapping from the motor encoder signals to the drive. To help with this
second step we have provided a description of the required characteristics of the A, B, Z,
U, V and W encoder signals.
The signal relationships of A, B, U, V and W required by the drive are shown in the phase
plots below. For clarity the time scale against which A and B are plotted is different from that
which U, V and W are plotted. Note that A leads B and U leads V and V leads W.
Plots like these are obtained by powering the encoder then rotating the motor while observing
the signals on an oscilloscope. It is important to note which direction of motor rotation (CW
or CCW) generates the phasing shown in the figures below.
Figure 138:
Phase Plot of A and B Encoder Channels
Figure 139:
Phase Plot of U, V and W Encoder Signals with CCW Rotation
If the signal phasing in the figure above is obtained by rotating the motor -, the Motor Encoder
Reference Motion is defined as - and the Motor Encoder Reference Motion parameter is set
to 0. If the signal phasing in the figure above is obtained by rotating the motor +, then the
Motor Encoder Reference Motion is defined as + and the Motor Encoder Reference Motion
is set to 1.
195
Modular Drive System Reference Manual
Note
It is important that all the encoder phases match the phase plot in the figure above. (i.e.,
A leads B, U leads V and V leads W. No particular phase relationship is required between
the A and B pair and the U, V, W signals.
Drive signal names are relatively standard. Your encoder signals may be named differently
or they may have the same names but the signals may be functionally different. You must
determine the proper encoder signal mapping to correctly wire your encoder to a drive.
Encoder signals are used for commutation. Incorrectly wired encoder signals can cause
damage to the drive.
Step 3: Determine Encoder Alignment
In order for the drive to commutate with a motor correctly, it must know how the encoder
commutation tracks and how the marker pulses are aligned with respect to the R, S and T
windings in the stator. The drive does not require any particular alignment position but
instead allows the alignment to be specified using the Motor Encoder U Angle and Motor
Encoder Marker Angle parameters.
If the motor under test has a defined encoder alignment which is repeated on all similar
motors, simply determine the proper angles then use the same settings on all similar motors.
If the motor under test does not have a specific encoder alignment, you should establish some
standard mechanical alignment before determining and setting the encoder electrical angles.
This will allow you to replace the motor with another one in the same alignment without
going through this procedure each time.
Reading Encoder Alignment
The reference motion for this test can be either CW or CCW. We will first use CCW. An
oscilloscope will be used to monitor the signals. This procedure must be performed with the
motor disconnected from the drive with the exception of the encoder power supply.
Be careful when using the drive encoder power supply for testing a motor. Shorting the 5
V drives encoder power supply will blow an internal fuse which can only be replaced at
the factory.
196
User Defined Motors
Figure 140:
Oscilloscope Connections
CCW Reference Rotation
Before reading the motor signals, zero the VTS oscilloscope channel on a horizontal
graduation marker to allow more accurate readings.
Couple the drill motor to the motor shaft. While spinning the motor counter-clockwise, use
an oscilloscope to examine the phase relationship between encoder channel U and positive
peak of VTS (the voltage at motor power terminal T with reference to S).
Use the figure below to determine the electrical angle at which the rising edge of U occurs.
This is the Motor Encoder U Angle. Note that with a CCW reference rotation the positive
peak of VTS is at zero electrical degrees and the electrical angle decreases from left to right.
197
Modular Drive System Reference Manual
Figure 141:
CCW Electrical Angle Plot
æ 180 ö
EUA = 90° + ç tu
÷
t1 ø
è
Where:
EUA = Motor Encoder “U” Angle
If EUA is >360° subtract 360°.
Next, use the oscilloscope to examine the phase relationship between Z and VTS. Use Figure
141 to determine the electrical angle at the rising edge Z. This is the Encoder Marker
Electrical Angle.
198
User Defined Motors
æ 180 ö
EMA = 90° + ç tz
÷
t1 ø
è
Where:
EMA = Motor Encoder Marker Angle
If EMA is >360° subtract 360°.
Many encoders are designed so that the encoder marker pulse occurs a specified number of
electrical degrees from the rising edge of U. You could obtain this value from the encoder
specification sheet however, to minimize errors in conversion, you should make this
measurement.
If you cannot obtain a stable angle measurement between U or Z and VTS, check the encoder
to verify it has the proper cycles per revolution for your motors pole count.
CW Reference Rotation
If the reference motion for the encoder is CW (i.e., Encoder Reference Motion parameter will
be set to 1), rotate the motor in the CW direction. Using an oscilloscope, look at the phase
relationship between the rising edge of U and negative peak of VTS. Use the figure below to
determine the electrical angle at the rising edge of U. Determine the marker electrical angle
in a similar manner.
199
Modular Drive System Reference Manual
Figure 142:
CW Electrical Angle Plot
In Figure 141 the electrical angle decreases from left to right and the positive peak of VTS
occurs at zero degrees electrical. In Figure 142 the electrical angle increases from left to right
and the negative peak of VTS occurs at zero degrees electrical. Note that with a CW reference
rotation the negative peak of VTS is at zero electrical degrees and the electrical angle
decreases from left to right.
Note
If you cannot obtain a stable angle measurement between U or Z and VTS, check the
encoder to verify it has the proper cycles per revolution for your motors pole count.
Establishing a Standard Alignment
A typical encoder alignment practice is to set the rising edge of U to zero crossing of the rising
wave of VSR with the motor rotating CCW.
200
User Defined Motors
Dynamic Alignment Method
This method is used at Control Techniques to establish the alignment on motors. It is
accomplished by spinning the motor CCW with another device while monitoring U and VSR.
Then while the motor is spinning CCW, the encoder body is rotated on it’s mounting until the
desired alignment is established. The encoder is then locked down. This will cause the rising
edge of V to line up with the rising edge zero crossing of VRT when the encoder reference
rotation is CCW.
Figure 143:
CCW Alignment Plot
Static Alignment Method
Another method to align the encoder is to apply DC current through the motor power phases
R to S and rotate the encoder on its mounting until the rising edge of U is detected with a
voltmeter or an oscilloscope. This procedure does not require spinning the motor.
201
Modular Drive System Reference Manual
Figure 144:
Static Alignment Schematic
The current applied through R to S should be the same polarity each time (i.e., + on R) and
the current must be controlled to no more than 50 percent of the RMS stall current rating of
the motor.
Note
Verify that you are seeing the rising edge of the U channel in the encoder reference
direction by twisting the motor shaft CCW by hand while the DC current is applied and
verifying that U goes high when the shaft is rotated in the encoder reference direction.
Step 4: Determine Motor Parameters
Measuring the actual motor Ke is recommended because not all motor manufacturers use the
same measurement techniques. Normally the number of motor poles and the Ke is specified
on the motor data sheet. If it not, or you wish to verify it, use the following tests.
Motor Ke
In this test you will be measuring the AC voltage generated by the motor or the CEMF
(Counter Electro-Motive Force). This measurement requires an AC voltmeter that can
accurately read sine waves of any frequency and some way to determine the motor speed at
the time of the measurement such as a photo tachometer or an oscilloscope.
202
1.
Connect the volt meter across any two of the motor power leads.
2.
Set the volt meter to read VAC at it’s highest range. You can usually expect to read about
20 to 300 VAC.
3.
Spin the motor in either direction at least 500 RPM.
4.
Determine the actual RPM using a photo-tachometer or by monitoring the frequency of
the Z channel with an oscilloscope.
User Defined Motors
Note
When using an oscilloscope, use the following formula to determine the motor velocity in
RPM.
RPM =
60
Seconds/Re volutions
Use the following formula to determine the Ke of the motor after the voltage and speed
measurements.
Ke = 1000
VRMS
RPM
Motor Pole Count
To determine the number motor poles, measure the number of electrical revolutions per
mechanical motor revolution. The number of poles in the motor is two times the number of
electrical cycles (360 degrees) per mechanical revolution. Use the following procedure:
1.
Attach a scope probe to the R winding referenced to the S winding and one to the encoder
Z channel referenced to the encoder power supply 0 volt.
2.
Connect S winding to the encoder power supply 0 volt wire thereby connecting the scope
ground clips together.
3.
Set the scope up to trigger on the Z channel.
4.
Rotate the motor in either direction at any speed.
Note
If you are using an electric drill to rotate the motor, the drill’s name plate should specify
the maximum RPM.
5.
Adjust the horizontal time base until at least two Z channel pulses are visible.
6.
Count the number of full cycles of the Motor waveform you see between the rising edges
of the Z pulses.
203
Modular Drive System Reference Manual
7.
Calculate the number of motor poles:
Number of Cycles · 2 = Number of Motor Poles
Step 5: Editing the MOTOR.DDF File
The PowerTools software obtains the names and parameters of user defined motors from the
Motor Data Definition File (MOTOR.DDF). This file is automatically loaded during the
PowerTools installation and is located in the same directory as the PowerTools software. This
file contains two sections: the Header and the Motor data. An example MOTOR.DDF file is
shown on page 282.
The MOTOR.DDF file is a text file setup with carriage returns as parameter separators. It can
be accessed and edited with any general purpose text editor such as Windows Notepad. In
order for some text editors to read the file and recognize it as a text file, you will need to copy
it over to another directory and change the file name suffix from .ddf to .txt.
Most text editors allow you to save the modified file as a text file if it was read originally as
a .txt file. You must be careful that the edited file is saved as a text file otherwise it will be
unusable as a .ddf file.
After you have completed editing the file, saved it as MOTOR.DDF file. Then copy it back
to its original directory, overwriting the existing MOTOR.DDF file. The next time
PowerTools is started it will automatically recognize the new MOTOR.DDF file.
Header
The header includes the revision and serial number information along with a count of how
many special motor definitions are included in the particular file. Standard Control
Techniques motors will not appear in this file because their data is hard coded into the drive’s
memory.
Revision
This parameter is fixed and is set by the PowerTools revision during installation.
NameCount
The Name Count parameter defines the number of motor sections contained in the .ddf file.
If four motor sections exist, this parameter should be set equal to 4 which will cause
PowerTools to recognize only the first four (4) motor definitions in the file.
Motor Data
The motor data section contains the names and parameters of one or more user defined
motors.
204
User Defined Motors
MotorID is used for each motor to mark the beginning of a new user defined motor definition.
The format is [MotorXX] where XX is the ID number starting with zero and incrementing by
one.
You must use both ID numbers. For example, an ID of 1 would be entered as 01. There is no
practical limit to the number of user defined motors allowed in the .ddf file. Only one set of
user defined motor data can be stored in a single drive at any one time.
The motor name is limited to 12 characters and must immediately follow the MotorID
marker. This is the motor name that shows up in the “Motor Type” combo box in PowerTools.
The motor parameters do not define with which drive they may be used. Therefore, any user
defined motor may be used with any drive.
[Definition]
revision=0x4132
nameCount=2
[Motor0]
name=User1
motorPoles=4
encoderLines=2048
encoderMarker=330
encoderU=330
encoderRef=0
rotorInertia=0.00010
motorKE=28.3
phaseResistance=20.80
phaseInductance=27.1
peakCurrent=4.29
continuousCurrent=1.43
maxOperatingSpeed=5000
encoderExponent=0
[Motor1]
name=User2
motorPoles=4
encoderLines=2048
encoderMarker=330
encoderU=330
encoderRef=0
rotorInertia=0.00017
motorKE=28.3
phaseResistance=7.30
phaseInductance=12.5
peakCurrent=7.80
continuousCurrent=2.60
maxOperatingSpeed=5000
encoderExponent=0
205
Modular Drive System Reference Manual
In this example, the parameters of two user defined motors are named “User1” and “User2”.
Abbreviated parameter identifiers are used in the .ddf file. The table below shows the
abbreviated identifier for each parameter followed by a description of each.
Motor Parameter
DDF Identifier
Motor Poles
motorPoles
Motor Encoder Lines Per Revolution
encoderLines
Motor Encoder Marker Angle
encoderMarker
Motor Encoder U Angle
encoderU
Motor Encoder Reference Motion
encoderRef
Motor Inertia
rotorInertia
Motor KE
motorKE
Motor Resistance
phaseResistance
Motor Inductance
phaseInductance
Motor Peak Current
peakCurrent
Motor Continuous Current
continuousCurrent
Motor Maximum Operating Speed
maxOperatingSpeed
Motor Encoder Exponent
encoderExponent
Motor Parameter Descriptions
Note
These parameters are valid and active only when a user defined motor is selected. When
an Control Techniques motor is selected, the data in these registers remain at the last value
set and do not update to reflect the data of the Control Techniques motor selected.
Motor Poles
Specifies the number of magnetic pole pairs (N-S) on the motor. The supported values are 2,
4, 6, 8, 10, 12, 14 and 16 poles.
Motor Encoder Lines Per Revolution
Specifies a coefficient for determining the number of encoder lines per mechanical
revolution. The supported values are 1 to 16383. The equation for determining the total
number of encoder lines per revolution is:
nLines = n*10x
where
206
nLines = Total number of Encoder Lines
n = Motor Encoder Lines per Rev Coefficient
x = Motor Encoder Exponent
User Defined Motors
The total number of encoder lines is used both for commutation and for position/ velocity
control. To properly commutate the motor, the drive must know the electrical angle (the angle
between the motor magnetic field and stator coils).
Motor Encoder Lines Per Revolution Coefficient
Specifies a coefficient for determining the number of encoder lines per mechanical
revolution. The supported values are 1 to 16383. The equation for determining the total
number of encoder lines per revolution is:
nLines = n * 10x
where:
nLines = Total Number of encoder lines
n = Motor encoder lines per rev coefficient
x = Motor encoder exponent
The total number of encoder lines is used both for commutation and for position/velocity
control. To properly commutate the motor, the drive must know the electrical angle (the angle
between the motor magnetic field and stator coils).
Motor Encoder Exponent
Specifies the exponent for determining the number of encoder lines per mechanical
revolution. The supported values are: 0, 1, 2, 3, 4. The equation for determining the total
number of encoder lines per revolution is:
nLines = n*10x
where:
nLines = Total Number of Encoder Lines
n = Motor Encoder Lines per Rev Coefficient
x = Motor Encoder Exponent
The total number of encoder lines is used both for commutation and for position/velocity
control. To properly commutate the motor, the drive must know the electrical angle (the angle
between the motor magnetic field and stator coils).
Motor Encoder Marker Angle
Specifies the electrical angle at which the marker (Z) pulse occurs with reference to VTS when
the motor is spun in the encoder reference direction. At power-up the drive obtains an initial
estimate of the electrical angle from the status of the U, V and W commutation tracks. This
estimate can be off by as much as 30 °.
When the drive receives the marker pulse, the drive will, within one second, gradually shift
the commutation to the more accurate electrical angle specified by this parameter. The system
207
Modular Drive System Reference Manual
will then operate more efficiently. See “Step 3: Determine Encoder Alignment” for a detailed
procedure on how to determine this parameter.
Motor Encoder U Angle
Specifies the electrical angle at which the rising edge of the U commutation track will occur
with reference to VTS when the motor is spun in the encoder reference direction.
At power-up the drive looks at the status of the U, V and W commutation tracks and, using
this parameter, obtains a crude (± 30 °) estimate of the electrical angle. See “Step 3:
Determine Encoder Alignment” for a detailed procedure on how to determine this parameter.
Motor Encoder Reference Motion
Specifies the direction of motion assumed in phase plots of the encoder’s quadrature and
summation signals. The supported values are CW(1) and CCW(0). Your encoder may have
the same phase plot but is generated from a different direction of rotation. This parameter
affects the way the drive interprets the quadrature and commutation signals.
Motor Inertia
This parameter specifies the inertia of the motor. The range is .00001 to .5 lb-in-sec2. The
drive uses this parameter to interpret the “Inertia Ratio” parameter. “Inertia Ratio” is specified
as a ratio of load to motor inertia.
Motor KE
Specifies the Ke of the motor. The units are VRMS/ kRPM. The line-to-line voltage will have
this RMS value when the motor is rotated at 1000 RPM. The range is 5 to 500.
Motor Resistance
Specifies the phase-to-phase resistance of the motor. You can determine this value by
measuring the resistance between any two motor stator terminals with an ohm meter. The
range is .1 to 50 ohms.
Motor Inductance
Specifies the phase-to-phase inductance of the motor. The range is 1.0 to 100.0 mH.
208
User Defined Motors
Motor Peak Current
Specifies the peak current allowed by the motor. The range is 1 to 100 ARMS. If the peak
current of the motor is greater than 30 ARMS, specify the peak as 30 ARMS. The drive will
limit the peak current to the drive’s capacity.
Motor Continuous Current
Specifies the continuous current allowed by the motor. It is used to determine the current
foldback point and the amount of current allowed during foldback. The drive can also limit
the continuous current to the motor based on the drive capacity. This means that the
operational “continuous current” may be different than the value specified here. The range is
1 to 100 ARMS.
Motor Maximum Operating Speed
Specifies the maximum operating speed of the motor. It is used by the drive to set the default
motor overspeed trip point and to limit the Velocity Command. The Velocity Command is
limited to 9/8ths (112.5 percent) of the Motor Maximum Operating Speed. If the actual
velocity exceeds 150 percent of this value, the drive will fault on Overspeed. Typically this
parameter is determined by the encoder bandwidth and/or other mechanical or electrical
parameters of the motor. The maximum value is 11,000 RPM.
Step 6: Configuring the Drive
Once you have determined the motor parameters and entered them into the MOTOR.DDF
file, you can configured the drive to the user defined motor using PowerTools software. Once
PowerTools is started it will read the MOTOR.DDF file and you will be able to select the nonControl Techniques motor.
Selecting a User Defined Motor
Use the following procedure to select the user defined motor with PowerTools:
1.
Start PowerTools and either open an existing file or start a new file offline.
Note
PowerTools will not allow you to select a "Motor Type" or "Drive Type" while online
with a drive.
2.
From the “Motor Type” list box on the EZ Setup tab (or from the Motor tab if you are in
Detailed Setup view) select your motor from the list of motors.
When you select a new motor, PowerTools will display the Motor Parameters dialog box.
In most cases you will want to select the default option which sets the Full Scale Velocity
parameter to the value you entered into the MOTOR.DDF file.
209
Modular Drive System Reference Manual
Figure 145:
Motor Parameters Dialog Box
3.
Select the correct drive type.
4.
Download the configuration to the drive.
5.
Select the OK button.
The drive will now be configured for the non-Control Techniques motor.
Step 7: Verification and Checkout
Once the cabling and interface circuitry have been assembled and the drive has been correctly
configured, you are ready to power-up the drive. Use the procedure below to power-up the
servo system and verify that it is operating correctly.
Note
For safety reasons, it is a good idea to double check that the key motor parameters below
have been specified correctly.
•
Motor Ke
•
Motor Resistance
•
Motor Inductance
•
Motor Peak Current
•
Motor Continuous Current
This procedure requires the use of PowerTools and some kind of I/O simulator. The simulator
is needed to generate a variable analog command voltage and to allow the drive to be enabled
and disabled. It is possible that the motor will “run-away” during the course of the test.
210
User Defined Motors
The motor may run away during this test. Make sure it is securely fastened and that there
is nothing connected to the motor shaft.
At a certain point in the test it will be necessary to manually rotate the motor through an
integral number of revolutions. This can only be done if the motor shaft and housing are
marked in some way so that the motor can be aligned to a specific position. A disk or pulley
can be installed during that portion of the test to make this alignment more precise.
There are four tests: Rotation test, Torque test, Commutation test and Velocity test. Each test
builds on the last. It is important to perform the tests in the order given.
Note
Do not attempt to perform a test if you have not been able to get the proceeding test to
work.
Rotation Test
This test verifies that the encoder has been correctly interfaced to the drive.
CW Rotation (+)
Figure 146:
CW Rotation of the Motor
Note
This test assumes that you have completed “Step 6: Configuring the Drive” on page 287.
1.
Power-up the drive but leave it disabled.
2.
While online with the drive, select the Status tab. Find the Position Feedback parameter
and note its value.
3.
Mark the motor shaft and the motor face. This is your reference starting point.
4.
Manually rotate the motor CW one revolution as accurately as you can. Verify that the
Position Feedback increased by one revolution. This verifies that the A and B encoder
211
Modular Drive System Reference Manual
signals are wired correctly and the Motor Encoder Reference Motion parameter is
correct.
5.
Manually rotate the motor as accurately as you can, CW 20 revolutions. The Position
Feedback should increase by exactly 20 revs. If the change has some significant
fractional part (20.5 for example) the Motor Encoder Lines Per Revolution parameter is
probably wrong.
6.
Select "View Motor Parameters" from the Tools menu. Note the value of the
Commutation Track Angle parameter. This parameter is obtained directly from the state
of the U, V and W commutation tracks.
7.
Slowly rotate the motor clockwise. The Commutation Track Angle should increase in 60
degree steps and will roll over to 0 at 360. If it does not change, there is a fundamental
problem with the U, V and W encoder signals. If it decreases or changes erratically there
is either a problem with the Motor Encoder Reference Motion parameter or the phasing
of U, V and W.
8.
Disconnect serial communications by clicking on the Disconnect button.
9.
Power-down the drive and wait for the status display to go blank and then power the drive
up again.
10. Re-establish communications with the drive by selecting the Upload button.
11. Select "View Motor Parameters" from the Tools menu. Note the value of the
Commutation Angle Correction parameter. Its value should be zero until the motor
encoder Z channel is detected. Rotate the motor through one or more complete
revolutions until the Z channel is detected.
12. The value should now have a non-zero value between ±40 degrees. If the parameter is
still zero, the drive is probably not seeing the marker pulse.
To confirm this repeat Steps 7-9 several times with different motor shaft starting
locations. If the absolute value of the parameter is greater than 40, there is either a problem
with the phasing of U, V and W or an inconsistency in the encoder alignment parameters.
Torque Test
The purpose of this test is to enable the drive in Torque mode and verify that a positive
command produces CW torque.
1.
Use PowerTools to select Torque mode and set Full Scale Torque to 5 percent. Then click
the Update button to download the changes to the drive.
With Full Scale Torque set to 5 percent, a maximum analog command of 10 volts will
generate 5 percent of continuous torque in the motor which should be enough to spin the
motor but not to damage it.
212
User Defined Motors
2.
Move to the Analog tab and find the "Analog Input" parameter.
3.
Using your simulator adjust the analog command until the value of this parameter is
approximately 0 volts.
4.
Enable the drive. It should not move. If the drive faults at this point you most likely have
a wiring problem (see “Step 1: Motor Wiring”).
5.
Gradually increase the analog command voltage. The motor should start moving with a
voltage level somewhere between 2 and 5 volts. Verify that the direction of motion is
CW.
6.
If there is no motion or CCW motion, there is a problem with encoder alignment
parameters. If the motor moves 30 to 90 ° and then stops, there could be one of several
problems:
•
The number of Motor Poles has been specified incorrectly.
•
The Encoder Lines Per Revolution parameter has been specified incorrectly
•
The motor terminals have been mis-identified (see “Step 1: Motor Wiring”).
Commutation Accuracy Test
This test will determine how accurately the encoder Z channel has been specified. It requires
that the motor be connected and ready to run but it will be spun by the drill motor while in
Torque mode with a zero torque command.
1.
Disable the drive.
2.
Set the Torque Limit to 0.
3.
Make the Torque Limit input function always active.
4.
Enable the drive.
5.
Select “View Motor Parameters” from the Tools menu so you can monitor the
Commutation Voltage.
6.
Spin the motor clockwise 500 to 1000 RPM, then counter-clockwise at the same speed.
The Commutation Voltage should be <10 percent. If the Commutation Voltage is higher
than 10 percent, the Motor Encoder Marker Angle was incorrectly specified and should
be re-tested.
7.
Reset the Torque Limit and the Torque Limit Enable input function to their previous
settings.
213
Modular Drive System Reference Manual
Velocity Test
214
1.
Disable the drive.
2.
Select Velocity Analog mode and set "Full Scale Velocity" parameter to 12 RPM.
3.
Use the simulator to adjust the analog command voltage to 5 volts.
4.
Enable the drive. Find the "Velocity Command Analog" parameter on the Status tab.
Adjust the analog command until this parameter reads exactly 6 RPM. The motor should
be moving at 6 RPM. If the system got through the Torque test, the motor should not runaway at this point. If it does, go back and repeat the Torque test.
5.
Confirm that the motor velocity is really 6 RPM by confirming that it takes 10 seconds
to make one revolution. If this is not the case, the problem may be that both the motor
poles and the encoder line density are off by the same factor.
6.
Reduce the analog command voltage to zero volts and disable the drive.
Modular Drive System Reference Manual
Specifications
MDS Specifications
Specifications
Power Requirements
AC Input Voltage
3 Ph, 342 to 528 VAC, 47 - 63 Hz (480 VAC for rated performance
AC Input Current
Output Continuous Current (5 kHz/10 kHz)
Output Peak Current (5 kHz/10 kHz)
Continuous Output Power
Model
Rating
MP-1250
17 Arms
MP-2500
35 Arms
MP-5000
70 Arms
MD-404
4 Arms / 2.8 Arms
MD-407
7 Arms / 5 Arms
MD-410
10 Arms / 6.5 Arms
MD-420
20 Arms / 14 Arms
MD-434
34 Arms / 22 Arms
MD-404
8 Arms / 5.6 Arms
MD-407
14 Arms / 10 Arms
MD-410
20 Arms / 13 Arms
MD-420
40 Arms / 28 Arms
MD-434
68 Arms / 44 Arms
MP-1250
12.5 kW
MP-2500
25 kW
MP-5000
50 kW
MD-404
3.3 kW
MD-407
5.8 kW
MD-410
8.3 kW
MD-420
16.7 kW
MD-434
28.3 kW
Switching Frequency
5 or 10 kHz ( Ratings based on 5 kHz performance)
Logic Power Supply (User Supplied)
21.6 to 26.4 VDC ( Current requirements based on system)
Encoder Supply Output
+5VDC, 250 mA maximum
System Efficiency
>90%
215
Modular Drive System Reference Manual
Specifications
Regeneration
Internal Energy Absorption (480V) System Bus Capacitance Drive Module and Power Module
Model
Rating
MP-1250
141 Joules
MP-2500
235 Joules
MP-5000
376 Joules
MD-404
10 Joules
MD-407
22 Joules
MD-410
33 Joules
MD-420
47 Joules
MD-434
47 Joules
Integral Transistor connected to External Resistor, 15 A continuous
I/O Power Supply (User Supplied)
Model
Rating
MP-1250
30 Ohm minimum, 6 kW max.
MP-2500
30 Ohm minimum, 6 kW max.
MP-5000
9 Ohm minimum, 12 kW max.
+ 10 to 30 VDC
Power Module Control Inputs
Digital (2)
+10 to 30 VDC, 2.8 kOhm, Sourcing, Optically Isolated
Power Module Control Outputs
Digital (6)
Relay Contact (1)
+10 to 30 VDC, 150 mA, Sourcing, Optically Isolated
AC Interlock, 24 VDC 5A
Drive Module Control Inputs
Analog (1)
Digital (5)
216
+/- 10 VDC, 14 bit, 100 kOhm, Differential
Analog Max Input Rating: Differential +/- 14 VDC
Each Input with reference to Analog Ground +/- 14 VDC
+10-30 VDC, 2.8 kOhm, Sourcing (active high) , Optically Isolated,
Max input response time is 500 µs, Input debounce: 0 - 2000 ms,
Software selectable
Specifications
Specifications
Software selectable Differential (RS422) or Single Ended (TTL Schmitt
Trigger)
Pulse (1)
Maximum input frequency:
Differential - 2 MHz per channel; 50% duty cycle (8 MHz count in
quadrature)
Single ended - 1 MHz per channel; 50% duty cycle (4 MHz count in
quadrature)
Ratio Capabilities: 20 to 163,840,000 PPR
Input Device = AM26C32
Vdiff = 0.1 - 0.2 V
V common mode max = +/- 7V
Input impedance each input to 0V = 12 - 17 kOhm
Drive Module Control Outputs
Analog (2)
+/- 10 VDC (single ended, 20 mA max) 10 bit software selectable output
signals
Digital (3)
+10-30 VDC 150 mA max, Sourcing, Optically Isolated, Input
debounce: Programmable range, 0 to 200 ms
Motor Over Temperature (1)
0 to +5 VDC, Single Ended, 10 kOhm
Differential line driver, RS-422 and TTL compatible
Scalable in one line increment resolution up to 2048 lines/rev of the
motor (MG and NT)
Pulse (1)
Output Device = AM26C31
20 ma per channel, sink and/or source
Vout Hi @ 20 ma = 3.8 - 4.5 V
Vout Lo @ 20 ma = 0.2 - 0.4 V
Vout diff w/100 ohm termination = 2.0 - 3.1 V
Vout common mode w/100 ohm termination = 0.0 - 3.0 V
Iout short circuit = 30 - 130 mA
Cooling Method
Model
Rating
MP-1250
Convection
MP-2500
Integral Fan
MP-5000
Integral Fan
MD-404
Convection
MD-407
Integral Fan
MD-410
Integral Fan
MD-420
Integral Fan
MD-434
Integral Fan
Environmental
Rated Ambient Temperature
32 to 104 F (0 to 40 C)
Maximum Ambient Temperature
32 to 122 F (0 to 50 C) with power derating of 3% / 1.8 F (1 C) above
104 F (40 C)
Rated Altitude
3280’ (1000 m)
217
Modular Drive System Reference Manual
Specifications
Maximum Altitude
For altitudes >3280’ (1000 m) derate output by 1% / 328’ (100m) not to
exceed 7560’ (2000 m)
Vibration
10 to 2000 Hz @ 2g
Humidity
10 to 95% non-condensing
Storage Temperature
-13 to 167F (-25 to 75 C)
Ingress Protection (IP) Rating
Power and Drive Module: IP20
MH motors: IP65
Molded motor and feedback cables: IP65
Serial Interface
RS-232 / RS-485
Internal RS-232 to RS-485 converter
Modbus protocol with 32 bit data extension 9600 or 19.2 k baud
Serial Communications
Max baud rate
19.2k
Start bit
1
Stop bit
2
Parity
none
Data
8
Weight
Model
MP-1250
Power Module
MP-2500
MP-5000
Rating
8.35 lbs
10.25 lbs
MD-404
MD-407
Drive Module
High Bus Voltage
880 VDC
Shunt Turn On
830 VDC
Shunt Turn Off (Hysteresis)
780 VDC
Nominal Bus Voltage 480 VAC
680 VDC
Transformer Sizing
KVA Rating at Max. Power (page 27)
218
8.35 lbs.
MD-410
MD-420
10.25 lbs
MD-434
12 lbs
Model
Size
MP-1250
25 KVA
MP-2500
50 KVA
MP-5000
100 KVA
Specifications
Specifications
AC Input Wire Gauge
Shunt Size
Logic and Digital I/O Power Sizing
Model
Gauge
MP-1250
16 GA
MP-2500
10 GA
MP-5000
4 GA
All Power Modules
16 GA
Model
Max. RMS Current (A)
MP-1250
Power Module
MP-2500
0.30
MP-5000
MD-404
MD-407
Drive Module
0.60/Module
MD-410
MD-420
MD-434
0.80/Module
All
0.40/FM Module
*
0.07/Encoder
FM Module
Synchronization Feedback Encoder
Specifications
Fuses
Power Module (page 27)
Drive Module (page 70)
Model
Type
Size
MP-1250
KTK-R, JKS or JJS
20A
MP-2500
JKSor JJS
40A
MP-5000
JJS
70A
MD-404
10 A
MD-407
16 A
MD-410
Shawmut A70QS
20 A
MD-420
32 A
MD-434
50 A
219
Modular Drive System Reference Manual
Drive and Motor Combination Specifications
Drive
MD-404
Motor
Cont.
Stall
Torque
lb-in
(Nm)
Peak
Stall
Torque
lb-in
(Nm)
Power
HP @
Rated
Speed
kWatts
Inertia
lb-in-sec2
(kg-cm2)
Max
speed
RPM
Encoder
resolution
lines/rev
Motor Ke
VRMS/
krpm
Motor Kt
lb-in/
ARMS
(Nm/
ARMS)
MH-316
21.5
(2.43)
58
(6.55)
0.83
0.0006725
(0.75987)
4000
2048
75
10.98
(1.24)
MH-340
46
(5.20)
135
(15.25)
1.31
0.0014275
(1.61296)
3000
2048
116
16.98
(1.92)
MH-455
65
(7.34)
140.56
(15.88)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-455
72.5
(8.19)
228.42
(25.81)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-490
105
(11.86)
225.4
(25.4)
1.78
0.006727
(7.60099)
3000
2048
110
16.1
(1.82)
MH-455
72.5
(8.19)
268.82
(30.37)
1.8
0.003557
(4.01914)
3000
2048
120
17.57
(1.99)
MH-490
105
(11.86)
322
(36.38)
1.78
0.006727
(7.60099)
3000
2048
110
16.1
(1.82)
MH-6120
119
(13.45)
336.8
(38.05)
3.25
0.010657
(12.04159)
3000
2048
115
16.84
(1.90)
MH-6120
119
(13.45)
353.64
(39.96)
3.25
0.010657
(12.04159)
3000
2048
115
16.84
(1.90)
MH-6200
234
(26.44)
673.6
(76.11)
3.41
0.018857
(21.30695)
3000
2048
115
16.84
(1.90)
MH-6300
299
(33.78)
673.6
(76.11)
3.74
0.027187
(30.71921)
3000
2048
115
16.84
(1.90)
MH-6200
234
(26.44)
729
(82.37)
3.41
0.018857
(21.30695)
3000
2048
115
16.84
(1.90)
MH-6300
299
(33.78)
932.09
(105.3)
3.74
0.027187
(30.71921)
3000
2048
115
16.84
(1.90)
MH-8500
530
(60.2)
997
(113.2)
9.95
0.078
(87.837)
3000
2048
121.6
17.8
(2.011)
MH-8750
748
(84.9)
1500
(170.3)
15.44
0.133
(150.24)
3000
2048
162
23.7
(2.68)
MD-407
MD-410
MD-420
MD-434
220
Specifications
Axial/Radial Loading
Motor
Max Radial
Load (lb.)
Max. Axial
Load (lb.)
MH-316
40
25
MH-340
40
25
MH-455
100
50
MH-490
100
50
MH-6120
150
50
MH-6200
150
50
MH-6300
150
50
MH-8500
250
100
Radial Loading
Axial Loading
1”
Maximum radial load is rated 1 inch from motor face.
Figure 147:
Axial/Radial Loading
IP Ratings
Motor
Rating
MH-316
MH-340
MH-455
MH-490
MH-6120
IP65
MH-6200
MH-6300
MH-8500
Encoder Specifications
Motor
Density
Output Type
Output Frequency
Output Signals
Power Supply
MH
2048 lines/rev
RS422 differential
driver
250 kHz per channel
A, B, Z, Comm U,
Comm W, Comm V
and all complements
5V, 150 mA ±10%
221
Modular Drive System Reference Manual
Power Dissipation
In general, the drive power stages are around 90 percent efficient depending on the actual
point of the torque speed curve the drive is operating. Logic power losses on the MDS Drive
Module is 11 W minimum to 21 W depending on external loading such as FM modules and
input voltages.
The values shown in the table below represent the typical dissipation that could occur with
the drive/motor combination specified at maximum output power.
Maximum Power Stage
Losses
(Pp) (Watts)
Total
Power Losses
(Watts)
MD-404 / MH-316
25
45
MD-404 / MH-340
36
56
MD-404 / MH-455
42
62
MD-407 / MH-455
48
68
MD-407 / MH-490
72
92
MD-410 / MH-455
60
80
MD-410 / MH-490
72
92
90
110
MD-420 / MH-6120
108
128
MD-420 / MH-6200
126
146
MD-420 / MH-6300
200
220
MD-434 / MH-6200
150
170
MD-434 / MH-6300
200
220
MD-434 / MH-8500
380
400
MD-434 / MH-8750
420
440
Drive Model
Logic Power Losses
(typ) Drive
(Pld) (Watts)
20
MD-410 / MH-6120
Power Dissipation Calculation
Calculating actual dissipation requirements in an application can help minimize enclosure
cooling requirements, especially in multi-axis systems. To calculate dissipation in a specific
application, use the following formula for each axis and then total them up. This formula is a
generalization and will result in a conservative estimate for power losses.
TPL =
TRMS · Vmax
+ Pld + Psr
1500
Where:
TPL = Total power losses (Watts)
TRMS = RMS torque for the application (lb-in)
Vmax = Maximum motor speed in application (RPM)
Pld = Logic Power Losses Drive (Watts)
222
Specifications
Psr = Shunt Regulation Losses (Watts)-(RSR-2 losses
or equivalent)
Note
TRMS * Vmax / 1500 = Power Stage Dissipation = Pp
A more accurate calculation would include even more specifics such as actual torque
delivered at each speed plus actual shunt regulator usage. For help in calculating these please
contact our Application Department with your system profiles and loads.
223
Modular Drive System Reference Manual
MDS Power Module Dimensions
2.75 [69.85]
1.75 [44.45]
1.38 [34.93]
.60 [15.24]
2.81
[71.37]
10.25
[260.35]
2.64
[67.04]
16.06
[407.92]
14.25 [361.95]
9.00 [228.60]
Figure 148:
224
MP-1250 and MP-2500 Dimensional Drawing
Specifications
3.50 [88.90]
1.75 [44.45]
1.38 [34.93]
0.60 [15.24]
PE
PE
2.64 [67.04]
2.83 [71.83]
16.08 [408.38]
14.25 [361.95]
10.25 [260.35]
9.00 [228.60]
Figure 149:
MP-5000 Dimensional Drawing
225
Modular Drive System Reference Manual
MDS Drive Module Dimensions
2.75 [69.85]
.55 [13.84]
.84 [21.32]
2.64 [67.04]
10.25 [260.35]
16.86 [428.23]
2.80 [71.12]
9.00 [228.60]
1.38 [34.93]
Figure 150:
226
11.80 [299.71]
MD-404, 407 and 410 Dimensional Drawing
Specifications
3.50 [88.90]
.55 [13.84]
.84 [21.32]
2.64 [67.04]
10.25 [260.35]
16.86 [428.36]
2.80 [71.12]
9.00 [228.60]
1.38 [34.92]
Figure 151:
11.80 [299.71]
MD-420 Dimensional Drawing
227
Modular Drive System Reference Manual
5.50 [139.70]
2.75 [69.85]
.55 [13.84]
.84 [21.32]
16.86 [428.16]
2.64 [67.04]
10.25 [260.35]
2.80 [71.12]
9.00 [228.60]
1.38 [34.93]
Figure 152:
228
11.80 [299.71]
MD-434 Dimensional Drawing
Specifications
Cable Diagrams
Drive Signal
CMDX, CMDO, ECI-44
CDRO
AX4-CEN
Analog Command In +
X
X
X
Analog Command In -
X
X
X
Encoder Out A
X
X
X
Encoder Out A/
X
X
X
Encoder Out B
X
X
X
Encoder Out B/
X
X
X
Encoder Out Z
X
X
X
Encoder Out Z/
X
X
X
Pulse In A
X
X
Pulse In A/
X
X
Pulse In B
X
X
Pulse In B/
X
X
Pulse In Z
X
Pulse In Z/
X
Pulse In A (single ended)
X
X
Pulse In B (single ended)
X
X
I/O Input Drive Enable
X
I/O Input #1
X
I/O Input #2
X
I/O Input #3
X
X
X
I/O Input #4
X
X
X
I/O Output #1
X
X
X
I/O Output #2
X
X
X
I/O Output #3
X
X
X
I/O Power + In (1st wire)
X
X
X
I/O Power + In (2nd wire)
X
X
X
I/O Power 0V In (1st wire)
X
X
X
I/O Power 0V In (2nd wire)
X
Analog Out 0V
X
X
X
Analog Out Channel #1 +
X
X
X
Analog Out Channel #2 +
X
X
X
External Encoder +5 Power Out (200
ma)
X
X
External Encoder Common
X
X
+15V Power Out (10 ma)
X
RS-485 +
X
RS-485 -
X
229
Modular Drive System Reference Manual
CMDX-XXX Cable
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
DRAIN
SHELL
COLOR CODE
FUNCTION
RED/BROWN STRIPE
INPUT I/O 1
BROWN/RED STRIPE
INPUT I/O 2
BLACK/BLUE STRIPE
INPUT I/O 3
BLUE/BLACK STRIPE
INPUT I/O 4
WHITE/ORANGE STRIPE
RS-485+
ORANGE/WHITE STRIPE
RS-485-
PURPLE/BLUE STRIPE*
MOTOR ENCODER OUTPUT A
BLUE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT A/
RED/BLUE STRIPE
EXT ENCODER 200mA max +5V
BLUE/RED STRIPE
EXT ENCODER 200mA max COMMON
BLACK/GREEN STRIPE
DRIVE ENABLE INPUT
GREEN/BLACK STRIPE
OUTPUT I/O 3
BLACK/BROWN STRIPE
OUTPUT I/O 2
BROWN/BLACK STRIPE
OUTPUT I/O 1
PURPLE/ORANGE STRIPE*
MOTOR ENCODER OUTPUT B
ORANGE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT B/
BLACK/RED STRIPE
SYNC ENCODER INPUT Z
RED/BLACK STRIPE
SYNC ENCODER INPUT Z/
PURPLE/GREEN STRIPE *
SYNC ENCODER INPUT A
GREEN/PURPLE STRIPE *
SYNC ENCODER INPUT A/
YELLOW/BLUE STRIPE
24V I/O
BLUE/YELLOW STRIPE
0V I/O
YELLOW/BROWN STRIPE
24V I/O
BROWN/YELLOW STRIPE
0V I/O
PURPLE/BROWN STRIPE*
MOTOR ENCODER OUTPUT Z
BROWN/PURPLE STRIPE*
MOTOR ENCODER OUTPUT Z/
PURPLE/GRAY STRIPE *
SYNC ENCODER INPUT B/
GRAY/PURPLE STRIPE *
WHITE/BLUE STRIPE
SYNC ENCODER INPUT B
COMMAND INPUT -
BLUE/WHITE STRIPE
COMMAND INPUT +
WHITE/RED STRIPE
ANALOG OUT AG 1 AND 2
RED/WHITE STRIPE
ENV+
WHITE/GREEN STRIPE
ANALOG OUT 1 +
GREEN/WHITE STRIPE
ANALOG OUT 2 +
YELLOW/GRAY STRIPE
NOT USED
GRAY/YELLOW STRIPE
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NC
NOT USED
NOT USED
NC
NOT CONNECTED
NC
NOT USED
SHELL
15
30
P1 MALE 44D
P2 MALE 44D
13 12
14
29
44
28 27
43
42 41
11
10
26 25
40
9
24
39
8
23
38 37
7
22
36
6
5
21 20
35 34
4
19
33
3
18
2
17
32
1
16
31
SOLDER SIDE
Note
Some CMDX cables may have White/Yellow and Yellow/White wires in place of the
White/Orange and Orange/White shown in the figure above (pins 6 and 21).
230
Specifications
CMDO-XXX Cable
PIN 1
2.10
COLOR CODE
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
DRAIN
1
2
3
4
6
21
8
9
11
12
16
17
18
19
23
24
25
39
27
41
34
32
33
31
37
38
40
26
14
15
29
28
43
44
20
36
5
7
10
13
22
30
35
42
FUNCTION
RED/BROWN STRIPE
INPUT I/O 1
BROWN/RED STRIPE
INPUT I/O 2
BLACK/BLUE STRIPE
INPUT I/O 3
BLUE/BLACK STRIPE
INPUT I/O 4
WHITE/ORANGE STRIPE
RS-485+
ORANGE/WHITE STRIPE
RS-485-
PURPLE/BLUE STRIPE*
MOTOR ENCODER OUTPUT A
BLUE/PURPLE STRIPE*
MOTOR ENCODER OUTPUT A/
RED/BLUE STRIPE
EXT ENCODER 200mA max +5V
BLUE/RED STRIPE
BLACK/GREEN STRIPE
EXT ENCODER 200mA max COMMON
DRIVE ENABLE INPUT
GREEN/BLACK STRIPE
OUTPUT I/O 3
BLACK/BROWN STRIPE
OUTPUT I/O 2
BROWN/BLACK STRIPE
OUTPUT I/O 1
PURPLE/ORANGE STRIPE*
MOTOR ENCODER OUTPUT B
ORANGE/PURPLE STRIPE*
BLACK/RED STRIPE
MOTOR ENCODER OUTPUT B/
SYNC ENCODER INPUT Z
RED/BLACK STRIPE
SYNC ENCODER INPUT Z/
PURPLE/GREEN STRIPE *
SYNC ENCODER INPUT A
GREEN/PURPLE STRIPE *
SYNC ENCODER INPUT A/
YELLOW/BLUE STRIPE
24V I/O
BLUE/YELLOW STRIPE
0V I/O
YELLOW/BROWN STRIPE
24V I/O
BROWN/YELLOW STRIPE
0V I/O
PURPLE/BROWN STRIPE*
MOTOR ENCODER OUTPUT Z
BROWN/PURPLE STRIPE*
PURPLE/GRAY STRIPE *
MOTOR ENCODER OUTPUT Z/
SYNC ENCODER INPUT B/
GRAY/PURPLE STRIPE *
SYNC ENCODER INPUT B
WHITE/BLUE STRIPE
COMMAND INPUT -
BLUE/WHITE STRIPE
COMMAND INPUT +
WHITE/RED STRIPE
ANALOG OUT AG 1 AND 2
RED/WHITE STRIPE
ENV+
WHITE/GREEN STRIPE
ANALOG OUT 1 +
GREEN/WHITE STRIPE
ANALOG OUT 2 +
YELLOW/GRAY STRIPE
NOT USED
GRAY/YELLOW STRIPE
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NOT USED
NC
NC
NOT USED
NOT USED
NC
NOT USED
NC
NOT USED
SHELL
15
30
14
29
44
13 12
28 27
43
11 10
9
26 25 24
42 41 40
8
23
7
22
39 38 37
6
5
21 20
36
35 34
4
3
19 18
33
2
17
32
1
16
P1 MALE 44D
31
SOLDER SIDE
Note
Some CMDO cables may have White/Yellow and Yellow/White wires in place of the
White/Orange and Orange/White shown in the figure above (pins 6 and 21).
231
Modular Drive System Reference Manual
CDRO-XXX Cable
PIN 1
WIRE COLOR SOLID/STRIPE
BLU/PUR
P
PUR/BLU
ORG/PUR
P
PUR/ORG
BRN/PUR
P
PUR/BRN
RED/BLU
P
BLU/RED
GRN/BLK
P
BLK/GRN
WHT/BLU
P
BLU/WHT
WHT/RED
P
RED/WHT
YEL/GRY
GRY/PUR
P
PUR/GRY
BLK/BRN
P
BRN/BLK
BRN/YEL
P
YEL/BRN
WHT/GRN
P
GRN/WHT
GRN/PUR
P
ENCODER OUTPUT A/
ENCODER OUTPUT A
11
12
34
16
14
15
29
ENCODER +5VDC SUPPLY
ENCODER SUPPLY COMMON
I/O SUPPLY +
4
19
26
40
18
17
31
33
43
44
41
27
INPUT #4
OUTPUT #1
ENCODER OUTPUT B/
ENCODER OUTPUT B
ENCODER OUTPUT Z/
ENCODER OUTPUT Z
DRIVE ENABLE INPUT
ANALOG COMMAND INPUT ANALOG COMMAND INPUT +
DIAGNOSTIC OUTPUT COMMON
N/C
GRY/YEL
P
9
8
24
23
38
37
PUR/GRN
PULSE INPUT B
PULSE INPUT B/
OUTPUT #2
OUTPUT #3
I/O COMMON I/O SUPPLY +
DIAGNOSTIC OUTPUT 1
DIAGNOSTIC OUTPUT 2
PULSE INPUT A/
PULSE INPUT A
N/C
15 14 13 12
11 10 9
30 29 28 27
8
26 25 24
44 43 42 41 40
7
6
23 22
39 38 37
36
5
35 34
SOLDER SIDE
232
4
21 20
3
2
1
19 18 17
33
32
16
31
Specifications
AX4-CEN-XXX Cable
ENCODER OUTPUT A/
9
ENCODER OUTPUT A
8
ENCODER OUTPUT B/
24
ENCODER OUTPUT B
23
ENCODER OUTPUT Z/
38
ENCODER OUTPUT Z
37
I/O SUPPLY+
34
DRIVE ENABLE INPUT
ANALOG COMMAND INPUT -
16
ANALOG COMMAND INPUT +
15
DIAGNOSTIC OUTPUT COMMON
29
BLU/PUR
PUR/BLU
ORG/PUR
PUR/ORG
PUR/BRN
N/C
RED/BLU
N/C
BLU/RED
BLK/GRN
BLU/WHT
N/C
I/O COMMON -
31
I/O SUPPLY +
33
DIAGNOSTIC OUTPUT 1
43
DIAGNOSTIC OUTPUT 2
44
OPEN COLLECTOR PULSE/
20
OPEN COLLECTOR DIRECTION
36
P
P
P
P
P
YEL/BRN
BRN/YEL
P
WHT/GRN
GRN/WHT
P
GRN/PUR
PUR/GRN
N/C
DRAIN WIRES
ENCODER OUTPUT B/
12
ENCODER OUTPUT B
23
ENCODER OUTPUT Z/
11
ENCODER OUTPUT Z
21
ENABLE CONTACT
9
8
ENABLE CONTACT
ANALOG COMMAND OUTPUT -
20
ANALOG COMMAND OUTPUT +
6
ANALOG COMMON
15
DISCRETE INPUT (DRIVE STATUS)
N/C
N/C
N/C
BLK/BRN
BRN/BLK
ENCODER OUTPUT A
24
N/C
GRY/PUR
PUR/GRY
ENCODER OUTPUT A/
13
N/C
P
GRY/YEL
YEL/GRY
N/C
17
RED/WHT
25
N/C
WHT/RED
N/C
OUTPUT #3
P
WHT/BLU
19
18
P
GRN/BLK
14
OUTPUT #2
P
BRN/PUR
N/C
OUTPUT #1
P
P
16
DISCRETE INPUT (CW TRAVEL LIMIT)
3
DISCRETE INPUT (CCW TRAVEL LIMIT)
14
OV I/O SUPPLY COMMON
2
+24V I/O SUPPLY
7
ANALOG INPUT 1
19
ANALOG INPUT 2
5
PULSE/OUTPUT
17
DIRECTION OUTPUT
4
CHASSIS GROUND
233
Modular Drive System Reference Manual
TIA-XXX Cable
PIN 1
PIN 1
2.5 MAX (2X)
0.250
.63 MAX (2X)
END VIEW
FEMALE
END VIEW
MALE
(SOCKETS)
(PINS)
5
2
3
4
9
6
7
1
8
5
3
2
4
9
6
7
1
8
BRAID +
DRAIN
SHELL
BLACK
WHITE
BLUE
NC
NC
NC
NC
NC
NC
SHELL
MALE DB-9 CONN
FEMALE DB-9 CONN
DDS-XXX Cable
DDS
DDS
P3
SHELL
DRAIN
WIRE
DB-9 MALE
BLACK
5
GND
4
485+
9
485-
5
5
GND
2
2
RX
3
3
TX
4
4
485+
9
9
485-
6
6
7
7
1
1
WHITE
BLUE
8
DB-9 FEMALE
P2
234
8
DB-9 MALE
P1
Specifications
TERM-H (Head) Terminator
1.22
R.195
.78
.67
.66
TERM-H
PIN #1
.20
.110 MAX (2)
.090 MIN
.67 REF
5
5
GND
2
2
R1 IN (RX)
3
3
T1 OUT (TX)
4
485+
9
485-
4
R2
9
R4
6
6
+5V
7
7
NOT USED
1
1
NOT USED
8
8
NOT USED
SHELL
DB-9 MALE
SHELL
DB-9 FEMALE
TERM-T (Tail) Terminator
1.22
.78
R.195
.67
.66
.20
PIN #1
5
2
R1
3
4
9
.110 MAX (2)
.090 MIN
.67 REF
R3
R2
R4
5
GND
2
R1 IN (RX)
3
T1 OUT (TX)
4
485+
9
485-
6
6
+5V
7
7
NOT USED
1
1
NOT USED
8
8
NOT USED
SHELL
DB-9 MALE
SHELL
DB-9 FEMALE
Note
See the "Multi-drop Communications" section for resistor values.
235
Modular Drive System Reference Manual
CMDS-XXX Cable
3.23
1.20
3.0 +/- 0.25
GRN/YEL
BRN
BLK
BLU
D
A
B
C
SHELL
A
G
B
H
F
E
C
D
SOLDER SIDE
CMMS-XXX Cable
3.99
1.40
3.0 +/- 0.25
GRN/YEL
BRN
BLK
BLU
D
A
B
C
SHELL
F
A
B
G
E
D
C
SOLDER SIDE
236
Specifications
CFCS-XXX Cable
2.24
3.16
1.18
1.55
OVERALL TIN/COPPER BRAID
SHELL
LARGE 18GA PAIR
RED/GRN OR
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
N/C
DRAINS
1
10
2
11
3
12
4
13
5
14
6
15
7
17
9
16
8
18
19
20
21
22
23
24
25
26
B
C
N
P
M
U
E
R
F
S
G
H
K
T
A
V
L
D
J
W
X
Y
Z
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
N/C
A
A/
B
B/
Z
Z/
U
U/
V
V/
W
W/
+5 VDC
GND
MOTOR OVERTEMP
NOT USED
CASE
= TWISTED PAIR
PIN 1
P
N
Y
M
A
B
R
L X
K
J
Z
S
T
W
V
H
G
U
C
D
E
F
SOLDER SIDE
SOLDER SIDE
237
Modular Drive System Reference Manual
CFCO-XXX Cable
2.24
PIN 1
1.55
PLUGGING SIDE
OVERALL T/C BRAID
1
BLU
10
ORN
2
GRN
11
BRN
3
BLK
12
YEL
4
WHT/BRN
13
BRN/WHT
5
WHT/GRAY
P
P
P
P
P
14 GRAY/WHT
RED/GRN OR
LARGE 18 GA PAIR
6
RED/ORN
15
ORN/RED
7
RED/BLU
17
BLU/RED
9
RED/GRN
16
GRN/RED
8
N/C
18
N/C
19
N/C
20
N/C
21
N/C
22
N/C
23
N/C
24
N/C
25
N/C
26
N/C
CONNECTOR SHELL
PIN 1
SOLDER SIDE
238
P
P
P
P = TWISTED PAIR
Specifications
CFOS-XXX Cable
3.16
1.18
OVERALL TIN/COPPER BRAID
SHELL
LARGE 18GA PAIR
RED/GRN OR
BLU
ORN
GRN
BRN
BLK
YEL
WHT/BRN
BRN/WHT
WHT/GRY
GRY/WHT
RED/ORN
ORN/RED
RED/BLU
BLU/RED
RED/GRN
GRN/RED
N/C
N/C
N/C
N/C
N/C
N/C
DRAINS
P
N
L X
K
J
Z
B
S C
T
W
V
H
= TWISTED PAIR
A
R
Y
M
B
C
N
P
M
U
E
R
F
S
G
H
K
T
A
V
L
D
J
W
X
Y
Z
G
U
D
E
F
SOLDER SIDE
239
Modular Drive System Reference Manual
240
Modular Drive System Reference Manual
Glossary
µs
Microsecond, which is 0.000001 second.
A
Amps.
ARMS
Amps (RMS).
AWG
American Wire Gauge.
Baud Rate
The number of binary bits transmitted per second on a serial communications link such as RS232. (1 character is usually 10 bits.)
Check Box
In a dialog box, a check box is a small box that the user can turn “On” or “Off” with the
mouse. When “On” it displays an X in a square; when “Off” the square is blank. Unlike option
(radio) buttons, check boxes do not affect each other; any check box can be “On” or “Off”
independently of all the others.
CRC
Cyclical Redundancy Check.
Dialog Box
A dialog box is a window that appears in order to collect information from the user. When the
user has filled in the necessary information, the dialog box disappears.
DIN Rail
Deutsche Industrie Norm Rail
DLL
In Microsoft Windows, a Dynamic Link Library contains a library of machine-language
procedures that can be linked to programs as needed at run time.
241
Modular Drive System Reference Manual
Downloading
The transfer of a complete set of parameters from PowerTools or a Function Module to a
drive.
EEPROM
An EEPROM chip is an Electrically Erasable Programmable Read-Only Memory; that is, its
contents can be both recorded and erased by electrical signals, but they do not go blank when
power is removed.
EMC
Electromagnetic Compatibility
EMI - Electro-Magnetic Interference
EMI is noise which, when coupled into sensitive electronic circuits, may cause problems.
Firmware
The term firmware refers to software (i.e., computer programs) that are stored in some fixed
form, such as read-only memory (ROM).
FM
Function Module - device which is attached to the front of the drive to provide additional
functionality.
Hysteresis
For a system with an analog input, the output tends to maintain it’s current value until the
input level changes past the point that set the current output value. The difference in response
of a system to an increasing input signal versus a decreasing input signal.
I/O
Input/Output. The reception and transmission of information between control devices. In
modern control systems, I/O has two distinct forms: switches, relays, etc., which are in either
an on or off state, or analog signals that are continuous in nature generally depicting values
for speed, temperature, flow, etc.
Inertia
The property of an object to resist changes in rotary velocity unless acted upon by an outside
force. Higher inertia objects require larger torque to accelerate and decelerate. Inertia is
dependent upon the mass and shape of the object.
Input Function
A function (i.e., Stop, Preset) that may be attached to an input line.
242
Glossary
Input Line
The actual electrical input, a screw terminal.
Least Significant Bit
The bit in a binary number that is the least important or having the least weight.
LED
Light Emitting Diode.
List Box
In a dialog box, a list box is an area in which the user can choose among a list of items, such
as files, directories, printers or the like.
mA
Milliamp, which is 1/1000th of an Ampere.
MB
Mega-byte.
MDS
Modular Drive System
Most Significant Bit
The bit in a binary number that is the most important or that has the most weight.
ms
Millisecond, which is 1/1000th of a second.
NVM
Non-Volatile Memory.
NTC
Negative Temperature Resistor
Option Button
See Radio Button.
Opto-isolated
A method of sending a signal from one piece of equipment to another without the usual
requirement of common ground potentials. The signal is transmitted optically with a light
243
Modular Drive System Reference Manual
source (usually a Light Emitting Diode) and a light sensor (usually a photosensitive
transistor). These optical components provide electrical isolation.
Output Function
A function (i.e., Drive OK, Fault) that may be attached to an output line.
Output Line
The actual transistor or relay controlled output signal.
Parameters
User read only or read/write parameters that indicate and control the drive operation.
PE
Protective Earth.
PID
Proportional-Integral-Derivative. An acronym that describes the compensation structure that
can be used in many closed-loop systems.
PLC
Programmable Logic Controller. Also known as a programmable controller, these devices are
used for machine control and sequencing.
PowerTools-FM and -PRO
Windows®-based software to interface with the Modular Drive System and Function
Modules.
Radio Button
Also known as the Option Button. In a dialog box, radio buttons are small circles only one of
which can be chosen at a time. The chosen button is black and the others are white. Choosing
any button with the mouse causes all the other buttons in the set to be cleared.
RAM
RAM is an acronym for Random-Access Memory, which is a memory device whereby any
location in memory can be found, on average, as quickly as any other location.
RMS
Root Mean Squared. For an intermittent duty cycle application, the RMS is equal to the value
of steady state current which would produce the equivalent heating over a long period of time.
244
Glossary
ROM
ROM is an acronym for Read-Only Memory. A ROM contains computer instructions that do
not need to be changed, such as permanent parts of the operating system.
RPM
Revolutions Per Minute.
Serial Port
A digital data communications port configured with a minimum number of signal lines. This
is achieved by passing binary information signals as a time series of 1’s and Ø’s on a single
line.
Uploading
The transfer of a complete set of parameters from PowerTools or an FM-P.
VAC
Volts, Alternating Current.
VDC
Volts, Direct Current.
Windows, Microsoft
Microsoft Windows is an operating system that provides a graphical user interface, extended
memory and multi-tasking. The screen is divided into windows and the user uses a mouse to
start programs and make menu choices.
245
Modular Drive System Reference Manual
246
Modular Drive System Reference Manual
Index
A
AC Interlock Connections, 45
AC Power Line Fusing, 27
AC Power Wire Size, 27
AC Supplies NOT Requiring
Transformers, 24
AC Supplies Requiring Transformers, 25
Achieving Low Impedance Connections, 6
Active State, 97
Advanced Tab, 162
Analog Command Wiring, 55, 95
Analog Input, 94
Analog Outputs, 96
Analog Submode, 82
Analog Tab, 148
Assigning Inputs, 117
Assigning Outputs, 118
AX4-CEN-XXX Cable, 233
Axial/Radial Loading, 221
B
Backplane Installation, 19
Brake Operation, 92
C
Cable Diagrams, 229
Cable to Enclosure Shielding, 8
CCW Reference Rotation, 197
CDRO-XXX Cable, 232
CFCO-XXX Cable, 238
CFCS-XXX Cable, 237
CFOS-XXX Cable, 239
Changing the Default View, 109
CMDO-XXX Cable, 231
CMDS-XXX Cable, 236
CMDX-XXX Cable, 230
CMMS-XXX Cable, 236
Command Cables, 54
Command Connector Wiring, 52
Communications with Drive, 120
Commutation Accuracy Test, 213
Commutation Basics, 189
Configuring the Drive, 209
Current Foldback, 91
CW Reference Rotation, 199
D
DDS-XXX Cable, 234
Debounce Time, 98
Declaration of Conformity, viii
Detailed Setup, 125
Detailed Setup View, 110
Determine Encoder Alignment, 196
Determine Motor Parameters, 202
Determining Friction, 172
Determining Inertia Ratio, 174
Determining Tuning Parameter Values
Initial Test Settings, 172
Diagnostic Analog Output Test Points,
182
Diagnostic Cable (DGNE) Diagram, 184
Diagnostic Display, 177
Diagnostics and Troubleshooting, 177
Differential input, 78
Digital Inputs and Outputs, 97
Disconnecting Communications, 123
Downloading the Configuration File, 121
Drive and Motor Combination
247
Modular Drive System Reference Manual
Specifications, 220
Drive and Power Module Removal, 69
Drive Faults, 184
Drive Modifiers, 86
Drive Module Assembly Installation, 35
Drive Module Backplane Dimensions, 16
Drive Module Dimensions, 18
Drive Module I/O, 49
Drive Module I/O Connections, 48
Drive overload protection, vii
Drive Setup Information, 111
Dynamic Alignment Method, 201
E
E Series EN Drive Options, 103
ECI-44 External Connector Interface, 103
Editing the MOTOR.DDF File, 204
Electromagnetic Compatibility, 6
Encoder Electrical Interfacing, 193
Encoder Logical Interfacing, 194
Encoder Output Signal Wiring, 56
Encoder Specifications, 221
Entering Load Parameters, 116
Environmental Considerations, 10
Epsilon Eb Drive Options, 103
Error Messages, 187
Establishing a Standard Alignment, 200
External Shunt Operation, 74
EZ Setup, 125
EZ Setup View, 109
F
Fault Codes, 178
Fault Descriptions, 180
Feedforwards, 170
FM-1 Speed Module, 105
FM-2 Indexing Module, 105
FM-3 and FM-3DN Programming Module,
248
105
FM-4 and FM-4DN Programming
Module, 105
Friction, 169
Functional Overview, 77
G
Glossary, 241
H
High Performance Gains, 169
History Tab, 160
How Motion Works, 77
I
I/O Status Tab, 151
In Motion Velocity, 90
Inertia Ratio, 168
Initial settings, 166
Input Functions, 98
Inputs Tab, 135
Installation, 5
Installation Notes, 6
Introduction, 1
IP Ratings, 221
L
Logic and Digital I/O Power Connections,
37
Index
M
MDS Overview, 13
Mechanical Installation, 12
Modbus Communications, 62
Motor Brake Wiring, 50
Motor Direction Polarity, 90
Motor Feedback Wiring, 61, 192
Motor Ke, 202
Motor Mounting, 68
Motor Pole Count, 203
Motor Tab, 144
Motor Wiring, 190
Multi-Drop Communications, 63
O
Offline Configuration Window, 111
Offline Setup, 109
Online Setup, 119
Opening an Online Configuration
Window, 121
Operation Verification, 123
Operational Overview, 73
Options and Accessories, 103
Output Functions, 100
Outputs Tab, 137
Overspeed Velocity Parameter, 89
P
PID vs. State-Space, 165
Position Error Integral, 170
Position Tab, 139
Power Dissipation, 222
Power Dissipation Calculation, 222
Power Module Assembly Installation, 34
Power Module Backplane Dimensions, 14
Power Module Dimensions, 15
Power Module I/O, 43
Power Module I/O Connections, 40
Power Module Status Indicators, 41
PowerTools Software, 75
Presets Submode, 83
Printing the Configuration File, 123
Pulse Mode, 77
Pulse Mode Parameters, 81
Pulse Mode Setup, 112
Pulse Mode Wiring, 57
Pulse Source Selection, 78
Pulse/Direction Submode, 79
Pulse/Pulse Submode, 81
Pulse/Quadrature Submode, 80
Q
Quick Start, 109
R
Ramp Units Conversion, 175
Reading Encoder Alignment, 196
Rebooting the Drive, 185
Resetting Faults, 184
Response, 169
RMS Foldback, 91
Rotation Test, 211
S
Safety Considerations, xi
Safety of Machinery, xi
Safety Precautions, xi
Saving the Configuration File, 123
Selecting a User Defined Motor, 209
Selecting an Operating Mode, 112
Serial Communications, 62
Setup, Commissioning and Maintenance, xi
249
Modular Drive System Reference Manual
Shunt Operation, 74
Shunt RMS Fault, 74
Single ended input, 79
Specifications, 215
Speed Torque Curves, 224
Stall Foldback, 92
Static Alignment Method, 201
Status Tab, 155
Summation Submode, 84
Switching Frequency, 127
System Grounding, 23
T
TERM-H (Head) Terminator, 235
Term-T (Tail) Terminator, 235
Thermal Switch Interfacing, 194
TIA-XXX Cable, 234
Torque Limit Function, 89
Torque Limit Setup, 115
Torque Limiting, 88
Torque Mode, 85
Torque Mode Setup, 115
Torque Tab, 143
Torque Test, 212
Transformer Sizing, 27
Travel Limit Application Notes, 87
Tuning Hints, 167
Tuning Parameters, 168
Tuning Procedure, 166
Tuning Procedures, 165
Tuning steps, 167
U
Underwriters Laboratories Recognition, vii
User Defined Motors, 189
User Interface, 73
250
V
Velocity Analog Submode Setup, 113
Velocity Limiting, 89
Velocity Mode, 82
Velocity Mode Setup, 113
Velocity Presets Submode Setup, 114
Velocity Summation Submode Setup, 114
Velocity Tab, 141
Velocity Test, 214
Vendor Contact Information, 239
Verification and Checkout, 210
View Motor Parameters, 186
Viewing Active Drive Faults, 185
W
Watch Window, 185
Wiring Notes, 11
Since 1979, the “Motion Made Easy” products, designed and manufactured in
Minnesota U.S.A., are renowned in the motion control industry for their ease of
use, reliability and high performance.
For more information about Control Techniques “Motion Made Easy” products
and services, call (800) 397-3786 or contact our website at
www.emersonct.com.
Control Techniques Drives, Inc
Division of EMERSON Co.
12005 Technology Drive
Eden Prairie, Minnesota 55344
U.S.A.
Customer Service
Phone: (952) 995-8000 or (800) 397-3786
Fax: (952) 995-8129
Technical Support
Phone: (952) 995-8033 or (800) 397-3786
Fax (952) 9995-8020
Printed in U.S.A.
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertisement