Sharp | R-410H | User`s manual | Sharp R-410H User`s manual

T200
PROGRAMMABLE
SERVO DRIVE
C27095-001
USER'S MANUAL
T200 User's Manual
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PAGE II
T200 User's Manual
T200 Servo-Drive Manual Overview
This manual is broken into 11 sections and 1 Appendix.
Section 1 is an overview of the functionality of the T200 Product Family. It outlines technical features and data of the
T200.
Section 2 is description of critical safety issues. It also outlines particular installation and configuration items that the
user must implement if the target machine installation is required to be CE-Marked. This section should be read by all
users, especially those who are installing a T200 for the first time.
Section 3 describes installation and wiring for the T200 and the servo-motor. It describes T200 mounting, terminal
connections and external components.
Section 4 is a description of Moog motors. It deals with motor mechanical issues. Section 4 also outlines how to
configure the T200 servo-drive for standard and non-standard motors.
Section 5 is a Quick-Start guide, for use with WinDrive, the MS-Windows setup and monitoring package.
Section 6 is a functional description of the T200. It contains explanations of how the Inputs of the T200 affect
functionality and how Outputs reflect status and other information. It describes how to tune control loops.
Section 7 is a description of the WinDrive user interface, including details on motor and optional T200 feature
configuration. It describes how to use WinDrive for tuning and diagnostics.
Section 8 is a description of the Hand Held Terminal user interface.
Section 9 contains wiring instructions on the Controller Area Network interface.
Section 10 is a Troubleshooting guide.
Section 11 contains Sales Outlet information.
Appendix A describes EMC test configurations, under which the T200 was tested for compliance with the European
Union's Electro-Magnetic-Compliance (EMC) Directive, in various T200 model and I/O configurations.
This manual describes the functionality and features of the present version of the T200 Product Family. Not all of
the described features are available in previous versions of the T200.
Information contained herein is subject to change without notification and should not be construed as a commitment by
Moog Inc. This manual is periodically reviewed and revised.
Moog Inc. assumes no responsibility for any errors or omissions in this document. Critical evaluation of the manual by
the user is welcomed. Your comments will assist us in future product documentation.
Copyright  2000 by Moog Inc. All rights reserved.
PAGE III
T200 User's Manual
Rev
Description
Date
Effectivity
Preliminary
Preliminary version of the T200 Manual
21/Oct/98
All
First Issue
First version of the T200 Manual
31/March/99
All
Second Issue
Revised version of the T200 Manual. Added
description of additional features as implemented in
A8/B8/P8 software and T200-3/4/5XXG, T200-610D,
T200-710C hardware. Added features are:
15/Sep/00
All
07/May/02
Sections 1, 7, 8,
-
Error logging
-
Fault detection via digital outputs
-
Extended regen resistor protection scheme
-
Extended functionality of Stepper Mode
-
Personality Plug
Output impedance of testpoints changed from
10kΩ to 100Ω
First release under Moog Ireland Part Number
-
A
C27095-001.
Previous revisions are stated to reflect document
history.
Revised version of the T200 Manual. Added features
10
are:
-
UL approval for T200-3/4/5XX
-
Changes for WinDrive2.2 (also changes necessary
to reflect entire functionality of WinDrive)
-
Added POD commands for inverting output
polarities
-
Extended meaning of F3 fault (DC bus fuse blown
now included in this fault)
PAGE IV
T200 User's Manual
Table of Contents
SECTION 1:
T200 OVERVIEW.............................................................................................................................. 1-1
1.1
INTRODUCTION.....................................................................................................................................1-3
1.2
T200 MODELS .........................................................................................................................................1-4
1.3
ENVIRONMENTAL SPECIFICATIONS................................................................................................ 1-6
1.4
DESIGN STANDARDS ...........................................................................................................................1-7
1.5
POWER RATINGS SPECIFICATIONS ..................................................................................................1-8
1.6
GENERAL FUNCTIONAL SPECIFICATIONS .....................................................................................1-12
SECTION 2:
SAFETY INSTRUCTIONS............................................................................................................... 2-1
2.1
GENERAL ................................................................................................................................................2-3
2.2
SAFETY REGULATIONS.......................................................................................................................2-4
2.3
SAFETY....................................................................................................................................................2-5
2.4
ELECTROMAGNETIC COMPATIBILITY (EMC)...............................................................................2-15
SECTION 3:
WIRING AND INSTALLATION..................................................................................................... 3-1
3.1
SYSTEM COMPONENTS .......................................................................................................................3-7
3.2
EQUIPMENT MOUNTING .....................................................................................................................3-14
3.3
POWER DISSIPATION ...........................................................................................................................3-22
3.4
T200 CONNECTOR TERMINALS .........................................................................................................3-23
3.5
GENERAL SYSTEM WIRING GUIDELINES .......................................................................................3-26
3.6
SEQUENCE OF COMPONENT WIRING RECOMMENDATIONS .....................................................3-28
3.7
THREE-PHASE A.C. MAINS POWER SOURCE CONFIGURATION.................................................3-29
3.8
SINGLE PHASE 230VA.C. MAINS CONFIGURATION ......................................................................3-31
3.9
SINGLE PHASE 120VA.C. MAINS CONFIGURATION ......................................................................3-33
3.10
PROVIDING D.C. BUS POWER FROM A T200-X10 UNIT TO T200-X00 UNITS ............................3-35
3.11
PARALLELING T200-X10 UNITS THROUGH THE D.C. BUS ...........................................................3-42
3.12
DAISYCHAINING CONTROL-BACKUP POWER CONNECTIONS TO T200'S ............................... 3-43
3.13
INTERNAL/EXTERNAL REGENERATION (REGEN) RESISTORS – CONFIGURATIONS............3-45
3.14
MOTORS - INSTALLATION..................................................................................................................3-56
3.15
T200 CONTROL INPUT AND OUTPUTS .............................................................................................3-68
3.16
INCREMENTAL ENCODER/STEPPER MOTOR INTERFACE INPUT DESCRIPTION . ..................3-79
3.17
ENCODER SIMULATION OUTPUT DESCRIPTION ...........................................................................3-80
PAGE V
T200 User's Manual
3.18
COMMUNICATIONS INTERFACE WIRING AND CONFIGURATION............................................ 3-82
3.19
T200 USER VISUAL INDICATIONS..................................................................................................... 3-90
SECTION 4
MOTOR GUIDE .................................................................................................................................4-1
4.1
MOTOR SERVO-DRIVE SYSTEM........................................................................................................ 4-4
4.2
GLOBAL MOTOR MODELS AND ELECTRICAL TYPES ................................................................. 4-4
4.3
CONFIGURING THE MOTOR IN THE T200 SERVO-DRIVE ............................................................ 4-8
4.4
MOTOR-DRIVE SELECTION................................................................................................................ 4-10
4.5
MOTOR PERFORMANCE DATA.......................................................................................................... 4-11
4.6
MOUNTING AND INSTALLATION ..................................................................................................... 4-13
SECTION 5:
5.1
QUICK-START ..................................................................................................................................5-1
GETTING STARTED .............................................................................................................................. 5-3
SECTION 6:
T200 FUNCTIONAL OVERVIEW...................................................................................................6-1
6.1
INTRODUCTION .................................................................................................................................... 6-5
6.2
T200 FUNCTIONALITY OVERVIEW ................................................................................................... 6-6
6.3
T200 CONVENTIONS............................................................................................................................. 6-11
6.4
POWER INTERFACE SECTION............................................................................................................ 6-12
6.5
INPUT AND OUTPUT FUNCTIONAL DESCRIPTION ....................................................................... 6-17
6.6
INTERNAL FUNCTION GENERATOR ................................................................................................ 6-25
6.7
CONTROL LOOP OVERVIEW .............................................................................................................. 6-28
6.8
FAULT DETECTION .............................................................................................................................. 6-51
6.9
SELF PROTECTION ............................................................................................................................... 6-61
6.10
ENCODER SIMULATION FUNCTION................................................................................................. 6-64
6.11
INCREMENTAL ENCODER INPUT ..................................................................................................... 6-66
6.12
STEPPER MOTOR INTERFACE............................................................................................................ 6-68
6.13
COMMUNICATIONS INTERFACES .................................................................................................... 6-70
6.14
PARAMETER STORAGE....................................................................................................................... 6-79
SECTION 7:
WINDRIVE .........................................................................................................................................7-1
7.1
INTRODUCTION .................................................................................................................................... 7-6
7.2
WINDRIVE SOFTWARE SET-UP ......................................................................................................... 7-6
7.3
STARTING WINDRIVE.......................................................................................................................... 7-7
7.4
RS232 AND RS485 COMMUNICATION .............................................................................................. 7-9
7.5
PASSWORD PROTECTION ................................................................................................................... 7-13
PAGE VI
T200 User's Manual
7.6
MAIN WINDOW - FEATURES ..............................................................................................................7-16
7.7
GENERAL FEATURES ...........................................................................................................................7-17
7.8
MENU OPTIONS .....................................................................................................................................7-19
7.9
WINDRIVE MONITORING FEATURES ............................................................................................... 7-24
7.10
DRIVE SET-UP ........................................................................................................................................7-31
7.11
CONTROL LOOP CONFIGURATION AND TUNING .........................................................................7-43
7.12
INCREMENTAL ENCODER INPUT CONFIGURATION ....................................................................7-51
7.13
EQUIPMENT AND PERSONAL SAFETY.............................................................................................7-52
7.14
DRIVE DISABLING ................................................................................................................................ 7-53
7.15
PROGRAMMABLE BEHAVIOUR OF OUTPUTS................................................................................7-53
7.16
BRAKE CONTROL .................................................................................................................................7-54
7.17
TROUBLE SHOOTING ...........................................................................................................................7-54
SECTION 8:
HAND-HELD-TERMINAL INTERFACE...................................................................................... 8-1
8.1
HAND HELD TERMINAL INTERFACE ("POD" MODE)....................................................................8-3
8.2
SERVO-DRIVE INITIALIZATION ........................................................................................................8-5
8.3
SERVO-DRIVE TUNING ........................................................................................................................8-9
8.4
T200 HAND HELD TERMINAL COMMAND SET...............................................................................8-10
SECTION 9:
CAN INSTALLATION...................................................................................................................... 9-1
9.1
INTRODUCTION.....................................................................................................................................9-3
9.2
CAN CABLE WIRING ............................................................................................................................9-4
SECTION 10: TROUBLE-SHOOTING GUIDE ................................................................................................... 10-1
10.1
INTRODUCTION.....................................................................................................................................10-4
10.2
POWER STATUS LED'S NOT ILLUMINATED....................................................................................10-5
10.3
SEVEN-SEGMENT DISPLAY STATUS ................................................................................................ 10-7
10.4
'F' SYMBOL FOLLOWED BY NUMBER ON SEVEN-SEGMENT DISPLAY (FAULTS) .................10-8
10.5
'U' SYMBOL FOLLOWED BY NUMBER ON SEVEN-SEGMENT DISPLAY (WARNINGS) ..........10-15
10.6
OTHER PROBLEM SOURCES...............................................................................................................10-26
SECTION 11: USER INFORMATON .................................................................................................................... 11-1
11.1
TECHNICAL SUPPORT..........................................................................................................................11-3
APPENDIX A: EMC TEST CONFIGURATIONS................................................................................................... A-1
PAGE VII
T200 User's Manual
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PAGE VIII
SECTION 1: T200 OVERVIEW
T200 User's Manual
SECTION 1: T200 OVERVIEW
C27095-001
PAGE 1-1
T200 User's Manual
SECTION 1: T200 OVERVIEW
TABLE OF CONTENTS
SECTION 1:
T200 Overview ....................................................................................................................................1-1
1.1
INTRODUCTION.................................................................................................................................................1-3
1.2
T200 M ODELS ..................................................................................................................................................1-4
1.3
ENVIRONMENTAL SPECIFICATIONS.................................................................................................................1-6
1.4
DESIGN STANDARDS .........................................................................................................................................1-7
1.5
POWER RATINGS SPECIFICATIONS..................................................................................................................1-8
1.5.1
Units with A.C. Mains Input Interface (T200-310 to T200-710) .............................................................. 1-9
1.5.2
Units with D.C. Bus Input Interface (T200-300, T200-400, T200-500) .................................................1-10
1.5.3
Optional Control Logic Backup Power...................................................................................................1-10
1.5.4
Power Amplifier......................................................................................................................................1-11
1.6
GENERAL FUNCTIONAL SPECIFICATIONS .....................................................................................................1-12
1.6.1
Digital Inputs ..........................................................................................................................................1-12
1.6.2
Digital Outputs........................................................................................................................................1-13
1.6.3
Other I/O .................................................................................................................................................1-13
1.6.4
Software Control Modes ......................................................................................................................... 1-14
PAGE 1-2
SECTION 1: T200 OVERVIEW
T200 User's Manual
1.1 Introduction
This section gives an overview of the available T200 models, ratings and general specifications. Detailed outlines of
installation and wiring, functionality, user interfaces and other technical data are given in later sections.
CAUTION: Repairs or modifications to the product by anyone other than a Moog authorized
repair facility may create unsafe operating conditions and will invalidate the product
warranty.
PAGE 1-3
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.2 T200 Models
The T200 family is available in eight base models. These eight models cover a range of output current ratings and
include units either with or without integral high voltage power supplies as shown below.
T200 Base Model
Units with High Voltage Power
Supply
T200-310
T200-410
T200-510
T200-610
T200-710
Units without High Voltage
Power Supply
T200-300
T200-400
T200-500
Amplifier Current Rating (Arms)
Continuous Current
Peak Current
5
10
20
40
60
Continuous Current
10
20
50
80
140
Peak Current
5
10
20
10
20
50
Table 1.1: T200 Family Models
These devices are intended for installation in a pollution degree 2 environment.
The T200 family uses a 13 character coding system to identify the unique attributes of each model. The coding system is
shown below:
T200 - AAAB - C SW
SW designates the Embedded Software Version
Ø Ax for standard drive functionality
Ø Bx for CAN Interpolation Mode functionality
Ø Px for custom POINT motion control
(where x is the release revision number)
C designates the Option Cards
Ø 0 for no option card
Ø 1 for POINT extended I/O card
Ø 2 - 9 reserved
B designates the hardware revision
AAA designates the Base Model
Ø see description above in Table 1.1.
PAGE 1-4
SECTION 1: T200 OVERVIEW
T200 User's Manual
Moog also provides a variety of accessories for the T200. Examples include:
• Operator terminals for applications requiring a user interface
• Hand held terminal for drive configuration and diagnostics
• EMC cable brackets for securing cable and grounding shields at the T200 (see Section 3.14.5)
• Personality plug for automated drive configuration
• Quick connect cables for interconnecting drives in a multi-axis application (see Section 3.1.8)
• Preconfigured motor cables
• Backup logic power supplies
• Step down transformers
Please consult your local Moog sales office or authorized distributor for part number and availability of these or other
products.
PAGE 1-5
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.3 Environmental Specifications
T200 Electronics
Temperature for transport and storage:
Operating temperature:
Relative Humidity:
Elevation:
Type of protection:
Installed position:
Overvoltage protection class:
Noise:
PAGE 1-6
-25 °C to 70 °C
0 °C to 55 °C
5 % to 95 %, non-condensing, 1 g/m3 to 25 g/m3,
in accordance with EN50178 class 3k3
3300feet
Derate output 2% per 1000 feet above 3300 feet
Components must be installed into an enclosure.
The enclosure must provide at least IP54 per standard
EN60529 or equivalent.
Vertical only.
Category 2 per standard VDE0110 / IEC664
Overall noise depends on the user installation and cabinet.
Noise from the electronic components is less than 55dBA.
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.4 Design Standards
The T200 has been designed to EN50178. It is CE-Marked under the EU's Low Voltage Directive. It has been designed
to allow easy compliance of customer's machines under the EU's EMC Directive (measures as directed in this manual
have to be taken to ensure EMC compliance). It is designed to the UL508C standard. T200 models –3xx, -4xx and –5xx
are UL-marked. UL is pending on the –610/710.
The T200 is considered professional equipment. Professional equipment is defined as equipment for use in trades,
professions, or industries and which is not intended for sale to the general public.
The T200 has been designed to the following specific standards:
Guidelines for engineering design
Dimensioning of creepage distances and clearances
Insulation coordination
General safety requirements
Reliable isolation
Marking
Grounding
Overvoltage protection
Ambient conditions
Short-circuit strength
Mechanical stresses
Protection by limitation of discharge energy
Type-testing
EMC
UL
EN 50178
EN 50178
IEC 664
EN 50178
EN 50178
EN 50178
EN 50178
EN 50178
IEC 68 Part 2-3, 2-6
EN 50178
IEC 68 Part 2-29
EN 50178
EN 50178
EN55011
EN50082-2
UL508C with reference
to UL840
Table 1.2: T200 Design Standards
PAGE 1-7
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.5 Power Ratings Specifications
The T200 family includes models with and without high voltage Power Supply Units (PSU's). These PSU's generate a
high voltage D.C. Bus by rectification of A.C. Mains. T200 models with PSU can supply D.C. Bus power to other T200
units which do not contain integral PSU's via D.C. Bus interconnect wiring. All current ratings are specified in ampere
r.m.s., unless otherwise stated.
PAGE 1-8
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.5.1
Units with A.C. Mains Input Interface (T200-310 to T200-710)
All current ratings are specified in ampere r.m.s.
T200-310
AC Mains Input Range
Minimum
Maximum
T200-410
T200-510
100Va.c. (120Va.c. -15%)
255Va.c. (230Va.c. +10%)
T200-610
T200-710
195Va.c. (230Va.c. -15%)
255Va.c. (230Va.c. +10%)
50..60Hz
Frequency Range
Continuous Input Power
Three-Phase
Single Phase 230Va.c.
Single Phase 120Va.c.
7.5kW
2.5kW
1.2kW
15kW
Not Available
Not Available
Max Rated Input Power (for
15 seconds)
Three-Phase 230Va.c.
Single Phase 230Va.c.
Single Phase 120Va.c.
15kW
5.0kW
2.4kW
30kW
Not Available
Not Available
Maximum Number of T200X00's (units without A.C.
Mains PSU) which can be
connected to a T200-X10
four
Note that application power requirements will also set a limit on the number of T200X00's (i.e. units without Mains PSU) which may be connected to a T200-X10 (unit
with Mains PSU). See Section 3.10 for guidelines on how to match application
power requirements for each T200-X10 unit.
D.C. Bus Rated Continuous
Output Power
(T200-310 to T200-710)
Internal Regeneration Power
Continuous Dissipation
Peak Dissipation
External Regeneration Power
Continuous / Peak
Soft-start Peak Inrush
Current/Phase
Power Supply Fault Detection
20Ad.c. at 325Vd.c. (6.5kW)
40W
2.8kW
200W / 14kW
(1 * 50Ω )
No internal regen
capability
600W / 14kW
(1 * 10Ω )
600W / 14KW (1 * 10Ω)
1250W / 18kW (1 * 8Ω)
2000W / 28kW (2 * 10Ω)
2500W / 36kW (2 *8Ω)
7Apeak
A.C. Mains not present
D.C. Bus Overvoltage
Internal Regeneration Fuse Blown
Power Supply Temperature Fault
Voltage Discharge after A.C.
Mains Removal
Fast Bus Discharge function
Bleed Resistors across high voltage section
Power Sequencing Control
Power Ready output provided to control power application
Table 1.3: T200-X10 Power Ratings
PAGE 1-9
T200 User's Manual
1.5.2
SECTION 1: T200 OVERVIEW
Units with D.C. Bus Input Interface (T200-300, T200-400, T200-500)
All current ratings are specified in ampere r.m.s. unless otherwise stated.
Nominal D.C. Bus Voltage
325Vd.c. (generated from rectified 230Va.c.)
D.C. Bus Maximum Voltage
400Vd.c. (generated from rectified 280Va.c.)
Maximum Continuous Input Current
T200-300
T200-400
T200-500
5Ad.c.
10Ad.c.
20Ad.c.
Table 1.4: T200-X00 Power Ratings
1.5.3
Optional Control Logic Backup Power
D.C. Bus Minimum Voltage
(below which 24Vd.c. or 120Va.c. Control-Logic
Backup supply is needed)
250Vd.c. (generated from rectified 170Va.c.)
24V Input
18Vd.c. to 36Vd.c.
2.0A inrush current /axis
1.5A steady state
Internal Resettable fuse in case where polarity has been
reversed
120Va.c. Input
+10%, -15% voltage range
0.3Ar.m.s. /axis
Table 1.5: T200 Control Logic Backup Power Ratings
PAGE 1-10
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.5.4
Power Amplifier
All current ratings are specified in ampere r.m.s. unless otherwise stated.
Power Amplifier Ratings (Ar.m.s. ):
T200-3
T200-4
T200-5
T200-6
T200-7
Max. Time at Ipeak
5Acontinuous/10Apeak
10Acontinuous/20Apeak
20Acontinuous/50Apeak
40Acontinuous/80Apeak
60Acontinuous/140Apeak
10s
10s
2s
2s
2s
Table 1.6: T200 Power Amplifier Ratings
PAGE 1-11
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.6 General Functional Specifications
1.6.1
•
•
•
Digital Inputs
All Optically Isolated, 12 .. 32V Input Range.
2.5kOhm input impedance.
Pull-Up or Pull-Down from I_COMMON line.
J1 Pin Name
(Pin Number)
10V Torque or
Velocity
Analog
Reference
Stepper
Interface Mode
Digital Inputs
Speed Mode
CAN Mode
• Profile Mode
‚ Interpolation
Mode
High Power
Enable Input
Power Ready
Input
Auto/Manual
Mode
• Home-Switch
‚ User defined
• Clockwise
Limit Switch
‚ Not used
• Counterclockwise Limit
Switch
‚ Not used
ENABLE
(5)
PWR_RDY
(6)
AUTO_MAN
(7)
TRQ_VEL
(8)
High Power
Enable Input
Power Ready
Input
Auto/Manual
Mode
Torque-Velocity
Mode Switch
High Power
Enable Input
Power Ready
Input
Auto/Manual
Mode
Not used
High Power
Enable Input
Power Ready
Input
Auto/Manual
Mode
Not used
CW_LIM
(9)
Clockwise Limit
Switch Input
Clockwise Limit
Switch Input
Clockwise Limit
Switch Input
CCW_LIM
(10)
Counterclockwise
Limit Switch
Input
Counterclockwise
Limit Switch
Input
Counterclockwise
Limit Switch
Input
BRK_IP
(11)
Brake Control
Brake Control
Brake Control
Brake Control
ROT_DIR
(12)
PROG_SPD_1
(13)
Reverse Direction
Not used
Reverse Direction
Not used
Not used
Not used
Programmable
Speed 1
PROG_SPD_0
(14)
Not used
Not used
Programmable
Speed 0
• Not used
‚ Quick-Stop
• Not used
‚ User defined
* Note that CAN Interpolation Mode uses the PROG_SPD_1 digital input as a Quick-Stop digital input.
Table 1.7: T200 Digital Inputs Overview
See Section 3.15 for a full description of the digital inputs electrical format, conventions and functionality.
PAGE 1-12
Point Mode
High Power
Enable Input
Power Ready
Input
Auto/Manual
Mode
General purpose
input
General purpose
input (default) OR
Clockwise Limit
General purpose
input (default) OR
Counterclockwise
Limit Switch
Input
General purpose
input (default) OR
Brake Control
General purpose
input
General purpose
input
General purpose
input OR Fast
Encoder
Registration
T200 User's Manual
SECTION 1: T200 OVERVIEW
1.6.2
•
•
•
Digital Outputs
All outputs are Optically Isolated.
Maximum ratings of 36V, 50mA.
Pull-Up or Pull-Down from O_COMMON line.
J1 Pin Name
(Pin Number)
THRM_LIM
(19)
DRV_ENBLD (20)
SPD/TORQ_
ACHVD
(21)
SPARE_DIG_OP_1
(27)
SPARE_DIG_OP_2
(28)
10V Torque or
Velocity Analog
Reference
Limit Activated
Stepper
Interface Mode
Digital Inputs
Speed Mode
Point Mode
Limit Activated
CAN-Profile,
Inter-polation
Mode
Limit Activated
Limit Activated
Drive Enabled
Speed/Torque
Achieved
Drive Enabled
Position
Following Error
Drive Enabled
Speed/Torque
Achieved
Drive Enabled
Speed/Torque
Achieved
Drive Enabled
General purpose
output
Fault Code Bit
Fault Code Bit
Fault Code Bit
User defined
Fault Code Bit
Fault Code Bit
Fault Code Bit
User defined
General purpose
output
General purpose
output
Limit Activated
Table 1.8: T200 Digital Outputs Overview
1.6.3
Other I/O
2 Analog Inputs
Analog Command (±10V, 12 bit, 10kΩ input impedance)
Analog Torque Limit (±10V, 12 bit, 10Ω input impedance)
2 Analog Outputs
Programmable Test Point 1 (±10V, 12 bit, 100Ω output impedance)
Programmable Test Point 2 (±10V, 12 bit, 100Ω output impedance)
Brake Control
3,5A, 30Vd.c. relay provided. Switched under user control or T200
software control.
Motor Position Feedback Type
Resolver Based
Incremental Encoder Interface
1 channel
1MHz RS422 Channel Input
5V/100mA power output with resettable fusing.
Communications Interfaces
Controller Area Interface
CANOpen (ISO11898) hardware-interface format (RS485 interface also
included on spare pins of 9 Way Sub-D Connector. See Section 9.)
Optically Isolated (internally supplied power)
5kBaud to 1MBaud programmable
RS232 Interface at 9600Baud
RS485 Interface at 9600Baud
Table 1.9: T200 Miscellaneous I/O Summary
PAGE 1-13
T200 User's Manual
1.6.4
SECTION 1: T200 OVERVIEW
Software Control Modes
±10V Torque, Velocity and Position Mode
Analog reference for torque, velocity or position slave mode. Encoder Simulation as standard.
Stepper Motor Emulation Interface (Positioning Mode)
T200 will emulate a stepper motor drive, with a Quadrature or STEP/DIR input format.
Digital Reference Speeds
T200 uses two digital inputs to set the reference speed. Speeds are software programmable.
CAN Interpolation Mode
§ Fine Interpolation of Position Commands at up to 2ms command rate
§ Parameterisation via CAN
CAN Profile Mode
§ Point to Point, Jog, Relative/Absolute moves etc.
§ Velocity Mode
§ Electronic Gearing and CAMing
§ Parameterisation via CAN
Point Stand Alone Motion Control Capability
§ Motion Control Language
§ Servo-Control Algorithms
§ Extended Digital I/O Capability
PAGE 1-14
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
SECTION 2: SAFETY INSTRUCTIONS
C27095-001
PAGE 2-1
T200 User's Manual
SECTION 2: SAFETY INSTRUCTIONS
TABLE OF CONTENTS
SAFETY INSTRUCTIONS ...........................................................................................................................................2-1
2.1
GENERAL .......................................................................................................................................................... 2-3
2.2
SAFETY REGULATIONS .....................................................................................................................................2-4
SAFETY .........................................................................................................................................................................2-5
2.3.1
System Safeguards....................................................................................................................................2-6
a)
b)
General Safety Requirements..........................................................................................................................................2-6
Specific Safety Requirements..........................................................................................................................................2-6
2.3.2
2.3.3
Equipment Safety......................................................................................................................................2-8
Safety Requirements for Cables..............................................................................................................2-10
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
Requirements - Conductors and Cables.........................................................................................................................2-10
Wiring Practices - Connections and routing ..................................................................................................................2-10
Wiring Practices - Conductor and cable runs ................................................................................................................2-10
Wiring Practices - Conductors of different circuits .......................................................................................................2-11
Wiring Practices - Identification of conductors .............................................................................................................2-11
Wiring Practices - Identification of the protective conductor ........................................................................................2-11
Wiring Practices - Identification of the neutral conductor............................................................................................. 2-11
Wiring Practices - Wiring inside enclosures..................................................................................................................2-11
Wiring Practices - Wiring outside enclosures................................................................................................................2-12
Wiring Practices - Ducts, connection and junction boxes.............................................................................................. 2-13
2.3.4
EMC requirements for cables .................................................................................................................2-14
2.4
ELECTROMAGNETIC COMPATIBILITY (EMC) ............................................................................................. 2-15
2.4.1
Specific Electromagnetic Compatibility (EMC) Requirements:............................................................. 2-15
PAGE 2-2
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
2.1 General
This user’s manual is intended to provide sufficient information on how to install, wire and tune a Moog brushless
electric motor system which includes all of the equipment outlined in Section 3.1. Section 2.2 covers Safety and System
Safeguards. Section 2.3 covers Electromagnetic Compatibility (EMC). This user’s guide must be read and understood
before applying power and operating the equipment described.
This equipment must be installed and serviced only by duly qualified service personnel. All information in this manual
is directed towards such persons only. Individuals responsible for the installation of the equipment described in this
user’s guide must ensure ;
1) only technically qualified individuals are employed to work on the installation,
2) these qualified individuals must have the accompanying documentation available at all times when working on the
installation and are obliged to use this documentation in a consistent manner, and
3) work on, or close to, the installation is prohibited for non-technically qualified individuals
Throughout this user’s guide may be found NOTES, CAUTIONS, and WARNINGS and CE-Compliance-Required.
They are defined as follows:
NOTES are general in nature and are intended to emphasise
information.
CAUTIONS are to alert personnel to actions that could cause
equipment damage, resulting in the equipment becoming
unsafe.
WARNINGS serve to make personnel aware of potentially
hazardous actions that may result in personal injury or death.
Required for
CE-Compliance
CE-Compliance indicates where a particular applicationrelated safety or EMC requirement is driven by the need for
CE-Compliance of the T200 when installed in the system.
Customers who do not need CE-Compliance on their machinery
may choose not to implement these features.
The T200 controller contains potentially lethal voltages. Extreme caution shall be observed whenever the equipment is
in operation. Incorrect installation of the motor or the controller may cause damage to the equipment, serious personal
injury or death. Consequently, the instructions in this user’s manual, as well as national and local rules and safety
regulations, must be complied with.
PAGE 2-3
T200 User's Manual
2.2
SECTION 2: SAFETY INSTRUCTIONS
Safety regulations
1.
The T200 controller must be disconnected from all power if repair work is to be carried out. Check that the mains
supply has been disconnected and that at least 5 minutes has passed, to allow for d.c. bus capacitors to discharge,
before removing motor and mains plugs.
2.
Correct protective earthing of the equipment must be established, the user must be protected against supply voltage,
and the motor must be protected against overload in accordance with applicable national and local regulations.
3.
Do not remove the plugs for the motor and mains supply while the T200 controller is connected to mains power.
Check that the mains supply has been disconnected and that the necessary time has passed before removing motor
and mains plugs.
Warning against unintended start
The installation of safety interlocks, additional control and protection devices must be done in accordance with the
relevant local safety requirements. Note that changes made through software can result in the motor starting suddenly.
PAGE 2-4
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
2.3 Safety
This user’s manual assumes that the user has a basic working knowledge of servo-drive products and the system motion
controller. The user should provide the necessary additional training for ALL personnel working within or around the
workcell.
NOTE - These safety precautions are guidelines only and are not claimed to be comprehensive.
The Moog Brushless Technology products described herein, in conjunction with the system
controller, provide the capability for control of remote devices. Typically, these remote devices
move at high speeds and exert considerable force. Like all mechanical systems and most
industrial equipment, they must be treated with respect by both the machine integrator, user and
the operator.
NOTE - This user’s guide defines “user” as the responsible person or company and “operator” as
a person who starts, stops or monitors workcell operation.
NOTE - This user’s guide should be read by all personnel who operate or who work within or
near the workcell.
Individuals responsible for the installation of the equipment described in this user’s guide must
ensure that only technically qualified service personnel are employed to work on the installation.
In the context of these safety instructions, skilled technical personnel means people who are
familiar with the product, and have the necessary technical qualifications required for the
performance of their functions.
PAGE 2-5
T200 User's Manual
2.3.1
SECTION 2: SAFETY INSTRUCTIONS
System Safeguards
a) General Safety Requirements
Users are required to implement safety measures with all equipment, systems and installations into which the T200
Servo-drive are installed. In addition, safeguards must be an integral part of workcell design, installation, operator
training and operator procedures where this equipment is used.
The T200 is suitable for use in a circuit capable of delivering not more than 5000 rms symmetrical amperes, 240 volts
maximum.
Required for
CE-Compliance
Users are directed to refer to the European Union (EU) Machine Safety
Directive: 89/392/EEC (as amended by EU Directives 91/368/EEC,
93/44/EEC and 93/68/EEC) and EU Low Voltage Directive 73/23/EEC
(as amended by EU Directive 93/68/EEC) for essential health and
safety requirements to be met. Furthermore the requirements of the EU
EMC Directive: 89/336/EEC (as amended by EU Directive 92/31/EEC
and 93/68/EEC) must be met by all equipment, systems and
installations into which the T200 Power Supply and Controllers are
installed.
Users are recommended to refer to the latest publications of the
European Union (EU) Commission and to local regulations for further
information on the requirements of these Directives of the EU.
b) Specific Safety Requirements
The specific safety measures described below are required to be installed by the user into all equipment, systems and
installations into which the T200 Series Controllers are installed.
The user is required to provide safety interlocks to prevent unexpected restart during servicing of the T200 Series
Controller and any equipment attached to or driven by these units.
The T200 Servo-drives themselves must be installed in enclosures or cabinets that provide a degree of ingress protection
against liquids and objects of at least IP54. These enclosures or cabinets must be accessible to technically qualified
service or maintenance persons only. All external Regen ( Regenerative circuit) resistors used with the T200 must be
installed in enclosures which provide a degree of ingress protection against liquids and objects of at least IP22 and
which are accessible to technically qualified service or maintenance persons only. Protection against electric shock must
be maintained when installing these resistors.
The T200 Servo-drive must be permanently and reliably connected to Earth and all conductive parts in the IP54 rated
enclosure or cabinet must be permanently connected to Earth. The impedance between the earth terminal and any
accessible part of the enclosure or cabinet shall be less than or equal to 0.1 ohms.
All electrical supply wires and cables to this equipment must be installed in wireways (cable routings) which are smooth
and free from sharp edges.
The optional 24V input is intended for use in the secondary of a Class 2 supply. Alternatively it should be fitted with a
UL Listed Current limiting type fuse rated 3A on the supply side to the device.
PAGE 2-6
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
All external d.c. supply voltages used with the T200 Series Controllers
must be derived from a Safety Extra Low Voltage (SELV) supply as
defined by standard EN60950. Such SELV voltages do not exceed a
value of 60 Vd.c. or 42.4 Va.c. peak under normal conditions and are
supplied by circuits which are separated from all hazardous voltage
conductors by permitted safety methods such as reinforced insulation.
Required for
CE-Compliance
All external electrical wiring connected to this equipment must be
colour coded in accordance with European Standard EN 60204-1
requirements. (Refer Section 2.6 of this manual).
All wires and cables entering and leaving the IP54 rated enclosures or
cabinets containing the T200 Power Supply, Controllers and Regen
resistor(s) must be protected and anchored in accordance with the
requirements of EN 60204-1. (Refer to Section 2.6 of this manual).
A mains circuit breaker must be installed with this equipment and be accessible to the user.
This circuit breaker shall be sized such that it provides adequate r.m.s protection based on primary voltage and power
rating (kW) of the T200 system. Surge tolerance and single phase protection should also be considered.
PAGE 2-7
T200 User's Manual
2.3.2
SECTION 2: SAFETY INSTRUCTIONS
Equipment Safety
All persons must observe sound safety practices during the operation and testing of all electrically powered equipment.
Prior to first use, power should not be applied to the T200 Servo-drive until all instructions in the Wiring and Installation
section of this User’s manual have been carried out.
WARNING – You must disconnect the T200 Servo-drive from all voltage supplies
(230 Va.c., 120 Va.c., 24 Vd.c.) before servicing.
WARNING - DO NOT remove or replace any assemblies, subassemblies or components
with primary power present.
WARNING - Lethal voltages remain present within this equipment when the mains power
is removed. It is recommended to refrain from commencing any servicing, maintenance,
repair or upgrading of this equipment until at least five minutes after power shutdown. It is
further recommended to measure the voltage level at all high voltage terminals before
commencing any such activities, to ensure that no lethal voltages are present.
WARNING – The removable plug-in connectors of the T200 Servo-Drives are for ease of
wiring installation. These removable plug-in connectors are not suitable for connection or
disconnection under power. All connections must be made with power removed.
WARNING - Repair or internal adjustments to the T200 Series Controllers must not be
attempted. All faulty items must be returned to Moog Service Centres for maintenance and
repair.
WARNING - Entering the workcell when HIGH POWER or PROGRAM RUNNING
indicators are ON may result in severe injury.
PAGE 2-8
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
WARNING - The equipment described in this user’s guide operates at voltage levels
which can exceed 400 volts d.c. and/or 230 volts a.c. These levels are a potential source
of severe electrical shock. DO NOT remove or replace any assemblies, subassemblies or
components with the primary power present. To avoid possible personal injury or
equipment damage, always remove power BEFORE attempting repair or upgrade
procedures. Wait at least 5 minutes after power shutdown to ensure power supply
capacitors have discharged. Then using a voltmeter, check for safe levels across all high
voltage power terminals.
Safe-guards should be an integral part of a workcell design, installation, operator training, and operator procedures. A
computer controlled system may activate remote devices under program control at times not anticipated by personnel. It
is critical that safeguards be in place to prevent personnel from entering the workcell whenever equipment power is
present. Moog highly recommends the use of workcell safety features such as light curtains, safety gates or safety floor
mats to prevent access to the workcell while power is present. Computer controlled systems have various
communication features which may aid the user in constructing system safeguards, including:
•
emergency stop circuitry
•
binary input and output lines
•
spare system-controlled user lines
The emergency power-off circuitry of a computer controlled system is generally capable of switching external power
systems, as well as detecting intrusion signals from safety barriers.
All personnel must observe sound safety practices during the operation and testing of all electrically powered
equipment. To avoid injury or damage to equipment, always remove power BEFORE attempting ANY repair or upgrade
activity.
PAGE 2-9
T200 User's Manual
2.3.3
SECTION 2: SAFETY INSTRUCTIONS
Safety Requirements for Cables
Required for
CE-Compliance
User's whose machine installations require CECompliance should read Section 2.3.3.
a) Requirements - Conductors and Cables
All cables and conductors used shall be specified as compliant with the requirements of European Standard EN 60204-1
and other known National and International Standards for the environment in which they are installed and for the voltage
and current carried.
Conductors and cables shall be specified and selected so as to be suitable for the operating conditions (e.g. voltage,
current, protection against electric shock, grouping of cables) and external influences (e.g. ambient temperature,
presence of water or corrosive substances, mechanical stress) which can exist.
Wherever possible, insulated conductors and cables which have flame-retardant properties shall be used.
Where insulated conductors and cables can constitute a fire hazard due to the propagation of a fire or the emission of
toxic or corrosive fumes (e.g. PVC), guidance from the cable supplier should be sought. In particular it is important to
maintain the integrity of circuits having a safety function (e.g. emergency stop) for as long as possible under these
conditions.
The mechanical strength and thickness of the insulation shall be such that the insulation cannot be damaged in operation
or during laying, especially for cables pulled into ducts.
The voltage drop on cables and conductors shall not exceed 5% of the nominal voltage. The current carrying capacity of
the conductors and cables is determined by both:
•
the maximum allowable conductor temperature under the highest possible steady state current under normal
conditions; and
•
the ultimate allowable short-time conductor temperature under short circuit conditions.
b) Wiring Practices - Connections and routing
All connections, especially those of the protective bonding circuit, shall be secured against accidental loosening.
c) Wiring Practices - Conductor and cable runs
Conductors and cables shall be run from terminal to terminal without splices or intervening joints
Where it is necessary to connect and disconnect cables and cable assemblies, sufficient extra length shall be provided for
this purpose.
The terminations of multicore cables shall be adequately supported where undue strain can be exerted on the
terminations of the conductors.
Wherever possible, the protective conductor shall be placed close to the associated live conductors in order to decrease
the impedance of the loop.
PAGE 2-10
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
d) Wiring Practices - Conductors of different circuits
Subject to the constraints for EMC suppression given in Sections 2.3 and Section 3 of this User’s manual, conductors of
different circuits may be laid side by side, may occupy the same duct (e.g. conduit, cable trunking system), or may be in
the same multicore cable, provided that the arrangement does not impair the proper functioning of the respective
circuits. Where these circuits operate at different voltages, the conductors shall be either separated by suitable barriers or
insulated for the highest voltage to which any conductor within the same duct can be subjected.
Circuits which are not switched off by the supply disconnecting device (circuit breaker) shall be either physically
separated from other wiring or distinguished by colour (or both) so that they can be identified as being live when the
supply disconnecting device is in the OFF or OPEN position.
e) Wiring Practices - Identification of conductors
For safety reasons, the colour Green or the colour Yellow shall not be used where there is a possibility of confusion with
the bicolour combination GREEN-AND- YELLOW.
Colour identification using combinations of colours may be used provided there can be no confusion and that GREEN or
YELLOW is not used, except in the bicolour combination GREEN- AND-YELLOW.
f) Wiring Practices - Identification of the protective conductor
The protective conductor shall be readily distinguishable by shape, location, marking or colour. When identification is
by colour alone, the bicolour combination GREEN-AND-YELLOW shall be used throughout the length of the
conductor. This colour identification is strictly reserved for the protective conductor.
For insulated conductors, the bicolour combination GREEN-AND-YELLOW shall be such that on any 15mm length,
one of the colours covers at least 30% and not more than 70% of the surface of the conductor, the other colour covering
the remainder of the surface.
Where the protective conductor can be easily identified by its shape, position or construction (e.g. braided conductor), or
where the insulated conductor is not readily accessible, colour coding throughout its length is not necessary but the ends
or accessible positions shall be clearly identified by the graphical symbol or by the bicolour combination GREENAND-YELLOW.
g) Wiring Practices - Identification of the neutral conductor
Where a circuit includes a neutral conductor identified by colour, the colour shall be LIGHT BLUE. LIGHT BLUE shall
not be used for identifying any other conductor where confusion is possible.
In the absence of a neutral conductor, a LIGHT BLUE conductor may be used for other purposes except for use as a
protective conductor.
Where identification by colour is used, bare conductors used as neutral conductors shall be either coloured by a LIGHT
BLUE stripe, 15 mm to 100 mm wide, in each compartment or unit or at each accessible position, or coloured LIGHT
BLUE throughout their length.
h) Wiring Practices - Wiring inside enclosures
Panel conductors shall be supported where necessary to keep them in place. Non-metallic channels or conduits shall be
permitted only when made with a flame-retardant insulating material. Where possible earthed shielded metal cable
ducting should be used to minimise EMC noise coupling.
It is recommended that electrical equipment mounted inside the enclosures be designed and constructed in such a way as
to permit modification of the wiring from the front of the enclosure. Where this is not possible and control devices are
connected from the rear of the enclosure, access doors or swing-out panels shall be provided.
PAGE 2-11
T200 User's Manual
SECTION 2: SAFETY INSTRUCTIONS
Connections to devices mounted on doors or to other movable parts shall be made using flexible conductors in
accordance with European standard EN 60204-1, to allow for the frequent movement of the part. The conductors shall
be anchored to the fixed part and the movable part independently of the electrical connections.
Conductors and cables that do not run in ducts shall be adequately supported.
Terminal blocks or attachment plug/socket combinations shall be used for control wiring that extends beyond the
enclosure.
Power cables and cables of measuring circuits may be directly connected to the terminals of the devices for which the
connections were intended.
i) Wiring Practices - Wiring outside enclosures
The means of introduction of cables or ducts with their individual glands, bushings, etc., into an enclosure shall ensure
that the degree of protection is not reduced.
Conductors and their connections external to the electrical equipment IP54 enclosures shall be installed in suitable ducts
(i.e. conduit or cable trunking systems) as described in Section 2.3.4, except for suitably protected cables, which may be
installed without enclosing ducts and with or without the use of open cable trays or cable support means.
Fittings used with ducts or multi-conductor cable shall be suitable for the physical environment.
Flexible conduit or flexible multi-conductor cable shall be used where it is necessary to employ flexible connections to
pendant push-button stations. The weight of pendant stations shall be supported by means other than the flexible conduit
or the flexible multi-conductor cable, except where the conduit or cable is specifically designed for that purpose.
Flexible conduit or flexible multi-conductor cable shall be used for connections involving small or infrequent
movements. They shall also be permitted to complete the connection to normally stationary motors, to position switches,
and to other externally mounted devices.
Connections to frequently moving parts shall be made with conductors suitable for flexing service in accordance with
European standard EN 60204-1. Flexible cable and flexible conduit shall be so installed as to avoid excessive flexing
and straining particularly at the fittings.
Cables subject to movement shall be supported in such a way that there is no mechanical strain on the connection points
nor any sharp bending. The loop shall have sufficient length to provide for a bending radius of the cable of at least ten
times its outside diameter.
Where cables subject to movement are close to moving parts, precautions shall be taken so that a space of at least 25mm
shall be maintained between the moving parts and the cables. Where this distance is not practicable, fixed barriers shall
be provided between the cables and the moving parts.
The cable sheath shall be resistant to the normal wear which can be expected from movement, and to the effects of
atmospheric contaminants (e.g. oil, water, coolants, dust).
Where flexible conduit is adjacent to moving parts, the construction and supporting means shall prevent damage to the
flexible conduit or cable under all conditions of operation.
Flexible metal conduit shall not be used for rapid or frequent movements, except when specifically designed for that
purpose.
PAGE 2-12
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
j) Wiring Practices - Ducts, connection and junction boxes
All sharp edges, flash, burrs, rough surfaces, or threads, with which the insulation of the conductors may come in
contact, shall be removed from ducts and fittings. Where necessary, additional protection consisting of a flame-retardant,
oil-resistant insulating material shall be provided to protect conductor insulation.
Ducts and cable trays shall be rigidly supported and positioned at a sufficient distance from the moving parts and in such
a manner so as to minimise the possibility of damage or wear.
Cable trunking systems external to enclosures shall be rigidly supported and clear of all moving or contaminating
portions of the machine or equipment into which they are installed.
PAGE 2-13
T200 User's Manual
2.3.4
SECTION 2: SAFETY INSTRUCTIONS
EMC requirements for cables
Required for
CE-Compliance
User's whose machine installations require for CECompliance should read Section 2.3.4.
Avoid close parallel routing of signal cables and power cables. Always use the minimum length of cable necessary and
install all cables in a fixed routing.
Data signal cables, motor power and resolver/signal cables, regen resistor cables and power input cables shall have
segregated routings. Where cable routings must intersect, it is recommended that they intersect at an angle of 90 degrees,
to minimise EMC noise coupling.
Where signal and power cables must run in parallel it is recommended that these cables are separated by at least 20 cm.
Where possible cables shall be routed in earthed shielded cable ducting, to minimise electromagnetic noise coupling.
Use shielded cable to connect the external regen resistor (if installed) to the T200 power supply. The length of this cable
shall be as short as possible. The shields of these voltage supply cables shall be earthed to Chassis Earth using the
optional EMC kit or the panel earth bar. Alternatively, if the cable is required to pass through an enclosure panel earthed
to Chassis Earth, the shield may be earthed to the panel by use of a 360 degree metal cable gland. (Refer to Section 2.3
and Section 3.13 for safety and other relevant installation requirements for Regen resistors).
Cables supplying external d.c. supply voltages to the T200 Servo-drive (For example, the 24 Vd.c. supply) must be as
short as possible. The supply wires shall be twisted together or alternatively shielded cable shall be used.
Cables connecting the 325 V d.c. bus from the T200 Servo-drives must be as short as possible. The supply wires shall be
twisted together.
Motor power cables must be shielded with the cable shield securely connected to Chassis Earth at both ends of the cable.
At the T200 end of the cable the shield shall be earthed to Chassis Earth using the optional EMC kit or the panel earth
bar.
Motor resolver/signal cables must be shielded with the cable shield securely connected to Chassis Earth at both ends of
the cable.
Signal cables must be shielded with the cable shield securely connected to make a good HF earth bond to Chassis Earth
at both ends of the cable.
PAGE 2-14
SECTION 2: SAFETY INSTRUCTIONS
T200 User's Manual
2.4 Electromagnetic Compatibility (EMC)
Required for
CE-Compliance
User's whose machine installations are intended for CECompliance should read Section 2.4. Otherwise reading
of Section 2.4 is not required.
The T200 Servo-drive are system components which must be installed in a correct manner to ensure that all
electromagnetic compatibility (EMC) requirements are met. The requirements of European Union (EU) EMC Directive:
89/336/EEC (as amended by EU Directives 92/31/EEC and 93/68/EEC ) must be met by all equipment, systems and
installations into which the T200 Servo-drive are installed.
For further information on the requirements of EU EMC Directive the user is recommended to refer to the latest
publications of the EU Commission and to local regulations.
The T200 Servo-drive have been tested for compliance with the requirements of the EU EMC Directive in so far as they
can be regarded as single functional units. The T200 Power Supply and Controller have been tested in typical
configurations and it has been found that these configurations meet the essential requirements of the EU EMC Directive.
Details of these configurations are given in Appendix A.
The EMC standards applied were as follows:
•
EMC Emission Standard EN 55011:1991, Limits and methods of measurement of radio disturbance characteristics
of industrial, scientific and medical (ISM) radio-frequency equipment. (Group 1, Class A).
•
EMC Immunity standard EN 50082-2:1995, Electromagnetic compatibility Generic Immunity Standard Part 2:
Industrial Environment.
Both these standards are published by CENELEC, the European Committee for Electrotechnical Standardisation,
Brussels.
2.4.1
Specific Electromagnetic Compatibility (EMC) Requirements:
The EMC measures outlined below are required to be installed by the user into all equipment, systems and installations
into which the T200 are installed. Further details are given in the referenced sections of this User’s Guide.
The T200 Servo-drive must be installed by mounting on a panel in a manner that ensures that EMC earthing
requirements are met. (Refer Section 3 of this User’s Guide).
An optional EMC kit is available to facilitate earthing of cable shields prior to entering the T200. Cable shields must be
bonded to either the panel earthing bar or the optional EMC kit.
For safety reasons the T200 Servo-drive, and the panel on which they are mounted must be installed in enclosures or
cabinets which provide a degree of ingress protection against liquids and objects of at least IP54. These enclosures or
cabinets must be accessible to technically qualified service or maintenance persons only.
PAGE 2-15
T200 User's Manual
SECTION 2: SAFETY INSTRUCTIONS
For Electrostatic Discharge (ESD) reasons all service or maintenance persons must ground themselves to the chassis of
the equipment when performing service functions inside the IP54 rated enclosure or cabinet in which the T200 Servodrive are installed.
All external d.c. supply voltages used with the T200 must be supplied from power supplies which are compliant with the
requirements of the EU EMC Directive. All other equipment that is connected to the T200 must be compliant with the
EU EMC Directive.
For single phase power applications an a.c. power input line filter is required to be installed by the user in the a.c. mains
power input supply lines to the T200 (not required for 120Va.c. control backup power input). For further details see
Appendix A. For three phase power applications an isolation transformer must be used for EMC compliance.
Shielded cable is required to be installed by the user for many external user cable connections to the T200. Details of
areas where shielded cable must be installed and details of earthing arrangements which must be implemented for the
shields of such cables are given in Section 2.3 and throughout Section 3 of this User’s Guide. Installation requirements
for external Regen (Regeneration Circuit) resistors are given in Section 3.13 of this User’ Guide. Common Mode noise
suppression ferrites must be used at both ends of cables connected to the Axis I/O Connector (J1) and optional Extended
I/O Card connector. In CAN (Controller Area Network) applications common mode noise suppression ferrites must be
used on the cables of the 24Vd.c. Control Logic Supply and CAN-IN terminal at the point of connection to the T200.
PAGE 2-16
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
C27095-001
PAGE 3-1
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
TABLE OF CONTENTS
WIRING AND INSTALLATION .................................................................................................................................3-1
3.1
SYSTEM COMPONENTS.....................................................................................................................................3-7
3.1.1
a.c. Mains Power Interface........................................................................................................................ 3-7
3.1.1.1 Single-Phase Mains Connection...................................................................................................................................3-8
3.1.1.2 Three Phase Mains Connection ....................................................................................................................................3-8
3.1.2
3.1.3
3.1.4
3.1.4.1
3.1.4.2
3.1.5
3.1.6
A.C. Input Circuit Breaker - (User Supplied) ........................................................................................... 3-9
Serial Set-up Terminal (User-Supplied)..................................................................................................3-11
Control-Backup Power Input (User Supplied) ........................................................................................ 3-11
24 Vd.c. Control-Backup Power Supply...............................................................................................................3-11
120 V a.c. Control-Backup Power Supply ............................................................................................................3-12
Note on cases where the user does not need to use a Control-Backup Power-Supply ............................ 3-12
Brushless Servo motors........................................................................................................................... 3-12
3.1.6.1 Brushless Motor Brake 24V Power Supply ................................................................................................................3-12
3.1.7
Heatsinks and Climatic Control ..............................................................................................................3-12
3.1.8
Mating Connectors, Cables and Wiring ..................................................................................................3-13
3.1.9
Option Cards ...........................................................................................................................................3-13
3.2
EQUIPMENT MOUNTING ................................................................................................................................ 3-14
3.2.1
CE Items for Mechanical Installation .....................................................................................................3-21
3.3
POWER DISSIPATION ......................................................................................................................................3-22
3.4
T200 CONNECTOR TERMINALS .....................................................................................................................3-23
3.5
GENERAL SYSTEM WIRING GUIDELINES ......................................................................................................3-26
3.5.1
Power Circuit Breaker (User Supplied) ..................................................................................................3-27
3.5.2
Drive Contactor (User Supplied) ............................................................................................................3-27
3.6
SEQUENCE OF COMPONENT WIRING RECOMMENDATIONS .........................................................................3-28
3.7
THREE-PHASE A.C. MAINS POWER SOURCE CONFIGURATION...................................................................3-29
3.8
SINGLE PHASE 230VA.C. MAINS CONFIGURATION ...................................................................................... 3-31
3.9
SINGLE PHASE 120VA.C. MAINS CONFIGURATION ...................................................................................... 3-33
3.10 PROVIDING D.C. BUS POWER FROM A T200-X10 U NIT TO T200-X00 U NITS .............................................3-35
3.10.1
Power Ready Signalling from T200-X10 to Connected T200-X00 Units ..............................................3-37
3.10.1.1 The Power Ready Interconnect scheme....................................................................................................................3-37
3.10.2
Power Cycling Frequency Limits............................................................................................................3-41
3.11 PARALLELING T200-X10 U NITS THROUGH THE D.C. BUS...........................................................................3-42
3.12 DAISYCHAINING CONTROL-BACKUP POWER CONNECTIONS TO T200'S.....................................................3-43
3.12.1
24Vd.c. Control-Backup Power Daisychaining ...................................................................................... 3-43
3.12.2
120Va.c. Control-Backup Power Daisychaining .................................................................................... 3-44
3.13 INTERNAL/EXTERNAL REGENERATION (REGEN) RESISTORS – C ONFIGURATIONS ....................................3-45
3.13.1
T200-310 External Regeneration Resistor Options.................................................................................3-48
3.13.2
T200-410 and T200-510 External Regeneration Resistor Connection ................................................... 3-50
3.13.3
T200-610 and T200-710 External Regeneration Resistor Connection ................................................... 3-52
3.14 MOTORS - INSTALLATION.............................................................................................................................. 3-56
3.14.1
Assembling Motor Resolver and Power Cables...................................................................................... 3-56
3.14.2
Motor Power Cable .................................................................................................................................3-57
3.14.3
T200 Resolver Cable............................................................................................................................... 3-57
PAGE 3-2
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.14.4
Crimping Tools for Motor Cables .......................................................................................................... 3-64
3.14.5
Terminating the Motor Cable Shield, for CE-Compliance (T200-3/4/5 only) ....................................... 3-65
3.14.6
Terminating the Motor Cable Shield (non-CE Applications) T200-3/4/5 only...................................... 3-66
3.14.7
T200-610 and T200-710 Motor Power Cable Shield Connection .......................................................... 3-67
3.14.8
Motor Brake Connection ........................................................................................................................ 3-67
3.15 T200 CONTROL INPUT AND OUTPUTS .......................................................................................................... 3-68
3.15.1
General Purpose Description of the Digital Inputs................................................................................. 3-69
3.15.2
General Purpose Description of the Digital Outputs .............................................................................. 3-71
3.15.3
General Purpose Description of the Analog Inputs ................................................................................ 3-73
3.15.4
General Purpose Description of the Analog Outputs ............................................................................. 3-74
3.15.5
I/O Overview and Usage in Different Software Modes ......................................................................... 3-76
3.15.6
Power Sequencing on Startup................................................................................................................. 3-78
3.16 INCREMENTAL ENCODER/STEPPER MOTOR INTERFACE INPUT DESCRIPTION. ......................................... 3-79
3.17
ENCODER SIMULATION OUTPUT DESCRIPTION ........................................................................................... 3-80
3.18 COMMUNICATIONS INTERFACE WIRING AND CONFIGURATION ................................................................. 3-82
3.18.1
RS232 Interface Description ................................................................................................................. 3-83
3.18.1.1 Wiring an RS232 Connection ..................................................................................................................................3-83
3.18.1.2 RS232 Set-up Parameters .........................................................................................................................................3-84
3.18.2
RS485 Interfaces Description................................................................................................................ 3-85
3.18.2.1 Wiring an RS485 Connection ..................................................................................................................................3-86
3.18.2.2 RS485 Adaptor for Conversion of RS232 to RS485 ................................................................................................ 3-86
3.18.2.3 RS485 Line Termination ..........................................................................................................................................3-88
3.18.2.4 RS485 Cable Maximum Length............................................................................................................................... 3-88
3.18.2.5 RS485 Address Set-up via Axis-ID-HEX-Switches on T200 front Panel ................................................................ 3-89
3.18.2.6 RS485 Set-up Parameters .........................................................................................................................................3-89
3.19
T200 USER VISUAL INDICATIONS ................................................................................................................. 3-90
PAGE 3-3
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Section 3 Table of Figures
Figure 3.1:- Typical T200 System Components .............................................................................................................3-10
Figure 3.2:- T200-3/4/5 Mechanical Mounting ..............................................................................................................3-15
Figure 3.3:- T200-3/4/5 Mechanical Dimensions ...........................................................................................................3-16
Figure 3.4:- T200-610 Mechanical Mounting.................................................................................................................3-17
Figure 3.5:- T200-610 Mechanical Dimensions .............................................................................................................3-18
Figure 3.6:- T200-710 Mechanical Mounting.................................................................................................................3-19
Figure 3.7:- T200-710 Mechanical Dimensions .............................................................................................................3-20
Figure 3.8:- T200-3/4/5 Front Panel (T200-X10 with Integral PSU) .............................................................................3-23
Figure 3.9:- T200-3/4/5 Front Panel (T200-X00 without Integral PSU) ........................................................................3-24
Figure 3.10:- T200-610 and T200-710 Front Panel ........................................................................................................3-25
Figure 3.11:- T200 Multi-Axis system with 3-Phase A.C. Mains Inputs .......................................................................3-30
Figure 3.12:- T200 Multi-Axis system with Single-Phase 230Va.c. Mains Input (T200-310/410/510 Models only)....3-32
Figure 3.13:- T200 Multi-Axis system with Single-Phase 120V A.C. Mains Inputs (T200-310/410/510 Models only)3-34
Figure 3.14:- Daisychaining the High Voltage D.C. Bus from a T200-X10 to T200-X00 Units ...................................3-35
Figure 3.15:- T200 Power Ready, 24V d.c. and 120V a.c. Backup Connections ........................................................... 3-38
Figure 3.16:- T200-610/710 Power Ready, 24V d.c. and 120V a.c. Backup Connections .............................................3-39
Figure 3.17:- Pull-up Power Ready Interconnect between T200-X10 and Connected T200-X00 Units (I_COMMON
connected to 24V RETURN) ..................................................................................................................................3-40
Figure 3.18:- Pull-down Power Ready Interconnect between T200-X10 and Connected T200-X00 Units (I_COMMON
connected to 24V+).................................................................................................................................................3-40
Figure 3.19: Paralleling T200-X10 Units through the D.C. Bus..................................................................................... 3-42
Figure 3.20: Daisychaining the 24Vd.c. backup power from one T200 to the next........................................................ 3-43
Figure 3.21: Daisy-Chaining the 120Va.c. backup Input from one T200 to the Next T200 ...........................................3-44
Figure 3.22: T200-310/410/510 External Regeneration and Mains Input, d.c. Bus Input and Output Connections .......3-46
Figure 3.23: T200-610/710 External Regeneration and Mains Input, d.c. Bus Input and Output Connections..............3-47
Figure 3.24:- T200-310 Regeneration Resistor 200W Option 1 – C22654-002 (Mounting and Connection) ................3-48
Figure 3.25:- T200-310 Regeneration Resistor 200W Option 2 – A76178-002 (Mounting and Connection) ................3-49
Figure 3.26:- T200-410 and T200-510 600W Regeneration Resistor Option 1 – C22654-006 (Mounting and Connection)
................................................................................................................................................................................3-50
Figure 3.27:- T200-410 and T200-510 600W Regeneration Resistor Option 2 – A76178-003 (Mounting and Connection)
................................................................................................................................................................................3-51
Figure 3.28:- T200-610 and T200-710: 600W Regeneration Resistor Option 1 – C22654-007 (Mounting and
Connection)............................................................................................................................................................. 3-52
Figure 3.29:- T200-610 and T200-710: 1.25KW Regeneration Resistor Option 2 – C22654-011 (Mounting and
Connection)............................................................................................................................................................. 3-53
Figure 3.30:- T200-610 and T200-710 Regeneration Resistor Option 3:- C22654-025 (Mounting and Connection) ....3-53
Figure 3.31:- T200-610 and T200-710 Regeneration Resistor Option 4:- two C09838-010 (Mounting and Connection) 354
Figure 3.32:- T200-3/4/5 Motor and Brake Connections................................................................................................ 3-58
Figure 3.33:- T200-610 and -710 Motor and Brake Connections ................................................................................... 3-59
Figure 3.34: Motor Power and Brake Cable ................................................................................................................... 3-60
Figure 3.35:- T200 J6 Resolver Cable ........................................................................................................................... 3-62
Figure 3.36:- Terminating the Motor Cabling for EMC CE-Compliance.......................................................................3-65
Figure 3.37:- Attaching the T200 Motor Cable Shield via the Clamp, for a G4x6 motor. .............................................3-66
Figure 3.38:- Motor Brake Cabling ................................................................................................................................ 3-67
Figure 3.39:- T200 Generic Digital Inputs...................................................................................................................... 3-69
Figure 3.40:- T200 Pull-Up or Pull-Down Options for Digital Inputs on J1 ..................................................................3-70
Figure 3.41:- T200 Generic Digital Outputs ................................................................................................................... 3-71
Figure 3.42:- T200 Pull-Up or Pull-Down Options for Digital Outputs on J1 ............................................................... 3-72
Figure 3.43:- T200 Analog Input Description ................................................................................................................3-73
Figure 3.44: T200 Analog Output Description ...............................................................................................................3-74
Figure 3.45: T200 Axis I/O Connector J1 ...................................................................................................................... 3-75
PAGE 3-4
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.46: Power Sequencing control using PWR_RDY and ENABLE .................................................................... 3-78
Figure 3.47: Incremental Encoder per channel Input Electrical Description.................................................................. 3-79
Figure 3.48: Encoder Simulation Output Electrical Description.................................................................................... 3-80
Figure 3.49: T200 Position Transducer Interfaces ......................................................................................................... 3-81
Figure 3.50: T200 Communications Terminals.............................................................................................................. 3-82
Figure 3.51: T200's J4 RS232 Wire Pin-out (to 9-Way and 25-Way Connectors) ........................................................ 3-83
Figure 3.52: T200 Multi-Axis RS485 System................................................................................................................ 3-85
Figure 3.53:- Adaptor between PC and RS232/RS485 Adaptor .................................................................................... 3-87
Figure 3.54:- RS485 Wiring and Termination ............................................................................................................... 3-88
Figure 3.55:- Axis ID HEX Switches Location.............................................................................................................. 3-89
Figure 3.56:- T200-X10 (with PSU) LED's and 7-Segment Display ............................................................................. 3-91
Figure 3.57:- T200-X00 (without PSU) LED's and 7-segment display.......................................................................... 3-91
Figure 3.58:- T200-610/710 LED's and 7-Segment display........................................................................................... 3-92
PAGE 3-5
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Section 3 Table of Tables
Table 3.1: T200 Input Power Ratings versus Single and Three Phase Mains Voltage Level ...........................................3-8
Table 3.2: T200 Accessory Cabling................................................................................................................................ 3-13
Table 3.3:- Estimated Power Dissipation for the T200 Servo-drives..............................................................................3-22
Table 3.4:- T200-310 Regeneration Resistor Options ....................................................................................................3-49
Table 3.5:- T200-410 and T200-510 Regeneration Resistor Options .............................................................................3-51
Table 3.6:- T200-610 and T200-710 Regeneration Resistor Options .............................................................................3-54
Table 3.7:- Motor Power Cable ......................................................................................................................................3-61
Table 3.8:- Motor Resolver Cable ..................................................................................................................................3-63
Table 3.9:- Overview of T200 Analog and Digital Inputs .............................................................................................. 3-76
Table 3.10:- Overview of T200 Analog and Digital Outputs ......................................................................................... 3-77
Table 3.11:- T200's RS232 Pinout on J4 ........................................................................................................................ 3-83
Table 3.12:- T200's RS485 Pinout on J2 and J3 (Same Pinout on both Connectors) ..................................................... 3-86
Table 3.13:- Wiring of PSM-EG-RS232/RS485-P/2D ...................................................................................................3-87
PAGE 3-6
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
This section covers the installation, wiring and cabling of the Moog T200 Servo-drive series. A pictorial diagram of a
single-axis system, with typical components included, is shown in Figure 3.1. Users are directed to read Section 2,
Safety Instructions, before proceeding with wiring and installation.
WARNING – You must disconnect the T200 Servo-drive from all voltage supplies
(230 Va.c., 120 Va.c., 24 Vd.c.) before servicing.
WARNING - This equipment must be permanently and reliably connected to Earth and all
conductive parts in the IP54 rated enclosure in which the T200 Series Servo-drive is installed
must be reliably connected to Protective Earth. A Protective Earth connection must come
directly from an approved a.c. mains network. Stranded copper -wire, is recommended to carry
the earth.
FAILURE TO PROVIDE AN ADEQUATE EARTH MAY CAUSE SERIOUS PERSONAL
INJURY AND EQUIPMENT MALFUNCTION.
3.1 System Components
The following components are required to build a Moog brushless motor velocity or torque digital control system (refer
to Figure 3.1). Section 6, Functional Overview of the T200, provides a more thorough description of the operation of
the T200. All components besides the T200, EMC-Brackets, G4XX motor, motor and other accessory cabling, and the
Hand Held Terminal are supplied by the user.
All T200 models encorporate internal overload protection for the motor load and are not required to be used with
external or remote overload protection. Details of this protection are given in Section 6 of this manual. The associated
software commands are given in Sections 7 and 8.
3.1.1
a.c. Mains Power Interface
The T200-310/410/510 may be connected in either single-phase or three-phase mode. The T200 a.c. mains input power
ratings are given in Table 3.1, for single phase and three-phase mode.
The T200-310/410/510 may be connected directly to single phase a.c. mains supply networks. Note, however, that it
operates at lower input power ratings, when coupled to single-phase a.c. mains.
In three-phase mode, where the T200 is capable of higher input power, a user supplied step-down transformer is usually
required, to drop the a.c. mains voltage to 230Va.c.. This transformer may also provide electrical isolation of the T200
from the neutral point of the three phase mains, as well as limit the inrush current from the mains on power-on.
PAGE 3-7
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.1.1.1 Single-Phase Mains Connection
The T200-310/410/510 can operate with single phase a.c. mains voltage sources from 120Va.c. to 230Va.c.. Note that
the input power must be linearly de-rated for mains voltages lower than 230Va.c., as shown in Table 3.1. The T200
does not require an input isolation transformer for single-phase operation, for Low Voltage Directive Compliance.
•
Table 3.1 gives an overview of the T200 in single-phase operation (230 Va.c. and 120Va.c.).
Servo-Drive
Model
T200-310
T200-410
T200-510
T200-610
T200-710
Three Phase 230Va.c. Rating
Single Phase 230Va.c. rating
Single Phase 120Va.c. rating
Rated
Continuous
Input Power
Rated
Continuous
Input Power
Rated
Continuous
Input Power
7.5kW
7.5kW
7.5kW
15.0kW
15.0kW
Rated
Continuous
DC Bus
Output Power
6.5kW
6.5kW
6.5kW
6.5kW
6.5kW
2.5kW
2.5kW
2.5kW
Rated
Continuous
DC Bus
Output Power
2.5kW
2.5kW
2.5kW
1.2kW
1.2kW
1.2kW
Rated
Continuous
DC Bus
Output Power
1.2kW
1.2kW
1.2kW
Single phase operation not available for T200-610 and T200-710
Table 3.1: T200 Input Power Ratings versus Single and Three Phase Mains Voltage Level
3.1.1.2 Three Phase Mains Connection
For three-phase operation it is usually required that a voltage-matching transformer is installed as part of the total
system. The transformer serves the following functions:
1.
Matching the mains supply line voltage to the required power supply input voltage.
2.
Limiting available short circuit fault current to be within the interrupting rating of the a.c. input circuit breaker.
NOTE - The T200 is designed to allow direct a.c. off-line operation from a 230 Va.c. (Vr.m.s) 50/60 Hz
three phase source capable of delivering not more than 5000 RMS (r.m.s.) symmetrical amperes. A 3
Phase step down transformer is typically used to drop the size of the a.c. mains voltage to 230Va.c.,
though the step down transformer is not needed if the a.c. mains magnitude is already 230Va.c.. The
transformer should be chosen by the user such that its KVA rating covers the maximum power
requirement of the application. If in doubt as to the application power requirements, a 7.5 KVA
minimum rating is recommended for use with a T200-310, -410 or -510, and a 15 KVA minimum
rating is recommended for use with a T200-610 or -710.
Transformers should be installed in a clean, dry, enclosed environment. Maximum ambient temperature should not
exceed 60°C (140°F).
PAGE 3-8
SECTION 3: WIRING AND INSTALLATION
3.1.2
T200 User's Manual
A.C. Input Circuit Breaker - (User Supplied)
It is recommended that an a.c. mains Circuit Breaker is used as a protective device.
A single or three phase automatic circuit breaker will ensure that all phases are interrupted in the event of a fault
condition. After a power loss to the servo-drive, the motor will continue running until it’s stored energy is dissipated
through friction alone, or will be stopped by a motor-equipped brake if a brake is available.
It is also recommended to install a contactor rated for the T200 input power (see Table 3.1: T200 Input Power Ratings
versus Single and Three Phase Mains Voltage Level) between the output of the transformer and the input of the T200
(refer to Figure 3.1). This contactor should be controlled directly by user supplied Emergency Stop Buttons and other
series connected safety switches to remove a.c. input power in any situation affecting personnel safety.
WARNING - The supply disconnecting device (circuit breaker) must be switched to
the OFF position before any service or maintenance activity is commenced.
PAGE 3-9
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.1:- Typical T200 System Components
PAGE 3-10
SECTION 3: WIRING AND INSTALLATION
3.1.3
T200 User's Manual
Serial Set-up Terminal (User-Supplied)
An RS-232 interface should be established for individual servo-drive communications, using a user supplied IBM
compatible service computer (PC) or a Hand Held Terminal (HHT). The IBM PC can run either a Terminal Emulation
program (e.g. Windows 95 HyperTerminal) or Moog's WinDrive Windows-based user-interface program.
Required for
CE-Compliance
The hand held service terminal or personal computer are service
engineer tools only and must be installed so that use of the key
sequences which allow control of the machine functions is accessible to
authorised qualified service personnel only. All such hand held service
terminals or service set-up computers must be CE -marked as
compliant with the EU EMC Directive.
For multi-drop communications of up to thirty (30) T200 Servo-drives, an RS-485 interface should be used. See Section
3.18.2.2 RS485 Adaptor for Conversion of RS232 to RS485, for further information.
3.1.4
Control-Backup Power Input (User Supplied)
The T200 requires a control power source to supply backup-power for the control electronics. This control-backup
power is useful where the user requires that the T200 does not loose absolute position data or status information when
a.c. mains power is removed from the T200. There are two possibilities for this control-backup supply
•
24Vd.c. Control-Backup Power Supply OR
•
120Va.c. Control-Backup Mains Supply
The user is directed to the local Moog sales office or authorised distributor for a recommended list of these control
power source devices.
3.1.4.1 24 Vd.c. Control-Backup Power Supply
The 24 Vd.c. control power option allows high voltage motor power to be removed from a T200 Series Servo-drive
without losing control power.
The acceptable voltage range for this supply is 18 to 36 Vd.c. with a minimum current rating of 2.0 Ad.c. per T200
Series Servo-drive connected. A low cost unregulated d.c. supply is adequate. However the instantaneous voltage
should never drop below 17.5Vd.c., (including ripple).
Required for
CE-Compliance
NOTE - The 24 V d.c. power supply must be compliant with the
requirements of the EU EMC Directive. The 24 V d.c. voltage output
from the power supply must be Safety Extra Low Voltage ( SELV - as
defined by European standard EN 60950 ).
PAGE 3-11
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.1.4.2 120 V a.c. Control-Backup Power Supply
The 120V a.c. Power Supply allows high voltage motor power to be removed from the T200 Series Servo-drive without
losing control power.
The acceptable voltage range for this supply is 120 V a.c. +10/-15%, with a minimum current rating of 0.3 A a.c. per
T200 Servo-drive connected.
Caution - The 120Va.c. backup must be isolated from the T200 a.c. mains input (in
both of the cases where the T200 a.c. mains connection is 3 phase or single phase).
3.1.5
Note on cases where the user does not need to use a Control-Backup PowerSupply
The T200 can generate control power from its internal high voltage D.C. Bus, if that internal high voltage is greater than
250Vd.c.
§ The critical mains input voltage level, above which logic backup power can be drawn from the ac mains, is
170Va.c. Below this voltage level, a separate 24V DC or 120Va.c. backup power supply must be used.
§ If 230Va.c. single or three phase mains is supplied directly to the T200, then the T200 can operate without a
control-backup power supply. It will however lose absolute position information when the a.c. mains power is
removed.
§ If 120Va.c. mains is used to supply the D.C. Bus, then the internal high voltage is not sufficient to generate control
power. In this case, the user must connect either a backup 120Va.c. isolated mains power source to the T200's
120Va.c. control-backup input, OR connect a backup 24Vd.c. power source to the T200's 24Vd.c. control-backup
input.
3.1.6
Brushless Servo motors
The T200 series Servo-drive is compatible with the Moog G4XX and G3XX range of brushless servo motors.
The G4XX series brushless motors are offered in five frame sizes (see Section 4 for an overview of the motor range).
Motors are also available with an optional static holding brake.
Normal connection to the motor requires two cables:- a power and a signal cable. The power cable provides three phase
stator power, protective earth and brake connections. The signal cable carries position transducer feedback signals and
motor temperature detection connections.
3.1.6.1 Brushless Motor Brake 24V Power Supply
Note that the motor brake requires a 24V ±15% supply for release. This should be rated to cover at least twice the sums
of the rated currents of all brakes connected (see Section 4.5.7). Moog recommends that, if long (>5m) motor power
cable runs are used in the application, that a separate 24V ±15% power source is used for the brakes.
3.1.7
Heatsinks and Climatic Control
The need for air conditioning will depend on the duty cycle of the system and the surrounding ambient temperature. The
maximum allowable ambient temperature is 55°C (131°F). The humidity range is 5-95% non-condensing.
All T200 Servo-drives incorporate internal cooling fans and integral heat sinks. Other than controlling ambient
conditions, additional heat sinking is not required.
PAGE 3-12
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.1.8
Mating Connectors, Cables and Wiring
Moog can provide the necessary cabling for interconnect of the motor to the T200. See Section 3.14 for details. Moog
also provides the following accessory cabling for interconnection of individual T200's:Function
Description
Length
between
Blocks
150mm
Overview Diagram
Moog
Part
Number
3-Axis System
T200-3/4/510
AC Mains Input
Connectors
Two AC Mains Blocks provided.
The User must provide the AC
Mains Input Block for the first
T200, as well as wire the AC
Mains input.
4-Axis System
T200-3/4/510
AC Mains Input
Connectors
Three AC Mains Blocks provided.
The User must provide the AC
Mains Input Block for the first
T200, as well as wire the AC
Mains input.
150mm
C08455-004
3-Axis System
T200-3/4/510
DC Bus Bridge
Connectors
The user may interconnect the
DC-Bus amongst 3 T200 units for
shared DC Bus power and
regeneration capability
150mm
C08454-003
4-Axis System
T200-3/4/510
DC Bus Bridge
Connectors
The user may interconnect the
DC-Bus amongst 4 T200 units for
shared DC Bus power and
regeneration capability
150mm
C08454-004
CAN to CAN
Connector
Connects
CAN
fieldbus
daisychain from T200 unit to the
next T200 unit.
180mm
C08450-001
CAN
Termination
Connector
Terminates the CAN fieldbus
with a 120Ohm connector
C08455-003
C08449-002
Table 3.2: T200 Accessory Cabling
All other cabling is user supplied.
3.1.9
Option Cards
The T200 incorporates an EF (extended functionality) slot for option cards, allowing for future system
expansion/enhancement. Contact Moog Sales Outlets for further information regarding option cards.
PAGE 3-13
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.2 Equipment Mounting
Figures 3.2 to 3.7 show the mechanical dimensions of the T200 chassis, as well as required clearances for cabling etc..
The T200 is designed to be panel or cabinet mounted. The T200 must be mounted in a vertical orientation. The T200
must be panel mounted within an enclosure or cabinet which provides a degree of ingress protection against liquids and
objects of at least IP54. Such enclosures or cabinets must be accessible to technically qualified service or maintenance
persons only. It is recommended that the cabinet be ventilated using filtered or conditioned air, free of corrosive or
electrically conductive contaminants. The accumulation of dust, dirt, etc. on the equipment must be avoided. A
minimum clearance of 40mm above and below the servo-drive is recommended for the T200-3, T200-4 and T200-5
models, and a minimum clearance of 60mm above and below the servo-drive is recommended for the T200-6 and T2007 models. If any of the T200 units is mounted in a closed cabinet, allow 60mm clearance at the front.
The T200 must be permanently and reliably connected to Earth and all conductive parts in the IP54 rated enclosure or
cabinet must be permanently connected to Earth. The impedance between the earth terminal and any accessible part of
the enclosure or cabinet should be less than or equal to 0.1 Ω.
NOTE - The T200 Series Servo-drives are system components that must be
installed in the correct manner to ensure that all electromagnetic compatibility
(EMC) requirements are met. (Refer to Section 2 of this User’s Guide).
The T200 must be mounted on a panel with a flat solid surface in a manner
that ensures that EMC earthing requirements are met.
Required for
CE-Compliance
PAGE 3-14
There must be a clean flat conductive surface at all of the mounting points.
Remove paint or other insulating materials and provide conductive corrosion
protection at the mounting points. It is important that there is good highfrequency bonding between the panel and the T200 Servo-drive. Conductive
hex socket head bolts (metric M5 or Imperial #10) with conductive locking
washers should be used.
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.2:- T200-3/4/5 Mechanical Mounting
PAGE 3-15
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.3:- T200-3/4/5 Mechanical Dimensions
PAGE 3-16
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.4:- T200-610 Mechanical Mounting
PAGE 3-17
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.5:- T200-610 Mechanical Dimensions
PAGE 3-18
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.6:- T200-710 Mechanical Mounting
PAGE 3-19
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.7:- T200-710 Mechanical Dimensions
PAGE 3-20
SECTION 3: WIRING AND INSTALLATION
3.2.1
T200 User's Manual
CE Items for Mechanical Installation
Additional electromagnetic compatibility (EMC) measures must be installed
on equipment associated with the T200 Servo-drive. The following measures
must be implemented:
•
All external Regen (Regenerative circuit) resistors used with the T200
must be installed in enclosures which provide a degree of ingress
protection against liquids and objects of at least IP54 and which are
accessible to technically qualified service or maintenance persons only.
Protection against electric shock must be maintained when installing
these resistors.
•
Use shielded cable to connect the external regen resistor (if installed) to
the T200 power supply. The length of this cable should be as short as
possible. The shields of these cables should be earthed to Chassis Earth
using the optional EMC Bracket kit or the panel earth bar. Alternatively,
if the cable is required to pass through an enclosure panel earthed to
Chassis Earth, the shield may be earthed to the panel by use of a 360
degree metal cable gland.
•
Cables supplying external d.c. supply voltages to the T200 Series Servodrives (for example, the 24 Vd.c. supply) must be as short as possible.
The supply wires should be twisted together or alternatively shielded
cable should be used.
•
Cables connecting the 325V D.C. Bus from the T200 Power Supply to
other T200 Servo-drives must be as short as possible. The supply wires
should be twisted together where possible or shielded cables should be
used.
•
Motor power cables must be shielded with the cable shield securely
connected to Chassis Earth at both ends of the cable. At the T200 Servodrive end of the cable, the shield should be earthed using the optional
EMC Bracket kit.
•
Motor resolver/signal cables must be shielded with the cable shield
securely connected to Chassis Earth at both ends of the cable.
•
Signal cables must be shielded with the cable shield securely connected
to make a good HF earth bond to Chassis Earth at both ends of the cable.
Required for
CE-Compliance
Further details for the correct installation and shielding of cables and
conductors are given in Section 2.
CAUTION - Enclosure or cabinet temperature control is critical for
performance, reliability and life of electrical components. Maintaining a
uniform temperature (check for hot spots) within the specified values for the
equipment will prevent premature failure due to temperature stress.
PAGE 3-21
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.3 Power Dissipation
To calculate cabinet cooling requirements, Table 3.3 provides approximate equipment power dissipation values. If the
application employs regeneration, be sure to add the regen resistor power dissipation to the numbers quoted in Table 3.3
below, (use the continuous wattage rating of the regen resistor if the actual application regen dissipation is unknown).
% of rated
continuous
output
current
0
25
50
75
100
T200300
[W]
35
50
65
80
97
T200310
[W]
48
63
78
93
110
T200400
[W]
35
65
100
130
160
Power Dissipation (Watts)
T200T200T200410
500
510
[W]
[W]
[W]
48
35
50
80
100
110
110
165
180
140
225
240
175
290
300
T200610
[W]
50
130
220
300
400
Table 3.3:- Estimated Power Dissipation for the T200 Servo-drives
PAGE 3-22
T200710
[W]
50
175
300
430
550
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.4 T200 Connector Terminals
Figures 3.4 and 3.5 below detail the connectors on the T200-X10 (unit with internal high power PSU) and the T200-X00
(unit without internal high power PSU) respectively.
Figure 3.8:- T200-3/4/5 Front Panel (T200-X10 with Integral PSU)
PAGE 3-23
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.9:- T200-3/4/5 Front Panel (T200-X00 without Integral PSU)
PAGE 3-24
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.10:- T200-610 and T200-710 Front Panel
PAGE 3-25
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.5 General System Wiring Guidelines
The following is a general reminder of the cable requirements for the T200 Series Servo-drives and related equipment.
NOTE - Cabling and component wiring is critical in obtaining successful operation of the
system. Pay close attention to specified wiring practice, cabling information, earthing and
shielding requirements. Improper wiring can result in electrical noise generation and
unstable motor performance.
Size wire in accordance with standard wiring practice and local codes for amperage and wire length requirements.
Avoid close parallel routing of signal wires and power wires, both inside and outside of the control cabinet. High
voltage bus wires should be twisted and their length should be minimised.
Ensure proper chassis earths on all equipment. Terminate all individual chassis earths from power supply and servodrives to a single tie point, (i.e. cabinet earth bus). Keep the distance from earth bus to earth ground as short as possible.
Similarly, keep distance from servo-drive and power supply chassis earths to the tie point as short as possible. Chassis
earth should be run close to D.C. Bus wires to minimise EMI. The impedance between the earth terminal and any
accessible part of the equipment enclosure or cabinet should be less than or equal to 0.1 Ω
Tighten all terminal screws securely to avoid faulty operation. Torque screws to the specified values noted on the
installation drawings.
All connections to the T200-3, 4 and 5 Series Servo-drives are through removable plug-in mating connectors. Do not
solder the ends of the cables to be inserted into screw clamp terminals. All connections to the T200-6 and T200-7
models are the same as those to the T200-4/5/6 models, with the exception that the motor power, ac mains, DC Bus and
regeneration connections to the T200-6 and 7 are via screw terminal connections.
WARNING – The removable plug-in mating connectors are for ease of wiring and are
not suitable for connection or dis-connection when power is applied. All disconnections must be made with power removed.
WARNING - All electrical supply wires and cables to this equipment must be installed
in conduits (cable routings) which are smooth and free from sharp edges.
CAUTION - Shielded cable is required to be installed by the user for many external
user cable connections to the T200 Servo-drive. Details of areas where shielded cable
must be installed and details of earthing arrangements which must be implemented for
the shields of such cables are given in the relevant sections.
PAGE 3-26
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
CAUTION - All external electrical wiring
connected to this equipment must be color coded
in accordance with European Standard EN
60204-1 requirements. Refer to Section 2.3.3.
Required for
CE-Compliance
CAUTION - Additional electromagnetic
compatibility (EMC) measures which must be
installed on equipment cables associated with the
T200 Servo-drive are given in Section 2.3.4 of
this User’s Guide.
CAUTION - All wires and cables entering and
leaving the IP54 rated enclosures or cabinets
containing the T200 Servo-drive and the Regen
resistor(s) must be protected and anchored in
accordance with the requirements of EN 60204-1.
(Refer to Section 2.3.3 of this Users Guide).
3.5.1
Power Circuit Breaker (User Supplied)
An a.c.-mains Circuit Breaker should be installed in series with the incoming a.c. primary power input lines. The circuit
breaker should be sized so that it provides adequate (RMS) r.m.s protection based upon power supply kW rating. See
Table 3.1: T200 Input Power Ratings versus Single and Three Phase Mains Voltage Level, for a list of the input power
ratings of the T200 at various common voltage levels. Surge current tolerance and single-phase protection should also be
considered when selecting a circuit breaker (supply disconnecting device).
3.5.2
Drive Contactor (User Supplied)
A contactor (suitably rated for the particular T200. See Table 3.1: T200 Input Power Ratings versus Single and Three
Phase Mains Voltage Level) should be installed just before the Mains Input Connector TB2 of the T200-X10 units. The
contactor acts as a remote switch which may cut off the mains supply in the event of an emergency shutdown. This
contactor should be sized based on the continuous power of the system. A rule of thumb of 5 amps/kW continuous
power can be used.
PAGE 3-27
T200 User's Manual
3.6
SECTION 3: WIRING AND INSTALLATION
Sequence of Component Wiring Recommendations
The following sequence for wiring is a recommendation. Individual wiring steps are denoted by a box character, which
can be used as an installation check off list.
The terminal block layout on all power supplies and servo-drives has been designed to isolate low voltage from high
voltage circuits. Cabinet conduits should be arranged to maintain this physical separation.
a) Power Circuit Wiring
•
Wire a.c. mains input to a user supplied Circuit Breaker. Make a secure and reliable connection between the chassis
of the equipment and Earth.
•
ONLY IF CE Compliance is required AND Single-Phase Mains is used:- Fit a suitable EMC Mains Line Filter,
e.g. Schaffner FN350-12-29, between the circuit breaker and the contactor. The current rating of the EMC Mains
Line Filter is application dependant. For details of the EMC test conditions, see Appendix A.
•
If a step down Mains Transformer is used, wire mains from the Circuit Breaker to the primary of the Transformer.
•
If a step down Mains Transformer is used, wire 230 V a.c. three phase from the transformer secondary or plant 230
V a.c. source to a user-supplied contactor. Otherwise wire the a.c. mains from the circuit breaker or the EMC filter
to the user-supplied contactor.
•
Wire a.c. mains from the user-supplied contactor to the power input poles at TB2 of the T200.
For T200 Servo-drives that do not have an Internal Power Supply:
•
Connect the D.C. Bus Input to either:
1.
the D.C. Bus output of a T200 Servo-drive with an Internal Power Supply (See Figure 3.14); or
2.
to the daisy-chained D.C. Bus output of a T200 Servo-drive without an Internal Power Supply (See Figure
3.14).
b) Servo-drive Wiring
•
Plug in Axis I/O cable to J1 and connect other end to user I/O equipment. In particular, connect the Power Ready
signalling between a T200-X10 and any T200-X00 units which draw power from its D.C. Bus.
•
Plug in resolver cable at J6.
•
Plug in 24 Vd.c. or 120 Va.c. Control-Backup Power cable to TB4 or TB5 respectively. Connect the other end of
the cable to the user supplied 24 V d.c. or 120 V a.c. power supply.
•
Connect appropriate communications cabling (RS232 at J4, RS485 at J2 and J3, or CAN at J2 and J3)
c) Motor Wiring
•
Repeat the steps listed in this Section for each motor in the system.
•
Plug in and screw tight resolver/signal cable to motor resolver connector.
•
Plug in and screw tight motor power cable to motor power connector. Also connect the brake terminations at TB7.
PAGE 3-28
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.7 Three-Phase A.C. Mains Power Source Configuration
The T200 may be supplied from a three-phase a.c. mains input. In this case the following user supplied options are
required:1.
Three-Phase Mains Circuit Breaker
2.
Mains Matching Transformer (400/440/480Va.c. to 230Va.c.)
3.
Mains Contactor
For a control-backup power source either of the following may be used:1.
24Vd.c. Power Source OR
2.
120Va.c. Power Source. This power source must provide galvanic isolation between the 120Va.c. output (to be
connected to the T200 at TB6) and the T200's a.c. mains inputs.
Note that if the a.c. mains is still applied, and the control-backup power is removed, then the T200 control section will
still operate correctly. Control power can still be generated from the high voltage D.C. Bus.
Figure 3.11 below outlines typical interconnect in a multi-axis T200 system, which is powered by 3-phase a.c. mains
supply.
Required for
CE-Compliance
NOTE - If the T200 is used in three-phase mode, then an isolation
transformer must be used
CAUTION If the 120Va.c. logic backup power supply option is used,
the 120Va.c. output for connection to the T200, MUST be galvanically
isolated from the T200's a.c. mains input, otherwise damage to the T200
may occur.
PAGE 3-29
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.11:- T200 Multi-Axis system with 3-Phase A.C. Mains Inputs
PAGE 3-30
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.8 Single Phase 230Va.c. Mains Configuration
The T200-310/410/510 Models only may be driven by single-phase 230Va.c.-mains input. In this case the following
user supplied options are required:1.
Single-Phase Mains Circuit Breaker
2.
Mains Contactor
For a control-backup power source, any of the following may be used:1.
24Vd.c. Power Source or
2.
120Va.c. Power Source. This power source must provide galvanic isolation between the 120Va.c. output (to be
connected to the T200) and the T200's a.c. mains inputs.
Note again, that if the a.c. mains is still applied, and the control-backup power is removed, then the T200 control section
will still operate correctly. Control power can still be generated from the high voltage D.C. Bus.
Figure 3.7 below outlines typical interconnect in a multi-axis T200 system, which is powered by single-phase 230V a.c.
mains.
NOTE - If the T200 is used in single-phase mode, an EMC a.c. mains
line filter is required to achieve conducted-emissions compliance.
Required for
CE-Compliance
CAUTION:- If the 120Va.c. logic backup power supply option is used, the
120Va.c. output for connection to the T200, MUST be galvanically isolated
from the T200's a.c. mains input, otherwise damage to the T200 may occur.
PAGE 3-31
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.12:- T200 Multi-Axis system with Single-Phase 230Va.c. Mains Input (T200-310/410/510 Models only)
PAGE 3-32
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.9 Single Phase 120Va.c. Mains Configuration
The T200-310/410/510 Models only may be driven by single-phase 120V a.c. mains input. In this case the following
user supplied options are required:1.
Single-Phase Mains Circuit Breaker
2.
Mains Contactor
For a control-backup power source, one of the following MUST be used:1.
24Vd.c. Power Source or
2.
120Va.c. Power Source
CAUTION:- In this case the user must supply either a 24Vd.c. or a 120Va.c.
control-backup power supply. The D.C. Bus is at too low a voltage level to allow
control power to be derived from it when 120Va.c. mains is used for the high
power input on TB2. If the 120Va.c. option is used, then the 120Va.c. supply
MUST be isolated from the 120Va.c. source used for the mains input supply.
Figure 3.13 below outlines typical interconnect in a multi-axis T200 system, which is powered by single-phase 120V
a.c. mains.
PAGE 3-33
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.13:- T200 Multi-Axis system with Single-Phase 120V A.C. Mains Inputs (T200-310/410/510 Models only)
PAGE 3-34
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.10 Providing D.C. Bus Power from a T200-X10 Unit to T200-X00 Units
A T200-X10 unit contains an a.c. mains rectification stage, which generates a D.C. Bus voltage from the a.c. mains. A
T200-X00 unit does not contain this rectification stage. It accepts a high power input only in the form of a high voltage
D.C. Bus. This D.C. Bus is fed from a T200-X10 unit to one or several T200-X00 units, which are connected to the
T200-X10 in a daisy-chain configuration.
WARNING:- For 230Va.c. mains input, the magnitude of the D.C. Bus voltage is
approx. 325Vd.c. The D.C. Bus terminals at TB3 of the T200-X10, and at TB2 and
TB3 of the T200-X00, have lethal voltages present. All T200 terminals should not be
accessed for service or other purposes before removal of all power and waiting 5
minutes for all internal voltages to decay to harmless levels.
Figure 3.14 shows the interconnect of the D.C. Bus from a T200-X10 to T200-X00 units which share high power via
the D.C Bus.
12AWG (4.00mm2) Wire
Twist DC+ and DC- Wires
1
2
1
3
2
3
DC+ DC- PE
DC+ DC- PE
Connector TB3
Connector TB2
T200-X10
(Unit with an Integral
High Power PSU)
1
2
3
DC+ DC- PE
Connector TB3
1
2
3
DC+ DC- PE
Connector TB2
T200-X00
T200-X00
(Unit without an Integral
High Power PSU)
(Unit without an
Integral High Power
PSU)
Figure 3.14:- Daisychaining the High Voltage D.C. Bus from a T200-X10 to T200-X00 Units
CAUTION:- The T200-X10 D.C. Bus output (on connector TB3) will conduct up to
20Ar.m.s. continuously. If the T200-X10 or T200-X00 D.C. Bus connections (D.C.+
and D.C.-) from a T200-X10 to a T200-X00 are reversed in polarity, then the T200 will
be damaged because of a high current which flows out of the T200-X10 DC+ terminal
on TB3. A T200-X10 which is damaged in this way must be returned to Moog for
repair, and should not be opened for service by the user.
PAGE 3-35
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
There is a limitation to the number of T200-X00 units that can be attached to a T200-X10. This limitation is
summarised below.
CAUTION:-
Limit on Number of Units without PSU Connected to a
T200 Unit with PSU (T200-X10)
The D.C. Bus output of a T200-X10 is capable of supplying up to 6.5kW continuously when
connected to three phase mains. The user should calculate the continuous electrical power
requirements for each axis in the application. The following conditions apply:-
§ The sum of the electrical power requirements, including all T200's (i.e. one T200-X10 and several
T200-X00’s) connected in a daisy-chain via the D.C. Bus, should not exceed the rated continuous
input power limit summarised for each T200-X10 model in the table below.
T200 Model
T200-310
T200-410
T200-510
T200-610
T200-710
Rated Continuous
Input Power
7.5kW
7.5kW
7.5kW
15.0kW
15.0kW
§ The sum of the electrical power requirements of all T200-X00's (i.e. all of the units which do not
contain an integral A.C. Mains PSU), connected in a daisy-chain via the D.C. Bus, should not
exceed 6.5kW.
§ The absolute maximum number of connected T200-X00 units is hard limited to 4, irrespective of
the calculations above.
If in doubt, consult Moog applications engineering for advice on sizing how many units without mains
interface PSU (T200-300 to T200-500) units can be connected to a unit with mains interface PSU
(T200-310 to T200-710).
PAGE 3-36
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.10.1 Power Ready Signalling from T200-X10 to Connected T200-X00 Units
The T200-X10 units contain a soft-start function. The soft-start function limits the inrush current into the T200's D.C.
Bus smoothing capacitors after the a.c. mains has been switched on. The T200 should not allow currents to flow in the
motor before the softstart has completed. Otherwise the D.C. Bus capacitors are drained by motor current during the
soft-start, and may never become fully charged.
3.10.1.1 The Power Ready Interconnect scheme
T200-X10 units will not allow high power to be applied to the motor phases before the soft-start has finished. This can
be accomplished because the T200-X10 control units are informed via internal signalling that the soft-start process is
still ongoing. However T200-X00 units, whose DC-Bus power is taken from a T200-X10, do not know, without some
control input, whether the T200-X10 soft-start process is ongoing. The T200-X10 provides the Power-Ready relay
output to signal to all connected T200-X00 units the status of its soft-start process.
CAUTION:- The T200-X10 can malfunction unless the Power Ready power sequencing
control scheme is used. This control scheme is described in this section of the T200 User
Manual. Users should ensure that this scheme is implemented if they intend to connect
ANY T200-X00 units to a T200-X10.
Note that the T200 allows two options for digital input connections:1.
The Pull-Up option is outlined in Figure 3.17
2.
The Pull-Down option is outlined in Figure 3.18
The pull-up or pull-down interconnect scheme used for the Power Ready power sequencing scheme should follow the
overall digital input scheme which is selected by the user.
PAGE 3-37
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.15:- T200 Power Ready, 24V d.c. and 120V a.c. Backup Connections
PAGE 3-38
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.16:- T200-610/710 Power Ready, 24V d.c. and 120V a.c. Backup Connections
PAGE 3-39
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
26AWG (0.15mm2) Wiring
User-PSU
24V+
24V-
1
2
PR+ PR-
Connector TB4
6
4
6
4
PWR_RDY
I_COMMON
PWR_RDY
I_COMMON
Connector J1
T200-X10
(Unit with an Integral
High Power PSU)
Connector J1
T200-X00
T200-X00
(Unit without an
Integral High Power
PSU)
(Unit without an
Integral High Power
PSU)
Figure 3.17:- Pull-up Power Ready Interconnect between T200-X10 and Connected T200-X00 Units (I_COMMON
connected to 24V RETURN)
26AWG (0.15mm2) Wiring
User-PSU
24V+
24V-
1
2
PR+ PR-
Connector TB4
T200-X10
(Unit with an Integral
High Power PSU)
6
4
6
4
PWR_RDY
I_COMMON
PWR_RDY
I_COMMON
Connector J1
Connector J1
T200-X00
T200-X00
(Unit without an
Integral High Power
PSU)
(Unit without an
Integral High Power
PSU)
Figure 3.18:- Pull-down Power Ready Interconnect between T200-X10 and Connected T200-X00 Units (I_COMMON
connected to 24V+)
PAGE 3-40
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.10.2 Power Cycling Frequency Limits
As outlined in a previous section, the T200-X10 units contain a soft-start function. The soft-start function limits the
inrush current into the T200's D.C. Bus smoothing capacitors after the a.c. mains has been switched on.
If the frequency of power cycling becomes too high, then the power dissipation in the soft-start resistor can be excessive.
In this case the softstart circuitry may become damaged.
CAUTION:- The following rule should be borne in mind when power cycling the a.c.
mains:Within any two minute period, the a.c. mains supply should not be
cycled on and off more than 6 times.
If this rate is exceeded then the internal softstart circuitry may be damaged, and the F3
fault will be displayed on the 7-segment display. In this case the T200 must be
returned to the Moog for repair.
There is also a restriction on the minimum time between a.c. mains power cycling. If
this rate is exceeded then the internal regeneration circuitry may be damaged and the
T200 will have to be returned to Moog for repair. Note that:The minimum time between any two consecutive a.c. mains power
cycles is 4.5 seconds.
PAGE 3-41
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.11 Paralleling T200-X10 Units through the D.C. Bus
T200-X10 units can be paralleled via the D.C. Bus, in order to share regeneration power. In Figure 3.19, below, the
T200-X10 units are shown with the a.c. mains inputs connected to all T200-X10 units. The user can also connect the
D.C. Bus outputs of the T200-X10's at TB3 in order to share regeneration power.
CAUTION:- If a T200-X10 unit does not see a high a.c. voltage at pins 1, 2 or 3 of
terminal TB2, then the T200-X10 will continuously activate the fast bus discharge.
This will cause damage to the internal regeneration circuitry, if a high d.c voltage is
present at connector TB3. The T200 will then have to be returned to the factory for
repair.
12AWG (4.0mm2) Wire
12AWG (4.0mm2) Wire for T200-3/4/5
8AWG (10.0mm2) Wire for T200-6/7
Twist DC+ and DC- Wires
a.c. Mains
L1
L2
L3
Protective
Earth
To further
paralleled
T200X10's
1
2
3
4
L1
L2
L3
PE
Connector TB2
T200-X10
3
1
2
3
4
DC+ DC- PE
L1
L2
L3
PE
1
2
Connector TB3
Connector TB2
1
3
Connector TB3
T200-X10
Figure 3.19: Paralleling T200-X10 Units through the D.C. Bus
PAGE 3-42
2
DC+ DC- PE
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.12 Daisychaining Control-Backup Power Connections to T200's
The T200 contains extra connector terminals which allow easy connection of the 24Vd.c. and 120Va.c. control-backup
power.
3.12.1 24Vd.c. Control-Backup Power Daisychaining
Connections to wire the 24Vd.c. control backup power are shown Figure 3.20 below.
NOTE:- The T200 contains a resetable fuse on the 24Vd.c. input. If the 24V backup power
is connected in reverse, then an over-current on the 24V+ and 24V- terminals will cause the
fuse to go open circuit. If the faulty connection is removed, the fuse will reset after a short
period.
Up to 18AWG (0.9mm2). Wiring needs to take 1.5A/axis, add axis
requirements
User-Supplied
24Vd.c.
Inputs
Twist 24V+ and 24V-Wires
24V+/DaisyChained to
further
T200's
1
2
1
2
1
2
1
2
24V+ 24V-
24V+ 24V-
24V+ 24V-
24V+ 24V-
IN
OUT
IN
OUT
Connector TB5
Connector TB5
Connector TB5
Connector TB5
T200-XX0
T200-XX0
Figure 3.20: Daisychaining the 24Vd.c. backup power from one T200 to the next
PAGE 3-43
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.12.2 120Va.c. Control-Backup Power Daisychaining
Connections to wire the 120Va.c. control backup power are shown in Figure 3.21.
ISOLATED
120Va.c. Logic
Backup Power Source
L
24AWG (0.25mm2 ) Wire. Wiring needs to take 0.3Arms/axis, add axis requirements.
N PE
120Va.c.
Backup
DaisyChained
to other
T200's
1
2
3
1
2
3
1
2
3
1
2
3
L
N
PE
L
N
PE
L
N
PE
L
N
PE
IN
OUT
IN
OUT
Connector TB6
Connector TB6
Connector TB6
Connector TB6
T200-XX0
T200-XX0
Figure 3.21: Daisy-Chaining the 120Va.c. backup Input from one T200 to the Next T200
PAGE 3-44
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.13 Internal/External Regeneration (Regen) Resistors – Configurations
Regeneration resistors can only be fitted to T200 servo-drives with an Internal Power Supply (i.e. Model Numbers.
T200-X10). The T200-310/410/510 do have an internal regen resistor with a continuous power rating of 40W, peek
power of 2.8kW. This regen resistor can be supplemented with an additional external regeneration resistor.
The T200-610/710 do not have an internal regen resistor. An external regen resistor is required in any case.
All external Regen resistors should be mounted to allow adequate heat dissipation and such that heat from the Regen
resistor is not directed to air intakes of other equipment.
Required for
CE-Compliance
For EMC purposes, use shielded cable to connect the external Regen
resistor to the T200. The length of this cable should be as short as
possible. The shields of these cables should be connected to Chassis
Earth using the optional EMC kit or the panel earth bar. Alternatively,
if the cable is required to pass through an enclosure panel earthed to
Chassis Earth, the shield may be earthed to the panel by use of a 360
degree metal cable gland.
Refer to Section 2.3.3 and 2.4 for further safety and EMC requirements
for cable installation.
NOTE - The internal regeneration resistor is protected by an internal electronic
circuit breaker, which disables regeneration when the internal resistor’s rating is
exceeded. For an externally fitted regeneration resistor, the T200 Servo-drive
monitors the regeneration duty cycle and reports a warning to the user via the
Thermal Limit output (THRMAL_LIM) and seven segment display. The
warning reports that the continuous regeneration power of the external resistor
has been exceeded.
WARNING - External regen resistors are connected to the T200 D.C. Bus
voltage that can reach 400 V d.c. Exposed metallic mounting parts of external
regen resistors must be connected to protective earth and the electrically
conducting parts mechanically shielded for safety. High voltage warning
stickers are also recommended.
Moog can supply users with external regeneration resistors. Contact your local Moog sales office or authorised
distributor for available resistor kits.
PAGE 3-45
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.22: T200-310/410/510 External Regeneration and Mains Input, d.c. Bus Input and Output Connections
PAGE 3-46
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.23: T200-610/710 External Regeneration and Mains Input, d.c. Bus Input and Output Connections
PAGE 3-47
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.13.1 T200-310 External Regeneration Resistor Options
Figure 3.24:- T200-310 Regeneration Resistor 200W Option 1 – C22654-002 (Mounting and Connection)
Moog offers two regeneration resitor kit options for use with the T200-310. Figure 3.24 shows the first option for an
external regeneration resistor for the T200-310 unit, which uses a 225W-rated resistor operated at a maximum
continuous dissipation of 200W. Table 3.4 outlines the external resistor's Moog part numbers and wire gauge to be used
when connecting the regeneration resistor options. Figure 3.25 shows the second option for the external regeneration
resistor for the T200-310 unit.
PAGE 3-48
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.25:- T200-310 Regeneration Resistor 200W Option 2 – A76178-002 (Mounting and Connection)
Regeneration
Resistor Option/
Continuous
Rating
50Ohm/55W
(Internal)
10Ohm/225W
(External)
10Ohm/350W
(External)
Actual
Continuous
Regen. Power
Peak Regen
Power
Regen Resistor
Kit Part Number
AWG/(mm2)
Wiring to connect
regen resistor
40W
2.8kW
No wiring needed
200W
14kW
200W
14kW
Already supplied
Internally!
C22654-002
(US only)
A76178-002
(Europe only)
22AWG/
(0.35mm2)
1.5mm2
Table 3.4:- T200-310 Regeneration Resistor Options
PAGE 3-49
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.13.2 T200-410 and T200-510 External Regeneration Resistor Connection
Figure 3.26:- T200-410 and T200-510 600W Regeneration Resistor Option 1 – C22654-006 (Mounting and Connection)
Moog offers two regeneration resitor kit options for use with the T200-410 and T200-510. Figure 3.26 shows the first
option for the external regeneration terminal connections for the T200-410 and T200-510 units, which use a 750W-rated
resistor operated at a maximum continuous dissipation of 600W. Table 3.5 outlines the external resistor's Moog part
numbers and wire gauge to be used when connecting the regeneration resistor options. Figure 3.27 shows the second
option for the external regeneration resistor for the T200-410 and T200-510 units.
PAGE 3-50
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.27:- T200-410 and T200-510 600W Regeneration Resistor Option 2 – A76178-003 (Mounting and Connection)
Regeneration
Resistor Option/
Continuous
Rating
50Ohm/55W
(Internal)
10Ohm/750W
(External)
10Ohm/1kW
(External)
Actual
Continuous
Regen. Power
Peak Regen
Power
Regen Resistor
Kit Part Number
AWG/(mm2)
Wiring to connect
regen resistor
40W
2.8kW
No wiring needed
600W
14kW
600W
14kW
Already supplied
Internally!
C22654-006
(US only)
A76178-003
(Europe only)
20AWG/
(0.60mm2)
1.50mm2
Table 3.5:- T200-410 and T200-510 Regeneration Resistor Options
PAGE 3-51
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.13.3 T200-610 and T200-710 External Regeneration Resistor Connection
MOOG offers four different regen options for the T200-610/710- Figures 3.28 ...3.31 show the different options. Table
3.6 outlines the external resistor’s Moog part numbers and wire gauge to be used when connecting these resistors.
The user need to calculate the application dependent regen power and select one of the options accordingly. Options 1..3
are available in the US option 4 is available in Europe. In case of option 4 only one regen resistor can be used if the max.
continuous regen power do not exceed 1kW.
Figure 3.28:- T200-610 and T200-710: 600W Regeneration Resistor Option 1 – C22654-007 (Mounting and
Connection)
PAGE 3-52
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.29:- T200-610 and T200-710: 1.25KW Regeneration Resistor Option 2 – C22654-011 (Mounting and
Connection)
Figure 3.30:- T200-610 and T200-710 Regeneration Resistor Option 3:- C22654-025 (Mounting and Connection)
PAGE 3-53
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.31:- T200-610 and T200-710 Regeneration Resistor Option 4:- two C09838-010 (Mounting and Connection)
Regeneration
Resistor
Option/
Continuous
Rating
Option 1
(10Ω/750W)
Actual
Continuous
Regen. Power
Peak Regen
Power
Fuse
Part Number
Fuse
Holder
Regen
Resistor
Part
Number
Regen
Resistor
Kit Part
Number
AWG/(mm2)
Wiring to
connect
regen resistor
600W
14kW
C09762-012000
DIN Rail 1)
B81493-007
C22654-007
20AWG/
(0.60mm2)
Option 2
(8Ω/1,5kW)
1,25kW
18kW
C09762-015000
DIN Rail 1)
B81493-002
(US only)
C22654-011
Option 3
(Two of 8Ω/
1.5kW in
parallel)
Option 4
(Two of 10Ω/
1kW in
parallel)
2,5kW
36kW
C09762-025000
DIN Rail 1)
B81493-002
(US only)
C22654-025
2kW
Mechanical dimensions see page 3-55
PAGE 3-54
14AWG/
(2.0mm2)
(US only)
28kW
C09762-012000
Fuse Block
A76178-003
Two of
C09838-010
(Europe only)
Table 3.6:- T200-610 and T200-710 Regeneration Resistor Options
1)
14AWG/
(2.0mm2)
2.5mm2
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Fuse Holder
WARNING - When performing any changes to the regen resistor configuration,
a.c. input power must be removed from the T200. Wait 5 minutes upon removal
of all power, to allow for D.C. Bus capacitors to discharge. Do not operate the
T200 with the cover removed.
WARNING - Operation of the T200 with other than the factory fitted fuse type
for the particular regen resistor configuration may cause equipment malfunction
and/or damage and may result in the equipment becoming unsafe.
PAGE 3-55
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.14 Motors - Installation
Motors should be sized by qualified personnel. Improper sizing will directly affect performance and reliability.
Motor performance data for Moog G4XX series is shown in separate data sheets, and in Section 4. Contact Moog
Applications Engineering for detailed motor technical information and application sizing, etc.
Standard motors should not be mounted directly onto a gearbox with the shaft inside the lubrication chamber. Motors
may be ordered with an optional shaft seal for these applications. When the motor is mounted, the lubricant level within
the gearbox must be below the shaft seal of the motor in order to avoid long term seepage and motor failure.
3.14.1 Assembling Motor Resolver and Power Cables
Use of the made-up cable sets is recommended for connecting the MOOG brushless servomotors. These cable sets are
available in standardized lengths. Refer to Table 3.7.
If MOOG cables are not used, the values specified below with regard to the cable make-up must be maintained in all
cases.
Contact your local Moog sales office or authorised distributor for selection of pre-made motor cables.
The following are listed for convenience:Europe and Asia
MOOG GmbH
Hanns-Klemm-Strasse 28
71034 Boeblingen
GERMANY
phone: +0049 - 7031 - 622 -0
fax:
+0049 - 7031 - 622 - 100
PAGE 3-56
North America
MOOG INC / Industrial Controls Division
Seneca and Jamison Roads
East Aurora, NY 14052
USA
phone: +001 - 716 - 655 - 3000
fax:
+001 - 716 - 687 - 4870
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.14.2 Motor Power Cable
Wire the motor power connector in accordance with Figure 3.32, Figure 3.33, Figure 3.34 and Figure 3.35.
Use wire sizes based on the motor’s continuous stall current (r m s) and wire length requirements.
Required for
CE-Compliance
Wiring must be in accordance with standard EN 60204-1 (See Section
2 of this Users Manual.)
For proper drive commutation of G400 series motors, it is required that the motor phase conductors, Phase U (A), Phase
V (B), and Phase W(C) be wired exactly as shown in Table 3.7.
3.14.3 T200 Resolver Cable
Wire the motor resolver connector in accordance with Figure 3.35.
NOTE:- Avoid running the resolver cable near other high power wiring, especially the motor
power cable, if possible.
PAGE 3-57
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.32:- T200-3/4/5 Motor and Brake Connections
PAGE 3-58
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.33:- T200-610 and -710 Motor and Brake Connections
PAGE 3-59
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.34: Motor Power and Brake Cable
PAGE 3-60
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Pin assignment for Motor Power Cable and Mating Connectors
Table 3.7:- Motor Power Cable
PAGE 3-61
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.35:- T200 J6 Resolver Cable
Find No.
1
2
•
3
Refer to
MOOG Part No.
B47886-001-xxx
C22297-001-xxx
•
C08309-001
B47885-001
•
n.a.
Description
Complete Cable Assembly
Quantity
1
Signal Mating Connector
OD Cable
5,5 mm to 12 mm
(.217 in to .472 in)
Wire Gauges
0,08 mm2 to 0.82 mm2
(AWG 28 to AWG 18)
Bare Cable
1
9 Pole Male (Plug) Sub-D:- User Supplied
1
1
Table 3.8 for detailed information
NOTE -
Required for
CE-Compliance
PAGE 3-62
1.
Cable Length not to exceed 90 meter (300 ft.)
2.
For CE-Compliance Shield has to be attached on both sides.
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Pin assignment for Motor Signal (Resolver) Cable and Mating Connector
Table 3.8:- Motor Resolver Cable
PAGE 3-63
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.14.4 Crimping Tools for Motor Cables
Contact your local Moog Sales for a detailed specification and Moog Part Numbers for cable/connector crimping tools.
PAGE 3-64
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.14.5 Terminating the Motor Cable Shield, for CE-Compliance (T200-3/4/5 only)
Required for
CE-Compliance
This section should be read by users who require their installation to
comply with the EMC-Directive of the EU.
The EMC Brackets shall be used where CE-Compliance under the EMC Directive is required, for the T200-3/4/5 units
only. Figure 3.36 below shows how to strip back cabling insulation to expose the shield. Clamp the shield securely
under the EMC-Bracket to ensure a good high frequency contact.
Figure 3.36:- Terminating the Motor Cabling for EMC CE-Compliance
PAGE 3-65
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.14.6 Terminating the Motor Cable Shield (non-CE Applications) T200-3/4/5 only
Moog motor cables are supplied with a terminating crimp for the motor shield. The T200 provides two means of
termination of the motor cable shield.
1. The motor cable shield crimp can be screwed into TB8-4 along with the MOTOR-GROUND crimp termination
from the motor cable. This is possible with G4x2, G4x3, G4x4 and G4x5 motor power cables.
2. The motor cable shield crimp can be clamped underneath the EMC-bracket as shown in Figure 3.37 below. This is
necessary for G4x6 motor power cables. The user must purchase an EMC-Bracket for this purpose, even though he
does not require CE-Compliance.
Motor Cable Shield Termination crimp:Connect under the EMC Bracket provided.
Figure 3.37:- Attaching the T200 Motor Cable Shield via the Clamp, for a G4x6 motor.
PAGE 3-66
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.14.7 T200-610 and T200-710 Motor Power Cable Shield Connection
The motor-power-cables shields should be clamped to a suitable Protective Earth bar made available where the cables
enter the user cabinet. The connection should be made 360degrees if possible around the cable shield, using P-Clips or
other means to ensure good high frequency contact with the Protective Earth
3.14.8 Motor Brake Connection
The T200 provides a motor break relay at connector TB7. The user supplies a 24Vd.c., Power Supply Unit for the brake
connections. Note that the current consumption of the different brake types is specified in Section 4.5.7.
User
Supplied
24V PSU
Motor
Power
Cable
*
TB7
1 24V+
2 Brake+
3 Brake4 24V_RET
Figure 3.38:- Motor Brake Cabling
* The pins of the brake terminals at the motor cable connector end depend upon the cable size. Refer to Figure 3.34 for
details.
PAGE 3-67
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15 T200 Control Input and Outputs
The following section contains a description of the control related Input/Output (I/O) available to the user. Functionality
is detailed in Section 6.
NOTE - An external 12Vd.c. to 32Vd.c. power source (user supplied) is required for the I/O
functions. The amperage rating of this power source will depend on the number of I/O
functions used. Supply currents can be calculated as a function of this number and the input
and output impedances quoted below.
PAGE 3-68
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.15.1 General Purpose Description of the Digital Inputs
The following electrical description applies to all the digital inputs of the T200.
Figure 3.39:- T200 Generic Digital Inputs
Note that:§ Input Impedance is 2.5k Ω.
§ Voltage Range is 12V to 32V from Digital-Input to the I_COMMON line.
§ Input voltages whose magnitude is less than 12V with respect to the I_COMMON line will not be
guaranteed to be recognised as an active signal input.
§ Input voltages whose magnitude is more than 5V with respect to the I_COMMON line will not be
guaranteed to be recognised as an inactive signal input
§ All digital inputs are optically isolated for noise immunity purposes. All T200 digital inputs are isolated from
high voltage circuitry internally by double insulation standard isolation, and are considered Safety Extra Low
Voltage circuitry.
§ Digital inputs can serve as high side or low side driven, to cope with a wide variety of digital output formats. For
example, I_COMMON can be connected to an external +24V supply, and the Digital Input connected to a pulldown output of a PLC. Alternatively I_COMMON can be connected to an external 24V-RETurn, and the Digital
Input connected to a pull-up output of a PLC.
PAGE 3-69
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
§ Figure 3.40 shows options for connection in pull-up or pull-down mode. Note that all inputs must be used in the
§
same mode for each T200.
Current flowing in the digital input implies the 'safer' of the corresponding active/inactive functions. For
example, when current flows in the clockwise limit switch input, then the limit is NOT active. See Table 3.9.
User-PSU
24V+
26AWG (0.15mm2) Wiring
OR
User's pull-up output
26AWG (0.15mm2) Wiring
User-PSU
24V+
24V-
4
Digital Input I_COMMON
24VUser's pull-down output
4
Digital Input I_COMMON
Connector J1
T200-XX0
Connector J1
T200-XX0
Figure 3.40:- T200 Pull-Up or Pull-Down Options for Digital Inputs on J1
PAGE 3-70
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15.2 General Purpose Description of the Digital Outputs
The following electrical description applies to all, except one, of the digital outputs of the T200. (One digital output,
SYS-RDY, uses a relay rather than an opto-coupler).
33Oh ms
Dig ital Output
39Vz
O_COMMON
DGND
Optocoupler Isolation
Figure 3.41:- T200 Generic Digital Outputs
Note that:§ Output Impedance is 33 Ω.
§ Voltage Range is 12V to 36V from Digital-Output to the O_COMMON line. Digital outputs switch only DC
voltages.
§ The maximum current carrying capacity is 50mA. The outputs are neither short circuit nor overload protected. The
user must ensure that the current is ≤ 50mA.
§ All digital outputs are optically isolated for noise immunity purposes. All T200 digital outputs are isolated from
high voltage circuitry internally by double insulation standard isolation, and are considered Safety Extra Low
Voltage circuitry.
§ Digital Outputs can serve as high side or low side drivers, to cope with a wide variety of digital input formats.
For example, O_COMMON can be connected to an external 24V supply, and the Digital Output can pull-up an
input of a PLC. Alternatively O_COMMON can be connected to an external 24V RETurn (low voltage side of the
24V PSU), and the Digital Output can pull-down an input of a PLC.
§ Current flowing in the digital output implies the function is active. For example, when current flows in the
DRV_ENABLED output, then the T200 is enabled.
CAUTION:- The circuitry connected to the digital outputs should contain current
limiting resistors, so that the maximum current of the T200 outputs is 50mA. The T200
digital outputs will be permanently damaged if the output current exceeds this amount.
PAGE 3-71
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
§ Figure 3.42 shows options for connection in pull-up or pull-down mode. Note that all outputs must be used in the
same mode for each T200.
User's pulled-down input
26AWG (0.15mm2) Wiring
User-PSU
24V+
User's pulled-up input
User Input
26AWG (0.15mm2) Wiring
User-PSU
24V+
24V-
OR
User Input
18
24V-
Digital Output O_COMMON
Connector J1
T200-XX0
18
Digital Output O_COMMON
Connector J1
T200-XX0
Figure 3.42:- T200 Pull-Up or Pull-Down Options for Digital Outputs on J1
PAGE 3-72
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15.3 General Purpose Description of the Analog Inputs
The T200 has two differential analog input stages (Analog-Reference REF± and Spare-Analog-Input SAIN± on
connector J1 as shown in Figure 3.45).
10kOhms
Analog_Input +
10kOhms
+
Analog_Input -
12Bit A/D Converter
10kOhms
10kOhms
AGND
Figure 3.43:- T200 Analog Input Description
Note that:
§ Input Impedance is 10k Ω.
§ Analog input maximum voltages
Maximum input voltage wrt PE:- 30V.
Maximum differential voltage:- 30V.
§ All T200 analog inputs are isolated from high voltage circuitry internally by double insulation standard isolation,
and are considered Safety Extra Low Voltage circuitry.
§ A/D Converter resolution is 12bits:- each 4.88mV input voltage step represents 1 conversion bit.
§ An approx. 1kHz analog filter is placed before the A/D converter
§ Analog Inputs are sampled approximately every 320microseconds to 500microseconds, depending upon the
software configuration.
PAGE 3-73
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15.4 General Purpose Description of the Analog Outputs
The T200 has two analog output connection points (TP1 and TP2 on connector J1 as shown in Figure 3.45).
Analog_OP
12Bit D/A Converter
+
_
100Ω
DGND
Figure 3.44: T200 Analog Output Description
Note that:
§ Output Impedance is 100Ω. An internal 100Ω series output resistor is provided in case of output short circuit.
§ All T200 analog outputs are isolated from high voltage circuitry internally by double insulation standard isolation,
and are considered Safety Extra Low Voltage circuitry.
§ D/A Converter resolution is 12bits:- each 4.88mV output voltage step represents 1 conversion bit.
§ Analog Outputs are sampled approximately every 320microseconds to 500microseconds, depending upon the
software configuration.
PAGE 3-74
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.45: T200 Axis I/O Connector J1
PAGE 3-75
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15.5 I/O Overview and Usage in Different Software Modes
Table 3.9:- Overview of T200 Analog and Digital Inputs
PAGE 3-76
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Table 3.10:- Overview of T200 Analog and Digital Outputs
PAGE 3-77
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.15.6 Power Sequencing on Startup
The timing of the digital inputs ENABLE and PWR_RDY must be considered carefully for proper power-on
sequencing.
Minimum Time from logic power
to SYS_RDY 15seconds
A.C. Mains to
PWR_RDY < 2s
Logic Power applied
24Vd.c. or 120Va.c.
A.C. Mains applied to
T200-X10
PWR_RDY of T200X10
SYS_RDY activated to
ENABLE transition can
be < 6ms
Delay from PWR_RDY to
SYS_RDY acknowledge
< 6ms
PWR_RDY input of a
connected T200-X00
ENABLE input of
T200-X10
DRV_ENBLD of T200X10
Delay from ENABLE to
DRV_ENBLD
acknowledge < 6ms
SYS_RDY output of
T200
Figure 3.46: Power Sequencing control using PWR_RDY and ENABLE
NOTE:- The T200 needs an inactive to active transition on the ENABLE input
before it will apply high power to the power amplifier and motor. If a fault is
present, and such a transition occurs, the T200 will not enable. A subsequent
inactive to active transition MUST occur once the fault has been removed, before
the T200 will allow itself to apply high power to the power amplifier and motor.
WARNING - It is UNSAFE to use the SYS_RDY output as a direct control for
the ENABLE. The SYS_RDY output will switch off when a software
configuration is carried out, and will switch on when the software configuration is
complete. This may result in an inadvertent enable of high power to the T200
high power amplifier, resulting in unexpected high voltage application or motion.
The System Motion Controller should examine the state of the SYS_RDY output
separately, and then enable the T200 high power amplifier if appropriate
PAGE 3-78
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.16 Incremental Encoder/Stepper Motor Interface Input Description.
The T200 has an RS422 based incremental encoder input on Connector J5 as shown in Figure 3.49. The same inputs are
used for the Stepper Motor inputs.
Figure 3.47: Incremental Encoder per channel Input Electrical Description
§ Input Impedance is 120Ω in series with a 1nF capacitor, to reduce driver power losses. A 10k resistor also
connects each input to Digital Ground (DGND).
§ Expected signal levels on the inputs are 0-5V differential.
§ A 5V power output line is provided to power the incremental encoder. The output power supply 5V line has a
100mA-continuous fuse which will open-circuit if the current exceeds 300mA. Note that the fuse is resetable.
25V Input+ to Input- differential
25V Input± to DGND or T200 PE connection
All T200 inputs are isolated from high voltage circuitry internally by double insulation standard isolation, and are
considered Safety Extra Low Voltage.
The Internal Inputs are fed to fast internal digital circuitry, which further digital filters these inputs to remove high
speed glitches which have passed through the differential amplifier.
Up to 1MHz input pulse rate.
§ Maximum input voltages:
§
§
§
PAGE 3-79
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.17 Encoder Simulation Output Description
The T200 has an RS422 based incremental encoder simulation output on connector J7 as shown in Figure 3.49.
Figure 3.48: Encoder Simulation Output Electrical Description
§
§
§
§
§
§
§
Galvanically isolated drivers must be supplied by a User-Supplied 5Vd.c..
5V Current demand is up to 80mA per axis for the isolated circuitry and output drivers stage.
Signal levels on the outputs are 0-5V differential.
Output drivers can withstand short to 5V or User-DGND for up to 1second.
All outputs are isolated from high voltage circuitry internally by double insulation standard isolation, and are
considered Safety Extra Low Voltage circuitry.
Recommended Cable is Belden 9891 or equivalent.
Maximum recommended cable length is 20m.
PAGE 3-80
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.49: T200 Position Transducer Interfaces
PAGE 3-81
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18 Communications Interface Wiring and Configuration
The T200 provides three serial communications interfaces:1.
RS232 for communications between one System Motion Controller and one T200
2.
RS485 for communications between one System Motion Controller and many T200's
3.
CAN for higher bandwidth communications between one System Motion Controller and many T200's (which can
handle motion commands between the System Motion Controller and T200's)
Figure 3.50: T200 Communications Terminals
PAGE 3-82
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18.1 RS232 Interface Description
The T200 provides an RS232 compatible communications interface on J4 (9-Sub-D Female (Socket) on the T200 side).
The RS232 port provides a one to one communication mechanism only.
3.18.1.1 Wiring an RS232 Connection
The RS232 port of the drive is configured as a null modem. The connector pins on the Serial Port 9-way D-Type
connector on the front-panel of the servo-drive are as follows:-.
Pin Number
1
2
3
4
5
6
7
8
9
Function
Reserved for future use
RS232 Receive Rx
RS232 Transmit Tx
Reserved for future use
GND
Reserved for future use
Reserved for future use
Reserved for future use
5V Supply for Hand Held Terminal
Table 3.11:- T200's RS232 Pinout on J4
The diagrams below show the wiring required for an RS232 cable between a PC (typically with a modem com port) and
T200 servo-drive.
T200
PC
2
3
Rx
Rx
Tx
Tx
Gnd
5
+5V *
n.c.
2
3
5
9
9-Way Female
9-Way male
D-Type
D-Type at J4
T200
PC
2
3
Tx
Rx
Rx
Tx
7
n.c.
25-Way Female
D-Type
Gnd
+5V *
2
3
5
9
9-Way male
D-Type at J4
Figure 3.51: T200's J4 RS232 Wire Pin-out (to 9-Way and 25-Way Connectors)
*
The +5V line is not used when connecting to a P.C. However it can be used to power a Hand Held Terminal
Device.
NOTE:- The +5V line on J4 is rated to operate at 100mA. If the current exceeds
this amount then a resetable fuse will open. When the excessive current drain is
removed, then the +5V line will be able to source current again.
The RS232 Cable shield should be connected to the metal body of the D-Type connector.
PAGE 3-83
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18.1.2 RS232 Set-up Parameters
The following port parameters are used to communicate with the T200 via the RS232 link:-
§ 9600 baud
§ 8 data bits
§ 1 stop bit
§ no parity bits
§ no hardware control/handshaking.
PAGE 3-84
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
3.18.2 RS485 Interfaces Description
The T200 provides an RS485 compatible communications interface on J2 and J3 (9-Sub-D Male and Female (Connector
and Socket) on the T200 side). The RS485 port provides one to many communications. Two Sub-D connectors are
provided to allow convenient daisy-chain connection of the RS485 cabling from one T200 to the next.
DAISYCHAINED
RS485 CABLE
Figure 3.52: T200 Multi-Axis RS485 System
PAGE 3-85
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18.2.1 Wiring an RS485 Connection
The connector pins on the Serial Port 9-way D-Type connectors on the front-panel of the drive are as follows:-
Pin Number
1
2
3
4
5
6
7
8
9
Function
Reserved for future use
CAN-Low
CAN_GND
RS485+
RS485CAN_GND
CAN_High
DGND
V_EXTF
Table 3.12:- T200's RS485 Pinout on J2 and J3 (Same Pinout on both Connectors)
CAUTION:- The RS485 Cable shield MUST be connected to the metal body
of the D-Type connector, in order to provide a good galvanic connection
between the host computer and the T200 local signal ground. If this is not
done then RS485 communications may be subject to spurious interruptions.
3.18.2.2 RS485 Adaptor for Conversion of RS232 to RS485
Recommended RS485 communication from a PC to a group of T200's is achieved by using an RS232/RS485 converter.
The RS232 side of the converter is connected to the selected communications port of the PC. The RS485 side of the
converter is connected to the drive via the RS485 port (J2) of the T200.
RS485 communication is achieved by interfacing a suitable RS232/RS485 adaptor between the PC and drive. See
Section 7 for recommendations on installing an RS485 interface with the WinDrive user interface
Adaptor Requirements
The following adaptor and cable requirements should be met by any adaptor that is used with Moog's WinDrive user
interface.
• Half Duplex Operation (Data Signals are both transmitted and received on two pairs wired in parallel (i.e. Tx/Rx (A)
= RS485+, and Tx/Rx (B) = RS485-).
• Method of Enabling of Transmitter of adaptor from the P.C. (e.g. use TxData line to enable adaptor transmission on
the RS485 line).
• Tx+ and Tx- Pull up/down resistors, (values depend on Adaptor used.).
• Screened twisted pair (nominal impedance 120 Ω).
• Cable end termination with user supplied 120Ω resistors.
In Half Duplex operation, the RS485 side of the adaptor must be able to enable its transmitter when the adaptor is ready
to transmit, and disable (i.e. tri-state) the transmitter when the adaptor is ready to receive. Some adaptors use the RTS
line from a PC' communications port as an enable signal to the transmitter. Other adaptors will implement the enabling
of the transmitter internally.
PAGE 3-86
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Example of PC Interface
If an external signal is required to enable the transmitter of the adaptor, the Transmit Data pin from the PC can be used
as an enable pin. An adaptor can be wired to ensure that the transmitter is enabled when data is sent, thus actively
driving Highs on the RS485+ line.
If the RTS line is used by the adaptor, the following adaptor can be placed between the PC Communications port, and
the RS232/485 Converter. WinDrive uses only the Transmit Data, Receive Data, and Signal Ground Pins on the PC
Communications port.
PC ComPort
9-Way D-Type
(Female)
RxD
TxD
Gnd
RTS
2
3
5
7
NC
2 RxD
3 TxD
5 Gnd
7 RTS
9-Way D-Type (Male)
to Plug into Converter
Figure 3.53:- Adaptor between PC and RS232/RS485 Adaptor
For details of wiring for a specific RS232/RS485 adaptor, consult the data-sheet for the particular device. The
RS232/RS485 Adaptor recommended by MOOG for operation with WinDrive and the RMC/DMC and T200 is
PSM-EG-RS232/RS485-P/2D, PN2761392 from Phoenix Contact.
PC COM PORT
1
2
3
5
SIGNAL
SHLD
RXD
TXD-RTS
GND
9-PIN D
NC
2
3&7
5
PHOENIX RS232
COMBICON
NC
5
4&7
8
T200 RS485
4
5
6
SIGNAL
RS485 +
RS485 GND
9-PIN D
3
8
2-7
PHOENIX RS485
COMBICON
6
8
4
Table 3.13:- Wiring of PSM-EG-RS232/RS485-P/2D
For further information consult MOOG applications engineering.
PAGE 3-87
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18.2.3 RS485 Line Termination
RS485 lines must be terminated in 120Ohm resistance, at each end of the cable, between the positive and negative
terminals (RS485+ and RS485-). Figure 3.54 below does not show a 120 Ω resistor at the adaptor end as this is
presumed to be part of the adaptor circuitry.
26AWG (0.15mm2) Wiring
RS485 Adaptor
GND RS485+ RS485-
Connect Cable Shields to
Metallic D-Sub Shell
Terminate RS485
lines in D-Shell
with 120 Ω
Total Cable
Distance <
1000m
4
5
4
5
4
5
4
5
RS485+ RS485-
RS485+ RS485-
RS485+ RS485-
RS485+ RS485-
Connector J2
Connector J3
Connector J2
Connector J3
T200
T200
Figure 3.54:- RS485 Wiring and Termination
3.18.2.4 RS485 Cable Maximum Length
The maximum combined length of all RS485 cabling is 1000m. Combined length is the sum of all cable segments,
including the cable from the RS485 adaptor to the first T200, and between subsequent T200's and the next, and so on to
the end of the cable.
PAGE 3-88
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.18.2.5 RS485 Address Set-up via Axis-ID-HEX-Switches on T200 front Panel
A unique RS485 address must be assigned to each T200 in an RS485 network. The two Node ID switches are used to
set this address. Note that a fine screwdriver should be used to set the HEX switches to the appropriate value. Node
addresses start at 1, rather than 0. The node address 0 is reserved for broadcast messages via RS485.
Figure 3.55:- Axis ID HEX Switches Location
The T200 has two HEX (modulo-16)
Switches that should be set to the axis
identification number of the T200.
Modulo-16 means that the number range
that can be selected is from 0 to 15.
Numbers in the range 10 to 15 are
represented by A to F. For example, to set
the axis identification number to 29, the
top switch should be set to 1 and the
bottom switch to D, since:MSB
LSB
29 = 16 by 1 plus 13
and
13 = D in the modulo 16 representation.
These switches are located on the front
panel of the T200 and are accessible
without opening the T200. The upper
most of the two switches is the most
significant.
3.18.2.6 RS485 Set-up Parameters
The following port parameter settings are used to communicate with the T200 via the RS485 link:-
§ 9600 baud
§ 8 data bits
§ 1 stop bit
§ no parity bits
§ no hardware control/handshaking.
PAGE 3-89
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
3.19 T200 User Visual Indications
The T200 product family provides the following diagnostic information to the user:•
On T200-X10 models (with integral High Power PSU), three power monitoring LED's are provided for user
diagnostic purposes (BUS ACTIVE, MAINS APPLIED, REGEN ACTIVE in Figure 3.56).
•
On T200-X00 models (without integral High Power PSU), one power monitoring LED is provided for user
diagnostic purposes (BUS ACTIVE in Figure 3.57).
•
On all models a 7-segment display is provided to display user diagnostic information.
LED Name
Color
Description of Operation
BUS ACTIVE
Green
MAINS APPLIED
REGEN ACTIVE
Amber
Amber
Illuminates when high voltage is present on the T200 DC Bus terminals
(on connector TB3)
Illuminates when A.C. Mains is applied (on connector TB2)
Illuminates when motor kinetic energy regeneration is active (voltage
applied via connector TB1)
7-Segment Display User Indication Codes
The appropriate characters of the code will appear at about 0.5 second intervals. Fault conditions will be displayed as
the highest priority, followed by abnormal conditions (warnings) and then normal operation codes.
Normal Operation Display
Fault Condition Display
U1
P
O
F1
E
AC Mains high power is not applied
T200 is self-parameterisating.
Indicates that no faults are present and
the drive is powered correctly.
High power is presently applied to the
motor phases (i.e T200 is enabled).
Abnormal Condition Display
[.]
E2/U2
E3/U3
E4/U4
E5/U5
E6/U6
E7/U7
E8/U8
U9
Ua
Ub
PAGE 3-90
The period indicates that servo-drive
current levels have been limited due to
thermal self protection reasons.
Motor temperature has exceeded 130°C.
Bridge temperature has exceeded a
defined warning threshold.
Position Following Error occurring.
Velocity Following Error occurring.
The continuous rating of the external
regeneration resistor has been exceeded.
Servo-drive Controller Area Network
(CAN) communications error.
Limit switches have been activated.
Internal software programming error.
Quick-Stop function active.
Incremental Encoder has been
disconnected.
F2
F3
F4
F5
F6
F7
F8
F9
Power Amplifier over-current fault has
occurred.
DC-Bus voltage has exceeded 400V.
Only for T200-X10 models, the internal
regeneration circuitry fuse has blown.
Only for T200-X10 models, the rectifier
heat-sink temperature is too high.
The Temperature of the Power Amplifier
heat-sink is too high.
The Temperature of the motor has
exceeded 155°C.
Fatal programming error or critical
software error has occurred.
Resolver position transducer error has
occurred.
Internal ±15V control voltage loss.
SECTION 3: WIRING AND INSTALLATION
T200 User's Manual
Figure 3.56:- T200-X10 (with PSU) LED's and 7-Segment Display
Figure 3.57:- T200-X00 (without PSU) LED's and 7-segment display
PAGE 3-91
T200 User's Manual
SECTION 3: WIRING AND INSTALLATION
Figure 3.58:- T200-610/710 LED's and 7-Segment display
PAGE 3-92
SECTION 4: MOTOR GUIDE
T200 User's Manual
SECTION 4: MOTOR GUIDE
C27095-001
PAGE 4-1
T200 User's Manual
SECTION 4: MOTOR GUIDE
TABLE OF CONTENTS
MOTOR GUIDE............................................................................................................................................................. 4-1
4.1
MOTOR SERVO-DRIVE SYSTEM....................................................................................................................... 4-4
4.2
GLOBAL MOTOR MODELS AND ELECTRICAL TYPES .....................................................................................4-4
4.2.1
Motor Model Identification Scheme .........................................................................................................4-4
4.2.2
Motor Nameplate ......................................................................................................................................4-5
4.2.3
Motor Part Number Cross Reference ........................................................................................................4-6
4.2.4
Motor Electrical Type Cross Reference ....................................................................................................4-7
4.3
CONFIGURING THE MOTOR IN THE T200 SERVO-DRIVE ...............................................................................4-8
4.3.1
Motor Configuration via WinDrive ..........................................................................................................4-8
4.3.2
Motor Configuration via Hand Held Terminal ......................................................................................... 4-8
4.4
MOTOR-DRIVE SELECTION ........................................................................................................................... 4-10
4.5
MOTOR PERFORMANCE DATA ...................................................................................................................... 4-11
4.6
MOUNTING AND INSTALLATION ....................................................................................................................4-13
4.6.1
Motor Dimensions ..................................................................................................................................4-13
4.6.2
Motor Installation Guideline ................................................................................................................... 4-15
4.6.3
Rated Bearing Load Capacity .................................................................................................................4-16
4.6.4
Coupling.................................................................................................................................................. 4-19
4.6.5
Runout..................................................................................................................................................... 4-20
4.6.6
Design Standards ....................................................................................................................................4-21
4.6.7
Motor Brake Data ...................................................................................................................................4-24
SECTION 4 TABLE OF FIGURES
Figure 4.1:- Example Nameplate ......................................................................................................................................4-5
Figure 4.2:- Motor Selection via WinDrive User Interface .............................................................................................. 4-8
Figure 4.3:- Radial Load Capacity G4x2 ........................................................................................................................ 4-16
Figure 4.4:- Radial Load Capacity G4x3 ........................................................................................................................ 4-17
Figure 4.5:- Radial Load Capacity G4x4 ........................................................................................................................ 4-17
Figure 4.6:- Radial Load Capacity G4x5 ........................................................................................................................ 4-18
Figure 4.7:- Radial Load Capacity G4x6 ........................................................................................................................ 4-18
Figure 4.8:- Motor Load Coupling..................................................................................................................................4-19
Figure 4.9:- Current/time and torque/time diagrams.......................................................................................................4-24
PAGE 4-2
SECTION 4: MOTOR GUIDE
T200 User's Manual
SECTION 4 TABLE OF TABLES
Table 4.1 :Motor Part Number Cross-Reference.............................................................................................................. 4-6
Table 4.2 :Motor Electrical Type Cross-Reference .......................................................................................................... 4-7
Table 4.3 Electrical Type and Standard Model Equivalency Table ................................................................................. 4-9
Table 4.4 Motor Performance Data ................................................................................................................................ 4-12
Table 4.5 Motor Dimensional Data ................................................................................................................................ 4-13
Table 4.6 Installation Loads .......................................................................................................................................... 4-16
Table 4.7 Shaft Runout .................................................................................................................................................. 4-20
Table 4.8 Flange Concentricity/Perpendicularity........................................................................................................... 4-20
Table 4.9 Motor Design Standards ................................................................................................................................. 4-21
Table 4.10 Electrical Design Standards ......................................................................................................................... 4-22
Table 4.11 Mechanical Design Standards ...................................................................................................................... 4-23
Table 4.12 G4XX Motor Brake Data ............................................................................................................................. 4-24
PAGE 4-3
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.1 Motor Servo-Drive System
A Moog T200 Servo-Drive system consists of a T200 and a G4XX servo-motor. The selection of a particular motor and
servo-drive for a specific application can be carried out with assistance of Moog selection sheets. These sheets are
provided by local Moog sales offices. Moog-Size, a PC-Windows based program, is also available to aid in the selection
process.
The T200 can be configured to support Moog's D31X.. series and 30X.. series of servomotors, for backward compatibility purposes. Consult Moog applications engineering for
support of these particular motors with the T200.
4.2 Global Motor Models and Electrical Types
There are almost 1000 model number variations of G4XX motors. Most of these variations arise because of differences
in the mechanical assembly of the motor. For example some motors have connectors rotated from the 'standard'
configuration. These motors are then assigned a 'non-standard' model number. However from the point of view of the
T200 servo-drive electronics, there is a much smaller number (about 45) of motors that have different electrical
parameters (called non-standard or custom motors). The G4XX motor nameplate (see Figure 4.1) lists both the motor
model and the motor's electrical type. The motor electrical type can also be used to configure the T200 with the
appropriate motor parameters.
4.2.1
Motor Model Identification Scheme
All motor specific data in this User Manual is associated to flange size and stack length of the motors.
Custom/Non-Custom
The 3rd character determines if the motor is a standard or a non-standard (custom). If the 3rd
character is a 0, then the motor is a non-standard (custom) model. (e.g. xx0x-xxx in the model
number G402-123). Note that the "Stack-Length" field is then used for a different purpose than
stack length indication:- it is then assigned sequentially to each of the custom motors.
Motor Size
Determined by the 4th character of the model number (e.g. Size G4x2-in the model number
G422-414).
Stack Length
Can be determined by means of the part number cross reference (see Table 4.1) by the 6th
character of the model number (e.g. length =L10 per in the model number G422-414).
Model Type
A model type designation (e.g. G2L10) is described by the following scheme:
GxLyyz with:x = motor size;
yy = motor length;
z = electric model (dropped for standard motors).
Brake
A description of an optional brake is added to the model type on the nameplate (for instance
G2L10, brake 0,9 Nm).
PAGE 4-4
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.2.2
Motor Nameplate
Figure 4.1:- Example Nameplate
S/N:
Date:
Model:
Type:
nN:
nmax:
P N:
J:
M0:
I0:
Rtt:
Ud:
serial number
production quarter and year
motor model number
electric model, description optional brake
nominal speed (speed at PN)
maximum speed
nominal power (maximum continuous power)
moment of inertia
continuous stall torque
continuous stall current
terminal to terminal resistance
bus voltage
Further electrical data can be found in the catalogue.
The nameplate serves to identify the product. Check whether the nameplate on the device
matches the nameplate illustrated above. This documentation must not be used for
commissioning and startup if the nameplates do not match. Devices without nameplate
are not covered by the manufacturer's warranty and must not be put into operation.
PAGE 4-5
T200 User's Manual
4.2.3
SECTION 4: MOTOR GUIDE
Motor Part Number Cross Reference
The order number for motors is made up as follows:
G4xx - xxxR
Global Product
400-Series
Configuration
Revision Index
Shaft Configuration
Code
4
5
6
7
Code
0
1
2
6
9
Special design •
300V US-version ‚
300V Europe-version ‚
600V-version ƒ
Ex-proof versionƒ
Frame Size
Code
2
3
4
5
6
55 mm Flange
70 mm Flange
100 mm Flange
140 mm Flange
190 mm Flange
Sealing
No
Yes
No
Yes
Brake Option
CODE
G4x2
G4x3
G4x4
G4x5
G4x6
0
1
2
0,9Nm
-
1,5Nm
3 Nm
6 Nm
15 Nm
15 Nm
25 Nm
25 Nm
50 Nm
Stack Length (in 0,1 inch)
• motors with special design do have a sequential
dash-number which does not specifiy the design
‚ US and Europe-model differ only in nameplate
ƒ see extra boxcar-drawing
CODE
G4x2
G4x3
G4x4
G4x5
G4x6
2
4
6
8
9
L05
L10
L20
L40
-
L05
L15
L25
L40
-
L05
L10
L20
L40
L60
L10
L20
L30
L50
-
L15
L30
L45
L60
L90
Table 4.1 :Motor Part Number Cross-Reference
Note that the T200 is not compatible with the 600V motor versions.
PAGE 4-6
Type
Slot & Key
Slot & Key
Plain
Plain
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.2.4
Motor Electrical Type Cross Reference
Table 4.2 :Motor Electrical Type Cross-Reference
PAGE 4-7
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.3 Configuring the Motor in the T200 Servo-Drive
There are two ways of telling the T200 which type of motor is connected, listed in Sections 4.2.1 and 4.2.2 below.
4.3.1
Motor Configuration via WinDrive
WinDrive contains a database of the 'standard' motor models. The user can select either the motor's electrical-Type or
the motor-Model as the search-key for the database. If the user has purchased a motor which has a 'non-standard' motorModel, then the user can specify the electrical 'Type' (see Figure1 Motor Nameplate, for information on where to find
this information on the motor) rather than the 'Model'. This selection is carried out via the Select-Motor dialog window's
'Motor Configured in Drive' field.
Figure 4.2:- Motor Selection via WinDrive User Interface
4.3.2
Motor Configuration via Hand Held Terminal
The 'SSM' (Set Standard Motor) or the 'SNM' (Set Non-Standard Motor) commands can be used to configure the T200
via the command line interface of the hand-held-terminal. Non-standard motors are not included in the hand-heldterminal's standard-motor list, though they may have a standard set of electrical parameters. Moreover the command
line interface does not support the entry of the electrical Type. If the motor has a standard electrical Type, then the user
can find the standard model which has the same electrical Type, and enter that standard model string using the SSM
command.
Check the electrical Type on the motor nameplate. Then cross-reference in Table 4.2 below in order to determine the
appropriate motor Model string to enter, using the SSM command.
PAGE 4-8
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.3.2.1 Example using SSM command
The motor nameplate shows a Motor Model of G404-123A (i.e. a non-standard motor model) and an electrical Type of
G4L20. By checking for G4L20 in the left hand column of Table 4.2, the user finds that the equivalent standard motor
is a G424-600. He uses the SSM command. He enters the string 'G424-600' and the T200 is configured automatically
with the correct electrical parameter set.
Electrical
Type
G2L05
G2L10
G2L20
G2L40
G3L05
G3L15
G3L25
G3L40
G4L05
G4L10
'Standard' Motor
String
to
be
entered
via
Command
Line
Interface
G422-200
G402-400
G422-600
G422-800
G423-200
G423-400
G423-600
G423-800
G424-200
G424-400
Electrical
Type
G4L20
G4L40
G5L10
G5L20
G5L30
G5L50
G6L15
G6L30
G6L45
G6L60
'Standard' Motor
String
to
be
entered
via
Command
Line
Interface
G424-600
G424-800
G425-200
G425-400
G425-600
G425-800
G426-200
G426-400
G426-600
G426-800
Table 4.3 Electrical Type and Standard Model Equivalency Table
If the motor electrical type is not listed in the Table above, then the user should consult Moog Applications Engineering
for support on motor entry.
PAGE 4-9
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.4 Motor-Drive Selection
Please consult your local Moog sales office or authorised distributor for selection of the appropriate T200 and motor for
your application.
PAGE 4-10
T200 User's Manual
SECTION 4: MOTOR GUIDE
4.5 Motor Performance Data
Temperature for Transport
and Storage:
-25 °C to 90 °C
Operating Temperature:
-25 °C to 50 °C (higher temperature rating on demand)
Degree of Protection:
IP67
(DIN
VDE
0470-1,
EN
(at shaft extension optional shaft seal is needed)
Installed Position:
Any (good heat dissipation permits higher continuous power)
Runout:
Class R (DIN 42955-R, IEC72)
60529,
IEC
529)
PAGE 4-11
T200 User's Manual
SECTION 4: MOTOR GUIDE
Table 4.4 Motor Performance Data
PAGE 4-12
SECTION 4: MOTOR GUIDE
T200 User's Manual
4.6 Mounting and Installation
4.6.1
Motor Dimensions
Table 4.5 Motor Dimensional Data
PAGE 4-13
T200 User's Manual
SECTION 4: MOTOR GUIDE
Additional dimensions, e.g. for connectors and mating connectors can be found in the motor datasheet catalogues
provided by Moog.
CAUTION - Do not hammer on, or press pulleys, gears, couplings, etc. onto the motor
shaft. Internal damage will occur.
PAGE 4-14
SECTION 4 MOTOR GUIDE
4.6.2
T200 User's Manual
Motor Installation Guideline
MOOG recommends that hexagon socket head screws to DIN 912 8.8 (see column H in) be used to secure the motor.
Assembly is made very much easier by using an Allen key with ball head, particularly in the cases of motor sizes 2 and
3. The screws used to install these motor sizes must not be more than 40 mm long.
MOOG motors can become very hot (up to 155°C winding temperature) in operation. Good heat dissipation must
therefore be ensured when installing the motor, i.e. it should be flanged onto a suitably solid metal part of the machine.
Adequate convection must also be ensured. In individual cases, the motor must furthermore be protected against contact
due to the risk of burns. Forced cooling (e.g. with fans) will increase the continuous power, while bad convection may
decrease the continuous performance.
Before connecting a coupling to the motor shaft, the shaft must be thoroughly degreased. When using a degreasing
agent, care must be taken to prevent it entering the bearing. Otherwise the bearings permanent lubrication can no longer
be guaranteed. Moog recommends the use of a clamp coupling or shrink connection to ensure reliable torque
transmission. An inexpensive and service friendly connection is possible with the slot and key option (ensure tight slot
tolerances).
Impermissibly high axial and radial forces on the shaft can result in motor damage during installation. The service life of
the motor is impaired if the bearing is damaged in any way. Adjusting the rotor shaft by force can impair the correct
functioning of the optional brake to such an extent that it has little or no braking effect. Excessive pressure and impacts
on the front end of the shaft and rear housing cover must therefore be avoided under all circumstances.
Delicate part (sticker on servomotor). A hammer must not be used to force the gearing or
gearwheel onto the shaft when installing such parts. The screw thread in the center of the shaft
must be used for this purpose. An extractor supported on the center of the shaft must be used
when dismantling the parts. The permissible axial and radial forces are in all cases exceeded by
the impulses due to hammering.
PAGE 4-15
T200 User's Manual
4.6.3
SECTION 4: MOTOR GUIDE
Rated Bearing Load Capacity
Radial load capacity, shown in Figure 4.3 to Figure 4.7, are for a B10 life of 20,000 hours. The load is applied at shaft
extension midpoint. Curves are based on minor axial shaft loads. Consult factory for other loading conditions.
Maximum permissible axial and radial forces for brushless MOOG servomotors during installation refer to Table 4.7.
Motor size
G4x2
G4x3
G4x4
G4x5
G4x6
Axial force 1)
150N
150N
300N
400N
500N
Radial force 1)
500N
500N
1000N
1600N
2000N
1): During installation. Lower loads apply for the rotating motor, see catalog.
Table 4.6 Installation Loads
Motor Series G4x2
12000
G4x2-2xx
10000
G4x2-4xx
G4x2-6xx
Speed [rpm]
8000
6000
G4x2-8xx
4000
2000
0
0
100
200
300
Radial Load Capacity [N]
Figure 4.3:- Radial Load Capacity G4x2
PAGE 4-16
400
500
T200 User's Manual
SECTION 4 MOTOR GUIDE
Motor Series G4x3
12000
G4x3-2xx
10000
G4x3-4xx
G4x3-6xx
Speed [rpm]
8000
G4x3-8xx
6000
4000
2000
0
0
100
200
300
400
500
Radial Load Capacity [N]
Figure 4.4:- Radial Load Capacity G4x3
Motor Series G4x4
12000
10000
G4x4-2xx
G4x4-4xx
Speed [rpm]
8000
G4x4-6xx
6000
G4x4-8xx
4000
2000
0
0
100
200
300
400
500
600
700
800
900
1000
Radial Load Capacity [N]
Figure 4.5:- Radial Load Capacity G4x4
PAGE 4-17
T200 User's Manual
SECTION 4: MOTOR GUIDE
Motor Series G4x5
8000
7000
G4x5-2xx
Speed [rpm]
6000
5000
G4x5-4xx
4000
G4x5-6xx
3000
G4x5-8xx
2000
1000
0
0
200
400
600
800
1000
1200
1400
1600
Radial Load Capacity [N]
Figure 4.6:- Radial Load Capacity G4x5
Motor Series G4x6
8000
7000
G4x6-2xx
Speed [rpm]
6000
5000
G4x6-4xx
4000
G4x6-6xx
G4x6-8xx
3000
2000
1000
0
0
200
400
600
800
1000
1200
1400
1600
Radial Load Capacity [N]
Figure 4.7:- Radial Load Capacity G4x6
PAGE 4-18
1800
2000
T200 User's Manual
SECTION 4 MOTOR GUIDE
4.6.4
Coupling
A flexible coupling offers the advantages of economy, allowance for misalignment, and reduction of backlash. Flexible
disc or bellows style couplings are recommended. The couplings are available for both plain shaft as well as for slot and
key configurations. The shaft key should then be a close clearance or light press fit into the coupling key-way. Refer to
Figure 4.8:- Motor Load Coupling , for flexible coupling detail.
CAUTION:- A rigid coupling should not be used. Normal runouts and eccentricities will
result in damage to motor and/or load shaft and bearings.
Figure 4.8:- Motor Load Coupling
PAGE 4-19
T200 User's Manual
4.6.5
SECTION 4: MOTOR GUIDE
Runout
The reduced runout provided by MOOG motors allows the attachment of various gear heads. The precision
manufacturing of the motor avoids loads caused by misalignments between motor and gear heads.
Diameter of the Shaft
Extension
øU [mm]
to 10
over 10 to 18
over 18 to 30
over 30 to 50
L=AH
see Table 4.6
Maximum Runout
Tolerance Class R
[mm]
0.015
0.018
0.021
0.025
Table 4.7 Shaft Runout
Pilot Diameter of
Mounting Flange
øAK [mm]
to 22
over 22 to <40
40 to 100
over 100 to 230
over 230 to 450
for øAK values)
Maximum Concentricity and
Perpendicularity
Tolerance Class R [mm]
0.025
0.03
0.04
0.05
0.063
Table 4.8 Flange Concentricity/Perpendicularity
PAGE 4-20
T200 User's Manual
SECTION 4 MOTOR GUIDE
4.6.6
Design Standards
The G400 series has been designed, assembled and tested in conformity with the following standards. (see Table 4.9
Motor Design Standards and Table 4.11 for design standards)
Standard
English
International
IEC
International
Electrotechnical
Commission
Europe
EN CENELEC
Europäisches
Komitee für
Elektrotechnische
Normung
Germany
DIN / VDE
Deutsche Industrie
Norm / Verband
Deutscher
Elektrotechniker
USA
NEMA / NEC
National Electric
Code MG.-...
Certified company
ISO 9001
EN ISO 9001
DIN ISO 9001
ISO 9001
Quality systems - model for
quality assurance in design /
development, production,
installation and servicing
ISO 9001
EN ISO 9001
DIN ISO 9001
ISO 9001
Machine guidelines
(CE Machine safety directive)
89/392/EWG,
91/368/EWG,
93/44/EWG
89/392/EWG,
91/368/EWG,
93/44/EWG
89/392/EWG,
91/368/EWG,
93/44/EWG
EMC guidelines
(CE-EMC directive)
89/336/EWG,
93/68/EWG,
93/44/EWG
89/336/EWG,
93/68/EWG,
93/44/EWG
89/336/EWG,
93/68/EWG,
93/44/EWG
Low voltage guidelines
(CE - Low voltage directive)
73/23/EWG,
93/68/EWG,
93/44/EWG
73/23/EWG,
93/68/EWG,
93/44/EWG
73/23/EWG,
93/68/EWG,
93/44/EWG
Standard for safety of electric
motors
Safety of machinery, electrical
equipment of machines, part 1:
general requirements
UL 1004
(1994)
IEC 204-1
EN 60204-1
DIN EN 60204-1
VDE 0113-1
Table 4.9 Motor Design Standards
PAGE 4-21
T200 User's Manual
SECTION 4: MOTOR GUIDE
Relevant standards for electrical equipment
Standard
English
International
IEC
International
Electrotechnical
Commission
Europe
EN CENELEC
Europäisches
Komitee für
Elektrotechn.
Normung
Deutschland
DIN / VDE
Deutsche Industrie
Norm / Verband
Deutscher
Elektrotechniker
USA
NEMA / NEC
National Electric
Code MG.-...
Rotating electrical machines,
Rating and performance
IEC 34-1
IEC 2/915/CDV:
1995
EN 60034-1
DIN EN 60034-1
VDE 0530-1
MG 1-1.65
Rotating electrical machines,
Methods for determing losses and
efficiency and performance
IEC 2G/73/FDIS
EN 60034-2
DIN EN 60034-2
VDE 0530-2
Rotating electrical machines,
Classification of degrees of
protection provided by enclosure
IEC 34-5
EN 60034-5
DIN EN 60034-5
VDE 0530-5
MG 1-1.25
MG 1-1.26
Rotating electrical machines,
Methods of cooling“ (IC-Code)
IEC 34-6
EN 60034-6
DIN EN 60034-6
VDE 0530-6
MG 1-1.25
MG 1-1.26
Rotating electrical machines,
Classification of types of
construction and mounting
arrangements (IM Code)
IEC 34-7
EN 60034-7
DIN EN 60034-7
VDE 0530-7
MG 1-4.03
Rotating electrical machines,
Terminal markings and directions
of rotation
IEC 34-8
EN 60034-8
DIN EN 60034-8
VDE 0530-8
MG 1-2.61
Rotating electrical machines,
Noise limits
IEC 34-9
EN 60034-9
DIN EN 60034-9
VDE 0530-9
N/A.
Insulation coordination for
equipment with low-voltage
systems. Part 1 Principles,
requirements and tests
IEC 664-1
VDE 0110-1
Insulation coordinates for
equipment with low-voltage
systems. Part 2 Partial discharge
tests, application guide
IEC 664-2
VDE 0110-2
Connectors and plug-and-socketdevices, for rated voltages up to
1000V a/c., up to 1200 V d/c. and
rated currents up to 500 A for each
pole
DIN VDE 0627
Table 4.10 Electrical Design Standards
PAGE 4-22
T200 User's Manual
SECTION 4 MOTOR GUIDE
Relevant standards for mechanical design
Standard
English
International
IEC
International
Electrotechnical
Commission
Europe
EN CENELEC
Europäisches
Komitee für
Elektrotechn.No
rmung
Degrees of protection provided by
enclosure (IP code)
IEC 529
EN 60529
Cylindrical shaft ends for electrical
machines
IEC 72
ISO/R 775-1969
Mounting flanges for rotating electrical
machinery
Deutschland
DIN / VDE
Deutsche
Industrie Norm /
Verband
Deutscher
Elektrotechniker
DIN EN 60529
VDE 0470-1
USA
NEMA / NEC
National
Electric Code
MG.-...
DIN 748-1 & 3
MG-11...
DIN 42948
Dimensions, tolerances and mounting
NEMA
MG-7
Tolerances of shaft extension run-out and of IEC 72
mounting flanges for rotating electrical
machinery
DIN 42 955
Mechanical vibration, balance quality
requirements of rigid rotors, determination
of permissible residual unbalance
ISO 1940-1
DIN ISO 1940-1
Mechanical vibration, balance quality
requirements of rigid rotors, Balance errors
ISO 1940-2
DIN ISO 1940-2
Ball bearings, conrad type, for electrical
machines, tolerances and radial clearance
DIN 42966
Drive type fastenings without taper action,
parallel keys, keyways, deep pattern
DIN 6885-1
ISO general purpose metric screw threads.
Part 1 coarse pitch threads in diameter
range 1 mm to 68 mm, nominal sizes
ISO 724
General tolerances, tolerances for linear and ISO 2768-1
angular dimensions without individual
tolerance indications
DIN 13-1
EN 22768
DIN ISO 2768-1
Table 4.11 Mechanical Design Standards
PAGE 4-23
T200 User's Manual
4.6.7
SECTION 4: MOTOR GUIDE
Motor Brake Data
The following are the specification data for the G4XX motor brakes. Options are specified via the box-car drawing.
Parameter
G4X2
Series
Brakes
G4X3 Series
Brakes
G4X4 Series
Brakes
G4X5 Series
Brakes
G4X6 Series Brakes
Option 1
Option 1
Option 2
Option 1
Option 2
Option 1
Option 2
Option 1
Option 2
Rated Braking
Holding Torque [Nm]
0.9
1.5
3.0
6.0
15.0
15.0
25.0
25.0
50.0
Inertia [kg cm2]
0.02
0.07
0.18
0.54
1
1
3.6
3.6
15.1
Rated Voltage [V]
24V±15%
24V±15%
24V±15%
24V±15%
24V±15%
24V±15%
24V±15%
24V±15%
24V±15%
Time to Disengage, t1
[ms]
20
20
20
30
50
50
80
80
120
Time to Engage, t2
15
15
15
25
35
35
40
40
45
0.46
0.46
0.42
0.54
0.79
0.79
1.0
1.0
1.25
[ms]
Current at 24V to
release [A]
Table 4.12 G4XX Motor Brake Data
Figure 4.9:- Current/time and torque/time diagrams
PAGE 4-24
SECTION 5: QUICK START
T200 User's Manual
SECTION 5: QUICK-START
C27095-001
PAGE 5-1
T200 User's Manual
SECTION 5: QUICK START
TABLE OF CONTENTS
QUICK-START .............................................................................................................................................................. 5-1
5.1
GETTING STARTED...........................................................................................................................................5-3
5.1.1
Initial Preparation......................................................................................................................................5-3
5.1.2
Power Up Sequence ..................................................................................................................................5-3
5.1.3
Starting the Drive......................................................................................................................................5-4
5.1.3.0
5.1.3.1
5.1.3.2
5.1.3.3
5.1.3.4
5.1.3.5
5.1.3.6
5.1.3.7
5.1.3.8
5.1.3.9
5.1.4
Preliminary Step:- Activate WinDrive....................................................................................................................5-4
Step 1:- Selection of the Motor ...............................................................................................................................5-4
Step 2:- Setup the Reference Source.......................................................................................................................5-5
Step 3:- Setup of the Torque and Velocity Limits...................................................................................................5-6
Step 4:- Setting Limit Switch Parameters ...............................................................................................................5-6
Step 5:- Basic Tuning .............................................................................................................................................5-7
Step 6:- Encoder Simulation...................................................................................................................................5-8
Step 7:- Regen Resistor Configuration ...................................................................................................................5-9
Step 8:- Saving the Settings ....................................................................................................................................5-9
Step 9:- Enabling the T200 and Causing Movement of the Motor .......................................................................5-10
Power-Down Sequence........................................................................................................................... 5-10
TABLE OF FIGURES
Figure 5.1:- Selecting the Motor.......................................................................................................................................5-4
Figure 5.2:- Selecting the Reference Source..................................................................................................................... 5-5
Figure 5.3:- Selecting the Velocity and Torque Limits.....................................................................................................5-6
Figure 5.4:- Setting Up the Limit Switches ...................................................................................................................... 5-6
Figure 5.5:- Setting Up the Control Mode and Tuning Parameters .................................................................................. 5-7
Figure 5.6:- Setting Up the Encoder Simulation...............................................................................................................5-8
Figure 5.7:- Regen Resistor Configuration....................................................................................................................... 5-9
Figure 5.8:- Setting Up the EEPROM .............................................................................................................................. 5-9
Figure 5.9:- Enable/Disable/Quick-Stop Floating Toolbar. ........................................................................................... 5-10
PAGE 5-2
SECTION 5: QUICK START
T200 User's Manual
5.1 Getting Started
The following section describes a “Quick Start” method for the Moog T200 Servo-drive. This will allow the user to
quickly and easily set up a T200 motor-drive system and start basic motor operations. The user should first read and be
familiar with sections 1, 2 and 3 of this manual before attempting to follow this quick start procedure. This is especially
true with respect to the safety notices and other hazard warnings.
5.1.1
Initial Preparation
Install the drive and wire the system as per Section 3. As a minimum, the a.c. mains input cable, the 24Vd.c. or
120Va.c. input cable, the Motor cable, the Resolver cable and the Axis I/O cables must be pre-wired. One of the drive
communication methods (e.g. PC based WinDrive, hand-held terminal etc.) must also be implemented.
NOTE: This quick start procedure assumes a first time power up on a
previously non-configured drive.
5.1.2
Power Up Sequence
Apply 24Vd.c. or 120Va.c. logic power to the T200. The T200 control section will begin its start up cycle. The T200
now needs to be initialised with valid start-up data so that the control card can complete this start up cycle. The T200
Servo-drive needs a valid motor to be configured to allow the control card to start.
PAGE 5-3
T200 User's Manual
5.1.3
SECTION 5: QUICK START
Starting the Drive
The MS-Windows-based Windrive interface may be used to quickly configure the T200, and check basic wiring and
installation as well as simple backward and forward motion of the connected load.
5.1.3.0 Preliminary Step:- Activate WinDrive
Install Windrive using the install instructions detailed in the WinDrive Software Kit, or as described in Section 7.2.
Note that the PC should be connected to the T200 using the RS232 serial cable described in Section 7.4.1.
Under the Drive Menu item, select the Basic Drive Setup option. This will lead the user through the following set of
steps, to perform a quick-setup on the T200.
5.1.3.1 Step 1:- Selection of the Motor
The first user choice concerns the selection of the motor. The user may select between standard and non-standard motor
types (non-standard if the motor Model has a 0 at the 3rd character e.g. G403-123). The motor is then selected by choice
of the motor Model or Electrical Type from the scrollable Motor List. The user should first check the Motor
Nameplate for the Electrical Type. The appropriate Electrical Type should then be selected from the Motor List. If the
user cannot find or see the Electrical Type on the Nameplate, then the motor Model should be checked (e.g. G423400A).
Once the appropriate motor is selected, then the user should left-click on the Download button to configure the T200
with the motor data set. Refer to Section 4.1 and Section 4.2 for a more detailed explanation of how the motor is
configured. Exit from this dialog to setup the Reference Source.
Model
or
Electrical Type
Figure 5.1:- Selecting the Motor
PAGE 5-4
T200 User's Manual
SECTION 5: QUICK START
5.1.3.2 Step 2:- Setup the Reference Source
The user should next select the reference source for the T200. The Reference Source determines where the reference
signal is coming from.
Figure 5.2:- Selecting the Reference Source
The appropriate choice should first be made by selection of the appropriate Radio Button. The Set-Up button should
then be left clicked to setup details of the particular reference mode, in order to ensure that the T200 is operating
correctly.
Moog recommends that the T200 unit is operated in Function Generator Mode, with very low excitation values (Speed
Amplitude 100RPM, Speed Offset 0RPM, Torque Amplitude 0.5Nm, Torque Offset 0Nm, Period 1s), in order to check
that the unit is wired correctly. (When the Quick-Start sequence is completed, then the unit can be enabled and the
movement checked, to do a simple check that the T200 is wired correctly.)
Please refer to Section 6 for a more detailed explanation of the operation of the T200 in various reference modes.
Click the update button to activate the settinge. Click Exit to leave the dialog box.
PAGE 5-5
T200 User's Manual
SECTION 5: QUICK START
5.1.3.3 Step 3:- Setup of the Torque and Velocity Limits
The T200 AUTO_MAN digital input sets the T200 into either the Automatic or the Manual mode of operation. The
Automatic mode corresponds to normal machine operation, at typical machine velocity and torque levels. The Manual
mode is provided to ensure that via a digital input, the T200 can be switched to lower levels of torque and velocity, to
ensure machine and personnel safety. The user should program the appropriate limits of torque and velocity for each
mode.
The user is now prompted to enter the appropriate velocity and torque limits for the motor. At this stage of the setup, it
is NOT recommended that the user disables the manual mode:- so that the Manual Mode Disable button should NOT be
ticked. The user should ensure that the Normal and Manual Velocity and Torque Limits are set to values which ensures
the safe operation of the machine.
Figure 5.3:- Selecting the Velocity and Torque Limits
Once the values are set, click the Update Button. Click Exit to leave the dialog box.
5.1.3.4 Step 4:- Setting Limit Switch Parameters
If hardware limit switches are used on the user's applications, then he should connect these using the appropriate digital
inputs as detailed in Section 3.15. The user may also disable the limit switches via a software command, by ticking the
Limit-Switches-Disabled box. The Quick-Stop Deceleration rate is set by default to 10000 rad/s2. This default value
should prevent damage to mechanical elements connected to the load. The user should program this to a value that
ensures a high deceleration rate but no damage to mechanical elements connected to the load, upon such a limit switch
activated safety-stop.
Figure 5.4:- Setting Up the Limit Switches
PAGE 5-6
SECTION 5: QUICK START
T200 User's Manual
5.1.3.5 Step 5:- Basic Tuning
The next step is to set the control mode. In order to check that the drive is wired correctly, Moog recommends that the
drive is placed in Velocity Mode with a function generator reference (Step 2) to cause slow backward and forward
movement. (Note however that if the axis is connected to a vertically mounted load or has a offset load torque, then this
option should not be used.).
In order to place the drive in Velocity Mode, left click on the Velocity button in the Mode menu. Note that the T200
default values for Velocity Loop Gain and Integral Time Constant should be sufficient to turn the motor.
Note that tuning is described in detail in Section 6.6.
Figure 5.5:- Setting Up the Control Mode and Tuning Parameters
Click the Update Button to activate the settings. Click Exit to leave the dialog box.
PAGE 5-7
T200 User's Manual
SECTION 5: QUICK START
5.1.3.6 Step 6:- Encoder Simulation
Many applications, especially those applications that use the T200 in ±10V command Velocity or Torque Mode, use the
T200's inbuilt Encoder Simulation to feed back the motor shaft position to a master Motion Controller System. The user
should set the number of Lines per Revolution to match that required by the Motion Controller by setting the Number of
Lines per Revolution input. Moog recommends the use of the 1024 or 512 lines per revolution options.
The Encoder Simulation is described in detail in Section 6.9.
Figure 5.6:- Setting Up the Encoder Simulation
Click the Update Button to activate the settings. Click Exit to leave the dialog box.
PAGE 5-8
T200 User's Manual
SECTION 5: QUICK START
5.1.3.7 Step 7:- Regen Resistor Configuration
If an external regen resistor is used in the user’s configuration the proper regen resistor need to be selected. This is
necessary to ensure proper functionality of the regen exceeded feature which indicates that the cont. regen power of the
selected regen resistor is exceeded.
Figure 5.7:- Regen Resistor Configuration
Click the Update button to activate the settings. Click Exit to leave the dialog box.
5.1.3.8 Step 8:- Saving the Settings
The user's parameter settings should now be saved to the T200's non-volatile memory, such that when power is
removed, and restored, the T200 will initialise itself with these parameters. To save the parameters to non-volatile
memory, the user should left-click on the Save button. A pop-up information will then alert him that the parameters
have been saved to EEPROM successfully.
Figure 5.8:- Setting Up the EEPROM
Exit from this dialog to energise the T200 and check basic movement of the load.
PAGE 5-9
T200 User's Manual
SECTION 5: QUICK START
5.1.3.9 Step 9:- Enabling the T200 and Causing Movement of the Motor
Apply 230Vac mains power to the mains inputs of the T200. Wait 5s for completion of softstart. After this time the
T200 should close the Power Ready Relay to indicate a successful soft start-up. Note that this relay should be used in an
interlock fashion to signal to all connected T200s that they can be enabled. Enabling in this case means that power is
applied to the output inverter bridge and means that the motor can be activated.
If the Power Ready output indicates that no fault exists on a T200 with integral PSU then the T200 and all connected
T200 without integral PSU may be enabled (i.e. high power applied to the motor windings).
The T200 may be enabled using the hardware ENABLE digital input of J1, which must be set active to allow the
application of high power to the motor. When the hardware enable is active, the T200 may be enabled and disabled
under software control using the F3 key when WinDrive is active. Note however that no T200 should be enabled before
the Power Ready relay has closed, including the T200 that contains the integral PSU.
If the user followed the recommended setup (Velocity mode, Function Generator reference), then the T200 may now be
enabled and the motion of the connected load checked.
Note that Section 10 contains recommendations for
troubleshooting.
Figure 5.9:- Enable/Disable/Quick-Stop Floating Toolbar.
WARNING - Ensure that all listed safety precautions are observed when
performing this tuning operation. Ensure that the motor is securely mounted on
a suitable fixture. Sudden and considerable movement of the motor, with a risk
of serious injury, will occur during high speed reversals if the motor is not
securely mounted.
When finished, close down WinDrive by left clicking on the File-Exit menu item, or by selection of other standard
Windows program exit mechanisms.
5.1.4
Power-Down Sequence
Disable the Power Amplifier (i.e. remove power to the motor windings). Save the parameters to non-volatile storage
using ‘Save to EEPROM’in the ‘File’– Menu.
Remove 230Va.c. mains. Wait at least 5minutes for the fast bus discharge. Note that in abnormal circumstances, if
damage has occurred to the T200 then it will take at least 5 minutes for the internal high voltage to discharge.
Remove 24Vd.c. or 120 Va.c. logic backup power from the T200
The sequences described above are those recommended for normal power up/down events. There will be circumstances
where these sequences cannot be maintained (e.g. mains power failure). The T200 is designed to survive simultaneous
mains and 24Vd.c. or 120 Va.c. logic backup power removal.
The above short sequence gives the user a step by step procedure on how to install, set-up, and operate the Moog T200
integrated servo-drive in its most basic format. The T200 drive system has many advanced features necessary for typical
servo applications that are not covered here.
PAGE 5-10
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
C27095-001
PAGE 6-1
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
TABLE OF CONTENTS
T200 FUNCTIONAL OVERVIEW .............................................................................................................................. 6-1
6.1
INTRODUCTION.................................................................................................................................................6-5
6.2
T200 FUNCTIONALITY OVERVIEW ..................................................................................................................6-6
6.2.1
Analog Command Interface ...................................................................................................................... 6-6
6.2.2
Controller Area Network (CAN) Interface Mode ..................................................................................... 6-7
6.2.3
Stepper Motor Interface Mode .................................................................................................................. 6-8
6.2.4
Digital Inputs Velocity Interface Mode ....................................................................................................6-9
6.2.5
Standalone Motion-Controller Custom Interface Mode ("Point") .......................................................... 6-10
6.3
T200 CONVENTIONS ......................................................................................................................................6-11
6.3.1
Direction of Rotation .............................................................................................................................. 6-11
6.4
POWER INTERFACE SECTION ........................................................................................................................ 6-12
6.4.1
T200 Model Types and High Power Interface ........................................................................................ 6-12
6.4.2
High Power Section Description.............................................................................................................6-12
6.4.2.1
6.5
High Power Circuit Description ...........................................................................................................................6-15
INPUT AND OUTPUT FUNCTIONAL DESCRIPTION.......................................................................................... 6-17
6.5.1
Reference Analog (±10V Command) Input ............................................................................................ 6-17
6.5.2
Spare Analog (Analog Torque Limit) Input ........................................................................................... 6-17
6.5.3
TP1 Analog Output .................................................................................................................................6-17
6.5.4
TP2 Analog Output .................................................................................................................................6-18
6.5.5
Limit Switch Function ............................................................................................................................ 6-18
6.5.6
Power Ready Input..................................................................................................................................6-19
6.5.7
Automatic and Manual Power Settings...................................................................................................6-19
6.5.8
Torque-Velocity Control Mode switching .............................................................................................. 6-20
6.5.9
Rotation Direction...................................................................................................................................6-20
6.5.10
Programmable Speed Functions..............................................................................................................6-21
6.5.11
Thermal Limiting Indication ................................................................................................................... 6-21
6.5.12
Drive Power Status .................................................................................................................................6-22
6.5.13
Speed Torque Achieved Indication .........................................................................................................6-23
6.5.14
System Ready Indication ........................................................................................................................ 6-24
6.5.15
Brake Control..........................................................................................................................................6-24
6.6
INTERNAL FUNCTION GENERATOR ...............................................................................................................6-25
6.6.1
Torque and Velocity Function Generator................................................................................................ 6-25
6.6.2
Position Function Generator ................................................................................................................... 6-26
6.7
CONTROL LOOP OVERVIEW .......................................................................................................................... 6-28
6.7.1
Torque Mode...........................................................................................................................................6-28
6.7.1.1
6.7.1.2
6.7.1.3
6.7.1.4
6.7.1.5
6.7.1.6
6.7.1.7
6.7.2
6.7.2.1
6.7.2.2
6.7.2.3
6.7.2.4
6.7.2.5
PAGE 6-2
Torque Command Sources ...................................................................................................................................6-30
Torque-Command Analog Offset Adjust..............................................................................................................6-30
Rate Limiting in Torque-Mode............................................................................................................................. 6-31
Programmable Torque Limiting in Torque Mode.................................................................................................6-32
Programmable Velocity Limiting in Torque Mode .............................................................................................. 6-32
Analog Torque Limiting in Torque Mode ............................................................................................................6-33
Torque Mode Functional Block Diagram .............................................................................................................6-34
Velocity Mode ........................................................................................................................................6-36
Velocity Mode Reference Sources........................................................................................................................6-36
Velocity Mode Offset Adjust................................................................................................................................ 6-36
Programmable Torque Limiting in Velocity Mode .............................................................................................. 6-36
Programmable Velocity Limiting in Velocity Mode ............................................................................................6-36
Rate Limiting in Velocity-Mode...........................................................................................................................6-37
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.2.6
6.7.2.7
6.7.2.8
6.7.2.9
6.7.2.10
6.7.2.11
6.7.3
6.7.3.1
6.7.3.2
6.7.3.3
6.7.2.4
6.7.3.5
6.7.3.6
6.7.3.7
6.7.3.8
6.7.3.9
6.7.3.10
6.7.3.11
T200 User's Manual
Analog Torque Limiting in Velocity Mode..........................................................................................................6-38
Velocity Mode Functional Block Diagram...........................................................................................................6-38
Velocity Loop Tuning ..........................................................................................................................................6-39
Velocity Observer Tuning and Usage................................................................................................................... 6-40
Auto-tuning the Velocity Loop Gains and the Velocity Observer ....................................................................6-43
Monitoring the Velocity Tracking .................................................................................................................... 6-44
Position Mode ........................................................................................................................................ 6-45
Position Mode Reference Sources ........................................................................................................................ 6-45
Position Mode Offset Adjust ............................................................................................................................... 6-45
Programmable Torque Limiting in Position Mode ............................................................................................... 6-45
Programmable Velocity Limiting in Position Mode............................................................................................. 6-45
Analog Torque Limiting in Position Mode...........................................................................................................6-46
Position Limits in Position Mode ......................................................................................................................... 6-46
Velocity Rate Limiting in Position Mode............................................................................................................. 6-46
Position Mode Functional Block Diagram ...........................................................................................................6-47
Position Loop Tuning ...........................................................................................................................................6-48
Monitoring the Velocity Tracking in Position Mode ........................................................................................ 6-49
Monitoring the Position Tracking in CAN Interpolation Mode ........................................................................6-50
6.8
FAULT DETECTION ........................................................................................................................................ 6-51
6.8.1
Faults and User Indication in the T200 .................................................................................................. 6-51
6.8.1.1
6.8.1.2
6.8.1.3
6.8.1.4
6.8.1.5
6.8.2
6.8.3
6.8.3.1
6.8.3.2
Faults and Warnings............................................................................................................................................. 6-51
Fatal Faults and Non-Fatal Faults......................................................................................................................... 6-51
Fatal Faults ........................................................................................................................................................... 6-52
Non Fatal Faults ................................................................................................................................................... 6-54
T200 Warnings ..................................................................................................................................................... 6-56
Fault History Record .............................................................................................................................. 6-57
Fault indication via digital outputs ......................................................................................................... 6-58
Mode 1: Fault indication via digital outputs disabled........................................................................................... 6-58
Mode 2: Fault indication via digital outputs enabled............................................................................................ 6-59
6.9
SELF PROTECTION......................................................................................................................................... 6-61
6.9.1
Sources of Torque Limits ....................................................................................................................... 6-61
6.9.2
Power Amplifier Thermal Protection Mechanism.................................................................................. 6-61
6.9.3
Motor Protection Thermal Protection Mechanism ................................................................................. 6-61
6.9.4
Cabling and Interconnect Protection Scheme......................................................................................... 6-61
6.9.5
Regeneration Resistor Protection Scheme.............................................................................................. 6-62
6.10 ENCODER SIMULATION FUNCTION ............................................................................................................... 6-64
6.11
INCREMENTAL ENCODER INPUT ................................................................................................................... 6-66
6.12 STEPPER MOTOR INTERFACE ....................................................................................................................... 6-68
6.12.1
Hardware Limit Switches....................................................................................................................... 6-68
6.12.2
Following Error Detection...................................................................................................................... 6-69
6.13 COMMUNICATIONS INTERFACES .................................................................................................................. 6-70
6.13.1
Axis Identification.................................................................................................................................. 6-70
6.13.2
Communications Protocol ...................................................................................................................... 6-70
6.13.2.0
6.13.2.1
6.13.2.2
6.13.2.3
6.13.2.4
6.13.2.5
Introduction ...................................................................................................................................................... 6-70
Serial Link Signal Specification ....................................................................................................................... 6-70
MESSAGE / REPLY FORMATS .................................................................................................................... 6-71
MODIFYING T200 PARAMETERS ............................................................................................................... 6-72
MONITORING T200 PARAMETERS ............................................................................................................ 6-74
BLOCK DATA FORMAT ............................................................................................................................... 6-76
6.13.3
Parameter Set Description ...................................................................................................................... 6-78
6.14 PARAMETER STORAGE .................................................................................................................................. 6-79
6.14.1
Personality Plug...................................................................................................................................... 6-80
6.14.2
Format of Log Files................................................................................................................................ 6-81
PAGE 6-3
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
Section 6 Table of Figures
Figure 6.1:- Analog Command Mode System Diagram ...................................................................................................6-6
Figure 6.2:- CAN Interface Mode System Diagram .........................................................................................................6-7
Figure 6.3:- Stepper Interface Mode System Diagram .....................................................................................................6-8
Figure 6.4:- Digital Velocity Reference Mode Block Diagram ........................................................................................ 6-9
Figure 6.5:- Point Mode Block Diagram ........................................................................................................................ 6-10
Figure 6.6:- Rotational Convention for Mechanical Process Variables .........................................................................6-11
Figure 6.7:- T200-X10 in Single-Axis Application ........................................................................................................6-13
Figure 6.8:- T200-X10 in Multi-Axis Application .........................................................................................................6-14
Figure 6.9:- Set Point Achieved Example....................................................................................................................... 6-23
Figure 6.10:- Torque and Velocity Function Generator Output Waveform ...................................................................6-25
Figure 6.11:- Position Mode Function Generator Output ............................................................................................... 6-26
Figure 6.12:- Torque Mode Analog Interconnect ...........................................................................................................6-29
Figure 6.13:- Torque Reference Rate Limiting...............................................................................................................6-31
Figure 6.15:- T200 Velocity Limiting Mechanism in Torque Mode ..............................................................................6-32
Figure 6.16:- Torque Limit Reduction as a function of Spare Analog Input (SAIN) ..................................................... 6-33
Figure 6.17:- T200 Torque Mode Block Diagram ..........................................................................................................6-34
Figure 6.18:- Velocity Reference Rate Limiting.............................................................................................................6-37
Figure 6.19:- Velocity Mode Block Diagram .................................................................................................................6-38
Figure 6.20:- T200 Observer Tuning .............................................................................................................................. 6-42
Figure 6.21:- Position Mode Block Diagram .................................................................................................................. 6-47
Figure 6.22:- Position Error Monitoring ......................................................................................................................... 6-50
Figure 6.23:- Detectable Short Circuit Faults .................................................................................................................6-52
Figure 6.24:- Encoder Simulation Signals on Connector J7 ........................................................................................... 6-64
Figure 6.25:- Quadrature Incremental Encoder Input on J5............................................................................................ 6-66
Figure 6.26:- Stepper Motor Interface Interconnect .......................................................................................................6-68
Figure 6.27:- Stepper Motor Interface Mode Signals on Connector J5 ..........................................................................6-69
Section 6 Table of Tables
Table 6.1:- Magnitude of the D.C. Bus........................................................................................................................... 6-15
Table 6.2 Digital Input Speed Programming .................................................................................................................. 6-21
Table 6.3 Digital/Relay Outputs (Mode 1) ..................................................................................................................... 6-58
Table 6.4 Status Indication via DO4 and DO5 (Mode 1) ............................................................................................... 6-58
Table 6.5 Digital/Relay Outputs (Mode 2)...................................................................................................................... 6-59
Table 6.6 Status Indication (Mode 2) ............................................................................................................................. 6-60
Table 6.7:- Incremental Encoder Input Specification .....................................................................................................6-66
PAGE 6-4
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.1 Introduction
This section describes the functionality of the T200. It details the various modes of operation and the I/O that operate
with these modes. The WinDrive Graphical User Interface or the Hand Held terminal can be used to configure and tune
a T200 and diagnose problems in a T200 application.
This section will provide an overview of functionality. Section 7 provides an overview of the T200's WinDrive user
interface, which provides access to these features. Section 8 provides a listing of the Hand Held Terminal interface.
PAGE 6-5
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.2 T200 Functionality Overview
The following section gives an overview of T200 functional options.
6.2.1
Analog Command Interface
The T200 provides a ±10 analog command interface. In this interface mode the T200 accepts a torque, velocity or
position command.
Control
Signalling:-
System Motion
Controller
RS232 / RS485
Moog T200
ENABLE
PWR_RDY
AUTO_MAN
TRQ_VEL
CW_LIM
CCW_LIM
BRK_IP
ROT_DIR
Position Command
Generation
Position Control
Loop
THRM_LIM
DRV_ENBLD
SPD/TRQ_ACHVD
Kp
D/A
3-Phase
Motor
Velocity Control
Loop
A/D
Analog
±10V
Interface
Incremental Encoder
Position Interface
Moog Motor
Vector-Controlled
Torque/Current
Loops
Resolver
Position
Transducer
Actual
Motor
Position
Digital to Encoder
Transformation
Resolver to Digital
Position Interface
Figure 6.1:- Analog Command Mode System Diagram
Note that the ENABLE, PWR_RDY and AUTO_MAN inputs are used consistently for all control modes.
•
•
•
•
•
•
The user selects the control mode as torque, velocity or position control, via the user interface. When the T200 is
programmed in velocity mode, the T200 may be switched on the fly between velocity and torque mode, via the
TRQ-VEL digital input.
The user interface provides programmable scaling in position and velocity mode. In torque mode, 10V scales to the
maximum torque achievable from the motor and Servo-drive combination. In velocity mode the user can program
the velocity at which the motor will rotate for a 10V input. In position mode the user can also program the shaft
position to which the motor will move for a 10V input.
The scaling of the Actual Motor Position feedback from the T200 to the System Motion Controller is set via the
user interface.
Control of drive power conditions and feedback of status information is achieved through digital input and output
interconnections.
High speed Torque Limiting is available, through an additional analog interface, for all modes of control.
Hardware limit switches are available. The rate at which the T200 slows down the motor, when a limit switch is
activated, may be programmed by the user.
PAGE 6-6
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.2.2
Controller Area Network (CAN) Interface Mode
The T200 provides a CAN fieldbus connection. The CAN interface provides:• Set-up of all drive parameters using a standard communications protocol (CANOpen).
• High-speed transfer of process and status information. This removes the need for extensive interconnect between
the T200 and the System Motion Controller.
Control Signalling (to/from
Machine Safety and Indication I/O)
ENABLE
PWR_RDY
AUTO_MAN
CW_LIM
CCW_LIM
BRK_IP (tied high)
HOME
Q-STOP
System Motion
Controller
THRM_LIM
DRV_ENBLD
Moog T200
RS232 / RS485
Moog Motor
Position Interpolation
and Trajectory
Generator Function
Position Command
Generation
Position Control
Loop
3-Phase
Motor
Velocity Control
Loop
CAN Interface
CAN Cable
CAN
Interface
Function
Vector-Controlled
Torque/Current
Loops
Resolver
Position
Transducer
Actual
Motor
Position
Digital to Encoder
Transformation
Resolver to Digital
Position Interface
Figure 6.2:- CAN Interface Mode System Diagram
Note that the ENABLE, PWR_RDY and AUTO_MAN inputs are used consistently for all control modes.
• Each T200 has network node identification switches provided on their front panel, such that each node may be
addressed uniquely via the CAN interface
• Motor configuration, control modes, control loop gains and other parameterisation information can be read from and
written to the T200. Extensive diagnostic information and fault history data can also be read back and analysed by
the System Motion Controller. Data sequences can be logged using complex trigger conditions and transmitted
back to the System Motion Controller.
• The T200 provides several positioning and velocity modes when operated via the CAN interface:1. Interpolation Mode. The System Motion Controller transmits target positions at high data rates, and the T200
finely interpolates these positions to follow the target trajectory.
2. Point to Point Mode. The System Motion Controller transmits a target position, velocity and acceleration via
the CAN interface. The T200 generates a smooth trajectory to the target position using this data.
3. Gearing Mode. A 'master' T200 generates a 'Master-Angle' position reference at a high rate. One or many
T200 'slaves' receive this reference. These slaves multiple the 'Master-Angle' by a user programmed factor,
and use the result as their command position.
4. Camming Mode. Slave T200's simulate a mechanical cam with high precision. Slave T200's transform the
'Master-Angle' through a user defined cam shape, and use the result as their command position.
5. Velocity Mode. The T200 operates in velocity mode, with the command velocity and torque limit transmitted at
high speed via the CAN interface.
PAGE 6-7
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
•
•
•
•
An internal home position routine can be called to reference the T200 position to the machine
A Jog function is provided to aid in machine start-up and positioning.
Software limits are provided for position, velocity and torque. Hardware limits are also provided for position.
Extensive T200 status information is transmitted regularly at high speed via CAN. Status information is also
available through digital outputs, if required.
CAN Profile and Interpolation modes are described in detail in additional documents:1. CAN Protocol for Interpolation Mode and
2. CAN Protocol for Profile Mode
These documents are available on request from Moog Sales Outlets (See Section 11 for addresses and phone numbers).
6.2.3
Stepper Motor Interface Mode
The T200 provides emulation of a stepper motor interface.
Control
Signalling:-
System Motion
Controller
Position Command
Generation
ENABLE
PWR_RDY
AUTO_MAN
TRQ_VEL
CW_LIM
CCW_LIM
BRK_IP
RS232 / RS485
THRM_LIM
DRV_ENBLD
SPD/TRQ_ACHVD
Moog T200
Position Control
Loop
3-Phase
Motor
Velocity Control
Loop
Forwards
Stepper
Interface
Function
Stepper Interface
Pulse Generator
Moog Motor
Vector-Controlled
Torque/Current
Loops
Backwards
Resolver
Position
Transducer
Actual
Motor
Position
Digital to Encoder
Transformation
Resolver to Digital
Position Interface
Figure 6.3:- Stepper Interface Mode System Diagram
Note that the ENABLE, PWR_RDY and AUTO_MAN inputs are used consistently for all control modes.
• The T200 accepts pulse rates of up to 1MHz, using an RS422 interface. Pulses are incremented in high speed
counter circuitry, so that reference pulses are never lost.
• The user may scale the number of steps per revolution of the motor shaft. The scaling can be set in steps of 128 to
8192 steps/revolution.
• Quadrature and Step/Direction format input pulses are accepted.
• Hardware limits are available.
• High speed Torque Limiting is available, through the additional analog interface.
• Status information is available through digital outputs, if required.
• The drive behaves as a standard stepper interface in other respects. In particular position homing is the
responsibility of the user.
PAGE 6-8
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.2.4
Digital Inputs Velocity Interface Mode
The T200 generates its velocity command as a function of the state of two digital inputs.
Control
Signalling:-
System Motion
Controller
Velocity Command
Generation
ENABLE
PWR_RDY
AUTO_MAN
TRQ_VEL
CW_LIM
CCW_LIM
BRK_IP
ROT_DIR
Moog T200
RS232 / RS485
THRM_LIM
DRV_ENBLD
SPD/TRQ_ACHVD
PROG_SPD0
Digital Outputs
PROG_SPD1
Moog Motor
Position Control
Loop
Digital
Reference
Interface
Function
3-Phase
Motor
Velocity Control
Loop
Vector-Controlled
Torque/Current
Loops
Resolver
Position
Transducer
Actual
Motor
Position
Digital to Encoder
Transformation
Resolver to Digital
Position Interface
Figure 6.4:- Digital Velocity Reference Mode Block Diagram
Note that the ENABLE, PWR_RDY and AUTO_MAN inputs are used consistently for all control modes.
• The user can program the 4 speeds at which the T200 can be operated.
• The drive behaves as a standard analog interface drive in other respects, as described under Section 6.1.1.
PAGE 6-9
T200 User's Manual
6.2.5
SECTION 6: T200 FUNCTIONAL OVERVIEW
Standalone Motion-Controller Custom Interface Mode ("Point")
The T200 provides a standalone motion control capability. Contact Moog sales offices for further information on the
Point software option.
User’s Control
Panel
Control
Signalling:ENABLE
PWR_RDY
AUTO_MAN
BRK_IP
THRM_LIM
DRV_ENBLD
SPD_TRQ_ACHVD
CAN Interface
(if required)
Analog and
Digital I/O
(as required)
Incremental
Encoder
Input
RS232 / RS485
Moog T200
Moog Motor
CAN
Interface
Function
Position Control
Loop
‘Point’
Standalone
Motion
Control
Capability
3-Phase
Motor
Velocity Control
Loop
Vector-Controlled
Torque/Current
Loops
Incremental
Encoder Interface
Digital to Encoder
Transformation
Resolver
Position
Transducer
Resolver to Digital
Position Interface
Actual
Motor
Position
Figure 6.5:- Point Mode Block Diagram
Note that the ENABLE, PWR_RDY and AUTO_MAN inputs are used consistently for all control modes.
•
•
•
•
•
•
•
•
The user can choose from a suite of function blocks called Servo-Control-Algorithms (SCA's). The user may
interlink the inputs and outputs of these function blocks to create control loop configurations. The user may use
analog and digital inputs and outputs as inputs and outputs of these function blocks.
A Motion Control Language (MCL) program can be created using a BASIC like language. This language includes
a set of arithmetic and logical operators, user variables and other constructs. All T200 input and output, including
CAN interface variables, can be accessed from this motion control language.
Programmable Logic Controller (PLC) functionality is available through the configuration of logic processing
blocks. PLC functionality is available through the MCL and the SCA's, for background (pre-empted) motion
control programs and as high priority function blocks.
All CAN operation parameters are accessible via user configurable parameters. The user can then direct CAN high
speed I/O to and from SCA function blocks. Through this mechanism interconnections can be made between
multiple T200's operating in stand-alone motion control mode.
An incremental encoder interface is provided. It can be accessed from the motion control interface and the SCA's
through a set of user-configurable parameters.
An internal home position routine can be called to reference the T200 position to the machine.
A jog function is provided to aid in machine start-up and positioning.
Software limits are provided for position, velocity and torque. Hardware limits are also provided for position.
The Point option is outlined in the T200 Point User's Manual.
PAGE 6-10
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.3 T200 Conventions
This section deals with commonly understood conventions for T200 operation.
6.3.1
Direction of Rotation
The positive direction of rotation is clockwise, when the motor is viewed from the shaft end, as shown in the diagram
below.
M otor Front
Clockw ise is Positive
Direction of Rotation
Figure 6.6:- Rotational Convention for Mechanical Process Variables
The direction convention applies to all torque, velocity and position variables. For example a positive analog torque
command should tend to rotate the motor in a clockwise direction when viewed from the shaft end.
CAUTION:- Position, Velocity and Torque variables transferred via Controller Area
Network interfaces have the OPPOSITE polarity to that listed above. CAN position
related variables increase numerically as the motor rotates in a COUNTERCLOCKWISE direction.
PAGE 6-11
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.4 Power Interface Section
6.4.1
T200 Model Types and High Power Interface
Two basic types of the T200 are available:1.
The T200-X10 models accept a.c. mains inputs with a nominal voltage level from 120Va.c. to 230Va.c. (where X
stands for a digit between 3 and 5). The T200-610/710 models accept a.c. mains input with a nominal voltage level
of 230Va.c.. The T200-310, T200-410, T200-510, T200-610 and T200-710 models include integrated high voltage
power supply, control and motor power sections.
2.
The T200-X00 models accept d.c. inputs with a voltage level from 30Vd.c. to 400Vd.c. (where X stands for a digit
between 3 and 5). The T200-300, T200-400 and T200-500 consist of control and motor power sections only.
The exact type of T200 which the user will require will depend upon the type of application:§ For single axis applications, a Servo-drive with integrated high power supply must be used (T200-X10).
§ For multiple- axis applications, a unit with integral PSU supplies D.C. Bus high power to units without an integral
PSU (T200-X10 with several T200-X00 units).
6.4.2
High Power Section Description
The high power supply section has the following features:
§ Single or Three Phase a.c Operation.
§ Direct Off-Line 120Vr.m.s. to 230 V r.m.s Operation.
§ Soft Start (a.c. Inrush Current Limiting).
§ Input MOV Transient Protection.
§ Internal 40W Regeneration capability, protected by an electronic circuit breaker (T200-310/410/510 models only).
§ Fast Bus Discharge.
§ Power Ready Relay.
§ Provision for External Regeneration Resistor.
§ Integral Shunt Regulator.
§ Integral Heat Sink and Cooling Fans.
These features are described in the next sections.
WARNING - The high power section contains large capacitors that maintain high
voltage on the d.c.+ to d.c.- terminals for several minutes after input power is
removed, if the regeneration circuit is not operating normally. Wait at least 5
minutes after power shutdown for capacitors to discharge. Then use a voltmeter to
check for safe voltage from the d.c.+ terminal to the d.c.- terminal before contacting
terminals or commencing any service or maintenance activities to ensure no lethal
voltages are present. Failure to follow this procedure may result in serious personal
injury or death.
PAGE 6-12
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Figure 6.7:- T200-X10 in Single-Axis Application
PAGE 6-13
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
Figure 6.8:- T200-X10 in Multi-Axis Application
PAGE 6-14
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.4.2.1 High Power Circuit Description
The high power supply section may be divided into functional blocks:
•
High voltage rectification and filtering
•
Soft-start of a.c. mains power-on
•
Low voltage control power supply
•
Regeneration circuit
•
Monitoring and fault logic circuits
a) High Voltage Rectification and Filtering
The a.c. mains input is rectified by a three phase diode bridge and filtered by a bank of electrolytic capacitors to generate
a nominal 325 V d.c. supply. This high power 325 V d.c. supply is unregulated and will vary in direct proportion with
the a.c. mains input voltage magnitude.
A.C. Mains Type
230V Single and Three Phase Mains
120Va.c. Mains
D.C. Bus Voltage Level
325Vd.c.
170Vd.c.
Table 6.1:- Magnitude of the D.C. Bus
b) Soft Start
Soft start is used to limit the inrush current to the d.c. bus capacitor bank on application of a.c. mains power. This is
intended to prevent nuisance tripping of circuit breakers or blowing of line fuses on power-up.
The soft start relay will close when the monitoring circuit senses that the high-voltage d.c. bus has charged up to close to
the value of the rectified a.c. mains.
Section 3.10 provides details on how the soft-start circuitry functions when T200-X00's are connected to a T200-X10 via
the D.C. Bus.
c) Low Voltage Control Power Supply
Control power for the logic circuits is generated by a DC/DC converter, which provides control-circuitry power that is
isolated from the mains input. This control voltage also powers the cooling fans. The DC/DC can generate control
power from three sources
1.
D.C. Bus if it is greater than 250Vd.c.
2.
24Vd.c. external supply which is provided by the user specifically for control-backup power.
3.
Isolated 120Va.c. external supply which is provided by the user specifically for control-backup power.
The T200 will always generate power internally from the D.C. Bus (if its voltage is greater than 250Vd.c.) even though
the 24Vd.c. and/or the 120Va.c. control-backup supplies are present.
d) Regeneration Circuit
Rapid motor deceleration or an overhauling load creates a situation in which energy is returned back into the D.C. Bus.
The Regeneration energy will charge up the power supply bus capacitors, causing their voltage to increase. To prevent
capacitor overvoltage, a shunt regulator circuit senses when the bus voltage exceeds the Regeneration cut-in voltage and
switches a Regeneration resistor across the D.C.Bus, (via a Regeneration transistor) to dissipate the Regeneration
PAGE 6-15
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
energy. The frequency at which the Regeneration circuit operates is dependent upon the magnitude of the Regeneration
energy.
The internal Regeneration resistor is protected by an internal electronic circuit breaker which disables Regeneration
when the internal resistor’s rating is exceeded.
If the Regeneration energy exceeds the capacity of the internal Regeneration circuit, a higher capacity external
Regeneration resistor must be used. Section 3.13 described how to install such a resistor. If the external resistor’s rating
is exceeded, the T200 Servo-drive reports a warning to the user, via both the 7-segment display (U6 or E6 warning) and
the activation of the THRM_LIM digital output.
A suitably rated fuse to short-circuit protect the external Regeneration resistor is fitted internally in the T200-310, 410
and 510 servo-drive. The fuse is sized to protect the external resistor option available for that particular T200 model, as
described in Section 3.13. The user should not change this fuse. If this fuse is blown, then the T200 must be returned to
Moog for repair. For T200-610 and T200-710 servo-drives, the fuse must be provided externally.
For further information regarding the implemented regen resistor protection scheme see section 6.8 - Self Protection.
e) Monitoring and Fault Logic
When a.c. mains power is first applied to the PSU, the inrush charging current is limited. When the T200 senses that the
D.C. Bus has been charged up, the Soft Start Relay energises to switch the power supply into its normal configuration.
Note that a blown Regeneration fuse or an open internal Regeneration resistor will prevent the power supply from
starting up, and generate a fault indication ('F3' on the 7-segment display) .
When a.c. power is removed, a fast discharge of the D.C. Bus occurs discharging internal high voltages.
WARNING. The fast bus discharge circuitry may become damaged during
operation, or may not be operational if the F3 fault is active. The user should still
wait for 5 minutes after all power has been removed to begin service operations
on the T200.
A thermistor on the high power section heatsink is used to generate a PSU Over-temperature fault if the temperature of
the a.c. mains rectification circuitry exceeds its rating.
A fault condition is caused by any of the following:
•
Regeneration Fuse Blown. The internal regeneration resistor fuse has been blown. Fault F3 is displayed on the 7segment display. The unit must be returned to Moog for repair.
•
PSU Thermal Fault:- The Bridge Rectification Circuitry Heatsink temperature is excessive. Fault F4 is displayed on
the 7-segment dispay.
•
Bus Overvoltage:- The D.C. Bus voltage exceeds 410Vd.c. The fault code F2 is shown on the 7-segment dispay.
Any faults detected are relayed to the control electronics where the appropriate diagnostic message will be displayed on
the seven segment display and appropriate action taken. T200 operation under fault conditions is described in Section
6.7.
High Power Section System Sequencing
High power sequencing is described in Section 3.10.
PAGE 6-16
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.5 Input and Output Functional Description
6.5.1
Reference Analog (±10V Command) Input
The Reference Analog Input is a ±10V differential analog Torque or Velocity command input from a System Motion
Controller. The Reference input is also used for general motion control purposes by the Point Motion Control subsystem. Section 3.15 outlines the electrical characteristics of the analog inputs. Note that in the velocity and torque
modes of control, the polarity of commanded movement can be inverted by use of the ROT_DIR digital input (see
Section 3.15).
In torque and velocity mode, calculations based upon the Reference are carried out and the actual motor torque modified
within a maximum of 430microseconds of the Reference being sampled.
Scaling of process variables (for example the Velocity-Command) are described in Sections 6.6.1 Torque Mode, 6.6.2
Velocity Mode and 6.6.3 Position Mode.
6.5.2
Spare Analog (Analog Torque Limit) Input
The Spare Analog Input is the primary means of measurement of an analog torque limit input from a Motion Controller.
It also serves as a secondary means of measurement of an analog command from a master control system. The Spare
input is also used for general motion control purposes by the Point Motion Control sub-system, when the T200 is
configured in that mode. Section 3.15.3 outlines the electrical characteristics of the analog inputs.
In torque, velocity and position mode, calculations based upon the Spare are carried out and the actual motor torque
modified within a maximum of 8milliseconds of the Spare being sampled.
The use of the Analog Torque Limit is described in more detail in Section 6.7.1.6
Analog Torque Limiting in
Torque Mode.
6.5.3
TP1 Analog Output
The TP1 Analog Output is used principally for diagnostic purposes. It can be programmed with a series of internal
software process variables which can be used to monitor and tune the T200. Section 3.15 outlines the electrical
characteristics of the analog outputs.
The following internal software variables may be monitored on TP1:1. Torque: The internal current command can be monitored. This is scaled as 10V= (min)(Motor Peak Current and
Drive Peak Current).
2. Commanded Velocity:- The velocity command can be monitored on TP1. This is scaled by the user-programmable
RPM-per-10V parameter.
3. Actual Velocity:- The actual velocity (feedback) can be monitored on TP1. This is scaled by the user-programmable
RPM-per-10V parameter.
4. Velocity Error:- The velocity error can be monitored on TP1. This is scaled by the user-programmable RPM-per10V parameter.
5. Reference Position:- The position command can be monitored on TP1. This is scaled by the user-programmable
Revs-per-10V parameter. The T200 contains a special function to zero-reference the present shaft position, such that
this position is taken as the zero-voltage-point of TP1 and TP2.
PAGE 6-17
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6. Actual Position:- The position feedback can be monitored on TP1. This is scaled by the user-programmable Revsper-10V parameter. As before, the T200 contains a special function to zero-reference the present shaft position, such
that this position is taken as the zero-voltage-point of TP1 and TP2.
7. Position Error:- The position error can be monitored on TP1. This is scaled by the user-programmable Revs-per10V parameter.
8. Filtered Actual Velocity:- The actual position is filtered using a first order filter. The filtered velocity can be
monitored on TP1 and is scaled by the user-programmable RPM-per-10V parameter.
9. Observer Estimated Velocity:- The velocity-observer's estimation of present motor velocity can be monitored on
TP1. This is scaled by the user-programmable RPM-per-10V parameter.
10. Observer Estimated Error:- The velocity-observer's estimation of present motor position error can be monitored on
TP1. This quantity is un-scaled and is displayed in internal software units.
11. Point Diagnostic Channel 1:- The Point Motion Servo-drive can utilise the analog outputs as flexible output
channels. Note that the user MUST program TP1 as the Point Diagnostic Channel 1 parameter, in order to display
Point parameters.
TP1 Display Latencies for Software Variables
§ Measured process variables (actual velocity (item 3) and actual position (item 6)) are displayed within
200microseconds of their equivalent analog signals' sampling and conversion to digital form.
§ Derived process variables (all other items of the list above) are displayed within 550microseconds of the
commencement of the process cycle within which they were calculated.
6.5.4
TP2 Analog Output
The TP2 Analog Output is again used principally for diagnostic purposes. The same internal software variables can be
programmed on TP2 as on TP1, with the exception that item 11 corresponds to Point Diagnostic Channel 2 rather than
Point Diagnostic Channel 1.
TP2 Display Latencies for Software Variables are the same as those of TP1.
6.5.5
Limit Switch Function
Limit switches are used to stop the motion of the motor outside permissible machine operation limits. A Limit Switch is
active when no current flows in it's digital input.
1. Torque Mode:- Activation of the Clockwise Limit switch will inhibit torque production in a clockwise direction.
Likewise activation of the Counter-Clockwise Limit switch will inhibit torque production in a counter-clockwise
direction.
2. Velocity Mode:- Activation of the Clockwise Limit switch will cause the velocity command to be ramped down at
the rate Emergency-Deceleration-Rate, to zero velocity, and will subsequently clamp the velocity command to zero.
Motion in the Counter-Clockwise direction may still continue, in the absence of activation of the counterwiseclockwise limit switch simultaneously! Likewise activation of the Counter-Clockwise Limit switch will cause the
velocity command to be ramped down at the rate Emergency-Deceleration-Rate, to zero velocity, and will
subsequently clamp the velocity command to zero. Motion in the Clockwise direction may still continue, in the
absence of activation of the clockwise limit switch simultaneously!
3. Position Mode:- The exact reaction to the Limit Switches depends upon the command generation mode:-
§ In Analog Position mode and Stepper Interface mode the reaction to the limit switches is the same as the
reaction in Velocity Mode.
PAGE 6-18
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
§ In CAN Profile Mode, activation of either limit switch will cause the T200 to perform a servo-stop, return to
Point to Point mode from whatever mode it was previously in, and allow motion in the opposite direction to the
direction of the active Limit Switch.
§ In CAN Interpolation Mode, the limit switches are ignored.
§ In Point mode, it is the responsibility of the user to use appropriately program use of Limit Switch type inputs.
Software Latency to Limit Switch Activation:- Software, where specified to react to Limit Switch activation, will start
a suitable reaction in less than 8ms of limit switch activation
6.5.6
Power Ready Input
The Power Ready input is only used by T200 units which do not have an integral PSU i.e. T200's with Model Number
T200-X00.. , though the input is present in all T200 units. The Power Ready input informs the T200-X00 that the T200
which is supplying it with high-power via the rectified high voltage DC-Bus, is ready to deliver such power, after a
mains power-on sequence has been successfully completed. If the T200-X00 were to start drawing high power before
the connected T200-X10 was ready, fuse-blown or other electrical damage to the T200-X10 might result because of
thermal overstress of softstart components.
See Section 3.10 for further details on interconnections between T200 units which share a high-voltage Power Supply.
Software Latency to Power Ready State :- The T200 software will disable the high power section in less than 8ms of
no current flowing in the Power Ready input.
NOTE:- A T200-X00 unit will NOT allow its high power section to be enabled if the PowerReady input is not active.
6.5.7
Automatic and Manual Power Settings
The T200 provides a lower power mode for user safety reasons. This mode is called Reduced-Power or Manual mode.
The T200 is switched into this mode by the status of the AUTO_MAN digital input.
§ Manual Mode:- If no current flows in this input, the T200 is placed in Manual Mode. In this mode the T200 uses
the Manual_Mode_Torque_Limit and the Manual_Mode_Velocity_Limit.
§ Automatic Mode:- If current flows in the digital input then the T200 is placed in Full-Power Mode or Automatic
Mode. In Automatic Mode the Automatic_Mode_Torque_Limit and the Automatic_Mode_Velocity_Limit apply.
Software Latency to Auto-Man State :- The T200 software will change the torque and velocity limits in less than 8ms
of a change of state of the Auto_Man digital input.
CAUTION:- the user can program the MANUAL_MODE torque and velocity limits to
be higher than the same limits in the AUTOMATIC_MODE. The user should ensure
that the correct limits are set-up in the T200 software, so that inadvertently limits are
not swapped or used incorrectly in either MANUAL or AUTOMATIC states.
PAGE 6-19
T200 User's Manual
6.5.8
SECTION 6: T200 FUNCTIONAL OVERVIEW
Torque-Velocity Control Mode switching
The TRQ-VEL digital input is used to switch the T200 from velocity mode to torque mode and back. This feature is
useful in nut-running and other applications. The TRQ-VEL input is only used when the user programs the T200 control
compensator to Velocity Mode. If the user programs either Torque or Position mode, then this input will be ignored.
The T200 will be placed in torque mode when current flows in the TRQ_VEL input. If no current flows, then the T200
will stay in or return to velocity mode.
When the T200 changes from torque control to velocity control, all velocity loop compensation variables are zeroed. In
particular the integral term of the velocity PI compensator is set to zero.
Software Latency to TRQ_VEL:- The T200 software will change the control mode in less than 8ms of a change of
state of the TRQ_VEL digital input.
6.5.9
Rotation Direction
Section 6.2.1 Direction of Rotation outlines the convention for positive direction of rotation. This convention is
reversed for the analog reference (REF±) input and for the Programmable Speed function described in Section 6.4.10,
when the ROT_DIR digital input is activated. When current flows in the ROT_DIR input, the convention for the torque
or velocity command will be reversed.
Software Latency to ROT_DIR:- The T200 software will change the direction of rotation in less than 1ms of a change
of state of the ROT_DIR input, in control modes where this digital input is actually used by software
PAGE 6-20
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.5.10 Programmable Speed Functions
The T200 provides a velocity command mode, in which the state of two digital inputs is used to command the motor to
rotate at one of four user-programmed speeds.
The reference speeds are specified in units of RPM and can be positive or negative. Note that the programmable speeds
is influenced by the ROT_DIR input as described in Section 6.4.9 Rotation Direction.
PROG_SPD_
1 Status
PROG_SPD_
0 Status
Speed Reference Used
0 (no current)
0 (no current)
Digital Input Reference 0
0 (no current)
1 (current)
Digital Input Reference 1
1 (current)
0 (no current)
Digital Input Reference 2
1 (current)
1 (current)
Digital Input Reference 3
Table 6.2 Digital Input Speed Programming
6.5.11 Thermal Limiting Indication
The Thermal Limit active THRM_LIM is used to indicate if one of the following sources of current limiting has
decreased the overall thermal current limit to the extent that the current allowed is less than that demanded.
§ Power Amplifier Thermal Protection:- The Thermal Limit output is opened (no current flowing) if the demanded
current is greater than that allowed to ensure the power electronics junction temperatures are less than the
manufacturer's recommended maximum (usually 150°C) less a considerable safety margin.
§ Motor Thermal Protection:- The Thermal Limit output is opened (no current flowing) if the demanded current is
greater than that allowed to ensure the temperature of the motor windings is kept to a safe limit (155°C).
§ RMS Current Protection:- The Thermal Limit output is opened (no current flowing) if the demanded current is
greater than that allowed to ensure RMS current over any averaging period is less than continuous current limit of
the T200.
§ Regeneration Resistance Protection:- The current flowing in the external regeneration resistor is monitored. If the
RMS current in the external regeneration resistor within any averaging period exceeds the continuous current rating
of the regeneration resistor, then the Thermal Limiting output will be opened.
Software Latency to Thermal Limiting Active:- The T200 software will change the Thermal Limiting output within 8
milliseconds of a current limiting occuring. Note however that motor thermal protection is calculated approximately
every 45milliseconds.
PAGE 6-21
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.5.12 Drive Power Status
The DRV_ENBLD opto-coupler output shows the enabled status of the T200's high power electronics. If the output is
closed (current flowing) then the power electronics are applying high power to the motor phases. If the output is open
(no current flowing), then the high power has been removed from the motor phases.
Note that the DRV_ENBLD output does not give any indication of the status of power application to the regeneration
resistor. It is possible that current is flowing in the regeneration resistor though the DRV_ENBLD output is opened (no
current flowing).
Software Latency to DRV_ENBLD:- The T200 software monitors the power electronics status and sets the output
according to that status every 8milliseconds.
WARNING:- The user should not attempt to touch T200 high power parts or perform
service on the T200 or debug of an application, if he relies on the status of the
DRV_ENBLD output alone. In this case he should remove all power, wait 5 minutes for
the internal high voltages to dissipate, and then perform the work.
PAGE 6-22
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.5.13 Speed Torque Achieved Indication
The SPD_TRQ_ACHVD opto-coupler output is used to indicate the status of achieving the programmed set-point
command, whether torque or velocity (in position mode this output is used to track the velocity command).
The user programs a Set-Point band, expressed as a percentage of a peak (Tmotor(MAX) in the case of torque
Nominal_Speed in the case of velocity). If the error (difference between the setpoint and the actual) is larger than the
Set-Point Band, then the digital output will open. If the error is less than the Set-Point Band, then the digital output will
close.
The diagram below indicates an extreme case, where the reference velocity is set equal to the programmed set-point
velocity. The actual velocity oscillates about the set-point due to poor tuning of a control loop. The digital output turns
off and on rapidly until the actual settles to a value close to the set-point.
Step Response
SetpointBand
SPD/TRQ_ACHVD
Output Status
Time
Figure 6.9:- Set Point Achieved Example
Four programmable variables are available to the user:-
§ Torque Setpoint Value:- The torque setpoint is specified in Nm.
§ Torque Setpoint Band:- The torque setpoint band is specified in Nm
§ Velocity Setpoint Value:- The velocity setpoint is specified in RPM.
§ Velocity Setpoint Band:- The velocity setpoint band is specified in RPM
§ Set-Point Function Enable:- The set-point detection function can be enabled and disabled using the setpoint enable
parameter.
PAGE 6-23
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.5.14 System Ready Indication
The System-Ready relay output (SYS_RDY±) indicates the error status of the T200. The relay will close when all fatal
faults have been removed. It will open when any fatal faults appear.
Note on application of a.c. mains power:-
§ The System-Ready relay will close only when the a.c. mains has been applied and all other faults have been
removed.
6.5.15 Brake Control
The T200 do have an integrated brake relay which allows the control of the motor brake. The control of the 3.5A,
30Vd.c. relay is dependent on the mode in which the T200 operates. The 24Vd.c. supply voltage for the
Motor brake must be supplied by the user and connected to TB7 as described in Section 3.14.2.
•
Velocity, Torque, Position Mode
The relay is user controlled. An active signal on J1/Pin11 causes the relay to close.
•
CAN-Mode
J1/Pin11 must be tied high. The relay can be controlled over CAN.
•
Custom POINT Mode
J1/Pin11 must be tied high. The relay can be controlled in the POINT application program.
PAGE 6-24
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.6 Internal Function Generator
An internal function generator is provided, which is used to generate square wave excitation signals in torque and
velocity mode, and a spline shape in position mode, to aid in control loop tuning and general drive debug work.
6.6.1
Torque and Velocity Function Generator
Function
Generator
Output
Period
Amplitude
Offset
On-Time
Time
Duty-Cycle = On-Time*100
Period
Figure 6.10:- Torque and Velocity Function Generator Output Waveform
In torque and velocity mode a square shaped waveform, with variable amplitude, offset, duty cycle and period is
generated as shown above in the diagram.
The following parameters can be set by the user:
§ Speed Amplitude:- The Speed Amplitude determines motor velocity. The Speed-Amplitude is specified in units
of RPM. If the Speed Offset was set to 0, then the Speed Amplitude would set equal magnitudes of velocity
command in both the clockwise and counter-clockwise direction. The Speed Amplitude must be a positive number.
§ Speed Offset:- The Speed Offset is specified in units of RPM. It is added to the Speed Amplitude for one direction
of rotation and subtracted for the other direction.
§ Torque Amplitude:- The Torque-Amplitude is specified in units of Nm. If the Torque Offset is set to 0, then the
Torque Amplitude would set equal magnitudes of torque command in both clockwise and counter-clockwise
directions. The Torque Amplitude must be a positive number.
§ Torque Offset:- The Torque Offset is used to bias the torque command in one direction of rotation. Specified in
units of Nm.
§ Period:- The Period determines the time taken for one cycle of operation of the servomotor. It is specified in
seconds.
PAGE 6-25
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
§ Duty-Cycle:- The Duty-Cycle determines the length of time the Speed or Torque Amplitude is of a more positive
polarity and is expressed as a percentage. For the remainder of the period, the Speed or Torque Amplitude is of a
more negative polarity.
CAUTION:- The function generator will apply steps of torque and velocity commands,
which may damage machinery due to a sudden jerk. The user is cautioned to start the
function generator torque or speed amplitude at a small value and increase it slowly to its
intended value, to ensure no damage to mechanical elements of the machine
6.6.2
Position Function Generator
In position mode, an S-shaped position profile is generated, with programmable acceleration, velocity, and position
traverse, as shown below in the diagram.
Acceleration
Acceleration
Velocity
Speed_Amplitude
Time
Position
Traverse
Period
Figure 6.11:- Position Mode Function Generator Output
The following parameters can be set by the user:
PAGE 6-26
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
§ Acceleration:- The Acceleration parameter will set the rate of change of the velocity command during the position
traverse. Specified in units of rad/s2.
§ Speed Amplitude:- The Speed Amplitude determines maximum motor velocity during the motion. The SpeedAmplitude is specified in units of RPM. If the traverse is short, it is possible that the speed command will not reach
the Speed-Amplitude. The Speed-Amplitude is therefore to be interpreted as a maximum speed limit.
§ Period:- The Period determines the time taken for one there-and-back motion of the servomotor. It is specified in
seconds. Note that if the Traverse is long, or the Speed-Amplitude or Acceleration small, then the time taken for
one there-and-back motion may exceed the Period.
§ Traverse:- The magnitude of the motion, expressed in revolutions of the motor shaft, is programmed using the
Traverse parameter.
The position function generator must be stopped when any of the motion parameters are to be changed. This is to ensure
that the motion does not exceed machine limits, in the case that motion is halted part-ways at a certain position, and
recommenced with a full traverse from that position, when the parameters update is complete. Special hand held
terminal and user interface commands are provided for this purpose.
PAGE 6-27
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7 Control Loop Overview
6.7.1
Torque Mode
The T200 can be operated in torque mode, with several sources of its torque command. In this mode the T200 acts as a
simple current amplifier, so that the torque produced by the motor is proportional to the analog command.
WARNING:- DANGER OF UNCONTROLLED MOTOR ACCELERATION
The T200 has specialised motor current compensation. For optimum performance the T200
operates a software model of the current loop. The correct motor electrical parameters are
required for this software model. Large errors in the motor parameters can result in uncontrolled
motion.
Small torque commands can result in a continuous motor acceleration. The velocity of the motor
can increase in an uncontrolled way if no counter-balancing torque is present. The user's control
system should ensure that the speed of the motor is monitored, and that a compensating torque
command is applied to control the motor speed if necessary.
PAGE 6-28
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
20m max
User Control
System
Torque Command
J1
O/P
DAC
0.25sq.mm
twisted pair
(24AWG)
Analog Torque Limit Command
O/P
DAC
0.25sq.mm
twisted pair
(24AWG)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
REF+
REFPE
I_COMMON
ENABLE
PWR_RDY
AUTO_MAN
TRQ_VEL
CW_LIM
CCW_LIM
BRK_ IP
ROT_DIR
PROG_ SPD_1
PROG_ SPD_0
15
16
17
18
19
20
21
22
23
24
25
26
27
28
SAIN+
SAINPE
O_COMMON
THRM_LIM
DRV_ ENABLED
SPD/TORQ_ACHVD
SYS_ RDY+
SYS_ RDYTP1
TP2
AGND
SPARE_DIG_OP_1
SPARE_DIG_OP_2
Figure 6.12:- Torque Mode Analog Interconnect
PAGE 6-29
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.1.1 Torque Command Sources
Three sources of torque command may be user-programmed:1/ Internal Function Generator. The T200 provides an internal software function generator. The function generator
produces rectangular pulses which provide a means of exciting the load, in order to diagnose applications problems or
tune the T200. The Torque Amplitude, Offset, Period of excitation and Duty Cycle are programmable. See section 6.5
Internal Function Generator for further information.
2/ Analog Source:- The analog command input is limited to the range ±10V. A 10V command corresponds to full
torque. The transfer function from voltage to torque is given by:-
Tmotor Tmotor ( MAX )
=
Vin
10V
where Tmotor(MAX) is the maximum torque the combination of motor and Servo-drive can produce at the motor shaft.
Vin is the input voltage.
3/ Point Motion Controller Source:- The T200's integral Point motion controller creates a torque command as an
output of loop closure function blocks. This function is available in the 'P' software version only.
6.7.1.2 Torque-Command Analog Offset Adjust
The analog input offset may be adjusted such that the net effect of an offset in the User's Control System and offsets in
the T200's input conditioning and Analog to Digital conversion circuitry are cancelled. The T200 provides an automatic
mechanism for cancellation of the offset. It is assumed that when the cancellation procedure is invoked, that the present
analog command corresponds to zero torque command. The procedure calculates the average of 100 samples of the
Analog Digital input, and subtracts this average thereafter from the analog input command.
PAGE 6-30
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.1.3 Rate Limiting in Torque-Mode
The T200 provides a means of limiting the rate of change of the actual torque. This limits the jerk (rate of change of
acceleration) which a sensitive load may experience during acceleration and deceleration phases of a motion.
The user can program the Torque Rate Value (specified in Nm) and the Torque Rate Time (specified in seconds). The
maximum allowable rate of change of actual torque is then given by:-
o
T command ( MAX ) =
Torque _ Rate _ Value
Torque _ Rate _ Time
Figure 6.13:- Torque Reference Rate Limiting
Torque Rate Value
Torque Command
Actual Torque
Torque Rate Time
Time
PAGE 6-31
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.1.4 Programmable Torque Limiting in Torque Mode
The T200 uses the Automatic and Manual Torque Limits as described in Section 6.4.7 Automatic and Manual Power
Settings, under the control of the AUTO_MAN digital input.
6.7.1.5 Programmable Velocity Limiting in Torque Mode
In torque mode, the T200 uses the velocity limits. The T200 will try to ensure that the actual velocity never exceeds the
particular velocity limit which is effective at the time (which is selected from either the
Automatic_Mode_Velocity_Limit and Manual_Mode_Velocity_Limit depending upon the status of the AUTO_MAN
input). The limit plus 10% is used as shown in Figure 6.15. Velocity limiting is implemented by bringing the torque to
zero when the motor actual velocity exceeds the applicable Velocity_Limit. If the user continues to command large
accelerating torque, the, T200 will ramp the actual torque back up so that the actual velocity again increases to the limit.
Actual Torque
Torque Command
Velocity Limit +10%
Velocity Limit
Motor Velocity
Torque applied, motor accelerates
T200 goes into velocity limiting mode
Figure 6.15:- T200 Velocity Limiting Mechanism in Torque Mode
PAGE 6-32
Time
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.7.1.6 Analog Torque Limiting in Torque Mode
The Spare Analog input (SAIN) is used in Torque Mode as a means of reducing the maximum allowable torque in a
continuous way. Figure 6.16 below shows the linear relationship between the Analog Torque Limit and the input
voltage level between the SAIN inputs.
Analog Torque Limit Tlimit
Tmotor
(MAX)
Tlimit as a function of SAIN differential voltage
(SAIN+) - (SAIN-)
0V
- 10V
Figure 6.16:- Torque Limit Reduction as a function of Spare Analog Input (SAIN)
§ If the SAIN differential voltage is -10V, then the Analog Torque Limit is set to 0Nm. Thus a 10V input will totally
zero the motor torque output.
§ If the SAIN differential voltage is 0V, then the Analog Torque Limit is set to Tmotor(MAX). Thus a 0V input will
allow maximum motor torque output.
§ Note that the electrical and time-related characteristics of the SAIN input pair is defined in Section 3.15.
NOTE:- If the user does not wish to use the Analog Torque Input, then the
SAIN input pins can be left unconnected. This results in a zero differential
voltage across the SAIN input pair.
PAGE 6-33
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.1.7 Torque Mode Functional Block Diagram
Figure 6.17:- T200 Torque Mode Block Diagram
PAGE 6-34
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
The diagram above outlines the operation of the T200 in torque mode. Note that Automatic/Manual mode is controlled
by the Auto_Man digital input. However the switch-over between Automatic and Manual modes can be disabled by
disabling the Manual Mode, leaving the T200 permanently in Automatic Mode (full power mode).
PAGE 6-35
T200 User's Manual
6.7.2
SECTION 6: T200 FUNCTIONAL OVERVIEW
Velocity Mode
In velocity mode the T200 closes a PI loop to track an analog command, a function generator command, a digital
reference input command, or a velocity command from an internal position loop.
6.7.2.1 Velocity Mode Reference Sources
Five sources of velocity command may be user-programmed:1/ Internal Function Generator. The T200 provides an internal software function generator. The function generator
produces rectangular pulses which provide a means of exciting the load, in order to diagnose applications problems or
tune the T200. The Velocity Amplitude, Offset, Period of excitation and Duty Cycle are programmable. See Section
6.5 Internal Function Generator for further information.
2/ Analog Source:- The analog command input is limited to the range ±10V. A 10V command will tend to rotate the
motor at the user-programmable RPM_Per_10V (RPM_per_10V defaults to the motor's Nominal Speed). The transfer
function from voltage to velocity command is given by:-
Vcommnd Nominal_Speed
=
Vin
10V
where Vin is the measured command voltage in volts, and Vcommand is the commanded motor velocity.
3/ Point Motion Controller Source:- The T200's integral Point motion controller creates a velocity command as an
output of loop closure function blocks. This function is available in the 'P' software version only.
4/ Digital Speed Reference Source:- The digital inputs PROG_SPD_0 and PROG_SPD_1 are used as indicators of the
velocity at which the T200 should rotate. The operation of these inputs is described in Section 6.4.10 Programmable
Speed Functions.
5/ CAN Velocity Mode:- As a subset of position mode operation, the T200 can be operated such that a digital velocity
reference and a torque limit are transferred cyclically via the CAN interface, in Profile Mode. Operation of the CAN
interface is described in Section 9.
6.7.2.2 Velocity Mode Offset Adjust
An automatic analog offset adjust mechanism exists for the analog velocity reference. This operates in exactly the same
way as the offset-adjust in torque mode. See Section 6.7.1.2 Torque-Command Analog Offset Adjust.
6.7.2.3 Programmable Torque Limiting in Velocity Mode
The T200 uses the Automatic and Manual Torque Limits as described in Section 6.4.7 Automatic and Manual Power
Settings, under the control of the AUTO_MAN digital input.
6.7.2.4 Programmable Velocity Limiting in Velocity Mode
The T200 applies the Automatic_Mode_Velocity_Limit and Manual_Mode_Velocity_Limits in velocity mode. The
T200 will ensure that the actual velocity never exceeds the particular Velocity_Limit (which is selected from either the
PAGE 6-36
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
Automatic_Mode_Velocity_Limit or the Manual_Mode_Velocity_Limit depending upon the status of the AUTO_MAN
input) by clamping the velocity command to the applicable Velocity Limit.
6.7.2.5 Rate Limiting in Velocity-Mode
The T200 provides a means of limiting the rate of change of the velocity command. This limits the acceleration (rate of
change of velocity) which a sensitive load may experience during acceleration and deceleration phases of a motion.
The user can program the Velocity Rate Value (specified in RPM) and the Velocity Rate Time (specified in seconds).
The maximum allowable rate of change of actual velocity is then given by:-
o
V command ( MAX ) =
Velocity _ Rate _ Value
Velocity _ Rate _ Time
Velocity Rate Value
Velocity Command
Rate-Limited
Velocity
Command
Velocity Rate Time
Time
Figure 6.18:- Velocity Reference Rate Limiting
PAGE 6-37
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.2.6 Analog Torque Limiting in Velocity Mode
The Analog Torque Limit functions in exactly the same way in velocity mode, as it does in torque mode. See Section
6.7.1.6 Analog Torque Limiting in Torque Mode.
6.7.2.7 Velocity Mode Functional Block Diagram
Figure 6.19:- Velocity Mode Block Diagram
PAGE 6-38
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.7.2.8 Velocity Loop Tuning
After completing drive initialisation (Motor Type selected, Options selected, etc.) the user should tune the velocity loop
to optimise performance. This section provides a recommended velocity mode standard tuning procedure for use with
either the WinDrive user interface or the Hand Held Terminal interface. The procedure should be followed in the
sequence listed.
It is recommended that the drive is tuned using a low frequency square wave velocity command while observing the
velocity response through the WinDrive Data Logger or an oscilloscope. The low frequency square wave can be
supplied from an external source (through the REFerence analog input), or by the internal software Function Generator
as described below.
CAUTION - Ensure that the application allows the use of this Speed Amplitude and length
of travel, (period, duty cycle), without damage to the machine before proceeding with the
tuning procedure.
Torque demand should be monitored through the IDC.CurrentMonitor variable in one of the two Data Logger Channels.
This signal should not saturate during motor acceleration/deceleration (i.e. must be less than 10V or less than any torque
limits which are applied). If the signal saturates then the Function Generator set up must be altered or the Servo-drive
torque limit increased until saturation does not occur. The Actual Velocity variable should be monitored through the
second Data Logger Channel. See Section 6.4.3 TP1 Analog Output and 6.4.4 TP2 Analog Output for a listing of the
variables which can be displayed on the WinDrive datalogger or the analog Test Point TP1 and TP2.
NOTE - Actual Velocity and Torque Demand (IDC.CurrentMonitor) can also be sent to
the TP1 and TP2 Test Points, through the Front Panel Test Points Dialog Box, and
monitored with an oscilloscope. A description of how to set-up the WinDrive datalogger
or the analog Test Points is given in Section 7 and Section 8.
The two principle parameters which affect the velocity loop dynamics are the Velocity Loop Proportional Gain (P) and
the Integral Time Constant (I). The proportional gain term P acts on the measured velocity error, which is the difference
between the requested velocity and the actual velocity. High P gain gives the system a faster response and tighter
velocity control, but if the gain is set too high the system may become unstable. For best velocity tracking results the P
gain should be set as high as possible without inducing severe overshoot or oscillation.
The Integral Time Constant I sets the gain for the integral term in the velocity error compensation. Integral gain is used
to remove any steady state velocity error, due to system imperfections or due to disturbance torques from the load.
Integral gain also provides disturbance rejection or ‘stiffness’in the motor’s reaction to an external torque load.
The following command description applies to the Hand Held Terminal. Similar commands for use with WinDrive
when tuning are described in Section 7.
§ The T200 will set the P and I terms to safe defaults when the T200 is configured with the appropriate motor.
§ The P term is the first term to be adjusted. The I gain is effectively turned off by setting the Integral Time Const in
the Tuning Dialog Box to a large value (e.g. 3 seconds).
§ The Servo-drive should then be enabled; either the Hardware Enable should be applied using the ENABLE input, or
the Software Enable can be used to conveniently control the drive power when the ENABLE is permanently active
during the tuning process.
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T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
•
Use the P command set to enter the gain adjust mode for the velocity loop proportional gain term. Using the PU
command increase the P gain until the shaft is turning. Use the PU command, while monitoring the velocity
response on the oscilloscope, to increase the P gain until a slight overshoot occurs in the velocity response (Fig 1
below). Use the PD command to decrease the P gain until the overshoot just disappears (Fig 2 below) .
•
Use the I command set to enter the gain adjust mode for the velocity loop integral time constant. Using the IU
command increase the loop response (this will actually reduce the Integral Time Constant) until a slight overshoot
occurs again .
•
Use the P command set to re-enter the P gain adjust mode. Use the PU command to improve the slope of the step
response. Fig 3 illustrates the velocity wave form for a properly tuned loop.
6.7.2.9 Velocity Observer Tuning and Usage
This Section explains the set-up and tuning of the velocity observer. The use of the observer will usually allow
significantly higher velocity loop gains and bandwidths to be achieved. The observer uses a software model of the
motor and load to calculate a velocity estimate. The user needs to tune only one additional parameter to use the
observer. The observer is set up using the following procedure:
•
Tune the velocity loop using the normal procedure described in Section 6.6.2.8 . Figure 6.20 (A) below shows a
typical tuned velocity loop response to a step reference command. It shows the torque response on the drives' TP1
test point and the actual velocity response on TP2. The size of the step velocity reference should be small enough to
avoid saturation of the torque signal. Note the single overshoot of about 24% in the velocity response and the 12 ms
settling time.
•
Tune the observer by setting up the observer inertia parameter, Jest. Monitor the observer error signal θerr at the
drives' TP1 test point (see Section 6.4.3 TP1 Analog Output and Section 8 for a description of the Hand Held
terminal interface). Figure (B) shows the usual starting point for tuning: Jest is too small. Use the JU command to
enter the gain adjust mode, (refer to Section 8 for an outline of hand held terminal commands). Jest may be
adjusted in this mode using JU and/or JD commands, or using the SJ / LJ commands,(refer to Section 8). Figure
PAGE 6-40
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
(B) also shows θerr when Jest is tuned correctly, θerr steps with a slight ripple superimposed. θerr is a measure of
the model uncertainty, and of any disturbance torque which may be present. Normally there will be some viscous
friction present, so that θerr will step appropriately when the shaft velocity makes a step change.
CAUTION:-If θerr oscillates excessively when the velocity makes a step change, as
shown in Figure (C), then do not use the observer, since the load may not be modeled
adequately by the observer.
•
As a final check of proper tuning, display observer velocity on TP1, and compare it with the actual velocity
response which was shown on TP2 in Figure (A). These should be identical.
•
Switch on the observer by using the OO command, (reference Section 8), and then Y to the subsequent prompt to
enable use of the observer velocity estimate. Figure (D) shows the velocity loop response when the observer is
switched into the loop. Note the lack of overshoot, because of a better measurement of velocity. The servo noise
generated is also reduced.
•
In order to achieve higher gains, the compensator filter frequency may now be set higher, using the SW command,
(refer to Section 8). Typically this frequency may be set to 600 Hz, depending on motor servo noise. The P and I
gains may now be tuned up again, in the normal fashion described in 6.7.2.8Velocity Loop Tuning. Figure (E)
compares the response of an observer based system with a normal velocity loop system. Now the response settles in
just 2.2 mS, whereas without the observer the step settled in about 12 mS. The observer response also shows a
smaller overshoot.
PAGE 6-41
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
OBSERVER
POSITION ERROR
OBSERVER
POSITION ERROR
Figure 6.20:- T200 Observer Tuning
PAGE 6-42
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.7.2.10 Auto-tuning the Velocity Loop Gains and the Velocity Observer
The T200 auto-tuner can only be used in conjunction with the WinDrive interface. WinDrive contains proprietary
algorithms which are used to stimulate motion in the load, using a excitation torque sequence, record the response of the
load to the excitation, analyse that response to determine the load mechanical parameters, and set loop gains to achieve a
user programmed velocity loop bandwidth.
CAUTION:- The auto-tuner places in T200 in velocity mode and excites the load using
a torque excitation signal. If the axis under control is a vertical axis or an axis that
counter-acts a torque load, then the axis may fall slightly when the auto-tuning
sequence is started. The Auto-tuner is not suitable for use with such an axis, unless a
slight drop of the vertical load or acceleration in one direction is acceptable to the user.
When the user selects the Auto Tune Button within the WinDrive Auto-tuning dialog, a pop-up dialog will be shown
which informs the user that the T200 will be disabled, switched into velocity mode, re-enabled and a torque excitation
signal will be applied. The user has the option to continue or exit from the sequence.
CAUTION - The drive is enabled when Auto Tuning is in progress, high frequency
excitation signals are applied to the motor. The user should ensure that the mechanical
coupling and load are capable of withstanding a high frequency torque content. If in
doubt, the magnitude of the torque excitation should be dropped to about 10% of peak.
The user can then slowly increase the magnitude of the excitation torque if the
response is not sufficient to identify the system.
NOTE:- The auto-tuner software will try to enable and disable the T200 high power
stage, as well as control the brake. For the T200 to actually enable the high power, and
release the brake, the user must have the following done BEFORE the auto-tuning is
started:1. Ensure that the enable digital input (ENABLE) is activated (see Section
3.15.5). High power cannot be applied to the motor if this input is not activated.
2. Ensure that the brake control input (BRK_IP) is activated (see Section 3.15.5).
The motor brake cannot be released unless this input is activated.
If the user chooses to Continue:
1. The T200 will be disabled automatically via software.
2. The T200 will switch into Velocity Mode
3. The high power amplifier will be enabled by software automatically
4. The motor brake, if present, will be released
5. The excitation signal will be generated by the GUI, using the user defined excitation signal amplitude.
6. The excitation signal will be downloaded to the T200
7. The excitation signal will be applied by the T200 via the motor to the load.
8. The Actual Position and the excitation Signal are data-logged, and uploaded to the WinDrive interface.
9. The motor brake, if present, is re-applied.
10. The T200 will be disabled.
11. System Identification is performed by WinDrive to determine the physical attributes of the motor/load
combination.
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T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
A Systems Parameters dialog box is then displayed showing the results of the System Identification. The user must
choose to calculate gains, and then exit the system parameters dialog.
When the user exits the system parameters dialog a pop-up dialog will be shown which informs the user that the
calculated gains will be downloaded to the T200, T200 will be switched into velocity mode, and a step response will be
obtained. The user has the option to continue or exit from the sequence.
If the user chooses to Continue:1. The calculated gains will be downloaded to the T200.
2. The determined inertia will be used to set-up the observer inertia of the T200.
3. The T200 will be switched into velocity mode.
4. The internal function generator will be set-up with a 200 RPM reference for the motor.
5. The T200 will be enabled, and will rotate less than one motor shaft revolution.
6. The Actual Velocity and the Torque Reference are datalogged, and uploaded to the GUI
7. The T200 will be disabled.
The System Identification can determine two possible motor/load characteristics:1. Lumped Inertia
2. Simple Resonant System (with a single resonance)
Higher order and more complex loads will cause the Identification Algorithm to prompt the user to tune the T200
manually.
NOTE:- If a Type 1 Load was found (non-resonant) after a successful Auto-Tuning
sequence, the user can enable the Velocity Observer, without further tuning of the
observer.
NOTE on Incorrect Detection of Resonant Systems:- If motor movements are small
during the auto-tuning excitation, because of a large load inertia, or the environment is
electrically noisy, the auto-tuning algorithm may detect a resonant load even though the
coupling between the motor and the load is extremely stiff. The user should run the
algorithm again to verify that the load is resonant. If the algorithm detects a Type 1 Load
(lumped inertia load) the second time the auto-tuner is run, then that identification is likely
to be correct, and the user can use the gain values suggested by the auto-tuner.
6.7.2.11 Monitoring the Velocity Tracking
The T200 will warn a user if the actual velocity is not tracking the velocity command, by indication on the seven
segment display. If the velocity error (difference between the velocity command and the actual velocity) is greater in
absolute terms than the Warning_Velocity for at least the Warning_Velocity_Time, then the seven segment display will
flash the warning. This can be useful when tuning a T200 initially in an application, as well as for ongoing monitoring.
Once the application is properly configured, the Warning_Velocity and the Warning_Velocity_Time can be reduced so
that if machine wear or other damage occurs, which causes excessive torque to track a command, the T200 will indicate
the difficulty in tracking the commanded velocity.
PAGE 6-44
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.3
T200 User's Manual
Position Mode
6.7.3.1 Position Mode Reference Sources
One of the following sources for position command need to be programmed by the user:1/ Internal Function Generator. The T200 provides an internal software function generator for position reference
generation. The function generator produces spline shaped position profiles, in order to tune the T200. Position loop
gains. The Acceleration, Traverse, Velocity Amplitude, Offset, Period of excitation and Duty Cycle are programmable.
See Section 6.5 Internal Function Generator for further information.
2/ Analog Source:- The analog command input is limited to the range ±10V. The transfer function from voltage to
position command is given by:-
Θ command Revs_Per_10V
=
Vin
10V
where
Vin is the input voltage
Revs_per_10V is a user-programmed scaling factor
Θ command is the commanded motor position
3/ Point Motion Controller Source:- The T200's integral Point motion controller creates a position command as an
output of loop closure function blocks. This function is available in the 'P' software version only.
4/ CAN Source:- The T200 can be operated in fine-interpolation positioning mode or point-to-point positioning profile
mode. See Section 9.
5/ Stepper Motor Interface Mode:- The T200 can use its RS422 type incremental encoder input as a means of
inputting stepper mode Up/Down, and Quadrature mode inputs. See Stepper Motor Interface.
6.7.3.2 Position Mode Offset Adjust
An automatic analog offset adjust mechanism exists for the analog position reference. This operates in exactly the same
way as the offset-adjust in torque mode. See Section 6.7.1.2 Torque-Command Analog Offset Adjust for a description.
6.7.3.3 Programmable Torque Limiting in Position Mode
The T200 uses the Automatic and Manual Torque Limits as described in Section Automatic and Manual Power Settings,
under the control of the AUTO_MAN digital input.
6.7.3.4 Programmable Velocity Limiting in Position Mode
The T200 applies the Automatic_Mode_Velocity_Limit and Manual_Mode_Velocity_Limits in position mode. The
T200 will ensure that the actual velocity never exceeds the particular Velocity_Limit (which is selected from either the
Automatic_Mode_Velocity_Limit or the Manual_Mode_Velocity_Limit depending upon the status of the AUTO_MAN
input) by clamping the velocity command, which is output from the internal position control loop, to the applicable
Velocity Limit.
PAGE 6-45
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.3.5 Analog Torque Limiting in Position Mode
The Analog Torque Limit functions in exactly the same way in position mode, as it does in torque mode. See Section
6.7.1.6 Analog Torque Limiting in Torque Mode for a full description.
6.7.3.6 Position Limits in Position Mode
There are two means of activation of position limiting in the T200, when it operates in position mode.
1. Hardware Limit Switches:- Hardware Limits Switches are described in Section 6.4.5 - Limit Switch Function.
The reaction of the T200 in various modes of operation are described in that section.
2. Software Position Limits:- CAN Profile and Interpolation modes, as well as the Point Motion Control system,
provide software limit switch functionality. See the Point Manual for the Point software position limits. (This
function is not provided in Stepper Motor Interface mode as the hardware limit switches are already active and there
is no Homing Cycle in that mode.)
6.7.3.7 Velocity Rate Limiting in Position Mode
The Velocity Command (as the output of the position loop section) may be limited in exactly the same fashion as in
velocity mode (see Section 6.6.2.5 Rate Limiting in Velocity-Mode).
PAGE 6-46
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.7.3.8 Position Mode Functional Block Diagram
Figure 6.21:- Position Mode Block Diagram
PAGE 6-47
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.3.9 Position Loop Tuning
Before tuning the position loop, the user should first tune the velocity loop as described in Section 6.6.2 Velocity Mode.
This makes the process of tuning the position loop easier, because the inner velocity loop has already been increased to
as high a bandwidth as the application will allow. Such a velocity loop tuning should make the position loop tuning
seem to be as easy as tuning a first order system. This section provides a recommended position loop standard tuning
procedure. The process applies to use of the Hand Held Terminal. However the user should follow a parallel process
using the WinDrive interface. The procedure should be followed in the sequence listed. The appropriate user manual
should be consulted for appropriate user interface commands.
§ Disable the Servo-drive, using the ENABLE digital input.
§ Set the Control Compensator to Position Mode.
§ The position loop is tuned using a low frequency square wave position command while observing the velocity
§
response on an oscilloscope. This low frequency square wave position command can be supplied from the internal
Position Mode software function generator as described below.
Set up the position loop function generator to produce a high acceleration trapezoidal velocity profile as follows:
- Traverse to 5 revolutions.
- Speed Amplitude to 10% of rated motor speed.*
- Acceleration to maximum allowed value. ( Note machine restrictions)
- Period to 10 seconds.
* Tuning speed should be set low enough to avoid saturation of the torque demand. Torque demand can be monitored by
directing the IDC_Current Monitor signal to one of the TP1 and TP2 analog output channels, and monitoring signal this
with an oscilloscope. This signal must not saturate during motor acceleration/deceleration (ie. must be less than 10V). If
the signal saturates then the function generator set up must be relaxed until saturation does not occur, by reducing the
Acceleration or the Speed_Amplitude parameter.
CAUTION:- Ensure that the application allows using this speed amplitude and length
of travel, (period, duty cycle), without damage to the machine before proceeding with
the tuning procedure.
To monitor actual Velocity, connect an oscilloscope to an analog O/P channel test point with the following settings:
Horizontal Amp: 20 mS/Division
Vertical Amp: 1 V/Division
Direct the velocity feedback signal to TP1 (See Section 8 for a description of the Hand Held Terminal commands).
PAGE 6-48
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Tuning the Position loop.
The following technique should be used to tune the position loop using the set-up loop described earlier.
§ Enable the Servo-drive; Hardware Enable first using the external enable I/P, then Software Enable, with the
function generator initialised as detailed above.
§ Use the GU command, while monitoring the velocity response on the oscilloscope, to increase the G gain (position
Loop Proportional Gain) until a slight overshoot occurs in the velocity response Fig 4. Use the GD command to
decrease the G gain until the overshoot just disappears (Fig 5).
NOTE:- If the autotuner has already been used successfully, then the user can try a
value of Bandwidth * 2.0 for the Position Loop Gain parameter (G). This should be a
good first estimate for the position gain.
6.7.3.10 Monitoring the Velocity Tracking in Position Mode
The T200 provides the same velocity monitoring in position mode as it does in velocity mode. See Section
6.7.2.11 Monitoring the Velocity Tracking, for a full description.
PAGE 6-49
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.7.3.11
Monitoring the Position Tracking in CAN Interpolation Mode
The T200 also provides monitoring of the position error in CAN Interpolation mode. Two parameters are provided for
the user to configure this tracking. These are:§ Static Loop Position Error Band:- This quantity is specified in position increments (see Section 7.10.1.3 CAN
Position Scaling for an explanation of the scaling). It is the maximum allowed position error that the user can allow
when the drive is not moving or moves at a very low velocity. The Static Loop Position Error Band can be
programmed using the STS Hand Held terminal command.
§ Dynamic Loop Position Error is the ratio of the slopes of the two lines shown in the Figure 6.22 below. A
position system that has no velocity feed-forward term will have a position error that is proportional to the actual
velocity. The Dynamic Loop Position Error in effect implies how many times greater a position error than this
expected position error, the user will tolerate in his application. Note that this parameter can be set to a value less
than 100%, for a system which uses velocity feed-forward terms (CAN systems use feed-forward terms, to reduce
the position loop error).
The warning condition will be indicated on the T200's seven-segment display, if the position error exceeds the Position
Error Allowed (see diagram below).
Actual Position
Error
Operating area in
which the Position
Error Warning is
set
Static
Position
Error
Position Error
Allowed as a
function of
velocity, with no
warning
Expected Position
Error of a positioning
system with no
velocity feedforward
Dynamic Error gives
difference in slopes
Actual Velocity
Figure 6.22:- Position Error Monitoring
PAGE 6-50
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.8 Fault Detection
6.8.1
Faults and User Indication in the T200
This sections outlines faults which are detected in the T200
6.8.1.1 Faults and Warnings
The T200 distinguishes between faults and warnings. Faults are those abnormal conditions that are of a serious enough
consequence to cause the T200 to halt operation. This will always result in removal of power from the T200 high power
amplifier, and will usually result in application of a motor brake, if present, with CAN and Point modes of functionality.
Warnings are those abnormal conditions that do not in themselves yet constitute a peril to the equipment or to personnel.
6.8.1.2 Fatal Faults and Non-Fatal Faults
The T200 distinguishes between two types of faults:-
§ Fatal Faults are those faults with which the T200 cannot continue to control the motor. The T200's reaction to a
fatal fault is to immediately disable the switching of the power amplifier. For example, if resolver position sensing
is lost, the motor cannot be commutated. The ability to control the motor output torque is therefore lost and the
T200 immediately disables high power from the motor.
§ Non-Fatal Faults are those faults which will likely lead to equipment failure or hazards to personnel, but the T200
is still capable of controlling the motor output torque. For example, a loss of CAN communication is treated as a
non-fatal fault, because the T200 can control a servo-stop of the motor. Non-Fatal faults lead to servo-stops of the
motor at the Emergency Deceleration Rate, and then the T200 high power amplifier is disabled.
Individual Fatal and Non-Fatal faults are described and categorised below.
PAGE 6-51
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.8.1.3 Fatal Faults
The following is an overview of the fault detection mechanisms in the T200. Note that the fault codes that are displayed
on the 7-segment display are explained in Section 3.19.
Power Amplifier Short Circuit [ F 1 ]
A power amplifier short circuit fault occurs when a short circuit between any one of the motor phases or between a
motor output phase and DC+ or DC- causes a fault current to flow. The Short Circuit detection circuitry detects such a
fault current and disables the T200 output inverter power amplifier. When the power amplifier is disabled the fault
current will cease but the fault remains latched until it is cleared by re-enabling the T200.
DC+
Phase A
Phase B
DC-
PE
Figure 6.23:- Detectable Short Circuit Faults
If a Power amplifier Short Circuit fault occurs the system should be checked to determine the source of the short circuit.
The problem should be rectified before attempting to re-start the drive.
Bus-Overvoltage Fault [ F 2 ]
A bus-over-voltage fault occurs when the high voltage D.C. Bus that supplies power to the inverter power amplifier
exceeds a pre-set high level. This level is primarily determined by the voltage rating of the components which sit on the
D.C. Bus. Bus-over-voltage faults generally occur due to dynamic braking of the servo motors. When brushless DC
servo motors are braking they supply power back to the D.C. Bus that supplies the output inverter. This causes the DC
reservoir capacitors on the D.C. Bus to charge up. A regeneration circuit normally dumps this energy in resistive loads
when the voltage on the D.C. Bus capacitors reaches set levels. However if the energy being produced by the braking
load exceeded the capability of the regeneration circuitry, or if this regeneration circuitry has malfunctioned, the D.C.
Bus continues to rise until D.C. Bus over-voltage levels are reached. When a D.C. Bus overvoltage fault is detected the
output inverter power amplifier is disabled. The fault remains latched until it is cleared by re-enabling the drive.
PAGE 6-52
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
Note:- the T200 provides a measurement of the Regeneration Continuous Power over the last averaging period. The
'?LRR' Hand Held terminal command will display the average energy which has been expended over that period. This
will help in sizing the regeneration resistance needed. This power measurement is accurate to ±10% of the actual
regeneration power being expended.
If WinDrive is used the calculated average regen
EXTREGEN.ACTUALPOWER within the EUI dialog box.
energy
can
be
displayed
via
the
parameter
NOTE:- If a D.C. Bus overvoltage fault occurs check that the regeneration circuit is suitable
for the application. Consult Moog for further details.
Resolver Fault [ F 8 ]
Moog Servo drive systems utilise resolver-based motor-shaft-position feedback. The resolver is an integral part of the
servo-motor and is connected to the servo-drive via a dedicated resolver cable. The T200 has built in resolver checking
algorithm that continually monitors the resolver inputs and checks for cable breaks. If resolver signals are not present
then the drive disables and the fault is latched.
CAUTION:- If this fault occurs check that the resolver cable is plugged in correctly at
both the motor and the Servo-drive. If this does not solve the problem check that the cable
is intact. If fault persists consult Moog.
Analog Power Supply Fault [ F 9 ]
This fault occurs in the event of the internal analog-control power-supply voltages falling below pre-set levels. This can
happen if the power supplies are overloaded. If this fault occurs then the drive is disabled and the fault is latched.
CAUTION:- If this fault occurs check that adequate voltage levels exist on the backup
power supply (24V and isolated 120Va.c.). If fault persists consult Moog.
PAGE 6-53
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.8.1.4 Non Fatal Faults
The following is an overview of the non-fault detection mechanisms in the T200. The fault codes that are displayed on
the 7-segment display are explained in Section 3.19.
A.C. Mains not applied or High Power Not Ready Fault [ U 1 ]
•
A.C. Mains not applied
This condition is treated as a Non Fatal Fault because most motion control system will power-on logic level power,
and carry-out self-configuration and self-diagnostics before application of a.c. mains power. If the Non Fatal Fault
does occur, it should be interpreted differently for each type of T200 (with and without integral high power PSU).
If the drive model is T200-X10 then no a.c. mains is present. If the drive model is a T200-X00, then the PowerReady signal from the T200-X10 is not beeing received, I.e. the DC-bus is not present. If this fault occures the drive
decelerate and disables.
•
High Power Not Ready Fault
The T200 Servo-drive has a soft start feature that limits the inrush current from the a.c. mains. While the Servodrive is in soft start mode then the High Power Not Ready fault is reported and the T200 cannot be enabled. When
the soft start is over then this fault is cleared and the output inverter power amplifier can be enabled. This
circumstance is brought to the attention of the user because if it occurs during normal operation, the drive will
decelerate and disable.
CAUTION:- If A.C. mains is applied and this fault occurs do not attempt to restart the
drive. Consult Moog for further instructions.
CAN Communications Loss [ U 7 ] or Programming Error [ U 9 ]
The T200 monitors the reception of messages expected on CAN and also checks that it could successfully transmit
messages as required. This fault indicates that the drive cannot establish or has lost reliable communications via CAN
with its Host controller. Also if the T200 is in CAN Profile mode, and an unachievable command is sent to the T200 via
the CAN interface (e.g. too high speed movement), the T200 will indicate the fault, decelerate and disable.
Quick Stop Active [ U A ]
Indicates that the Quick Stop digital input is active. The drive will decelerate and disable when this input is active.
Incremental Encoder or Stepper Motor Input Loss [ U b ]
This fault is only active when the drive is configured for a Stepper Motor Reference, or the Point system uses the
incremental encoder, and the appropriate signals are not present. In this case the drive will not disable, but will simply
hold its present position.
Regen Fuse Blown [ F 3 ]
A regeneration fuse blown fault occurs when the protection fuse for the internal regeneration circuitry blows. This can
happen by excessive switch on/off cycles of the a.c. mains (see Section 3.10) or if the internal regeneration circuit power
transistor fails. When a regeneration fuse blown fault occurs, the drive decelerates and disables and the fault is latched.
PAGE 6-54
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
If the drive is powered down after the internal regeneration fuse has blown and then powered up again, the high voltage
D.C. Bus will not charge up and the T200 will report that all PSU related faults have occurred.
CAUTION:- If a regeneration fuse blown fault occurs, the user should not attempt to
restart the drive. Consult Moog for further details.
A.C. Mains PSU Temperature Fault [ F 4 ]
A PSU temperature fault occurs if the PSU main rectifier heatsink exceeds a pre-determined level. This can occur if the
cooling fan(s) fail or the airflow is restricted. When this fault occurs then the drive decelerates and disables and the fault
is latched.
CAUTION:- If this fault occurs then the operation of the cooling fan(s) and airflow
restrictions should be checked. If the fault still occurs then consult Moog for further
details.
Power Amplifier Temperature Fault [ F 5 ]
A power amplifier temperature fault occurs if the power inverter heatsink temperature exceeds a pre-determined level.
This fault should not occur if the Servo-drive is operated within its environmental specifications due to the operation of
thermal foldback self-protection algorithms. However the fault can occur if the cooling fan(s) fail or the airflow is
restricted. When this fault occurs then the drive decelerates and disables and the fault is latched.
CAUTION:- If this fault occurs then the operation of the cooling fan(s) and airflow
restrictions should be checked. If the fault still occurs then consult Moog for further
instructions.
Motor Temperature Fault [ F 6 ]
A motor temperature fault occurs if the temperature of the motor windings exceeds 155°C. This can occur if the motor is
operated outside its maximum continuous ratings or if the motor does not have adequate heatsinking. When this fault
occurs the drive is disabled and the fault is latched.
CAUTION:- If this fault occurs then motor operation and motor mounting/cooling should
be checked. If the fault still occurs then consult Moog for further instructions.
PAGE 6-55
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.8.1.5 T200 Warnings
The following is an overview of the warnings detection mechanisms in the T200. Note that the warning codes that are
displayed on the 7-segment display are explained in Section 3.19.
Thermal Foldback Active [ . ]
This warning is active when the torque command is limited due to thermal current limiting (See Self Protection). In this
case the user may interrogate using either WinDrive or the Hand Held Terminal to check the present thermal limit.
Motor Thermal Warning [ U 2 ]
This warning indicates that the motor winding temperature has exceeded 130°C.
Power Amplifier Thermal Warning [ U 3 ]
This warning indicates that the power transistor heatsink temperature has exceeded an appropriate temperature.
Position Tracking Error [ U 4 ]
This warning indicates that the position error has exceeded a user-set threshold. This error will only be present when the
drive is in position mode.
Velocity Tracking Error [ U 5 ]
This warning indicates that the velocity error has exceeded a user-set threshold. This error will be checked in all position
and velocity modes.
Regeneration Limit Exceeded [ U6 ]
The T200 monitors the status of the external regeneration resistor duty cycle, in order to determine if the resistor's
continuous thermal rating is being exceeded. If it is then the T200 will issue a warning. See Section 3.13 for
specifications of the regeneration resistors for each particular T200 model.
Limit Switch(es) Asserted [ U 8 ]
Indicates whether the clockwise and counter-clockwise digital inputs are active. If in Velocity mode, if the limits are
enabled the motor will not rotate in the direction for which the input was activated. For example if the clockwise digital
input is in-active there will be no motion in that direction. Note that if the limit switches are disabled, then the warning
U8 will not flash even if the limit switch hardware is activated.
PAGE 6-56
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.8.2
T200 User's Manual
Fault History Record
The T200 records all faults and warnings as these occur in a special non-volatile memory. Approximately every
0.5seconds the T200 checks have any new faults been reported. The time stamp is relative to the time the drive is
powered.
The T200 has sufficient space to record 1024 such faults or warnings, so that it should be able to continue recording
such fault and warning data for a significant number of fault occurrences. No way of erasing this data is provided.
To avoid filling up memory space with irrelevent data, recorded data are separated in two categories, Faults and
Warnings.
Faults will be latched and need to be reset with a positive transition of the enable signal. Only the first occurence of a
fault after it is reset will be recorded. Faults are recorded in both Enabled and Disabled Drive state.
Warnings will only be recorded at their first occurence if the T200 is enabled. This avoids repetitive recording of e.g.
position following errors.
Faults and warnings are described in section 10, Trouble-Shooting Guide.
The WinDrive interface provides a means of uploading the fault data and printing this to an ASCII file with a user
record of the application. See Section 7.9.6 for further details.
PAGE 6-57
T200 User's Manual
6.8.3
SECTION 6: T200 FUNCTIONAL OVERVIEW
Fault indication via digital outputs
To allow drive status and fault diagnostics with a PLC drive status and fault information is available on the digital
outputs of the T200.
Fault indication via digital outputs is only available if the drive operates in the following modes:
•
Velocity mode with analog reference.
•
Torque Mode with analog reference.
•
Digital Speed Input
•
Stepper Mode (only Mode 1 available)
6.8.3.1 Mode 1: Fault indication via digital outputs disabled.
This mode allows a limited fault indication as only two digital outputs can be used.
Digital / Relay Outputs (functionality dependent on control mode)
Digital Output
Current/Velocity
Mode
(±10V Reference,
Digital Speed
Input)
Position Mode
(Custom POINT,
for Simple Point
see spec)
Position Mode
CAN ProfileMode
Position Mode
CAN Interpolation Mode
Stepper Mode
DO1 (J1/19)
Limit Active
Limit Active
Limit Active
Limit Active
Limit Active
DO2 (J1/20)
Drive Enabled
Drive Enabled
Drive Enabled
Drive Enabled
Drive Enabled
DO3 (J1/21)
Speed/Torque
achieved
User defined
Speed/Torque
achieved
User defined
Following Error
exceeded
DO4 (J1/27)
Fault Code Bit 1
User defined
Undefined
User defined
Fault Code Bit 1
DO5 (J1/28)
Fault Code Bit 2
User defined
Undefined
User defined
Fault Code Bit 2
Relay
(J1/22, J1/23)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output
Table 6.3 Digital/Relay Outputs (Mode 1)
Digital outputs four and five indicate the following drive status.
Dig. Output DO5
(Fault Code Bit 2)
Dig. Output DO4
(Fault Code Bit 1)
Status of the drive
0
0
Drive ok. No faults
0
1
Motor Fault
1
0
Amplifier Fault
1
1
Limit Switch Active
Table 6.4 Status Indication via DO4 and DO5 (Mode 1)
Note:
0 means a logical 0. I.e. no current flowing.
1 means a logical 1. I.e. current flowing.
PAGE 6-58
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
Drive Status in Mode 1 has the following meaning:
1. Drive ok
This status indicates that the drive has no faults. The status is independent of AC-mains. I.e. “Drive ok” will be indicated
even when AC-mains is not applied. PSU faults, which can only be evaluated when AC-mains is applied, will be
indicated.
2. Amplifier Fault
This fault is enabled when one or more of the following faults are active:
•
Bridge Overcurrent
•
Bus Overvoltage
•
Regen Fuse Blown
•
PSU Overtemperature
•
Bridge Overtemperature
•
±15V Fault
•
Encoder Input Missing
3. Motor Fault
This fault is enabled when one or more of the following faults are active:
•
Motor Temperature Fault
•
Resolver Fault
4. Limit Switch Active
This status information indicates that one of the two Limit Switches (CW or CCW) is active.
6.8.3.2 Mode 2: Fault indication via digital outputs enabled
This mode makes use of four digital outputs to indicate the drive status to the PLC. The meaning of digital outputs one
and three is redefined as described in Table 6.5. As indicated in the table this is only valid if the drive is not using Point
or CAN as a reference source.
Digital / Relay Outputs (functionality dependent on control mode)
Digital Output
Current/Velocity
Mode
(±10V Reference,
Digital Speed
Input)
Position Mode
(Custom POINT,
for Simple Point
see spec)
Position Mode
CAN ProfileMode
Position Mode
CAN Interpolation Mode
Stepper Mode
(Fault indica-tion
Mode 1;
Mode 2 not supported!)
DO1 (J1/19)
Fault Code Bit 1
Limit Active
Limit Active
Limit Active
Limit Active
DO2 (J1/20)
Drive Enabled
Drive Enabled
Drive Enabled
Drive Enabled
Drive Enabled
DO3 (J1/21)
Fault Code Bit 2
User defined
Speed/Torque
achieved
User defined
Following Error
exceeded
DO4 (J1/27)
Fault Code Bit 3
User defined
Undefined
User defined
Fault Code Bit 1
DO5 (J1/28)
Fault Code Bit 4
User defined
Undefined
User defined
Fault Code Bit 2
Relay
(J1/22, J1/23)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output)
System Ready
(relay output
Table 6.5 Digital/Relay Outputs (Mode 2)
PAGE 6-59
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
The dedicated digital outputs indicate the drive status as follows.
Drive Status
FAULTS AND STATUS
Drive OK. No Faults.
Foldback
Bridge Overcurrent
Bus Overvoltage
Regen Fuse Blown
PSU Temperature Fault
Bridge Temperature Fault
Motor Temperature Fault
Programming Error
Resolver Fault
±15V Fault
WARNINGS
Bus Not Active
Regen Exceeded
Limit Switch Activated
Inc. Encoder
Warning Temperature
Indication
DO1,DO3...DO5
(DO1=LSB)
O
[.]
F1
F2
F3
F4
F5
F6
F7
F8
F9
0000
0001
0010
0011
0100
0101
0110
0111
1000
1001
1010
U1
U6
U8
Ub
U2 | U3
1011
1100
1101
1110
1111
Table 6.6 Status Indication (Mode 2)
See Section 10 for a description of the meaning of the faults.
“Warning Temperature” is a logical or of “Motor Warning Temperature” and “Bridge Warning Temperature”.
If more than one fault or if more than one warning is present the time period a warning/fault is indicated is one second.
I.e. the first fault/warning will be displayed for 1s then the second one will be displayed for 1s and so on.
The selection between the two modes can be done via the WinDrive EUI interface or via a POD command as described
in section 8.
The command to set the drive in one of the above mentioned modes is “SFI” . The command to read the currently active
mode is “LFI”.
PAGE 6-60
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.9 Self Protection
6.9.1
Sources of Torque Limits
There are three sources of torque limitation within the T200:1.
2.
3.
Programmable Torque Limits:- The user may program Automatic_Mode and Manual _Mode Torque_Limits.
These are described in Section Automatic and Manual Power Settings.
Analog Torque Limit:- The Spare Analog Input is used as a means of reading in a analog torque limit command.
This is described in Section 6.6.3 Position Mode.
Thermal Torque Limits:- The T200 provides a comprehensive thermal protection of the motor, the power
electronics and cabling and interconnect. These are described below in greater detail.
The minimum of these sources at any time is used to limit the available current. Note however that the Limit_Active
digital output function will only activate when the current demand is greater than a Thermal-Limit. This is because the
other limits are set by the user anyway.
6.9.2
Power Amplifier Thermal Protection Mechanism
The power amplifier is protected by using a scheme called Thermal-Foldback. The T200 is rated to operate at an
ambient temperature of up to 55°C.
§ The Foldback scheme is designed to ensure a very conservative temperature margin is maintained between power
device manufacturer's rated maximum temperatures (semiconductor junction temperature) and the actual
semiconductor junction temperature.
§ The Running Thermal Limit applies when the speed of the motor is greater than approximately 50RPM. The Stall
Thermal Limit applies for motor shaft speeds of less than approximately 50RPM. The Stall Limit will become less
than the peak current capability of the amplifier only at elevated ambient temperatures and high continuous
operating loads.
6.9.3
Motor Protection Thermal Protection Mechanism
§ The T200 measures the temperature of the motor by means of measurement of the Negative Temperature
Coefficient thermistor buried within the motor windings.
approximately 25°C and 175°C.
The motor temperature is measurable between
§ Software calculates the motor thermal limit based upon the motor windings temperature. The motor protection
scheme is intended to ensure that the temperature of the motor core will not exceed 155°C.
6.9.4
Cabling and Interconnect Protection Scheme
Each T200 model has a continuous current rating. The T200 operates an algorithm that limits the overall RMS level of
motor phase current appropriately, over a time window that extends over the last averaging period. This is intended to
protect the connectors and internal circuitry, which would otherwise be thermally over-stressed.
PAGE 6-61
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
The T200 measures the motor phase currents at a high frequency. Approximately 2 times per second, a new RMS
current limit is calculated. The algorithm measures the RMS phase current for the last averaging period. It calculates
the remaining amount of current for the next 0.5 seconds, for which the total current over the averaging period would be
20Arms. This remainder becomes the RMS current limit for the next 0.5second period.
The RMS current over the last averaging period is made available to the user. The "?LMR" command lists the actual
RMS current value via the Hand Held Terminal interface.
6.9.5
Regeneration Resistor Protection Scheme
The regeneration function dissipates energy that is returned to the T200 from a decelerating load or from a counteracting
torque. Regenerative energy dumping is handled by thermal dissipation through conduction of current through
regeneration resistors. There are two resistive regeneration mechanisms in the T200:1.
Internal Regeneration Resistor:- The T200 has an internal regeneration resistor which provides a 40W
continuous/2.8kW peak dissipation capability. The internal regeneration resistor is protected by an Electronic
Circuit Breaker. The breaker will inhibit the conduction of current in the internal regeneration resistor if the
continuous conduction capability of the resistor is exceeded. In an application where high levels of regenerative
power are fed back into the mains, an external regeneration resistor is needed. When the ratings of the internal
regeneration resistor are exceeded, the Electronic Circuit Breaker will inhibit further conduction in the internal
resistor. This will leave the external resistor to handle dissipation of further regenerative energy.
2.
External Regeneration Resistor:- The conduction of the external regeneration resistor is monitored in order to
detect if its continuous rating has been exceeded. Note that the THRM_LIM Thermal Limit Active output of
the T200 will activate if the external regeneration resistor's ratings have been exceeded.
CAUTION:- The user's application should monitor for the activation of the
THRM_LIM Thermal_Limit_Active digital output, and take action to reduce or remove
further thermal stress on the T200, regeneration resistors and motor. If action is not
taken then the external regeneration resistor may be damaged, or the fuse may be blown
by an over-current.
Due to the possible variations in connecting the power section of T200’s (see section 3.10, 3.11) the functionality for
indication that the max. continuous regen power is exceeded can be adapted to the needs of the users application.
The following drive reactions can be selected:
•
Regen Exceeded disabled
There will be no reaction of the T200 if the calculated continuous regen power exceeds the max. continuous regen
power of the selected regen resistor.
This is especially necessary in applications where the DC-Bus of T200’s with internal PSU is paralleled. In such a
configuration only one T200-X10 will have an external regen resistor attached. As the calculated regen energy is
based on the assumption that an external regen resistor is connected the calculated regen energy of all drives without
an external regeneration resistor is wrong and the warnings are misleading.
WARNING:- It is the users responsibility to ensure that the Regen Exceeded
functionality is only switched off when no external regen resistor is used for this T200.
There is no other indication that the cont. regen power is exceeded. Exceeding
continuous regen power will damage the regen resistor and can cause the resistor to
catch fire.
PAGE 6-62
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
•
Regen Exceeded Enabled
Mode 1 (Warning Indication):
As soon as the max. continuous regen power is exceeded digital output J1/19 will be switched off and E6 or U6 will
be displayed on the 7-segment display.
This warning is not a latched warning. I.e. as soon as the calculated regen power is less than the max. continuous
regen power output J1/19 will be switched on and E6/U6 will no longer be displayed.
If this warning occurs the first time since the drive is enabled this warning will be put in the error logfile as well.
•
Mode 2 (Drive disable):
As soon as the max. continuous regen power is exceeded digital output J1/19 will be switched off, E6 will be
displayed on the 7-segment display, the T200 performs a Quick Stop and disables. U6 will be displayed until the
drive is reenabled.
Regen Exceeded is a latched fault. I.e. the indication U6 will be displayed until the drive is reenabled. This allows
the user to figure out the reason for the Quick Stop. Output J1/19 will be switched on again as soon as the cont.
regen power is no longer exceeded. This is to allow reenabling the T200 via the PLC.
The message “Regen Exceeded” will be put into the error logfile.
Note: Output J1/19 is the “Thermal Limit Active”-output. This output indicates as well if the torque is limited due to a
thermal limitation
The Regen Exceeded functionality can be enabled or disabled via the Regen Resistor Configuration box in WinDrive as
described in Section 7.10.1.8 or via the Hand-Held-Terminal command “RE”. Default is Regen Exeeded functionality
enabled.
The drive reaction if the continuous. regen power is exceeded can be selected via the Regen Resistor Configuration
dialog box in WinDrive or via the Hand-Held-Terminal command “ORM”.
MOOG offers a range of regen resistors with the appropriate fuses for short circuit protection as described in section
3.13. If the user do want to use a different regen resistor the appropriate parameters of the resistor need to be set up.
The parameters can be set up either with WinDrive (see section 7.10.1.8) or via a Hand-Held-Terminal-Command.
The Hand-Held-Terminal-Command to set up the external regen resistor is: “ORR”
“Regen Resistor”
“Resistance [Ohm]”
“10 [Ohm]”
“?”
“Power [Watt]”
“200 [Watt]”
“?”
The default value and the max. regen power depends on the size of the T200. Default values are:
Regen resistor resistance
T200-310
10Ω
T200-410
10Ω
T200-510
10Ω
T200-610
4Ω
T200-710
4Ω
Range for the resistance: 4Ω...100Ω.
Range for the max. continuous regen power: 10W...10000W.
Max. continuous power
200W
600W
600W
2500W
2500W
The calculated continuous regen power can be read either with the POD-Command “?LRR” or via WinDrive. This value
is only sensible if an external regen resistor is connected to the T200. The value can be read out independent of the
regen exceeded functionality.
PAGE 6-63
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.10 Encoder Simulation Function
The Encoder Simulation generates incremental encoder formatted output signals from a resolver position transducer.
See Section 3.17 for an electrical description of the interface. The following signals are generated:-
C lock w is e
C o u n te r- C lock w is e
A le a d s B
B le a d s A
(ESM ) A
(ESM )
B
L o n g Z e ro
M A RKER
S h o rt Z e ro
M A RKER
In c re a s in g M o t o r Sh a ft
P o s it io n
Figure 6.24:- Encoder Simulation Signals on Connector J7
The T200 implements two types of encoder simulation:1.
High Bandwidth Encoder Simulation ("ESM3"):- This mode is recommended when the T200 is used in torque
mode. The encoder simulation is carried out directly via analog hardware, with a feedback bandwidth of between
800 and 1000Hz. In this case the Number of Lines per Revolution is limited to the values 128, 256, 512 or 1024.
2.
Flexible Line Count Encoder Simulation ("ESM1"):- This mode is recommended when the T200 is used in
velocity mode. In this case the encoder simulation is implemented as a hybrid hardware and software module, and
the feedback bandwidth is limited to approximately 400Hz.
The user must set the Number of Lines per Revolution parameter to an even number between 128 and 8192. If the User
sets the Number of Lines per Revolution to a value of 128, 256, 512 or 1024, then the high bandwidth solution is chosen.
If the user selects any other value then option 2) above is selected automatically by software. For both options 1) and 2)
above the following software configurable options are available:-
§ Zero-Marker-Offset:- The user may specify an offset (in mechanical motor shaft degrees) of the Zero-Marker of the
Encoder Simulation output, with respect to the motor’s own resolver-position sensor natural zero position.
§ Marker-Length:- Long Marker and Short Marker (see Figure 6.24 above) options are provided, as user selectable
items.
PAGE 6-64
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Note on Maximum Speeds:- The T200 Encoder Simulation Output is galvanically isolated.
There is a maximum rate of pulses which may be transferred without loss of position
information, through the isolation circuitry. The maximum pulse rate for the Channel A,
Channel B and Zero-Marker is 200kHz. The user is informed by the WinDrive interface what is
the maximum motor rotational speed for that number of Lines-Per-Revolution.
NOTE on Line-counts and Control Modes
ESM3 Linecounts (128, 256, 512 or 1024) are recommended for use when the T200 is
operated in torque mode.
Other even line-counts (any even number between 100 and 8000, excepting those listed
above as ESM3 linecounts) can be used when the T200 is operated in velocity mode
PAGE 6-65
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.11 Incremental Encoder Input
A quadrature incremental encoder input is provided on the T200. This encoder is not used for motor commutation
purposes, but for feedback of relative position information to the Point motion control software or CAN interface
system. The encoder interface accepts Channel A, Channel B and Zero Marker Differential Inputs in RS422 electrical
format. A position latch function is also provided via connector J1, such that the encoder position is latched when the
latch digital input transitions from inactive to active (i.e. current flows in the input).
C lockwise
C o unte r-C lockwise
A leads B
B lead s A
ENC_A
ENC_B
ENC_M A R K E R
Increasing Encoder Position
Figure 6.25:- Quadrature Incremental Encoder Input on J5
Specification Area
Specification Description
Maximum Line Frequency
Up to 1MHz Line Frequency (i.e. 4MHz edge frequency)
Input Voltage Range
Input Line Voltages are RS422 compatible.
Channel Input Impedances
Encoder Input is terminated with 120Ohms impedance
Encoder Fault Detection
The following faults are detectable:Disconnected encoder lines (via monitoring of encoder voltages)
Position Registration Latch
The Position Registration Latch input is provided as a means of latching position
upon detection of an event. The encoder position is latched within 1us of the
inactive to active transition of this input.
Voltage Supply for Encoder
The T200 provides a 5V non-isolated supply for an external encoder. Note that
an internal resetable fuse in series with the output will provide protection in the
event that the external encoder device goes short circuit.
Table 6.7:- Incremental Encoder Input Specification
PAGE 6-66
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Note that the following user programmable parameters are available for the Encoder Input:Number of Lines per Revolution:- The user may program this parameter to set the number of encoder lines per
revolution of the motor shaft. This allows the T200 software to translate a rotary encoder's shaft position into its own
internal position units for motion control calculations.
Zero-Marker Offset:- The user may program the offset (in lines) between the encoder’s actual zero-marker and that
which is registered in software. This function is reserved for future motion control functionality.
Present Position:- The present position of the encoder, in lines, may be examined by reading this parameter. This
feature is useful for debug of encoder cabling and setup.
PAGE 6-67
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.12 Stepper Motor Interface
In Stepper Motor Inerface Mode the T200 can be used to replace a stepper motor if the dynamics of the stepper motor do
not satisfy the requirements of the application. This mode allows as well an easy implementaiton of an electronic
gearing. In Stepper Motor Interface Mode the T200 operates in Position Mode. This means that the Position Loop needs
to be tuned for proper operation. Tuning of the Position Loop is described in Section 6.6.3. Setup with the WinDrive
Graphical User Interface is described in Section 7.10.1.3.
In Quadrature Mode, the edges of ENC_A and ENC_B will generate a movement of ¼ of a step, i.e. each edge is 1
count. The relative phase of ENC_A and ENC_B will determine direction. For example, if the number of steps is 1024
and a 1024 line encoder is attached, then the motor shaft will turn 1 rev for 1 revolution of the encoder. The motor
rotation is clockwise viewed from the motor flange when ENC_A leads ENC_B.
In Step and Direction Mode, ENC_A is used to trigger a step for each pulse on ENC_A, ENC_B is used to determine
direction. When ENC_B+ is low and ENC_B- is high, the motor rotation is clockwise viewed from the motor flange. For
counter-clockwise rotation, ENC_B+ must be high and ENC_B- must be low.
.
20m max
User Control
System
Channel A Pair
O/P
Line
Driver
O/P
Line
Driver
0.5sq.mm
twisted pair
J5
1
2
3
4
5
6
7
8
9
DGND
ENC_MARkERENC_BENC_AENC_VCC
ENC_MARKER+
ENC_B+
ENC_A+
PE
Channel B Pair
Figure 6.26:- Stepper Motor Interface Interconnect
If the T200 is in Stepper Mode the additional functionality is supported:
6.12.1 Hardware Limit Switches
If the drive is in Stepper Mode the HW Limit Switches can be enabled or disabled via the Hand-Held-Terminal
command “OL” or via the “Limit Switch”-Window in WinDrive.
If a Limit Switch is hit and Limit Switches are enabled the drive ramps down to 0rpm in Position Mode with the
Emergency Deceleration Rate and stays enabled. Further movements in the direction where the Limit Switch is hit are
not possible. Movements in the other direction are possible.
PAGE 6-68
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.12.2 Following Error Detection
Indication and reaction of the drive when the Following Error Limit is exceeded
The “Speed/Torque Achieved” output (SPD/TORQ_ACHVD pin 21 of J1), is used to indicate to the user that the
Following Error Limit is exceeded. As soon as the Following Error Limit is exceeded the SPD/TORQ_ACHVD output
will be turned on. The SPD/TORQ_ACHVD output will stay turned on until the drive is disabled. The Following Error
will be clamped to the Following Error Limit.
The 7-segment display will display “E4” if the Following Error Limit is exceeded.”E4” is ba sed on the actual Following
Error. I.e. if the drive catches up with the stepper pulses “E4” will no longer be displayed even when the
SPD/TORQ_ACHVD output is still switched on.
If the Following Error Limit function is disabled (parameter set to 819200) the max. following error will be clamped to
50revs but there will be no user indication. Neither the SPD/TORQ_ACHVD output will be set nor “E4” will be
displayed.
Setting of the Following Error Limit parameter
The max. allowed Following Error can be set up via the Dynamic Error (incs) in the WinDrive “Tracking Monitoring”
window or via the POD command “SFFE”/”LFFE”.The Following Error Limit need to be set up in increments. One
motor revolution equals 16384 increments.
The parameter range is from 1024incs up to 819200incs. Any value beyond this range will cause a parameter error. The
default value is 819199 increments (49.99 revolutions). The value of 819200 increments (50 revolutions) disables the
Following Error Limit feature.
The Static Error does not apply. In WinDrive the Static Error will be greyed out if the drive is in Stepper Mode.
If in Stepper Mode the Drive Status Window displays “Following Error Exceeded” instead of “Speed/Torque Achieved”
(“Set Point Achieved”).
Clockwise (A leads B)
a) Quadrature
Counterclockwise (B leads A)
ENC_A
ENC_B
b) Step and Direction
ENC_A
ENC_B
Figure 6.27:- Stepper Motor Interface Mode Signals on Connector J5
PAGE 6-69
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.13 Communications Interfaces
6.13.1 Axis Identification
See Section 3.18 for an overview of set-up of the axis-ID switches to set the T200 communications network address.
6.13.2 Communications Protocol
The T200 supports two protocols over its RS232 and RS485 communications links. These are:1.
Hand Held Terminal Pneumonics Protocol. Simple 1, to 5 letter strings (followed by a <CR> Carriage Return)
are used as command verbs which operate on particular parameters. The user enters a parameter value where
appropriate. This protocol is used to support simple interfaces like the Hand Held Terminal or PC-based Terminal
Emulation Programs (e.g. MS-Windows HyperTerm). This protocol is described in Section 8.
2.
'PSC' Protocol. This protocol is intended as an interface to machine controllers via RS232 and RS485. It supports
read and write of many data types, including floats, longs, integers, booleans and file-blocks. This protocol is
described in this section.
6.13.2.0 Introduction
This specification describes the serial set-up protocol that allows access to T200 parameters over RS232 or RS485 serial
networks.
T200 acts as a ‘slave’device that only responds to messages sent by a Host ‘master’controller. The Host can be any PC,
PLC or other intelligent device that is capable of implementing the communication protocol. Use of the serial channel
permits the control Host to read or modify most T200 parameters .
T200 parameters can be 4 bytes (Long or Float parameters) or 2 bytes (Word parameters) in size. Each parameter also
has an identifying number appropriately called the Parameter Number. All data is represented as 2’s complement, sign
extended with the least significant byte as the first byte in a muli-byte value.
6.13.2.1 Serial Link Signal Specification
Communications Parameters Specification
•
Baud rate
9600
•
Start bits
1
•
Stop bits
1
•
Parity
None
•
Data bits
8
Signal Connections
Serial connections on the T200 Card are accessed via a 9 way D type female connector designated ‘J4’ . Refer to
Section 3.18 for wiring details.
PAGE 6-70
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.13.2.2 MESSAGE / REPLY FORMATS
Message Transmission to T200
All messages transmitted to T200 will be assembled in the following format:
Byte
Use
1
Number of bytes to follow (i.e. Message size - 1)
2
Address of T200
3
Command code
:
Command data
:
:
N
Additive checksum modulo 256
Note:
•
All numbers are restricted to 8 bits (0..255)
•
The T200 address for RS232 or single node RS485 is ‘0’ .
•
Delay from start of message to end of message must be less than 0.25 seconds
•
For multi-node RS485, addresses from 1 to 127 must be used to address individual nodes ( RS485 not currently
implemented ) .
•
On a multi drop network, the transmitter must be disabled within 5mS of sending the last byte of the message. This
allows the T200 to acknowledge the message sent.
•
The content of the command data depends on the command code .
T200 Reply to Host Transmission
All T200 replies to the Host will be assembled in the following format:
Byte
Use
1
Number of bytes to follow (i.e. Message size - 1)
2
Master address incorporating slave address.
3
Command code
4
Acknowledge status
:
Acknowledge data
:
N
Additive checksum modulo 256
PAGE 6-71
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
The address refered to by byte 2 is made from a bitwise OR between the T200 ‘slave’ address and the Host ‘master’
address (Master fixed at 80 hex). For RS232, address = 80 hex or 128 decimal .
The ‘acknowledge status’byte has the following bit definitions:
Bit
Meaning
0
Reserved
1
Acknowledge (Command OK)
2
No Acknowledge (Command NOT OK)
3-7
Reserved
An acknowledgement will normally be received after approximately 10ms, though this may vary greatly depending on
the command sent, the amount of data transmitted (in the command or response), and the "load" of the application within
the T200.
As a comparison, the standard "time out" period used in WinDrive is 5 second for a parameter read/write, and up to two
seconds for each paragraph of block data read/written.
6.13.2.3 MODIFYING T200 PARAMETERS
Message Transmission to T200
The command code for modifying a parameter is 02. The data required is:
•
Parameter number (least significant byte followed by most)
•
Parameter write value ( 2 or 4 bytes depending on parameter size). The order is from least significant to most
significant byte .
To modify a parameter, the following message (series of bytes) should be sent to the T200:
Write Two Byte Parameter
Write Four Byte Parameter
Byte
Value
Meaning
Value
Meaning
1
07
Length of command
09
Length of command
2
00
Address
00
Address
3
02
Command (write param)
02
Command (write param)
4
P0
Param no (least significant)
P0
Param no (least significant)
5
P1
Param no (most significant)
P1
Param no (most significant)
6
D0
Param val (least significant)
D0
Param val (least significant)
7
D1
Param val (most significant)
D1
Param val (next significant)
8
CK
Checksum
D2
Param val (next significant)
9
D3
Param val (most significant)
10
CK
Checksum
PAGE 6-72
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
T200 Acknowledgement to Modify Parameter
There is no data returned with an acknowledgement to a parameter write command. The RS232 ( slave address ‘0’ )
acknowledgement would be:
Byte
Value
Meaning
1
4
Length of command
2
128
Address
3
2
Acknowledge write parameter
4
2
Acknowledge status
5
136
Additive Check sum MODULO 256 of 4, 128, 2, 2
Example
To modify the parameter UPar1 (Parameter Number 46300, 4 bytes) to the value 8000, the following bytes should be
sent:
Byte
Value
Meaning
1
9
Length of command
2
0
Address
3
2
Write parameter
4
220
Least significant part of Parameter Number 46300
5
180
Most significant part of Parameter Number 46300
6
64
Least significant part of Data value
7
31
Data Byte 2
8
0
Data Byte 3
9
0
Most significant part of Data Value
10
250
Additive Check sum MODULO 256 of 9, 2, 180, 220, 64, 31
The T200 acknowledgement will be as follows:
Byte
Value
Meaning
1
4
Length of command
2
128
Address
3
2
Acknowledge write parameter
4
2
Acknowledge status
5
136
Additive Check sum MODULO 256 of 4, 128, 2, 2
PAGE 6-73
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.13.2.4 MONITORING T200 PARAMETERS
Message Transmission to T200
The command code for monitoring a parameter is 01. The data required is:
•
Parameter number (least significant byte followed by most)
•
Size of parameter to read (2 or 4 bytes).
To monitor a parameter, the following message (series of bytes) should be sent to the T200:
Byte
Value
Meaning
1
06
Length of command
2
00
Address
3
01
Command (read param)
4
P0
Param no (least significant)
5
P1
Param no (most significant)
6
SZ
Parameter size (2/4)
7
CK
Checksum
T200 Acknowledgement to Monitor Parameter
The acknowledge ‘data’for a parameter read command is the ‘value of the parameter’to be read. The value may be 2 or
4 bytes long, and will be transmitted in the order of least significant to most significant bytes:
Acknowledge Two Byte Parameter Read
Command
Acknowledge Four Byte Parameter Read
Command
Byte
Value
Meaning
Value
Meaning
1
06
Length of command
08
Length of command
2
128
Address
128
Address
3
01
Command (read param)
01
Command (read param)
4
02
Ack Status
02
Ack Status
5
D0
Param val (least significant)
D0
Param val (least significant)
6
D1
Param val (most significant)
D1
Param val (next significant)
7
CK
Checksum
D2
Param val (next significant)
8
D3
Param val (most significant)
9
CK
Checksum
PAGE 6-74
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Example
To monitor the parameter UFlag1 (Parameter Number 46316, 2 bytes) the following bytes should be sent to T200:
Byte
Value
Meaning
1
6
Length of command
2
0
Address
3
1
Read parameter
4
236
Least significant part of Parameter Number 46316
5
180
Most significant part of Parameter Number 46316
6
2
2 Byte parameter
7
169
Additive Checksum MODULO 256 value of 6, 1, 236, 180, 2
If the value of Uflag1 is - 5 , the T200 acknowledgement would be:
Byte
Value
Meaning
1
6
Length of command
2
128
Address
3
1
Acknowledge read parameter
4
2
Acknowledge Status OK
5
251
Least significant part of Data value
6
255
Most significant part of Data Value
7
131
Additive Checksum MODULO 256 of 6, 128, 1, 2, 251, 255
PAGE 6-75
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.13.2.5 BLOCK DATA FORMAT
Write Block Data to T200
Block data is different from parameter data in that it may be relatively large. Block data is written to the T200 in
sections of up to 64 bytes, known as paragraphs.
The command code for writing a block of data to the T200 is 18 . The data required is:
•
•
Block number.
Paragraph number.
Paragraphs should be written in the correct order (starting at 0), and should all be 64 bytes long except for the last, which
may be up to 64 bytes long.
To write a paragraph of block data, the following message (series of bytes) should be sent to the T200:
Byte
Value
Meaning
1
LN
Length of command (Paragraph size + 5)
2
00
Address
3
18
Command (Write paragraph of block data)
4
PA
Paragraph no
5
BL
Block number
6
DA0
Data byte 0
7
DA1
Data byte 1
N+6
DAN
Data byte N
N+7
CK
Checksum
:
T200 Acknowledgement to Block Data Write
There is no data returned with an acknowledgement to a block data write command. The acknowledgement would take
the form:
Byte
Value
Meaning
1
4
Length of command
2
128
Address
3
18
Acknowledge write paragraph of block data
4
2
Acknowledge status
5
152
Additive Check sum MODULO 256 of 4, 128, 18, 2
PAGE 6-76
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
Read Block Data from T200
Block data is read from the T200 in sections of up to 64 bytes, known as paragraphs.
The command code for reading a block of data from the T200 is 17 . The data required is:
•
•
•
Block number.
Paragraph number.
Number of bytes to be read.
Paragraphs should all be 64 bytes long except for the last, which may be up to 64 bytes long.
To read a paragraph of block data from T200, the following message (series of bytes) should be sent to the T200:
Byte
Value
Meaning
1
06
Length of command
2
00
Address
3
17
Command (Read paragraph of block data)
4
PA
Paragraph no
5
BL
Block number
6
LP
Length of paragraph
7
CK
Checksum
T200 Acknowledgement to Block Data Read
The acknowledge data for a block data read command is the value of the data to be read. The acknowledgement will
take the form:
Byte
Value
Meaning
1
04
Length of command
2
128
Address
3
17
Acknowledge read paragraph of block data
4
2
Acknowledge status
5
151
Additive Check sum MODULO 256 of 4, 128, 17, 2
PAGE 6-77
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.13.3 Parameter Set Description
A detailed description of the T200 parameter set can be provided on request. See Section 11 for phone numbers and
addresses of Moog Sales outlets.
PAGE 6-78
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.14 Parameter Storage
The T200 provides non-volatile storage for user-programmable parameters in both its internal Flash, and via the
Personality Plug module.
Parameter Storage and initialisation
There are four user-configuration data storage locations of significance to the user.
1.
T200 Flash database (non-volatile storage):- The T200 internal non-volatile Flash provides storage for all user
parameters and for the POINT application program. The T200 draws it’s parameter set from internal Flash when no
Personality Plug is connected to the serial port J4.
2.
T200 Personality Plug Database:- The Personality Plug provides an additional storage facility. If a T200 powers
up or resets up, and the module is detected, then the personality module database will take priority over that of the
internal database. The contents of the internal Flash databse will automatically get overwritten with the Personality
Plug database.
3.
T200 RAM Database:- The RAM database is the operational database for all online database operations. All
parameters are transferred from non-volatile storage to RAM (during power up and reset) and from RAM to nonvolatile storage (during parameter save). The T200 operates only with the data from the RAM database.
4.
PC-based .log files:- User parameters sets are stored in ASCII .log files which can be inspected using standard
ASCII text editors.
All T200 parameter transactions take place via the RAM Database. For example, it is not possible to alter the Flash
database without altering the RAM database. Download of a PC-based .log file will only update the RAM database. An
explicit command to save the RAM database to the Flash and personality plug databases has to be given in order to save
the RAM parameters to non-volatile storage.
PAGE 6-79
T200 User's Manual
SECTION 6: T200 FUNCTIONAL OVERVIEW
6.14.1 Personality Plug
The Personality Plug (Part No.: C25226-001) is a module which allows permanent storage of all T200 user parameters.
The module allows the configuration of the T200 without a PC. I.e. in case a T200 need to be replaced in the field the
T200 can be configured in connecting the plug to the serial interface J4 and powering up the T200.
T200
RS232
PORT
(J4)
RS232
The following paragraphs describe saving and restoring of user parameters.
Saving using Windrive
•
Click on the ‘File’ menu then the ‘ Save to EEPROM’ option. Click on the ‘ Save’ button. When ‘ Successfully
saved to EEPROM’message pops up the process is complete. The plug can now be removed.
Saving using a Handheld terminal
•
At the ‘>’ prompt, type ‘ C’ and press the ‘ Enter’ key. When the ‘ >’prompt appears the process is complete. The
plug can now be removed.
When the configuration has been saved, the user should correctly identify the plug using the label supplied on the side of
the plug.
Saving the Custom Point Configuration
•
Establish communications using the MOOG EUI (Engineering User Interface) program.
•
Type the command ‘dbcontrol 2’ and press the ‘ Enter’ key. When the ‘* OK*’ message appears, the process is
complete. This will take several seconds, but when it has been completed the plug can then be removed.
When the configuration is restored from the plug, the configuration that is already
stored in the T200 Internal Flash will be over-written.
Care should be taken to ensure that the configuration is correct before activating the
motor as erratic behaviour can result.
Restoring a Configuration from the Plug
To restore the configuration, remove all power from the T200 drive. Insert the plug into connector J4 on the front of the
drive. It is recommended to apply only 24V power to the drive. The drive will then over-write the configuration in the
internal flash. If this is successful, these parameters will then used to configure the drive. In the case of an error, no error
code will be indicated on the display of the T200. The user should therefore verify that the configuration has been
loaded correctly using Windrive or a Handheld terminal before applying the 220VAC supply to the drive.
PAGE 6-80
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
6.14.2 Format of Log Files
An example .log files is shown below. It contains:-
§ A description of the application, date, user notes etc.
§ A Listing of the units which are used for Torque, Temperature, Current etc.
§ A parameter-by-parameter listing of values.
This file format is relatively easy to review and modify. The example listed below is intended to be indicative of the file
structure and is not rigorous in listing all T200 parameters.
;
;
;
;
;
;
;
;
File Name :
User Name :
Company :
Date :
Application :
Controller Type:
Software Version:
Comment :
AXIS12.LOG
B. McDuff
MOOG
13. September. 2000
Bend INC
T200-310
C09931-009
T200 Metal-bending Application at Bend INC
; Unit Information :
;*Torque=Nm
;*Temperature=DegC
;*Current=Arms
;*KT=Nm/Arms
;*Velocity=RPM
;*Inductance=mH
;*Inertia=kgcm2
; Motor Name (Block 12):
#12 = G424-400
; T200.CFG FILE
; Feb 17, 2000
CNFG.ACCESSPARAMS = TRUE
MOTOR.CURRENTLIM = 9.999904
MOTOR.CONTCURRENT = 4.800000
MOTOR.KT = 0.540000
MOTOR.NOMINALSPD = 5500.000000
OBS.INERTIA = 3.100000
MOTOR.POLES = 12
MOTOR.RTT = 2.700000
MOTOR.MAXIMUMSPD = 8000.000000
RESOLVER.POLES = 2
MOTOR.THERMPRES = TRUE
MOTOR.LD = 3.500000
MOTOR.LQ = 3.600000
MOTOR.ILOOPGAIN = 6
MOTOR.VDCBUS = 320.000000
MOTOR.CONFIG = TRUE
PAGE 6-81
T200 User's Manual
RES.OFFSET = 0.000000
CNFG.ACCESSPARAMS = FALSE
REFERENCESELECT = 1
ANALOG.OFFSET = 0.000000
VELOCITY.SCALE = 8000.000000
FG.VELOCITY = 0.000000
FG.TORQUE = 0.000000
FG.DUTYCYCLE = 50.000000
FG.VELOCOFFSET = 0.000000
FG.TORQUEOFFSET = 0.000000
FG.PERIOD = 1.000000
VELLOOPGAIN = 0.010000
INTEGRALTIMECONST = 0.200000
COMP.SELECT = 4
OBS.ENABLE = FALSE
FILTER.FREQ = 190.985931
MANUALMODEDISABLE = FALSE
LIMITSW.DISABLE = TRUE
QSTOP.DECEL = 10000.000000
FP.SIGNAL.TPA = 8
FP.SIGNAL.TPB = 1
IT.CONTCURRENT = 4.800000
IT.PEAKCURRENT = 9.999904
IT.TIME = 1.000000
THERMAL.SELECT = 2
RS485.USERAXISID = 0
NORMALTORQUELIMIT = 5.400052
REDUCETORQUELIMIT = 0.540005
NORMALVELOCTYLIMIT = 8000.000000
REDUCEVELOCTYLIMIT = 800.000000
WARNING.VELOCITY = 2000.000000
WARNING.VELOCITYTIME = 0.050000
RATELIMIT.TORQUE.RISETIME = 0.000400
RATELIMIT.TORQUE.MAX = 300.000000
RATELIMIT.ACCELTIME = 0.000400
RATELIMIT.VELOCITY.MAX = 10000.000000
ESM1.POSITONOFFSET = 0.000000
ESM1.LINECOUNT = 1024
ESM1.MARKERWIDTH = 1
POSITION.SCALE = 1.000000
VELOCITY.OFFSET = 0.000000
AUTOANALOG.OFFSET = FALSE
QUICK.STOP = FALSE
ENC.LINECOUNT = 0
ENC.ZEROMARKEROFFSET = 0
TRIGGER.ENABLE = 0
TRIGGER.FLAG = 0
TRIGGER.MODE = 0
TRIGGER.PREVDATA = 0
TRIGGER.LEVEL = 0
POSLOOPGAIN = 6.000000
POSLOOPINTTIMECONST = 50.000000
VELFEEDFORWARDGAIN = 0.000000
TORQUEFEEDFORWARDGAIN = 0.000000
PAGE 6-82
SECTION 6: T200 FUNCTIONAL OVERVIEW
SECTION 6: T200 FUNCTIONAL OVERVIEW
T200 User's Manual
FG.ACCEL = 100.000000
FG.TRAVERSE = 0.000000
FG.STOPFLAG = FALSE
ENC.LINECOUNT = 0
ENC.ZEROMARKEROFFSET = 0
DIGIN.REFVEL0 = 0.000000
DIGIN.REFVEL1 = 0.000000
DIGIN.REFVEL2 = 0.000000
DIGIN.REFVEL3 = 0.000000
STEPPERIN.SCALING = 0
STEPPERIN.COMMAND = 2
CAN.COMMCYCLEPERIODUS = 6000
CAN.COMMANDWINDOW = 2000
CAN.ACTUALWINDOW = 2000
CAN.POSITIONSCALING = 1
CAN.KBAUDRATE = 1000.000000
CAN.DIRECTIONFLAG = FALSE
CAN.MODE = 2
LIMIT.POSITION.CLK = 99999999
LIMIT.POSITION.CCLK = 99999999
LIMIT.POSITION.DISABLE = FALSE
LIMIT.SWITCH.DISABLE = TRUE
LIMIT.SWITCH.POLARITYFLAG = TRUE
BRAKEON.FAULTFLAG = TRUE
STATICLOOPERROR = 1000
FOLLOWINGLOOPERROR = 400
HOME.CRAWLSPEED = 200.000000
HOME.ANGLE = 0.000000
HOME.SWITCHACTIVELOW = FALSE
CAM.TABLEDATA = 0
CAM.TABLEBOUNDSIGN = FALSE
CAM.TABLEBOUND = 2147483648
GEARBOXN = 1
GEARBOXM = 1
REFMACHINEANGLEFLAG = TRUE
CAM.SUBINDEX = 0
GRAVITYTORQUE.OFFSET = 0.000000
EMERGENCYMODE.BRAKINGSPEED = 50.000000
EMERGENCYMODE.TORQUELIMIT = 5.400052
TRIPPOINT.VELOCITY = 800.000000
TRIPPOINT.VELOCITY.HYS = 20.000000
TRIPPOINT.TORQUE = 0.540005
TRIPPOINT.TORQUE.HYS = 0.250000
TRIPPOINT.ENABLE = FALSE
FILTER.DAMPING = 0.700000
ANALOGTORQUELIMIT.DISABLE = FALSE
SERVOSTOP.DRVDISABLEDELAY = 0.100000
DISABLEBRAKE.DELAYTIME = 0.250000
FAULTINDICATOR.MODE = 1
STEPPER.FOLLOWERROR.LIMIT = 819199
EXTREGEN.DISABLE = TRUE
EXTREGEN.RESISTANCE = 10.000000
EXTREGEN.CONTPOWER = 200.000000
EXTREGEN.DRVDISABLE = FALSE
PAGE 6-83
T200 User's Manual
INVERT.SYSTEMREADY = FALSE
INVERT.THERMALLIMIT = FALSE
PAGE 6-84
SECTION 6: T200 FUNCTIONAL OVERVIEW
SECTION 7: WINDRIVE
T200 User's Manual
SECTION 7: WINDRIVE
C27095-001
PAGE 7-1
T200 User's Manual
SECTION 7: WINDRIVE
TABLE OF CONTENTS
WINDRIVE.....................................................................................................................................................................7-1
7.1
INTRODUCTION.................................................................................................................................................7-6
7.2
WINDRIVE SOFTWARE SET-UP ........................................................................................................................ 7-6
7.2.1
System Requirements................................................................................................................................ 7-6
7.2.2
Installation ................................................................................................................................................7-6
7.3
STARTING WINDRIVE ......................................................................................................................................7-7
7.3.1
Communication Link between WinDrive and Drive ................................................................................7-7
7.4
RS232 AND RS485 COMMUNICATION .............................................................................................................7-9
7.4.1
RS232 Connection ..................................................................................................................................7-10
7.4.2
RS485 Communication........................................................................................................................... 7-11
7.4.2.1
7.4.2.2
RS485 Interfacing Connection ............................................................................................................................. 7-11
RS232/RS485 adapter...........................................................................................................................................7-12
7.5
PASSWORD PROTECTION ............................................................................................................................... 7-13
7.5.1
Off-line Mode .........................................................................................................................................7-15
7.5.2
Switching Between Communications modes.......................................................................................... 7-15
7.5.3
WinDrive On-line Help System..............................................................................................................7-15
7.6
MAIN WINDOW - FEATURES .......................................................................................................................... 7-16
7.6.1
Function Keys .........................................................................................................................................7-17
7.6.2
Shortcut Keys..........................................................................................................................................7-17
7.7
GENERAL FEATURES......................................................................................................................................7-17
7.7.1
Floating Toolbar .....................................................................................................................................7-17
7.7.2
WinDrive Help System ........................................................................................................................... 7-17
7.7.3
Main Window Button Console ...............................................................................................................7-18
7.7.4
Data Logger ............................................................................................................................................7-18
7.7.5
Auto Tuning (Velocity Mode Only) .......................................................................................................7-18
7.8
MENU OPTIONS ..............................................................................................................................................7-19
7.8.1
File Menu Options ..................................................................................................................................7-19
7.8.2
Drive Menu Options ............................................................................................................................... 7-20
7.8.3
Log Files Menu Options ......................................................................................................................... 7-21
7.8.4
Data Logger Menu Options..................................................................................................................... 7-22
7.8.5
Low Level Menu Options ....................................................................................................................... 7-22
7.8.6
Plots Menu Options.................................................................................................................................7-22
7.8.7
View Menu Options................................................................................................................................ 7-23
7.8.8
Help Menu Options.................................................................................................................................7-23
7.9
WINDRIVE MONITORING FEATURES ............................................................................................................7-24
7.9.1
Data Logger ............................................................................................................................................7-24
7.9.2
Engineering User Interface ..................................................................................................................... 7-26
7.9.3
Block Data ..............................................................................................................................................7-26
7.9.4
Manual Block Operations ....................................................................................................................... 7-27
7.9.5
Front Panel Test Points ........................................................................................................................... 7-27
7.9.6
Drive Status.............................................................................................................................................7-28
7.9.7
Fault Status .............................................................................................................................................7-29
7.9.8
Fault History ...........................................................................................................................................7-30
PAGE 7-2
SECTION 7: WINDRIVE
T200 User's Manual
7.10 DRIVE SET-UP ................................................................................................................................................ 7-31
7.10.1
Basic Velocity Mode Drive Set-up......................................................................................................... 7-31
7.10.1.1 Units Set-up ............................................................................................................................................................. 7-31
7.10.1.2 Select Motor Dialog Box .........................................................................................................................................7-32
7.10.1.3 Reference Source Selection......................................................................................................................................7-34
7.10.1.4 Reference Rate Limit Set-up ....................................................................................................................................7-38
7.10.1.5 Normal and Reduced Power (Automatic and Manual Mode) Limits Set-up............................................................ 7-38
7.10.1.6 Hardware Limit Switches Set-up ............................................................................................................................. 7-39
7.10.1.7 Drive Tuning ............................................................................................................................................................ 7-40
7.10.1.8 Encoder Simulation (ESM) ......................................................................................................................................7-40
7.10.1.9 Regen (Brake) Resistor Configuration ..................................................................................................................... 7-40
7.10.1.10 Saving a Configuration to Non-Volatile Storage....................................................................................................7-41
7.10.2
Torque Mode Operation ......................................................................................................................... 7-42
7.11 CONTROL LOOP CONFIGURATION AND TUNING .......................................................................................... 7-43
7.11.1
Control Mode Selection.......................................................................................................................... 7-43
7.11.2
Torque Mode Tuning.............................................................................................................................. 7-45
7.11.3
Velocity Loop Tuning ............................................................................................................................ 7-45
7.11.3.1 Combined Tuning Window......................................................................................................................................7-45
7.11.4
Advanced Options .................................................................................................................................. 7-46
7.11.4.1 Velocity Estimation.................................................................................................................................................. 7-46
7.11.4.2 Control Mode ........................................................................................................................................................... 7-47
7.11.5
Auto Tuning (Velocity Loop Only)........................................................................................................ 7-48
7.11.5.1 Auto Tuning System Parameters.............................................................................................................................. 7-48
7.11.5.2 Auto Tuning Advanced Options .............................................................................................................................. 7-49
7.11.6
Tracking Monitoring .............................................................................................................................. 7-50
7.11.7
Position Loop Tuning............................................................................................................................. 7-50
7.12 INCREMENTAL ENCODER INPUT CONFIGURATION ...................................................................................... 7-51
7.13 EQUIPMENT AND PERSONAL SAFETY ........................................................................................................... 7-52
7.13.1
Manual Mode / Automatic Mode ........................................................................................................... 7-52
7.13.2
IT Thermal Limits .................................................................................................................................. 7-52
7.14 DRIVE DISABLING.......................................................................................................................................... 7-53
7.15
PROGRAMMABLE BEHAVIOUR OF OUTPUTS ................................................................................................ 7-53
7.16
BRAKE CONTROL .......................................................................................................................................... 7-54
7.17
TROUBLE SHOOTING ..................................................................................................................................... 7-54
PAGE 7-3
T200 User's Manual
SECTION 7: WINDRIVE
Section 7 Table of Figures
Figure 7.1: Communication Port Dialog Box ................................................................................................................... 7-8
Figure 7.2: Adapter between PC and RS232/RS485 Adapter......................................................................................... 7-12
Figure 7.3: Password Dialog Box ...................................................................................................................................7-13
Figure 7.4: Controller Type (offline) Dialog Box...........................................................................................................7-15
Figure 7.5: WinDrive Main Window.............................................................................................................................. 7-16
Figure 7.6: Floating Toolbar ...........................................................................................................................................7-17
Figure 7.7: Main Configuration Console ........................................................................................................................ 7-18
Figure 7.8: File Menu Options........................................................................................................................................7-19
Figure 7.9: Drive Menu and Drive/Set-up Menu Options .............................................................................................. 7-20
Figure 7.10: Log Files Menu Options............................................................................................................................. 7-21
Figure 7.11: Data Logger Menu Options ........................................................................................................................ 7-22
Figure 7.12: Low Level Menu Options........................................................................................................................... 7-22
Figure 7.13: Plots/Display Menu Options....................................................................................................................... 7-22
Figure 7.14: Plots/Grid Lines Menu Options.................................................................................................................. 7-23
Figure 7.15: View Menu Options ...................................................................................................................................7-23
Figure 7.16: Help Menu Options ....................................................................................................................................7-23
Figure 7.17: About MOOG WinDrive Dialog Box ........................................................................................................7-23
Figure 7.18: Data Logger Set-up Dialog Box .................................................................................................................7-24
Figure 7.19: Trigger Flag Set-up Dialog Box .................................................................................................................7-25
Figure 7.20: Data Logger Run Dialog Box..................................................................................................................... 7-25
Figure 7.21: Engineering User Interface (EUI) Dialog Box ........................................................................................... 7-26
Figure 7.22: Block Data Dialog Box .............................................................................................................................. 7-26
Figure 7.23: Manual Block Operations Dialog Box .......................................................................................................7-27
Figure 7.24: Front Panel Test Points Dialog Box ...........................................................................................................7-27
Figure 7.25: Drive Status Dialog Box............................................................................................................................. 7-28
Figure 7.26: Fault Status Dialog Box ............................................................................................................................. 7-29
Figure 7.27: Fault History Dialog Box ........................................................................................................................... 7-30
Figure 7.30: Fault History Upload Dialog Box...............................................................................................................7-30
Figure 7.31: Units Dialog Box........................................................................................................................................7-31
Figure 7.32: Select Motor Dialog Box............................................................................................................................ 7-32
Figure 7.33: Nonstandard Motor Parameters Dialog Box............................................................................................... 7-33
Figure 7.34: Reference Source Dialog Box .................................................................................................................... 7-34
Figure 7.35: Analog Input Dialog Box ........................................................................................................................... 7-35
Figure 7.36: Function Generator Dialog Box .................................................................................................................7-35
Figure 7.37: CAN Dialog Box ........................................................................................................................................7-36
Figure 7.38: Digital Speed Input Dialog Box .................................................................................................................7-37
Figure 7.39: Stepper Input Dialog Box ........................................................................................................................... 7-37
Figure 7.40: Rate Limit Dialog Box ............................................................................................................................... 7-38
Figure 7.41: Limits Dialog Box ......................................................................................................................................7-39
Figure 7.42: Limit Switches Dialog Box ........................................................................................................................ 7-39
Figure 7.43: Encoder Simulation Dialog Box.................................................................................................................7-40
Figure 7.44: Regen Resistor Configuration Dialog Box .................................................................................................7-41
Figure 7.45: Save to EEPROM Dialog Box ................................................................................................................... 7-41
Figure 7.46: Tuning Dialog Box .....................................................................................................................................7-43
Figure 7.47: Combined Tuning Main Screen View ........................................................................................................7-45
Figure 7.48: Advanced Options Dialog Box................................................................................................................... 7-46
Figure 7.49: Auto Tuning Dialog Box ............................................................................................................................ 7-48
Figure 7.50: Auto Tuning System Parameters Dialog Box............................................................................................. 7-49
Figure 7.51: Advanced Options (Auto Tuning) Dialog Box........................................................................................... 7-49
Figure 7.52: Tracking Monitoring Dialog Box ...............................................................................................................7-50
Figure 7.53: Encoder Dialog Box ...................................................................................................................................7-51
Figure 7.54: Limits Dialog Box ......................................................................................................................................7-52
PAGE 7-4
SECTION 7: WINDRIVE
T200 User's Manual
Figure 7.55: IT Thermal Limits Dialog Box .................................................................................................................. 7-52
Figure 7.56: Invert System Ready Relay / Thermal Limit Output Dialog Box.............................................................. 7-53
Figure 7.57: Apply Brake and Release Brake options on the Drive Menu .................................................................... 7-54
Section 7 Table of Tables
Table 7.1: Wiring of PSM-EG-RS232/RS485-P/2D ...................................................................................................... 7-12
Table 7.2: Available Units ............................................................................................................................................. 7-31
Table 7.3: Digital Input Speed Programming................................................................................................................. 7-37
PAGE 7-5
T200 User's Manual
SECTION 7: WINDRIVE
7.1 Introduction
Two user interface options are available:
a.) Graphical User Interface, WinDrive System.
b.) Hand Held Terminal. This is described in Section 8.
The WinDrive Graphical User Interface (GUI) is a standard windows based product used with MOOG’s T200 ServoDrive. WinDrive is used as a tool for the user friendly configuring, tuning and monitoring of a T200.
NOTE: The Hand-Held terminal device uses the same RS232 link to the T200 as
the PC. The drive cannot communicate via both interfaces (PC and Hand Held
Terminal) at the same time.
7.2 WinDrive Software Set-up
7.2.1
System Requirements
Minimum PC requirement
486 DX/2-66 processor,
8Mb RAM,
6Mb free on hard disk.
Operating System -
Windows 3.1 or 3.11 (with MS-DOS version 3.1 or later),
Windows 95 or Windows NT (version 4.0 or later).
Screens sizes to fit -
640x480 display,
A VGA resolution video adapter.
7.2.2
Installation
To Install WinDrive, run the setup program on the distribution disks. This can be done using File Manager or Explorer,
by double clicking on the setup executable, or by selecting Run from the File menu. For example, if the distribution
disk is in drive A, then select/run the file A:\setup.exe. All other Windows programs should be closed when installing
WinDrive, because the installation program needs to change certain Windows configuration files.
The installation program indicates the progress of the installation to the user, and allows for various installation options:
•
The default target directory for WinDrive is C:\WINDRIVE. This directory can be modified if required.
•
If any files in the target directory have the same name as those being taken from the distribution disk, the user is
prompted to overwrite or cancel the copying of that file.
When the installation is complete, a new program group (MOOG WinDrive) will be created. The group will contain
the WinDrive program (i.e. WINDRIVE.EXE), the WinDrive Help File (WINDRIVE.HLP), a Text File
(README.TXT). For Windows 3.11, an uninstall utility is also placed in the group. Additional files are installed
which are not listed in the group. The names and purpose of these files are listed in this help. The group will be added
to the program task bar under Windows 95/NT, or will be added as a group icon under Windows 3.1.
PAGE 7-6
SECTION 7: WINDRIVE
T200 User's Manual
When setup is complete, remove the WinDrive Distribution Disk and reboot the PC. WinDrive can be run by double
clicking on the WinDrive icon.
WinDrive can be uninstalled if required. In Windows 3.1 select the uninstall Icon in WinDrive’s group. In Windows
95/NT select the Add/Remove Programs within the Control Panel.
7.3 Starting WinDrive
WinDrive can be run by double-clicking on the MOOG WinDrive icon under Windows 3.1, or selecting it from the
Programs Task Bar under Windows 95/NT. When WinDrive is loading up, the WinDrive Logo is displayed, and the
contents of WINDRIVE.INI are extracted:
1.
If there are any problems in reading this file, an error message is displayed. Otherwise it will load and check the
contents of a parameter database file specified by windrive.cmd.
2.
It will then load and check the contents of configuration files specified for each Drive type (.cfg extensions).
3.
WinDrive will then load and check the contents of motor database files (.mot extensions).
4.
It will also extract information relating to Communications port, Data Logger, Tuning options etc.
Finally, if there are no errors in these files, dialog pop-ups prompt the user to configure the Communication Link
between WinDrive and the T200.
7.3.1
Communication Link between WinDrive and Drive
WinDrive uses the serial port of a PC to communicate with a drive via the MOOG “Set-up Link” protocol, using RS232
or RS485 serial standards. WinDrive software and the physical link between the PC and the drive must both be
configured correctly.
NOTE - The T200 requires some time to start communications after power-on or reset. Approximately
15s should be allowed after power-on or reset before establishing serial communications with the T200. A
special start-up sequence is required to place the T200 in WinDrive communication mode. (This is
necessary because WinDrive must send a particular character sequence (Ctrl P, S, C (0x10, 0x53, 0x43) )
to switch the drive into the required set-up Link Protocol). This sequence is transmitted by WinDrive
immediately after a communications port is selected. The T200 will accept this sequence only after selfinitialization is complete. T200 self-initialization takes approximately 15s.
PAGE 7-7
T200 User's Manual
SECTION 7: WINDRIVE
NOTE on Communications Robustness between WinDrive and T200.
MOOG has made the communication between WinDrive and T200 as robust as possible by
implementation of message error checking, and message-retransmission upon errors, as well as message
time-out checking. Due to the wide variation in operating conditions under different versions of Windows
and PC configurations, the user may experience occasional difficulties in establishing secure
communications.
In particular, to re-establish communications after power has been removed from a T200, ensure that the
WinDrive time-out message has appeared before re-applying power to the T200. If this is not done, then
the user may experience intermittent Windows General Protection faults. If such an error occurs, the user
should remove all power from the T200, re-apply power, then wait until the T200 has completed selfinitialisation, before resetting communications from WinDrive.
When WinDrive is started, the user is first prompted to select from
one of 4 possible Comm -Ports on the PC in order to set WinDrive
in On-line mode with the drive, or alternatively to operate the GUI
in Off-line mode.
•
•
If one of the Comm-Ports is selected, the user is prompted to
select the Recommended Standard (RS) type, as either RS232
or RS485. The Comm-Port configuration is fixed to match the
serial requirements of a drive and operates always at
•
9600 Baud, with
•
No parity,
•
8 Data bits and
•
1 Stop Bit.
•
If RS485 is selected the user is also prompted to
select the RS485 Axis Address.
If Off-line is selected, the user is prompted to select from one
of the three supported drives (T161 RMC, T164 DMC or
T200).
Figure 7.1: Communication Port Dialog Box
NOTE - If the wrong communications port is selected, WinDrive will time-out after several
seconds and display an error message box asking if off-line operation is required. This time-out
will take approximately 20seconds, as 4 attempts to communicate are made, each lasting 5
seconds.
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SECTION 7: WINDRIVE
T200 User's Manual
7.4 RS232 and RS485 Communication
RS232 is a serial data standard, which allows WinDrive to communicate directly to a single drive. Both WinDrive
software and the physical link between the PC and the Drive must be configured correctly, in order to establish
communication.
The RS-Type must be set as RS232 at WinDrive start-up. If the user is unsure of the RS-Type, the RS-Type can be reset
by selecting the Low Level/Reset Comm menu item. WinDrive then sends the initial character sequence (Ctrl P,S,C) to
the drive, to switch into the required protocol. WinDrive generates requests to determine the drive type, motor and
software version. A timeout of 20 seconds is implemented on these requests, which will result in an error message if
WinDrive is unable to establish communication.
An RS232 connection must be made between the selected Comm-Port of the PC and the Serial Port 9-Way D-Type
connector J4 on the front panel of the drive.
PAGE 7-9
T200 User's Manual
7.4.1
SECTION 7: WINDRIVE
RS232 Connection
The RS232 port of the drive is configured as a modem. The connector pins on the Serial Port 9-way D-Type connector
on the front-panel of the drive are as follows:
Pin 2
RS232 Receive Rx
Pin 3
RS232 Transmit Tx
Pin 5
Signal Ground
The diagrams below show the wiring required for an RS232 cable between a PC and drive.
Drive to 9 Way D Type (Terminal Equipment)
Drive
PC with Terminal
Comm-Port
Drive to 9 Way D Type (Modem Equipment) See note below.
Drive
PC with Modem
Comm-Port
NOTE Modem Equipment configuration is what is typically used with most
IBM compatible PC’s.
Drive to 25 Way D Type (Terminal Equipment)
Drive
PC with Terminal
Comm-Port
Drive to 25 Way D Type (Modem Equipment)
Drive
PC with Modem
Comm-Port.
NOTE: D type lead is available from MOOG. MOOG’s Order part Number is B75923 .
PAGE 7-10
SECTION 7: WINDRIVE
7.4.2
T200 User's Manual
RS485 Communication
RS485 is multidrop serial data standard, which allows WinDrive to communicate with a number of T200's, each of
which has a unique Axis Address. The communications protocol is the same as for the RS232 link but demands that the
drive address identifier be included in order to address individual T200's.
NOTE When using WinDrive, the RTS line of the PC Communications Port
should not be used to enable the Transmitter of the adapter.
The RS-Type must be set as RS485 at WinDrive start-up. If unsure of the RS-Type, it can be reset by selecting the Low
Level/Reset Comm menu item. The RS485 Axis Address must also be set at WinDrive start-up. This dialog allows the
user to select the axis number, and also allows for a drop-down list of all previously accessed axes off the RS485 line.
WinDrive then sends the initial character sequence (Ctrl P,S,C) to the drive, to switch into the required protocol.
WinDrive generates requests to determine the drive type, motor and software version. A timeout of 20 seconds (i.e.
including 3 retries) is implemented on these requests, which will result in an error message if WinDrive is unable to
establish communication.
RS485 communication is achieved by using an RS232/RS485 adapter or converter. The RS232 side of the converter is
connected to the selected Comm-Port of the PC. The RS485 side of the converter is connected to the drive via the RS485
port of the drive.
7.4.2.1 RS485 Interfacing Connection
RS485 communication is achieved by interfacing a suitable RS232/85 adapter between the PC and drive. Important
aspects of the connection are that:
• Some RS232/RS485 adapter manufacturers suggest the use of RTS line on the PC’s communications port, to enable
the transmitter of the adapter. WinDrive does not control the RTS line, due to the fact that the RTS line cannot be
accurately controlled because of latencies in the Windows Operating System.
• WinDrive expects and requires a local echo (Receiver sees what is transmitted) to be sent from an RS232/RS485
adapter.
Adapter Requirements
The following adapter and cable requirements should be met by any adapter which is used with WinDrive.
• Half Duplex Operation (Data Signals are both transmitted and received on two pairs wired in parallel (i.e.
Tx/Rx (A) = RS485+, and Tx/Rx (B) = RS485-).
• Method of Enabling of Transmitter.
• Tx+ and Tx- Pull up/down resistors, (recommended values depend on adapter used).
• Screened twisted pair (nominal impedance 120 Ohms).
• Cable end termination with 120Ω resistors if cable length is over 20m.
In Half Duplex operation, the RS232/RS485 adapter must be able to enable its transmitter when the adapter is ready to
transmit, and disable (i.e. tri-state) the transmitter when the adapter is ready to receive. Some adapters will use the RTS
line from a PC, or other external signals, as an enable signal to the transmitter. Other adapters will implement the
enabling of the transmitter internally.
PAGE 7-11
T200 User's Manual
SECTION 7: WINDRIVE
Example of PC Interface
If an external signal is required to enable the transmitter of the adapter, the Transmit Data pin from the PC can be used
as an enable pin. An adapter can be wired to ensure that the transmitter is enabled when data is sent, thus actively
driving Highs on the RS485 line.
If the RTS line is used by the RS232/RS485 adapter, the following adapter can be placed between the PC
Communications port, and the RS232/485 converter. WinDrive uses only the Transmit Data, Receive Data, and Signal
Ground Pins on the PC Communications port.
PC ComPort
9-Way D-Type
(Female)
RxD
TxD
Gnd
RTS
2
3
5
7
NC
2 RxD
3 TxD
5 Gnd
7 RTS
9-Way D-Type (Male)
to Plug into Converter
Figure 7.2: Adapter between PC and RS232/RS485 Adapter
For details of wiring for a specific RS232/RS485 adapter, consult the data-sheet for the particular device.
7.4.2.2 RS232/RS485 adapter
The RS232/RS485 adapter recommended by MOOG for operation with WinDrive and the RMC/DMC and T200 is
PSM-EG-RS232/RS485-P/2D, PN2761392 from Phoenix Contact.
PC COMM PORT
1
2
3
5
SIGNAL
SHLD
RXD
TXD-RTS
GND
9-PIN D
NC
2
3&7
5
PHOENIX RS232
COMBICON
NC
5
4&7
8
T200 RS485
4
5
6
SIGNAL
RS485 +
RS485 GND
9-PIN D
3
8
2-7
PHOENIX RS485
COMBICON
6
8
4
Table 7.1: Wiring of PSM-EG-RS232/RS485-P/2D
For further information consult MOOG applications engineering.
PAGE 7-12
T200 User's Manual
SECTION 7: WINDRIVE
7.5 Password Protection
This dialog box appears at system start-up and is used to enter a User Password. Two levels of user access are supported:
•
Access Level 0 = General User Access (Enable, Disable, and Monitor a Drive).
•
Access Level 1 = Privileged User Access (Drive Tuning and Configuration plus all Access Level 0 privileges).
If a valid User Password is not accepted by the servo-drive, Access Level 0 will be invoked by default. At this level,
changes to configuration and tuning parameters are not allowed.
NOTE: Access Level 1, Privileged User Access shall be restricted to technically
qualified service and maintenance persons only.
Required for
CE-Compliance
Figure 7.3: Password Dialog Box
The Password must be a number between 0 and 9999 and is set to 0 when the MOOG WinDrive compatible servo-drive
software is shipped. If password protection is not desired, this value should not be changed (just enter 0 and select OK).
If password protection is desired, the User password should be changed via the Password Change dialog box and saved
to EEPROM (under the File menu). Once saved to EEPROM this password MUST BE KNOWN AND
REMEMBERED by each User requiring configuration and tuning access (Access Level 1) for a specific servo-drive.
NOTE - In off-line mode, the password capability is disabled and the Password dialog box
does not appear at start-up.
If the saved password is forgotten, a MOOG Application Engineer must be called to reset the saved User Password to a
known value.
NOTE - If the Changed Password is not saved to EEPROM using Save To EEPROM in the File
Menu, it will only be valid while power to the servo-drive is maintained.
PAGE 7-13
T200 User's Manual
SECTION 7: WINDRIVE
To change a saved password, the old password is entered in the Password Dialog box. The Change Password Dialog box
may then be displayed by selecting the Change button in the Password Dialog box. The new numeric value should be
entered in the Password field and the OK button selected. A message will appear informing the user that the User
Password has been changed.
PAGE 7-14
SECTION 7: WINDRIVE
7.5.1
T200 User's Manual
Off-line Mode
Off-line Mode occurs when the PC communications port is not
connected to a servo-drive, the servo-drive is not powered on, or the
User has selected Off-line in the Communications Port Dialog box.
In off-line mode, the Password Dialog box will not appear since no
actual servo-drive configuration or tuning can take place. Instead, a
Controller Type Dialog box is shown, from which the desired
controller type should be selected. Items in the various menu bars will
be “greyed out” when not applicable to the selected servo-drive.
Access to the WinDrive Main Screen is available after selecting the
Figure 7.4: Controller Type (offline) Dialog
controller type.
Box
NOTE - In on-line mode the servo-drive type is
read automatically from the drive.
7.5.2
Switching Between Communications modes
If the user needs, at any stage, to switch between communications ports (if more than one drive is being configured in
RS232 mode), Reset Comms should be selected from the Low Level Menu. The user can also work off-line at any
stage by selecting Set Offline from the Low Level Menu. When operating in RS485 mode, multiple servo-drives may
be configured individually by selecting Select Axis from the Drive Menu. If an Enable, Disable or Stop command is
required to be sent to all connected servo-drives, Broadcast should be selected from the Drive Menu.
7.5.3
WinDrive On-line Help System
The WinDrive Help System is started from the File Manager by clicking on the Help Icon, or when WinDrive is
running, by pressing the F1 key or from the Help Menu. Starting the Help system in any of these ways opens the Help
Contents Dialog box which features a list of Help topics. Clicking on any of these topics opens a dialog box with a list of
related topics.
When help is required for a specific subject, Search should be selected from the Help Menu. The Help contents will be
listed in alphabetical order, double click on the item and then select it from the Topic Window. Click on Go To to open
the appropriate Help Dialog box.
Help may also be started from all of WinDrive’s dialog boxes. Click on the Help button in the dialog box to open the
specific Help file for that dialog box.
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SECTION 7: WINDRIVE
7.6 Main Window - Features
The WinDrive Main window is divided into several sections:
§ Outer Frame - Standard Microsoft Windows Frame with minimise/maximise and exit Icons.
§ Menu Bar - Pull-down menus to access all WinDrive features.
§ Main Tool Bar - Icon buttons for various functions and commands.
§ WinDrive Status Bar 1 - Compensator Mode/Drive Status/Fault Status/Axis ID (RS485).
§ Main Window Button Console - Six buttons to access the primary configure/tune dialog boxes.
§ Data Logger Plots - Contains the output of two data logging channels for drive parameters.
§ Log File Display - Displays log file contents while recording, or a previously recorded log file.
§ WinDrive Status Bar 2 - Read & Writes/Drive State/Limit Switches/GUI Mode/Logging/ Communications.
§ PC Interface Bar - Tool Bar Help/Caps Lock/Num Lock/Scroll Lock.
§ Floating Toolbar (when enabled) - Quick Stop/Enable Drive/Disable Drive buttons.
Figure 7.5: WinDrive Main Window
PAGE 7-16
SECTION 7: WINDRIVE
T200 User's Manual
The Main Window Button Console, Log File Display, and Data Logger Plots sections are part of a three way “splitter
window”. The mouse cursor converts to a vertical or horizontal bar as it moves over these vertical or horizontal window
dividers. The size of each split section can be changed, by holding down the left mouse button and moving the window
divider. The Button Console window has a minimum size, regardless of the application size.
7.6.1
Function Keys
F1 is used to open the WinDrive Help System. If there are no dialog boxes open, the Help Contents Page is displayed
when the F1 key is pressed. If the F1 key is pressed while a dialog box is open and active, Help for that specific dialog
box is displayed. Selecting the Help button within a dialog box has the same result.
F2 is used to Quick Stop (servo stop) a turning motor. The drive is still enabled after F2 is pressed and its position held
constant. The drive must first be disabled before it can be enabled again to re-start the motor.
F3 is used to Enable a T200. If a reference source has been set-up, the motor should begin turning when the drive is
enabled.
F4 is used to Disable a T200. If a motor is turning when F4 is pressed, the motor will stop.
7.6.2
Shortcut Keys
Each of the WinDrive pull-down menus can be opened via the “Alt” key and the underlined letter in the menu option.
E.g. the “Alt” and “F” key combination is used to open the File Menu. Once a given menu is displayed, the items inside
can be selected by pressing a single keyboard letter.
Various dialog boxes can also be directly opened using a second set of “Shortcut Keys”. If a menu item has this alternate
shortcut key access, the key sequence will be displayed to the right of the menu item. The mouse can also be used to
select menu options.
7.7 General Features
7.7.1
Floating Toolbar
The Floating Toolbar can be enabled by using the View/Floating Toolbar menu
item, or by pressing the Ctrl+F key combination. The toolbar is always on top
when enabled, and can be moved as required about the screen. Drive Quick Stop
(F2), Drive Enable (F3), and Drive Disable (F4) commands are accessible from
the Floating Toolbar. The buttons can be selected with the mouse or the
appropriate function key. The (always on top) Floating Toolbar operates
exclusively in the foreground, and may still be used if WinDrive is being run as a
background task (the WinDrive application window must not be minimised within
Windows for this feature to work).
7.7.2
Figure 7.6: Floating Toolbar
WinDrive Help System
On-line assistance is provided to the WinDrive user by the Help system. The WinDrive Help system can be accessed via
Contents under the Help Menu, the F1 key, or the Help button on each dialog box. Details of each WinDrive dialog
box, field, and button are available from the Help system.
Shift-Up/Down Arrow and Shift Right/Left Arrow keys can be used to select splitter window bars. Subsequent use of
Up/Down arrows can be used to move the splitter bars. The Tab key can also be used to toggle focus between dialog
boxes in the View Menu.
PAGE 7-17
T200 User's Manual
7.7.3
SECTION 7: WINDRIVE
Main Window Button Console
The Main Window Button Console allows for
quick access to the most frequently used dialogs. It
consists of six icons which are selected in order to
set, or adjust the main parameters required to
configure a T200. From the Main Window Button
Console, the Reference Source, Tuning Parameters,
Velocity and Torque Limit values, Motor Type and
parameters, Limit Switch and Encoder settings may
be viewed and altered.
The functionality of the Button Console changes,
dependent upon whether the T200 is in Configure
or Tune mode. For example, if the T200 high
power is enabled, setup of a motor is not allowed.
Figure 7.7: Main Configuration Console
7.7.4
Data Logger
The behaviour of a motor and servo-drive can be observed using the Data Logger Function. Two user configurable
channels, for servo-drive and motor feedback, are provided to plot data in the Data Logger Plots Window. Logging of
data begins either when the Data Logger is triggered by the user set trigger signal, or is automatically updated on a
regular basis.
7.7.5
Auto Tuning (Velocity Mode Only)
Auto Tuning greatly reduces the time needed to configure and tune the T200's velocity loop gain parameters (Note that
the Auto Tuner sets the velocity loop gains only). Auto Tuning tunes a drive automatically by applying a torque
excitation signal to the motor. The motor response data is used to determine the characteristics of the motor and load,
and in turn is used to tune the drive. Minimum input is required from the user. The user is prompted if he wishes to
continue at all stages of the Auto Tuning process. Note that Auto Tuning is described in detail in Section 6.6.2.10.
PAGE 7-18
SECTION 7: WINDRIVE
T200 User's Manual
7.8 Menu Options
7.8.1
File Menu Options
•
Open - Opens a previously saved log (file extension *.log) or Data Logger (file extension *.mdl) file.
•
Save - Saves the current Data Logger or log file data to disk for future use.
•
Print Plots - Three options are available from the Print Plots option:
1.
Print Graph - Prints the selected plot.
2.
Print Page - Prints plots for both Data Logger channels.
3.
Print Options - Allows printing parameters to be changed.
•
Print Logfile - Prints the current log file.
•
Print Setup - Printer and printing options are configured using Printer Setup.
•
Save to EEPROM - Saves the current drive configuration to the servo-drive
non volatile storage.
•
Configuration Upload - Transfers the drive parameters listed in the *.cfg file
from the drive to a specified log file.
•
Configuration Download - Transfers parameters stored in a *.log file to the
drive.
•
Passwords - Allows the set-up and changing of servo-drive access passwords.
•
Exit - Exits the WinDrive system.
Figure 7.8: File Menu Options
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7.8.2
SECTION 7: WINDRIVE
Drive Menu Options
Set-up – The following options are available
from the Set-up option:
Ø Reference Source - Set the
reference source for the servo-drive.
Ø Tuning - Adjust the drive tuning
parameters.
Ø Limits - Set and adjust torque and
velocity limits.
Figure 7.9: Drive Menu and Drive/Set-up Menu Options
Ø Motor - Motor parameters are entered using this option. For standard MOOG motors, parameters are selected
automatically from a motor parameter database. A number of MOOG non-standard motors is listed in the nonstandard motor database. Parameters for motors not listed in either of the databases, must be entered by the
user.
Ø Limit Switches - Limit Switches may be enabled or disabled using this option and the quick stop deceleration
entered or adjusted.
Ø Encoder Simulation - Sets and adjusts Encoder Simulation parameters.
Ø Encoder - Encoder input parameters are set by the user with this option.
Ø Front Panel Test Points - Two user configurable test points are available at the T200 Axis Signals connector,
J1. The Front Panel Test Points option determines the output signal type at each test point.
Ø Advanced Options - Used for more precise drive tuning.
Ø IT Thermal Limits - Sets and adjusts the IT (current/time) thermal limits. If thermal foldback is being used,
this option will be disabled.
Ø Combined Tuning - Combined Tuning opens a dialog box featuring tuning constants, function generator
parameters and Data Logger options. Use of this option avoids skipping back and forth between dialog boxes
whilst configuring a drive.
Ø Auto Tuning - Having entered servo-drive and motor information, Auto Tuning is used to tune a motor servodrive combination automatically.
NOTE - While the Auto Tuning feature tunes a drive to a high degree of accuracy, for
optimum performance, manual tuning should be used. Auto Tuning will always tune the T200
control loop parameters so that there is some safety margin in the controlled system.
Ø Regen Resistor - This dialog enables the user to configure the T200 for an internal or external Regeneration
(Regen) Resistor, as well as determine the behaviour should the maximum regen power be exceeded.
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SECTION 7: WINDRIVE
Ø Invert System Ready Relay / Thermal Limit Output - For certain applications, it can be desirable to invert
the polarity of the System Ready Relay or Thermal Limit Output. These can be set in this dialog.
•
Basic DriveSetup - A basic drive set up is the fastest means of manually tuning and configuring a drive. All
parameters essential for the basic set-up are set by the user.
•
Quick Stop - Performs the same function as the F2 key or the Stop button of the Floating Toolbar. This function
performs a servo-stop on the connected motor.
NOTE - The drive must be disabled before normal drive operation can be
resumed, after a Quick Stop has been activated.
•
Enable Controller - The enable controller function is available by pressing F3, pressing the Enable button on the
Floating Toolbar and from the Drive Menu. This function enables the servo-drive to switch power to the connected
servomotor.
•
Disable Controller - Also available from the Floating Toolbar or by pressing F4, the disable function removes
power from the motor.
•
Broadcast (RS485 only) - Broadcast transmits Stop, Enable and Disable commands to every servo-drive in an
RS485 daisychain communications interface.
•
Select Axis (RS485 only) - When operating in RS485 mode, each servo-drive is assigned an axis-identification
number via the two Hex switches on the T200 servo-drive. Select Axis (RS485 only) determines which servo-drive
is interfaced by WinDrive.
•
Drive Status - Drive Status provides a table of current servo-drive data.
•
Fault Status - Fault Status provides an overview of drive faults and warnings.
•
Fault History - Fault History provides a list of errors recorded by the controller.
•
Torque/Speed Trip Point - This dialog allows the user to set trip-points (which will in turn set digital outputs
high), when torque or velocity exceed certain value ranges around a particular set-point.
•
Extended Function Cards - Extended Function Cards displays which option cards have been detected by the
WinDrive software.
•
System Parameters - This option is only available in on-line mode and when Auto Tuning has been performed. It
displays the full set of system parameters.
•
Apply Brake - Applies the optional motor brake.
•
Release Brake - Releases the optional motor brake.
•
Units - The units in which WinDrive displays torque, temperature, current, kt (torque constant), velocity,
inductance and inertia may be changed with this option.
7.8.3
Log Files Menu Options
• Start Record - In order to begin writing a log file, the Start Record option is
selected. The log file window is automatically updated as new parameters and commands
are entered. Current units are written to the window as soon as Record is selected.
•
Stop Record - On completion of log file recording, Stop Record is selected.
• Clear Record - Clear record is used to erase the Log File Display Window. A Save
option is displayed before the current log file is cleared.
Figure 7.10: Log Files Menu Options
PAGE 7-21
T200 User's Manual
•
SECTION 7: WINDRIVE
Logfile Player - The log file player “plays” log files which send communication requests to the drive. Log files
may be played as a continuous stream of commands or in a string, stepped through line by line. An Echo to File
option allows the servo-drive response to each command to be saved to disk. A loop function allows the log file to
be continuously played to the drive.
7.8.4
Data Logger Menu Options
Set-up - All Data Logger parameters are entered in this dialog box. The user can define a specific
trigger variable to the software which determines when the Data Logger begins the recording of
data.
• Run - The Data Logger Run dialog shows the current status of both data logging channels
and provides access to the Run command which enables the Data Logger to record data.
Figure 7.11: Data Logger Menu Options
7.8.5
Low Level Menu Options
EUI Input - The EUI, or Engineering User Interface, provides access to
individual servo-drive parameters, which, depending on user access level, may be
read from or written to the drive.
• Block Data - Information on the motor type and the controller type, software
version number and software version release date.
• Manual Block Operations - This dialog box allows the transfer of block
data from a file to the servo-drive and alternatively from the servo-drive to a file.
Figure 7.12: Low Level Menu Options
•
Set Offline - If working with a connected, powered servo-drive and the user wishes to operate off-line, this option
should be selected.
•
Reset Comm. - Reset Comm. is used if switching communications ports or switching from off-line to on-line mode.
7.8.6
Plots Menu Options
•
Display - Several options are available from the Display option:
Ø Superimposed - Superimposes the two Data Logger plots to allow for ease
of comparison.
Ø Individual - Displays the Data Logger plots individually.
Ø Blowup Graph - Expands the selected Data Logger plot to fill the Data
Logger display window.
Figure 7.13: Plots/Display Menu Options
Ø Restore Graph - Restores undeleted graphs to the Data Logger Plot
Display Window.
Ø Keep Previous - Stores the previous Data Logger plots in memory.
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SECTION 7: WINDRIVE
•
Grid Lines - Two options are available from the Grid Lines option:
Ø Horizontal Grid - Adds a horizontal grid to the current Data Logger
plot.
Ø Vertical Grid - Adds a vertical grid to the current Data Logger plot.
Figure 7.14: Plots/Grid Lines Menu Options
•
Save Plots - Saves the current Data Logger plots to disk for future use.
•
Load Plots - Allows the user to load previously saved plots to the Data Logger plot display window.
7.8.7
View Menu Options
The View Menu determines whether the following features are visible or not:
Toolbar - The icons for general WinDrive use, the toolbar, may be concealed or
revealed using the View/Toolbar menu option.
Status Bar - Showing servo-drive and software information, the WinDrive Status bar
2 at bottom of the WinDrive main window may be concealed, increasing the size of
the Data Logger plot window.
Figure 7.15: View Menu Options
Floating Toolbar - When required, the Floating Toolbar may be displayed using the View option, also available with
the Ctrl + F key combination.
The View menu also lists any open dialog boxes and if selected, “focus” is given to that dialog. This allows for transfer
of focus between dialogs when the application is used without a mouse.
7.8.8
Help Menu Options
•
Contents - Displays the contents of the WinDrive Help system.
• Using Help - Provides a full guide to using the WinDrive On-line Help
system.
• About MOOG WinDrive - Gives information on the version of WinDrive
software being used.
Figure 7.16: Help Menu Options
Figure 7.17: About MOOG WinDrive Dialog Box
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SECTION 7: WINDRIVE
7.9 WinDrive Monitoring Features
7.9.1
Data Logger
WinDrive’s Data Logger function is used for monitoring and
recording system parameters. This information is read by
WinDrive and plotted in the Data Logger Output Window.
Before the Data Logger can be used, the operating
parameters must be set-up, using either the Data Logger
Set-up Icon, or the Set-up option from the Data Logger
Menu.
a) Set-up
Channel - The Data Logger function has two channels for
data recording, each one should be configured in turn. The
following parameters must be set:
Data Logger Enable - The Data Logger channels must be
enabled before they can gather data.
Vertical Axis Variable - This option determines what
variable is plotted on the y-axis of the Data Logger plot, e.g.
Torque Demand. The variable will be plotted in units which
are suitable for it. Time, in seconds, is always plotted on the
x-axis.
Horizontal Axis Number Of Data Points - Determines the
number of sample points to be recorded by the Data Logger
in the set Data Logger sampling period. The maximum
number of points which can be recorded per channel is 4096.
Horizontal Axis Logging Rate - Determines how frequently
data samples are recorded by the Data Logger. A logging
rate of 1 will cause the Data Logger to record data from the
servo-drive at each sample instant. Higher rates (e.g. every
second or third sample) will reduce the time-resolution of the
displayed data.
Pre-Trigger - Allows data to be gathered up to the point of
the trigger occurring.
Post-Trigger - Data is gathered after the trigger has
occurred.
Figure 7.18: Data Logger Set-up Dialog Box
NOTE - The Data Logger
Enable Checkbox must be
checked for each channel
before any data logging can
be performed.
Trigger Variable - The Trigger Variable setting determines the
parameter upon which the start of data logging depends, and is set to trigger data logging in three ways:
1.
The Function Generator Trigger flag starts data logging when a function generator period starts.
2.
If triggering is desired from some drive variable, select the Trigger Flag option as the Trigger Variable. In this
case, a user-defined variable set in the Trigger Flag Set-up dialog will trigger the Data Logger.
3.
The DataLogger Sync flag allows to begin recording of data when the Run button is clicked in the Data Logger
Run dialog.
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SECTION 7: WINDRIVE
Several parameters must be set by the user in the Trigger
Flag Set-up dialog:
Data Trigger Enable - The Data Trigger feature must be
enabled before it can trigger the gathering of data.
Rising Edge - When this option is selected, data recording
will start when the Trigger Source variable rises above the
value determined in Trigger Level.
Falling Edge - For Falling Edge mode, the Trigger Source
variable falling below the Trigger Level will trigger the
Data Logger.
Trigger Source - The Trigger Source is selected by the
user from a list of possible variables.
Trigger Level - The Trigger Level determines above
(Rising Edge) or below (Falling Edge) which level of the
Trigger Source variable recording of data will start.
Figure 7.19: Trigger Flag Set-up Dialog Box
NOTE - When using the Trigger
Flag option, the Data Trigger Enable
Checkbox must be checked.
b) Data Logger Usage
When set-up of the Data Logger is complete, the Data Logger
Run dialog is used to start the Data Logger.
Selecting Run from this dialog box begins the recording of
data. Note that despite starting the Data Logger, information
will only be recorded when the trigger variable value becomes
true.
Following the completion of data logging, the information is
plotted on charts in the Data Logger Display Window. The
plot in the upper half of the display window is that of channel
one, whilst the lower plot is that of channel two. The labelling
of Data Logger plots is edited by double clicking on the
chosen label. A Text Parameters Dialog box, with fields for
text, font, color, size and style allows editing of the plot text.
Figure 7.20: Data Logger Run Dialog Box
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T200 User's Manual
7.9.2
SECTION 7: WINDRIVE
Engineering User Interface
The Engineering User Interface (EUI) is opened by selecting the EUI Icon or the EUI Input option from the Low Level
Menu. The EUI dialog box has four main fields: the input (Command) and output (Result) displays, and Command
and Result History fields. Three buttons, Exit, Update and Help are located at the bottom of the dialog box.
The EUI provides the user with a full set of system parameters, which are listed in the Command box drop-down list.
This list can be opened by clicking on the right-hand arrow button of the Command box. By selecting a command and
clicking on Update, the value of the selected variable is retrieved by querying the drive memory. When a query is sent,
following a short pause, the response from the servo-drive is returned to the Result field and the Result History is
updated. The EUI may also be used to write values to the drive. After a parameter name has been entered in the
Command field, a space or an “=” sign should follow and the desired value entered for the parameter. This value will be
written to the drive on pressing “Enter” or clicking the Update button.
Figure 7.21: Engineering User Interface (EUI) Dialog Box
7.9.3
Block Data
The Block Data option is accessed from the Low Level Menu.
Block data is held in the memory of the connected drive. The
Block Data Dialog box provides the following data:
Block No.
Data (Chars)
12
Motor Type
13
Servodrive Type
14
Software Version
15
Release Date
PAGE 7-26
Figure 7.22: Block Data Dialog Box
T200 User's Manual
SECTION 7: WINDRIVE
7.9.4
Manual Block Operations
Block data may be saved to disk for future use by selecting Manual Block Operations from the Low Level menu,
selecting Save to File, as well as the Block Data Number and Length, entering the path and File name and clicking the
Update button. This information may be saved in either BYTE or Word format. To recall block data from disk, select
the Read from File option from the Low Level menu, enter the block data path and File name (or use the Browse
facility) and click on Update.
Figure 7.23: Manual Block Operations Dialog Box
7.9.5
Front Panel Test Points
Two programmable analog output channels are available with every WinDrive compatible servo-drive. The output at
each of the channels is set with the Front Panel Test Points Dialog box.
Accessed via the Set-up option in the Drive menu, the Front Panel Test Points Dialog box contains two lists of variables
which may be assigned to each test point, a field labelled Velocity Scaling and a button labelled Zero Displayed
Position.
If either of the Front Panel Test Points is set up to indicate a velocity variable, then the Velocity Scaling parameter
entered in this dialog box will determine the scaling of that velocity variable at this Front Panel Test Point.
The Zero Displayed Position button should be clicked before starting a motion of the motor when an Actual Position is
assigned to a test point. This zeroes the displayed position to give a correct reading.
Figure 7.24: Front Panel Test Points Dialog Box
CAUTION - Changing the Velocity Scaling value will modify the actual
motor velocity if the Analog Input is selected as the servo-drive's reference
source. If the overall machine control configuration is a position loop, the
gain of the position loop will also be modified by changing the Velocity
Scaling value.
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T200 User's Manual
7.9.6
SECTION 7: WINDRIVE
Drive Status
Figure 7.25: Drive Status Dialog Box
Available by selecting Drive Status from the Drive Menu, the Drive Status Dialog box provides a table of current drive
and motor parameters and is constantly updated by the WinDrive software. The appearance of this dialog box changes to
facilitate Reference Source settings. This dialog shows all essential system parameters and is useful in both diagnostic
and system querying procedures.
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SECTION 7: WINDRIVE
7.9.7
Fault Status
Figure 7.26: Fault Status Dialog Box
This dialog is available by selecting Fault Status from the Drive Menu. This dialog box provides an overview of
current fault and warning conditions and is constantly updated by the WinDrive software. This dialog is useful in
diagnostic as well as system querying procedures.
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T200 User's Manual
7.9.8
SECTION 7: WINDRIVE
Fault History
The T200 provides a means of uploading and displaying the fault history data stored in the T200 non-volatile storage.
Using this dialog box, all error data
recorded by the drive can be accessed.
When the dialog opens, the first 10
records of errors are uploaded
automatically. A further 10 records can
be uploaded by clicking on the Upload
Record button. The viewed records
can be saved by clicking on the Save
button. All records can be saved by
clicking on the Save All button.
The time index is organised such that
the most recent fault is displayed at
time 00:00:00 and the previous faults
are displayed with a negative time
index. If more than one fault occurs at
the same time, then the individual
faults will be displayed with the same
time index.
Figure 7.27: Fault History Dialog Box
The drive can only track time while there is logic power applied, since it does not have a real-time clock. When the drive
is powered, a record is maintained of the time the drive is enabled and the time it is disabled. When a fault occurs both
times are written to the flash memory in the drive along with the fault code. The sum of these times is the time between
faults.
Fault (records): This list box displays the fault records read
from the drive. Ten records are displayed (if available) when
the dialog is opened, and when the Upload Record button is
clicked on.
Save: This button allows the present faults displayed to be
saved to a file. The user is prompted for the same
information that is used in Configuration Upload i.e. File
Name, Customer, software version etc.
Save All: This button allows all of the recorded faults to be
saved to a file. The list box is not updated when this occurs.
The user is prompted for the same information that is used in
Configuration Upload i.e. File Name, Customer, software
version etc.
Upload Record: This button allows the user to upload and
automatically display the next 10 fault records.
Fault History Upload: This dialog allows the user to also
write helpful information to the .FLT file. This information is
located at the top of the file
Figure 7.30: Fault History Upload Dialog Box
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SECTION 7: WINDRIVE
7.10 Drive Set-up
The drive can be configured in either Position Mode, Velocity Mode or Torque Mode via WinDrive. Note that the T200
defaults to the Velocity loop configuration mode, with an analog ±10V reference type. Configuration of the T200 into
other modes besides Velocity Mode is described in Section 6.
7.10.1 Basic Velocity Mode Drive Set-up
This section describes a basic set-up method for a servo-drive, using the Basic DriveSetup option from the Drive
Menu. A sequence of dialog boxes follows the selection of this option.
7.10.1.1 Units Set-up
Unit Type
Metric
Imperial
Torque
Nm
lb-in
Temperature
°C
°C
Current
A
Arms
KT
Nm/A
lb-in / Arms
Nm/Arms
Velocity
RPM
Inductance
H or mH
Inertia
RPM
2
H or mH
kg cm
kg cm2
or kg m2
or kg m2
Table 7.2: Available Units
Figure 7.31: Units Dialog Box
Prior to configuring the drive, the Units Dialog box should be opened from the Drive Menu. The units in which the
parameters torque, temperature, current, KT (torque constant of motor), velocity, inductance and inertia are measured
should be set as required by the user. Update should be clicked to store the units to memory. These units are typically
available in metric or imperial units.
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SECTION 7: WINDRIVE
7.10.1.2 Select Motor Dialog Box
The motor is selected by the user. Motor types are divided into standard (MOOG standard range) and non-standard
motors (MOOG custom designed or non- MOOG motors). See Section 4 for a review of motor naming terminology and
standard or non-standard motors. Note that all MOOG G3XX and G4XX Global motors are included in the standard
motor database. When not running the Basic DriveSetup sequence from the Drive menu, the user selects the motor type
by clicking on the Motor Icon (see Section Main Window Button Console) or, by selecting the Drive/Set-up/Motor
menu option.
NOTE: The T200 supports MOOG 's D31X series and 30X series of servo-motors, for
backward compatibility purposes. Consult MOOG applications engineering for support of
these products with the T200.
CAUTION: The user should ensure that his machine is placed in a safe non-operational
mode when configuring the motor. When the motor selection is downloaded to the T200,
the T200 high power will be removed and control of the motor-shaft and load will be lost.
The machine-position may need to be re-referenced when the configuration is complete.
a) Standard Motor Selection
WinDrive contains a database of the MOOG standard motor. The user can select either the motor's electrical type or the
motor model as the search-key for the database. If the user has purchased a motor which has a 'non-standard' motormodel, then the user can select the electrical 'type' rather than the 'model' from the Select Motor dialog’s Motor List
(See Section 4 for an overview of the motor nameplate data). The Standard field is ticked by default in the Motor Type
section.
Having selected the correct motor from the Select Motor Dialog box, the Download button should be clicked to
download the motor data set to the T200. This action will take several seconds, as the servo-drive power section is
disabled, the T200 put in a special data reception mode, and the data downloaded. During the period of download, a
special icon will appear, which indicates that the user must wait until the action is completed. The Close button should
be clicked to progress to the next dialog box when download is complete.
model
or
electrical type
Figure 7.32: Select Motor Dialog Box
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SECTION 7: WINDRIVE
b) Non Standard Motor Selection
Non-standard motor entry should only be necessary when using MOOG's older 30X series motors, when using MOOG
custom designed motors, or when configuring the T200 to function with a motor from another manufacturer. For nonstandard motors, the parameters necessary for drive interfacing must be known (or determined) by the user.
To view or edit non-standard motor data, the user should first click on the Non-Standard field of the Motor Type
section of the Select Motor dialog. The Motor List will automatically change to display all 'known' non-standard
motors, i.e. 30X series, MOOG custom designed motors and previously edited non-MOOG motors. These 'known'
motors can be selected and their parameters be viewed and downloaded in the same way as the standard MOOG motors.
Figure 7.33: Nonstandard Motor Parameters Dialog Box
Parameter information for non-standard motors may be added to a non-standard motor database by selecting the Add
Motor button. Information may also be removed by selecting the motor and then clicking on the Remove Motor button.
Parameters may be edited by the user by selecting the Edit button.
CAUTION: Entry of invalid non-standard motor data may cause non-optimal performance of the
motor, or in an extreme case, damage to the user's machine.
If the non-standard motor is manufactured by MOOG, the non-standard motor data set is available
from MOOG, and the user may already possess this data. However the T200 Current Loop Gains
may not be known by the user. The user should consult MOOG Applications Engineering if he does
not know the value of all of the motor parameters required above.
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SECTION 7: WINDRIVE
NOTE - G40X series MOOG motors usually have an equivalent standard MOOG motor. The G40X
motors and their equivalent standard motors have the same electrical parameters, though may differ in
mechanical configuration. The T200 only needs to be configured with the correct electrical parameters.
Consult the MOOG sales outlet for information on the equivalent standard motor. If this equivalent is
known, the standard motor may be entered instead of a non-standard motor.
NOTE - When the Motor Type is set to standard, the Remove Motor, Add Motor and Edit features are
disabled.
7.10.1.3 Reference Source Selection
The servo-drive’s reference source is chosen using the Reference Source Dialog Box shown below. Reference sources
are explained in Section 6. Note that the reference rate limits are also outlined in that section.
Figure 7.34: Reference Source Dialog Box
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SECTION 7: WINDRIVE
a) Analog Input Reference
The Analog Input is a ±10V signal which is used as a
command reference. When the Analog Input is being used as
the reference source, several parameters must be set in the
dialog box. Enter this dialog via Set-up from the Reference
Source dialog.
Velocity Scaling: The Velocity Scaling is defined as the
commanded motor speed (in RPM) when the analog input
value is +10V. The maximum desired motor velocity is usually
entered in this field, so that the motor will rotate at this speed
when the analog input voltage is +10V. This is always a
positive number.
Figure 7.35: Analog Input Dialog Box
Input Offset: The Input Offset is used to adjust the input
voltage offset. It is entered in Millivolts (mV). The default
value in the Input Offset field is zero.
Position Scaling: If the T200 is operated in Position Mode,
then the analog reference can be used as a positioncommand.
The Position Scaling can be used to set the number of motor
shaft revolutions corresponding to 10V.
Automatic Input Offset Zero: The T200
automatically calculates the analog offset voltage upon clicking this button. It assumes that the present command voltage
corresponds to zero torque, velocity command or to the 'home' position.
NOTE - The operation of the Analog I/O is specified in detail in Section 6.4.
b) Function Generator Reference
WinDrive compatible servo-drives feature a software
based function generator that is used as the reference
source for drive tuning. Enter this dialog via Set-up from
the Reference Source dialog.
Speed Amplitude: If the Speed Offset was set to 0, then
the Speed Amplitude would set an equal magnitude of the
speed reference command in the clockwise and counterclockwise direction. The Speed Amplitude must be a
positive number. It is specified in units of RPM.
Speed Offset: Used to bias the commanded velocity. It can
be positive or negative. The Speed Offset is specified in
units of RPM.
Torque Amplitude: This is specified in units of Nm or lbin. If the Torque Offset was set to 0, then the Torque
Amplitude would set equal magnitude of the torque
command in the clockwise and counter-clockwise
direction. The Torque Amplitude must be a positive
number.
Figure 7.36: Function Generator Dialog Box
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SECTION 7: WINDRIVE
Torque Offset: The Torque Offset is used to bias the torque of the motor in one direction of rotation. It can be positive
or negative. It is specified in units of Nm or lb-in.
Period: The Period determines the time taken for one cycle of operation for one cycle of the Function Generator. This is
specified in seconds.
Duty Cycle: The Duty Cycle determines the length of time the Speed (Velocity Mode) or Torque Amplitude (Torque
Mode) is of a positive polarity and is expressed as a percentage of the Period. For the remainder of this time, the Speed
or Torque Amplitude is negative. A Duty Cycle of 50% means that Speed or Torque Amplitude have positive and
negative polarity for the same length of time during one Function Generator Period.
Distance: The Distance is used when the T200 is in Position Mode. The T200 generates an S-shaped position profile,
with maximum acceleration, speed and end position determined by the Function Generator's Acceleration, Speed
Amplitude and Distance (in revolutions) parameters, respectively.
Acceleration: The Acceleration is used by the Profile Generator in Position Mode as described under the Distance
parameter and specified in radiants / second2.
NOTE - The operation of the Function Generator is specified in detail in Section 6.5.
c) CAN Reference
The Controller Area Network (CAN) interface mode
is described in Section 9. Enter this dialog via
Set-up from the Reference Source dialog.
Mode: The Mode field selects between CAN Profile
Mode and CAN Interpolation Mode.
CAN Baud Rate: The user can choose the baud rate
from the following selection: 1000kBaud,
800kBaud, 666kBaud, 500kBaud, 400kBaud,
320kBaud, 250kBaud, 200kBaud, 160kBaud,
125kBaud,
100kBaud,
80kBaud,
50kBaud,
40kBaud, 20kBaud, 10kBaud, 5kBaud.
CAN Communication Cycle Period: The CAN
cycle period (time between SYNC messages) is
entered via this window. Units are microseconds.
CAN Command Window: The time from the
SYNC message arrival to the time when the T200
checks for COMMAND messages is called the
Command Window. Units are microseconds.
Figure 7.37: CAN Dialog Box
CAN Actual Window: The time from the
transmission of the ACTUAL message until the next
SYNC message is called the Actual Window. Units
are microseconds.
CAN Position Scaling: The user can select 16384, 8192 or 4096 CAN increments per motor shaft revolution. This
scaling is applied to all CAN position variables.
NOTE - The operation of the CAN Interface is specified in detail in other MOOG documents. These
can be provided by the MOOG sales outlets listed in Section 11 on request.
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SECTION 7: WINDRIVE
T200 User's Manual
d) Digital Speed Input Reference
The Digital Speed Input functionality is described in
Section 6. The reference speeds corresponding to the
state of the 2 digital inputs are specified in units of
RPM. Enter this dialog via Set-up from the Reference
Source dialog.
PROG_
SPRD_1
Status
PROG_
SPRD_0
Status
Speed Reference Used
0
0
Digital Input Reference 0
0
1
Digital Input Reference 1
1
0
Digital Input Reference 2
1
1
Digital Input Reference 3
Figure 7.38: Digital Speed Input Dialog Box
Table 7.3: Digital Input Speed Programming
e) Stepper Input Reference
The Stepper Input Position Reference is set-up using the dialog shown below. It can be entered by clicking the Set-up
button in the Reference Source dialog.
Two formats for the protocol are detailed in
Section 6. One of the two can be selected by
choosing one of the Quadrature or Step/Direction
radio buttons in the Command-Signal field.
Scaling is set by the number of stepper pulses per
revolution. Note that in Quadrature mode, there is
an effective resolution increase by a factor of 4
over other modes because each pulse edge can be
used as a position increment. For example if the
Steps per Motor Revolution field is set at 10, the
number of discrete position steps per revolution
will correspond to 40 if a Quadrature type
Command Signal was selected. However only 10
such steps will exist if the Step/Direction mode is
chosen.
Figure 7.39: Stepper Input Dialog Box
NOTE - The operation of the stepper interface is specified in detail in Section 6.11.
f) Custom POINT Reference
If integral motion control is used as a command source, the Custom POINT option is selected. This option is only
available if the T200 embedded software version is 'Pn', where n is the software revision. Use of this software is covered
in the 'T200-POINT User's Manual' MOOG Part Number C09661-001.
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T200 User's Manual
SECTION 7: WINDRIVE
7.10.1.4 Reference Rate Limit Set-up
The Rate Limit Dialog box allows limiting of the rate of
change of the velocity and torque commands that are
applied to the drive. Enter this dialog via Set-up from the
Reference Source dialog. Note that this functionality has
been outlined in Section 4.
When in Torque Mode, the T200 torque command is
allowed to climb to the Maximum Torque (specified in
Nm) in a time Torque Rise Time (specified in seconds).
If the T200 is in velocity mode, then the velocity
command is allowed to climb to the Maximum Velocity
(specified in RPM) in a time given by the Acceleration
Time (specified in seconds).
Figure 7.40: Rate Limit Dialog Box
NOTE - The operation of the reference rate limiting is specified in detail in Sections 6.6.1 and 6.6.2.
NOTE – There is a lower limit to the rate limit that can be configured, for both Velocity and Torque
Modes. If the user sets the rate limiting at too low a value (corresponding to seconds to reach peak
torque or nominal motor velocity), then the T200 will impose a minimum rate limit.
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SECTION 7: WINDRIVE
T200 User's Manual
7.10.1.5 Normal and Reduced Power (Automatic and Manual Mode) Limits Set-up
The Limits Dialog box allows the user to specify operating limits for both torque and velocity to the servo-drive to
ensure proper tuning and safe operation of the system (see Section 6 for a description of functionality). Automatic, or
normal mode operation is used after a servo-drive has been tuned and configured successfully and the values for both the
torque and velocity limits are set higher than those for manual mode.
Manual Mode Disable: The user can disable
Manual Mode if he does not wish to wire up the
Manual/Automatic digital input (connector J1, pin
#7). The Manual Mode Disable box should be
ticked to disable the T200 from entering Manual
Mode.
Automatic Mode Parameters
Normal Velocity Limit: The velocity command
limit is specified in RPM.
Normal Torque Limit: The torque command
limit is specified in Nm or lb-in.
Manual Mode Parameters
Reduced Velocity Limit: The
command limit is specified in RPM.
Figure 7.41: Limits Dialog Box
velocity
Reduced Torque Limit: The torque command
limit is specified in Nm or lb-in.
WARNING: The user should only consider disabling of Manual Mode when he is assured that
the T200 is properly configured and no dangers to equipment or personnel are present e.g. if
the machine safety cage is open then disabling of Manual Mode is not advised.
7.10.1.6 Hardware Limit Switches Set-up
Clockwise and Counter-Clockwise hardware Limit
Switches connected to the drive system can be
disabled from the Limit Switches Dialog box. The
Limit Switches Disabled checkbox should be ticked
to disable the hardware Limit Switches.
Figure 7.42: Limit Switches Dialog Box
CAUTION - The safety Limit Switches of
the machine must be connected through
hardware limit circuits such that the drive is
hardware disabled if a limit switch is
activated.
Velocity Mode: If a Limit Switch is activated when
the T200 is in Velocity Mode, the motor is brought to
a Servo Stop by the drive, and further movement in
the direction of that Limit Switch is not allowed. The
Quick Stop Deceleration Rate at which the motor
2
stops is determined by the user, in units of rad/s .
Movement in the other direction is still possible.
Torque Mode: If the Limit Switch is activated when
the T200 is in Torque Mode, then the torque
command will be clamped to zero in that direction.
Torque generation in the other direction is still
possible.
A comprehensive explanation of the Limit Switch functionality can be found in Section 6.4.5 Limit Switch Function.
PAGE 7-39
T200 User's Manual
SECTION 7: WINDRIVE
7.10.1.7 Drive Tuning
This dialog enables the user to select the Control Mode for the drive, set up the Tuning Gains as well as enter additional
tuning related dialogs. Refer to section 7.11.1 Control Mode Selection.
7.10.1.8 Encoder Simulation (ESM)
The functionality of an incremental rotary encoder may be
emulated with Encoder Simulation software. Feedback
information is read from the motor resolver where it is
interpreted by a software/hardware model (depending on ESM
mode) and converted into Encoder Simulation information.
The user must enter a value for the Number of Lines per
Revolution. Two modes of Encoder Simulation are available,
High Bandwith and Low Bandwith.
1.
2.
High Bandwidth ('ESM3'): This is recommended for
use when the T200 is placed in Torque Mode. This uses
an analog hardware solution for the Encoder Simulation,
but only values of 128, 256, 512 or 1024 may be used for
the Number of Lines per Revolution. A position
feedback bandwidth of between 800 and 1000 Hz is
available when High Bandwidth mode is used.
Low Bandwidth (ESM1): This is recommended for use
when the T200 is placed in Velocity Mode. Any other
even number between 128 and 8192 entered for the
Number of Lines per Revolution will result in Low
Bandwidth operation. A hybrid of software and
hardware, the feedback bandwidth of Low Bandwidth
mode is limited to 400 Hz.
Figure 7.43: Encoder Simulation Dialog Box
The user may determine the Zero Marker Offset in mechanical motor shaft degrees of the zero marker of the Encoder
Simulation output, with respect to the motor’s own resolver position sensor natural zero position. Both the Maximum
Drive Speed and Present Encoder Position fields are determined by the software and system parameters. The Marker
Width options are selectable from Short Marker (90 Electrical Degrees) and Long Marker (180 Electrical Degrees).
7.10.1.9 Regen (Brake) Resistor Configuration
The Regen Resistor Configuration dialog box allows the user
to set up the selected regen (regeneration) resistor. The
correct parameters for the regen resistor are essential for a
proper operation of the Regen Exceeded functionality as
described in section 6.8.5.
External Regen Resistor Connected: Enables the Regen
Exceeded functionality which indicates that the maximum
continuous power of the external regen resistor is exceeded.
This box needs to be ticked if an external regen resistor is
connected to the T200.
Disable Drive if Regen Exceeded: If this box is ticked the
T200 will perform a Quick Stop and disable as soon as the
maximum continuous regen power is exceeded. Otherwise
only regen exceeded will be indicated but no Quick Stop is
performed. For further description see section 6.8.5.
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T200 User's Manual
SECTION 7: WINDRIVE
Figure 7.44: Regen Resistor Configuration Dialog Box
Select Regen Kit: Allows the selection of the regen kit used in the application. The selection is based on the maximum
continuous power of the regen resistor kit. Data of a regen resistor not supplied by MOOG can be set up under “Other”.
This option allows the setting of the resistor value and the maximum continuous power of the resistor.
WARNING: It is the user’s responsibility to ensure that the correct regen configuration is set
up. The Regen Exceeded functionality is the only protective mechanism which indicates to the
user that the continuous regen power for the regen resistor is exceeded. Excessive regen power
will thermally damage the regen resistor. Dependent on the material of the regen resistor the
resistor may catch fire.
7.10.1.10 Saving a Configuration to Non-Volatile Storage
On completion of the Basic DriveSetup, the completed
tuning information is downloaded to drive EEPROM using
the Save to EEPROM function. By clicking on the Save
button, the parameters which have been set in the T200
volatile storage are transferred into non-volatile storage,
and the T200 will be configured with these parameters the
next time the T200 is powered-on or reset.
Figure 7.45: Save to EEPROM Dialog Box
PAGE 7-41
T200 User's Manual
SECTION 7: WINDRIVE
7.10.2 Torque Mode Operation
In Torque Mode, the input command reference is a current command to the power amplifier that drives the motor. The
term Torque Mode is adopted because the motor produces a nearly linear torque per ampere of input current. The tuning
of the inner current loops of WinDrive compatible servo-drives is pre-programmed during drive initialization, by
selection of the motor model or the electrical type.
The Control Compensator should be set to Torque Mode, using the Tuning Dialog box (see Section 7.11.4.2 Control
Mode). Offsets in the servo-drive and the user’s torque analog command may be trimmed out using the offset
adjustment methods available (see Section 7.10.1.3 Reference Source Selection, Analog Input, Input Offset). The
desired Automatic and Manual Mode Torque Limit should be entered in the Limits Dialog Box (See Section 7.10.1.5
Normal and Reduced Power (Automatic and Manual Mode) Limits Set-up).
The Encoder Simulation should also be set-up (see Section 7.10.1.8 Encoder Simulation (ESM) ).
Parameters should be saved to non-volatile storage once configuration is complete (see Section 7.10.1.10 Saving a
Configuration to Non-Volatile Storage).
PAGE 7-42
T200 User's Manual
SECTION 7: WINDRIVE
7.11 Control Loop Configuration and Tuning
This section describes how WinDrive allows easy configuration and monitoring access to T200 internal variables, to
facilitate quick configuration of control loops and estimation of control loop gain values. The Auto Tuning feature is
described as well.
NOTE: The user should review Section 6.6.2, Velocity Loop Tuning, before starting the
tuning process.
7.11.1 Control Mode Selection
The user should choose the appropriate control mode for the application.
§ The T200 provides selection of Torque, Velocity or Position Mode control configurations.
§ Additionally, if the drive is configured in
Velocity Mode, the T200 can switch between
Velocity and Torque Mode under the control of
the TRQ_VEL digital input. Mode switching is
not possible if the user has selected any other
mode besides Velocity.
Mode: The appropriate control mode is selectable
by clicking on either the Torque, Velocity or
Position button. The user is also informed of the
present control mode of the T200.
Gains: The Velocity Loop Gain, Integral Time
Constant and if enabled, the Position Loop Gain,
Position Loop Integral Gain, Velocity Feed
Forward Gain and Torque Feed Forward Gain
can be set from the Gains menu. These items will
be described in 7.11.4.1 Velocity Estimation,
Velocity Loop Tuning and Section Position Loop
Tuning.
While the Tuning dialog box is active, the Up and
Down arrow keys on the keyboard or the arrows to
the right of any tuning parameter field can be used
to adjust the respective parameter up or down by 5%
with each key or mouse button press. The
Automatic Update check box within the
Combined Tuning dialog box is checked to force
changes made to any tuning parameter to be
immediately sent to the T200.
Figure 7.46: Tuning Dialog Box
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SECTION 7: WINDRIVE
Options: Advanced Options for T200 control loops, Auto-Tuning and control loop Tracking Monitoring parameters
can be accessed from the Options group. These features are described in Sections Advanced Options, Section Auto
Tuning and Tracking respectively.
Update: This button is used to write the tuning parameter values shown in the dialog to the T200.
PAGE 7-44
T200 User's Manual
SECTION 7: WINDRIVE
7.11.2 Torque Mode Tuning
As mentioned earlier, tuning of the current loops is performed during drive initialization. Hence no parameter tuning is
required in Torque Mode.
7.11.3 Velocity Loop Tuning
After completing drive configuration per Section Drive Set-up the user must tune the velocity loop to optimise velocity
loop performance. This section provides a recommended velocity mode standard tuning procedure for use with
WinDrive. Note that a generic velocity loop tuning procedure (WinDrive or the Hand Held Terminal interfaces can be
used with this procedure) is given in Section 6.6.2. The procedure should be followed in the sequence listed, noting all
warnings appropriately. Velocity Mode should be selected from the Tuning dialog box (see Section Control Mode
Selection). Tuning can be carried out in Reduced Power mode (Manual Mode) where there is a concern about safety.
7.11.3.1 Combined Tuning Window
The Drive/Set-up/Combined Tuning main screen configuration provides a convenient way of monitoring T200
variables whilst setting loop gains. The WinDrive Data Logger and the Combined Tuning dialog are immediately
visible in this mode. The Data Logger may be immediately re-triggered once the control loop gain is suitably adjusted.
The Function Generator parameters may also be adjusted in the Combined Tuning dialog.
Figure 7.47: Combined Tuning Main Screen View
PAGE 7-45
T200 User's Manual
SECTION 7: WINDRIVE
It is recommended to monitor the Torque Demand and the Actual Velocity variables during Velocity Loop tuning. The
Data Logger will be set up by default to monitor these variables. See Section 7.9.1 Data Logger for a description of how
to set up these variables as the logged data set.
The servo-drive should be enabled first through the External Enable digital input, and then software enabled using the
F3 key, Floating Toolbar or Main Tool Bar (Function Generator initialised as detailed above).
While the Combined Tuning dialog box is active, the Up and Down arrow keys on the keyboard or the arrows to the
right of any tuning parameter field can be used to adjust the respective parameter up or down by 5% with each key or
mouse button press. The Automatic Update check box within the Combined Tuning dialog box should be checked to
force changes made to any tuning parameter to be immediately sent to the servo-drive. If the Automatic Update check
box is not ticked, parameters in the drive can be updated by clicking the Update button.
A full description of the manual tuning procedure is given in Section 6. This should be reviewed before starting to tune
with WinDrive.
7.11.4 Advanced Options
This section details the use of the Advanced Options for tuning, found in the Options of the Tuning dialog and
Drive/Set-up/Advanced Options Menu.
Upon selecting the Advanced Options, the Advanced Options dialog box appears. It contains two sections, Velocity
Estimation and Control Mode.
Figure 7.48: Advanced Options Dialog Box
7.11.4.1 Velocity Estimation
The default value for this option is Use dp/dt velocity estimate, where the software estimates the velocity of the motor
from position and time data. A more accurate value for the motor velocity may be obtained by selecting the option Use
observer velocity estimate. This system uses a software simulation of the servo-drive and motor configuration to
determine a more accurate motor velocity signal. The user can adjust this model by tuning of the Observer Inertia
PAGE 7-46
SECTION 7: WINDRIVE
T200 User's Manual
parameter. Tuning of the software model for the user applications is described in Section 6.6.2. Note that the Data
Logger can be used to record Torque Demand and Observer Position Error, in a convenient way during observer tuning.
While the Advanced Options dialog box is active, the Up and Down arrow keys on the keyboard or the arrows to the
right of the Observer Inertia field can be used to adjust the parameter value up or down by 5% with each key or mouse
button press. The Automatic Update check box should be checked to force changes made to the Observer Inertia field
to be immediately sent to the servo-drive. If the Automatic Update check box is not ticked, the parameter value in the
drive can be updated by clicking the Update button.
7.11.4.2 Control Mode
The torque command, which is generated in Velocity Mode, is filtered using an internal digital filter. It may be
necessary in some applications to optimise this digital filtering.
Velocity Mode 1 st Order: A first order filter is used whose only setting is its Low Pass Cutoff filter frequency in Hz.
Velocity Mode 2 nd Order: A second order filter is used which needs a Low Pass Cutoff filter frequency in Hz and a
Damping Factor to be specified.
NOTE: The Low Pass Cut-off and the Damping Factor are set to safe values which
depend upon the motor model selected. Consequently the motor should be configured
before changing these values.
PAGE 7-47
T200 User's Manual
SECTION 7: WINDRIVE
7.11.5 Auto Tuning (Velocity Loop Only)
Auto Tuning of T200 Velocity Loop Gain parameters and the Velocity Observer is only available through WinDrive. If
quick tuning of a T200 is required by the user, WinDrive's Auto Tuning feature can be used to determine the values of
both the velocity loop gain and the integral time constant terms. Auto Tuning can be selected from the Drive/Set-up
Menu or via the Auto-Tuning button in the Tuning dialog.
A software generated excitation signal is fed to the motor by WinDrive and the response is recorded. Using the response
information, values are determined for Velocity Loop Gain (P) and Integral Time Constant (I). It should be noted that
Auto Tuning defined values for P and I are not optimum values. The velocity loop bandwidth (a measure of the
quickness of response of the velocity loop to changes in the velocity command) that is achieved using the Auto Tuner is
set to a default value of 50Hz.
Excitation Amplitude: The user can set
the level of excitation torque as a
percentage of the peak torque available
from the T200 - motor combination. It is
recommended that this level is set as high
as possible so that as large a movement as
possible is created without damaging the
user machine.
System Parameters: This will allow for
view of system parameters that were
identified during Auto Tuning (load inertia
etc.).
Figure 7.49: Auto Tuning Dialog Box
Advanced Options: This sub-dialog
allows the user to set advanced tuning
features and view the calculated response
of the Auto Tuning process.
Auto Tune: Clicking on this button starts
the Auto Tune process.
CAUTION: The Auto Tune algorithm causes the motor to be excited with a high frequency
torque. This is typical of most tuning algorithms. The machine should be capable of
withstanding such an excitation torque, which contains a significant number of torque steps.
NOTE
The ENABLE digital input must be active to allow the T200 to apply torque to the load and
measure the response. The user should ensure that he has hardware-enabled the T200 via the
DRV-ENABLE digital input.
The BRK-IP digital input must also be active to allow the T200 to release the brake during the
Auto Tuning process. Note that the WinDrive interface will release the brake automatically at
the appropriately times, when it expects that movement is required to estimate the load. The
user should ensure that he has hardware-released the brake of the motor (if a brake is present)
via the BRK_IP digital input.
PAGE 7-48
SECTION 7: WINDRIVE
T200 User's Manual
7.11.5.1 Auto Tuning System Parameters
The System Parameters dialog provides a means of
viewing and setting various Auto Tune parameters
and results:
The user is informed if the load system is resonant. If
the system is resonant then there is some flexibility in
the coupling of the load to the motor. If the system is
found to be significantly resonant and the loops
cannot be tuned safely by the Auto Tuner, then the
Auto Tuning process will be aborted and the user be
informed of that.
Lumped System Parameters: When the Auto
Tuning process has run, the Lumped (Observer)
Inertia value in kgcm2 indicates the value of the
motor and load inertia reflected to the motor side of
any gearbox or coupling mechanism.
Bandwidth: The default Desired Velocity Loop
Bandwidth is 50Hz, which is sufficient for most
servo-drive applications.
Figure 7.50: Auto Tuning System Parameters Dialog Box
However if additional stiffness or disturbance
rejection is required, then the user can increase the Desired Velocity Loop Bandwidth.
Calculated Gains: The P and I gains suggested by the Auto Tuner are displayed when the Calculate Gains button is
clicked. Note that if the Desired Velocity Loop Bandwidth is set to a value different from the default, the Calculate
Gains button should be re-clicked.
7.11.5.2 Auto Tuning Advanced Options
The Advanced Options (Auto Tuning) dialog enables the
user to load or save an excitation signal from / to a file,
respectively.
Load Excitation Signal From File: This checkbox has
to be ticked when an excitation signal is to be
downloaded from an Input File to the T200.
Save Excitation Signal To File: This checkbox has to be
checked when an excitation signal is to be uploaded from
the T200 to an Output File.
Figure 7.51: Advanced Options (Auto Tuning) Dialog Box
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T200 User's Manual
SECTION 7: WINDRIVE
7.11.6 Tracking Monitoring
The Tracking Monitoring dialog box is available from the Tuning dialog box. This dialog is used to set warning
thresholds, such that if these thresholds are exceeded, the T200 will flag the warnings to users via the 7-segment display,
and through feedback via the CAN channel.
Velocity Tracking: The Velocity Error is the difference
between the velocity command and the Actual Velocity. The
Velocity Following Error warning will be set if the absolute
value of the error velocity exceeds the Warning Velocity for
the Warning Velocity Time.
Position Tracking: The Position Error is the difference
between the position command and the Actual Position. The
Position Following Error warning will be set
1.
if the absolute value of the position error exceeds a
quantity equal to
Actual Velocity • Dynamic Error/(100 • Position
Loop Gain).
This quantity is the expected Position Error of a
position loop with no Velocity Feedforward
compensation, multiplied by the Dynamic Error
factor.
or,
Figure 7.52: Tracking Monitoring Dialog Box
2.
if the absolute value of the Position Error exceeds the
Static Error (expressed as position increments - see
Section 7.10.1.3 Reference Source Selection, CAN
Reference Source, CAN Position Scaling).
7.11.7 Position Loop Tuning
After completing drive configuration as per Section Drive Set-up, the user must tune the position loop to optimize
position loop tracking and disturbance rejection performance. This section provides a recommended Position Mode
tuning procedure for use with WinDrive. Note that a generic position loop tuning procedure (WinDrive or the Hand
Held Terminal interfaces can be used with this procedure) is given in Section 6.6.3. The procedure should be followed in
the sequence listed, noting all warnings appropriately. Position Mode should be selected from the Tuning dialog box
(see Section Control Mode Selection). Again tuning can be carried out in Reduced Power Mode (Manual Mode) where
there is a concern about safety.
The recommended practise for tuning the Position Loop is:
1.
First tune the Velocity Loop by following Section Velocity Loop Tuning. The Velocity Observer can also be used to
increase Velocity Loop Gains, by following Section 7.11.4.1 Velocity Estimation. Note that the Auto Tuner can be
used to adjust the Velocity Loop Gains.
2.
Change the control mode to Position Mode (see Section Control Mode Selection). Now tune the Position Loop Gain
using the procedure described in Section 6.6.3.
Tuning of the Position Loop Gain is facilitated by use of the Data Logger (see Section Data Logger) and the T200's
built-in Function Generator. Set the Data Logger to record Reference Velocity on Channel 1 and Error Position Low
on Channel 2. Set the Reference Source to the Function Generator with appropriate Distance, Acceleration, Speed
Amplitude and Period parameters.
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SECTION 7: WINDRIVE
T200 User's Manual
7.12 Incremental Encoder Input Configuration
The T200 Incremental Encoder input can be set-up via WinDrive. A description of the incremental encoder input is
given in Section 6.10.
Number of Lines per Revolution: The user
sets this input to scale the encoder. The
encoder input is used in Stepper Mode and
POINT Mode. The motor cannot be
commutated with the incremental encoder.
The Number of Lines per Revolution is
usually available from the encoder nameplate.
Zero Marker Offset (Lines): The rotational
offset of the Incremental Encoder position is
set by the user via this parameter. It is scaled
in encoder lines.
Figure 7.53: Encoder Dialog Box
Present Position (Lines): The present encoder position may be read using this display. Pressing the Update button
updates the value displayed for Present Position. Note that the Present Position cannot be set by the user, since it is the
output of a hardware module.
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SECTION 7: WINDRIVE
7.13 Equipment And Personal Safety
WinDrive contains several functions to ensure equipment and personal safety.
7.13.1 Manual Mode / Automatic Mode
Manual and Automatic operating modes are set from
the Limits Dialog box. Values are entered for both
the Manual and Automatic Mode limits for Torque
and Velocity. Manual Mode limits are always set
below those for Automatic Mode resulting in lower
Velocity or Torque operation than in Automatic
(normal) Mode.
Figure 7.54: Limits Dialog Box
7.13.2 IT Thermal Limits
The IT (current time) Limits Dialog box is opened under the
Drive/Set-up/IT Thermal Limits menu. Three limits may be set
here, the Peak Current, the Continuous Current and the IT
Time (peak current time) with IT Time being the maximum time
Peak current is allowed for. The IT Thermal Limits may be
defined as those of the motor - servo-drive configuration. To
maintain equipment safety, all three values should be set to lower
values than those corresponding to the rated peak current, the
continuous current and the peak current time of the connected
servomotor or servocontroller, whichever features the smaller
rating.
Figure 7.55: IT Thermal Limits Dialog Box
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SECTION 7: WINDRIVE
T200 User's Manual
7.14 Drive Disabling
The drive may be disabled at any time through several means. In case of emergency F2 may be pressed, the Stop Icon
clicked or Quick Stop selected from the Drive Menu to perform a Quick Stop.
The drive may be disabled by pressing the F4 key, clicking the relevant icon on the Floating Toolbar
Disable from the Drive Menu.
or selecting
CAUTION: The user should ensure that sufficient means exist to immediately disable the
T200 through hardware means in the event of a communications or other software
malfunction. This may be accomplished by switching the ENABLE digital input of the
T200 with the main machine safety switch (Red Emergency Button).
CAUTION: The user should be aware of any potential hazard for personnel or equipment
when disabling / Quick Stopping a motor. On disable, torque is removed from the motor
completely so that any vertical axis may fall down. Additionally, if the motor is fitted with
an optional brake, this brake stays open (released) when the drive is disabled. On Quick
Stop, the servo-controller generates a zero command, holding the motor in its current
position, and a warning is issued informing the user that the drive has to be disabled before
it can be re-enabled. Disabling the drive under these conditions will result in the same
behaviour as described for "normal" disabling above. If the motor is fitted with an optional
brake, the brake may be applied after commanding a Quick Stop. This causes the brake to
be applied and the controller to be disabled so that the motor shaft is held at its present
position.
7.15 Programmable Behaviour of Outputs
In certain applications it may be desirable to change the polarity of the System Ready Relay and / or the Thermal Limit
Output. These are programmable in the Invert System Ready Relay / Thermal Limit Output dialog.
Invert System Ready Relay Polarity: When the polarity
of the System Ready Relay is not inverted, it will be
closed if no fault or warning condition is present and
open in case of a fault or warning being detected by the
controller. Check the Invert System Ready Relay
Polarity checkbox to invert the polarity of the System
Ready Relay.
Invert Thermal Limit Output Polarity: When the
polarity of the Thermal Limit Output is not inverted, it
will be closed if no Foldback fault is present and open in
case of a Foldback fault being detected by the controller.
Figure 7.56: Invert System Ready Relay / Thermal Limit Check the Invert Thermal Limit Output Polarity
Output Dialog Box
checkbox to invert the polarity of the System Ready
Relay.
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SECTION 7: WINDRIVE
7.16 Brake Control
If an optional motor brake is fitted, this
may be controlled from the Drive Menu
with the Apply Brake and Release
Brake commands.
Figure 7.57: Apply Brake and Release Brake
options on the Drive Menu
7.17 Trouble Shooting
If WinDrive is unable to communicate with a servo-drive then the Graphical User Interface will issue a Communication
Time-Out message. If this occurs, check the following:
•
Check control and mains power to the drive.
•
Check the serial communications cable for correct connection and wiring.
•
Ensure that the drive has completed its boot-up cycle. WinDrive cannot communicate with the controller during
drive boot-up. Allow approximately 20 seconds for the drive to boot up, before attempting communication with
WinDrive.
If a time-out occurs during Log File upload / download or Save to EEPROM:
•
The Serial Cable should be checked for correct connection.
•
The value of the parameter “Timeout” under [[ComRs232] in the WinDrive.ini file may have to be increased for
older PC’s (default value: Timeout = 15000).
If other application problems are experienced when using WinDrive, the circumstances should be noted and MOOG
Applications Engineering should be contacted.
PAGE 7-54
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
C27095-001
PAGE 8-1
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
TABLE OF CONTENTS
HAND-HELD-TERMINAL INTERFACE ..................................................................................................................8-1
8.1
HAND-HELD-TERMINAL INTERFACE ("POD" MODE) ...................................................................................8-3
8.1.1
Establishing Serial Communications ........................................................................................................8-3
8.1.2
Command Line Format............................................................................................................................. 8-3
8.2
SERVO-DRIVE INITIALIZATION ........................................................................................................................ 8-5
8.2.1
Motor Configuration .................................................................................................................................8-6
8.2.2
Standard Motor Configuration .................................................................................................................. 8-6
8.2.3
Non-Standard Motor Configuration..........................................................................................................8-8
8.3
SERVO-DRIVE TUNING .....................................................................................................................................8-9
8.4
T200 HAND-HELD-TERMINAL COMMAND SET ............................................................................................ 8-10
8.4.1
Drive Set-up Commands......................................................................................................................... 8-11
8.4.2
Motor Set-up Commands........................................................................................................................ 8-11
8.4.3
Drive Limits Commands......................................................................................................................... 8-12
8.4.4
Digital Reference Velocity Commands...................................................................................................8-12
8.4.5
Encoder Simulation Commands..............................................................................................................8-12
8.4.6
Incremental Encoder Commands ............................................................................................................8-12
8.4.7
Incremental Encoder Commands ............................................................................................................8-12
8.4.8
Manual Mode Disable Commands..........................................................................................................8-12
8.4.9
Stepper Motor Interface Commands .......................................................................................................8-12
8.4.10
Loop Tuning Commands ........................................................................................................................ 8-12
8.4.11
Diagnostics Commands........................................................................................................................... 8-13
8.4.12
Warnings Commands.............................................................................................................................. 8-14
8.4.13
CAN Configuration Commands..............................................................................................................8-14
8.4.14
Local Mode Control Commands.............................................................................................................8-14
8.4.15
Invert Output Polarity Commands ..........................................................................................................8-14
8.4.16
Thermal Protection Commands...............................................................................................................8-15
8.4.17
User-Calibration Commands................................................................................................................... 8-15
PAGE 8-2
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
8.1 Hand-Held-Terminal Interface ("Pod" Mode)
Configuration and Tuning of the T200 is possible using a Hand Held Terminal. This section details the use of this
device.
WARNING - A User supplied hardware enable/disable switch wired so that the motor
can be stopped quickly in a emergency must be provided at all times. Software
enable/disable commands do not meet safety requirements and should never be used in
lieu of a hardware circuit. Refer to European standard EN 60204-1 for requirements for
Emergency Stop devices.
Required for
CE-Compliance
8.1.1
NOTE: Instruction on the use of the key sequences for hand held terminal, which allow
changes to the T200 configuration and tuning should be restricted to technically
qualified service and maintenance personnel only.
Establishing Serial Communications
For individual servo-drive communication the RS232 interface should be used. For multiple servo-drive applications,
RS-485 multi-drop communications may be used. Connect the terminal to the T200 Series Servo-drive Serial Port
Connector, see Figures 3.48 and 3.49.
Set the terminal serial interface parameters to 9600 baud, 1 stop bit, 8 data bits and no parity bits. There is no hardware
handshaking. See Section 3.18.1 RS232 Connection for a description of the cabling required to connect PC Serial Port to
the T200's J4 Serial Port. If terminal emulation software is used to configure the drive, the serial port of the PC should
be connected to that of the T200.
8.1.2
Command Line Format
Commands used when programming via a terminal consist of a max. string length of five characters (one, two and three
letter lengths are the most common). The first letter is common to a group of parameters and determines the action
desired. The second, third, fourth and fifth letters determine parameters. Each of the following letters represents the
initial character in a command string and indicates a functional group.
S: Set Parameter.
L: List Parameter.
O: Set/List Drive Option.
M: Drive Commands.
? : Enquire Commands.
Most parameters are entered as real numbers and are stored accurate to a very high precision. Numbers may be entered
using decimal or scientific notation with up to six significant digits. Examples of valid numeric entries:
PAGE 8-3
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
> -2.9 E -2 <CR>
Enter numbers and press RETURN.
> .029 <CR>
> 0.029 <CR>
> 203789 <CR>
> 203.789e3 <CR>
All string entries should be terminated by pressing the RETURN (<CR>) key.
If a command entry error is detected by the software, the following message will be displayed along with a prompt to reenter:
Invalid
Command
>
All numeric parameters entered are compared against an acceptable range. If a parameter is outside this range, then the
parameter remains at its present value.
CAUTION: In some case the T200 internal software truncates the entry, for safety or other
internal reasons. Note that no message is displayed when entries are truncated. Thus, it is good
practice to list all parameters using the appropriate [L] command after they have been entered.
All parameters may be set or listed when the motor is running. However, it is advisable to avoid large changes in
parameters in this case.
Other features of the Hand Held Terminal interface are:
§ The [CTRL H] key combination accesses a backspace function, allowing the deletion of incorrect command and
parameter entries. When configuring the T200 via terminal emulation software, user entries may be deleted with the
delete or backspace key.
§ The [CTRL X] key combination will reset the T200 Series Servo-drive and has the same effect on servo-drive
software as turning the power off then on.
§ Commands entered are not case sensitive, e.g. [ SP] and [ sp ] are both recognized.
§ When ( - more - ) is displayed, press carriage return to continue.
§ When current values of parameters are presented, they may be accepted by pressing RETURN (<CR>).
§ The Q button may be pressed at any time to exit a parameter entry/ parameter list table.
PAGE 8-4
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
8.2 Servo-drive Initialization
NOTE - The installation and wiring described in Section 3 should be completed
and verified before proceeding with servo-drive initialization.
CAUTION - The T200 Series Servo-drives with integrated power supply units
have a built in soft start feature. An on-board interlock disallows enabling of the
output inverter bridge until the soft start period has expired. This interlock
signal is also supplied to the user via the power ready relay. The output of the
power ready relay should be used in series with the enable interlock circuitry of
any T200 servo-drive without integrated power supply that takes its d.c. bus
power from the T200 with integrated power supply. Refer to Section 6.3.
WARNING - Perform all servo-drive initialization and configuration with the
servo-drive hardware enable OFF and power ON. Failure to follow the correct
procedure can result in machine damage and/or personal injury.
1.
Power should be applied to the T200 Series Servo-drive.
2.
The 7 segment display will illuminate all segments for a period of about 5 seconds. After this time a ‘P’ character
will be displayed on the 7 segment display.
3.
When the servo-drive has been properly initialised, then the appropriate fault, warning or operational status message
will be displayed on the 7 segment display.
4.
If a fault or warning message is displayed, refer to Section 10, Troubleshooting and correct the fault before
proceeding.
If the EEPROM contains configuration data, the servo-drive will display the following message:
T200 Monitor:
Starting Drive
EEPROM Start
Wait...
Doing Self
Calibration
Wait...
“Code Version”
EEPROM ID 0
>
PAGE 8-5
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
The servo-drive saves data in its Flash EEPROM, which is a non-volatile memory that retains data when power is
removed. When power is applied, the servo-drive will attempt to initialize itself using the data in its EEPROM. See
Section 6.13 for a description of the operation of the data storage systems of T200.
The servo-drive will be ready to enable once the 7 segment display on the front of the T200 displays either an ‘O’
character (for T200 is OK) or a ‘U’(warning character) followed by a digit.
If the user knows the configuration and parameters are satisfactory the servo-drive may be enabled without any further
input from the terminal. This would be the normal procedure after initialization and tuning have been completed.
8.2.1
Motor Configuration
The T200 Servo-drive has motor parameters installed for the G4XX series motors. These are considered “standard
motors”. Consult the factory for non-standard motor parameters. See Section 4.2 for a description of how to handle nonstandard motors. The cross-reference table in Section 4.2 should resolve almost all Moog-non-standard entry issues. This
table should help the user to find and enter a standard motor model (which has the same electrical type as the
non-standard motor, in most cases), for which the T200's own electrical model database contains all of the required data.
The motor's electrical Type, which is printed on the motor nameplate, is used as the table search key to establish the
equivalent standard motor model
8.2.2
Standard Motor Configuration
Drive configuration establishes what motor is connected to the T200 Series Servo-drive. The user must perform drive
configuration during initial commissioning or replacement of the equipment and any time a different motor is connected
to the servo-drive. If the servo-drive does not have valid configuration data in EEPROM, a cold start will occur upon
power-up. When a cold start occurs the servo-drive automatically executes a drive configuration command. A ‘P’
character is displayed on the 7 segment display to indicate that the T200 is in the parameterisation mode. The user will
be prompted by the message
SETUP THE MOTOR
(SSM/SNM) >
if a valid motor is not already set-up, in order to configure the drive with the appropriate motor.
The command [SSM] (Set Standard Motor) is used for drive initialization, if the motor is from Moog’s standard range of
motors. If the motor is a special design, then the command [SNM] (Set Non-Standard Motor) should be used. Example
of drive configuration for a Standard Motor:
SETUP THE MOTOR
(SSM/SNM) >SSM<CR>
Enter Drive Configuration Command.
Motor
?
NOTE - The SSM command is used to configure the T200 to operate with a
STANDARD Moog motor. If the motor is a NON-STANDARD motor, then the SNM
command should be used. This command prompts the user to enter all appropriate motor
parameters. Consult the Moog factory for values of these motor parameters
PAGE 8-6
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
After entering the SSM command, the user should then enter a valid motor model number. An example of such a model
number is given below.
Drive Disabled
Motor:? Enter appropriate motor model number here e.g. G424-400
>
NOTE - It is important that the motor model number is entered correctly as the T200 Series
Servo-drive sets many parameters automatically based on this configuration. It is also important
to confirm that the proper servo-drive model is connected to the proper motor. The servo-drive
type can be checked by using the 'LC' command. The motor type can be checked by using the
'LM' command.
The servo-drive is pre-programmed with all motor parameters for standard motor models, (refer to Tables 4-4 and 4-5).
For non-standard motor models the user must manually enter the motor parameters (refer to Section Non-Standard
Motor Configuration).
Upon entry of the motor model number the T200 will respond as follows:
Wait
Doing Self
Calibration
Wait...
Defaults Set
>
NOTE - Re-configuring the drive by changing the motor type, the compensator etc. will cause all
previous tuning information to be lost.
The T200 has now initialised and has set its parameters to the following default values before returning to the input
prompt
§ Servo-drive in Velocity Mode.
§ Limit switches enabled.
§ Manual mode enabled.
§ Speed scaling set to nominal value of motor speed.
§ Low P gain and long I time constant for velocity loop compensator.
This new configuration data will be lost when power is removed unless it is saved to the Flash EEPROM. However, all
setup and tuning procedures of Section 6 should be completed before performing this step.
PAGE 8-7
T200 User's Manual
8.2.3
SECTION 8: HAND-HELD-TERMINAL INTERFACE
Non-Standard Motor Configuration
Applications employing non-standard motor models (other than the G4XX series) require the data listed in Table 8.1
PARAMETER
Torque Constant (Kt)
Stator Resistance (Rtt)
Quadrature
Axis
Motor
Inductance
Direct Axis Motor Inductance
Nominal Motor Speed
Maximum Motor Speed
Peak Rated Motor Current
Current Loop Gain
Number of Motor Poles
Rated Continuous Motor Ø
Current (Ic)
Rated Peak Motor Ø
Current (Ip)
Motor Nominal Speed
Current Loop Gain
Motor Observer Inertia (Jm)
Resolver Pole Pairs
Motor Thermistor
UNITS
Nm/Ar.m.s. or Nm/Aeff
Ohms (Ω)
Millihenries (mH)
Millihenries (mH)
RPM
RPM
Ar.m.s. or Apeak
0 to 15
Usually 8 or 12 for Moog motors
Ar.m.s. or Apeak
Ar.m.s. or Apeak
RPM
0 to 15
kg-cm2
Usually 2 for Moog motors
True or False
Table 8.1:- Non-Standard Motor Parameter Set
NOTE - The following conversions are useful for motor parameters:
Kt (Nm/ Ar.m.s.) = .113 * Kt (lb-in/Ar.m.s.)
Ic (Ar.m.s.) = Tc (Nm) / Kt (Nm/Ar.m.s.)
Ip (Ar.m.s.) = Tp (Nm) / Kt (Nm/Ar.m.s.)
where:
Ic = Rated Continuous Motor Phase Current
Tc = Rated Continuous Motor Torque
Ip = Rated Peak Motor Phase Current
Tp = Rated Peak Motor Torque
To configure for a non-standard motor, proceed with drive initialization as outlined previously. Use the [SNM]
command. Enter the non-standard motor model number when prompted for the motor model number. After confirming
the model number entered, the servo-drive will recognize a non-standard motor model number and prompt for entry of
the motor parameters listed above.
PAGE 8-8
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
8.3 Servo-drive Tuning
Section 6 already contains a comprehensive overview, which is oriented at the Hand-Held terminal interface, on how to
tune the T200 control loops. Please refer to this section for a procedure on how to tune the loops.
PAGE 8-9
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
8.4 T200 Hand-Held-Terminal Command Set
The following is a list of commands for the hand held pod interface of the T200.
User Information: If the Win-Drive User Interface was previously used with the T200, and the Hand Held Terminal is
subsequently used without power cycling of the T200, the user may experience difficulty in establishing communication
with the Hand Held Terminal. If this occurs simply type <CR> several times at the Hand Held Terminal and the prompt
‘>’ will appear on the display. This prompt indicates that the T200 is now communicating properly with the Hand Held
Terminal.
PAGE 8-10
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
8.4.1
LC
LV
C
*
SUP
OR
OC
SD
LD
SU
or Imperial units.
For current units, input
[A] or [Arms], in order to enter Apk or
Arms.
Drive Set-up Commands
List the Servo-drive Size and Power
Configuration
List the Software Version
Save all parameters to non-volatile
storage
Enter the Password to enable
privileged mode access
Modify the Password (once in
privileged mode)
Set the drive control loop reference
source. Options:
1. Analogue Input used as the
control loop Reference Source
2. Internal Function Generator
used as the control loop Reference
Source
3. Point Motion Control Reference
Source used as the control loop
Reference Source. Only available
when ‘Px’software is programmed
in the T200.
4. CAN Profile Mode Reference
Source used as the control loop
Reference Source
5. Digital Inputs Speed Reference
6. Excitation Source (self tuner sets
this up automatically). This is used
exclusively by WinDrive.
7. Stepper Motor Interface (use
OSM and OSL to set up the mode
and the number of pulses per
revolution)
Set the drive control loop operational
mode. Options:
1. Torque Mode only
2. Velocity Mode with 2nd Order
torque filter
3. Velocity Mode with 1st Order
torque filter
4. Position Loop mode
Sets the axis ID. If this number is set
to a non-zero value, then the hardware
HEX Switches are ignored and the
value entered here used instead.
List the axis identification number
set by the HEX switches on the front
panel of the T200
Set the Parameter Units
e.g. for torque units, input
[Nm] or [lb-in] in order to setup metric
8.4.2
SSM
SNM
LM
RO
RP
SBV
Motor Set-up Commands
Set STANDARD motor parameters.
This command is used in the case
where the motor is a Moog standard
catalogue item.
Set
NON-STANDARD
motor
parameters, which prompts the user for
the following information, which is
available from the motor datasheet:§ Motor Name e.g. G424-123
§ Number of Motor Poles
§ Kt (Motor Back-EMF Constant)
§ Rtt (Motor phase to phase
resistance constant)
§ Ltt (Motor phase to phase
inductance)
§ Ld (Motor direct axis inductance)
§ Lq (Motor quadrature axis
inductance)
§ Nominal Speed (i.e. rated motor
speed)
§ Maximum Speed (maximum
allowed speed for the motor
mechanics)
§ Peak Current Limit
§ Current Loop Gain (I-Gain)
§ Number of Resolver Poles
§ Continuous Stall Current
§ Motor
temperature
sensing
thermistor present or not
§ Inertia of motor and load, if
available
Lists all motor parameters with
which the drive has been configured.
Set the Resolver Offset Angle
Set the number of Resolver Poles
Set the Bus Voltage. This is given by
(rms phase to phase mains voltage *
1.414)
PAGE 8-11
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
8.4.3
8.4.7
SE
SLA
SLM
STA
STM
STT
STV
SRT
SRV
Drive Limits Commands
Set the Emergency Deceleration Rate
for Quick-Stops and Limit Switch
activation.
Set the Automatic Mode Velocity
Limit
Set the Manual Mode Velocity Limit
Set the Automatic Mode Torque
Limit
Set the Manual Mode Torque Limit
Set the Torque Rate Time (i.e. the
time over which the torque is allowed
to increase to the Torque-Rate-Value)
Set the Torque Rate Value
Set the Velocity Rate Time (i.e. the
time over which the velocity is allowed
to increase to the Velocity-Rate-Value)
Set the Velocity Rate Value
8.4.4 Digital Reference Velocity
Commands
SS
Set Digital Reference Velocities for
digital reference mode
OL
8.4.8
OM
8.4.9
OSL
OSM
SFFE
LFFE
Encoder Simulation Commands
OEL
Set the Encoder Simulation Line
Count
Set the Encoder Simulation Encoder
Angle
Set
the
Encoder
Simulation
Short/Long Marker
Enable or disable the Encoder
Simulation Filter, if not in high
bandwidth mode.
OEA
OEM
OEO
8.4.6
SR
SI
IU
ID
SP
PD
PU
SW
Incremental Encoder Commands
SZ
OIL
OILA
PAGE 8-12
Set the number of Incremental
Encoder Lines per Revolution
Set the number of Incremental
Encoder Offset Lines, from its zero
marker
Enable/Disable the Hardware Limit
Switches
Manual Mode Disable Commands
Enable or Disable Manual Mode
Stepper Motor Interface
Commands
Set the Stepper Motor Number of
Pulses per Revolution
Set the Stepper Motor Mode:1. Quadrature Mode
2. Step and Direction Mode
3. Up/Down Mode
Set Following Error Limit
List Following Error Limit
8.4.10 Loop Tuning Commands
SN
8.4.5
Incremental Encoder Commands
SGI
Set the Velocity Scaling of the analog
input channels, in units of RPM per
10V
Set the Position Scaling of the analog
input channels, in units of Revolutions
per 10V
Set the Integral Time Constant of the
velocity loop compensator
Decrease the Integral Time Constant
of the velocity loop compensator
Increase the Integral Time Constant
of the velocity loop compensator
Set the Velocity Loop Gain P
Increase the Velocity Loop Gain P
Decrease the Velocity Loop Gain P
Set the torque Filter Frequency (used
only when in velocity mode and
position mode using ‘OC’command)
Set the torque Filter Damping (used
only when in velocity mode using ‘OC’
command)
Set the Position Loop Integral Gain
GI
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
SGP
GD
GU
SGT
SGV
SJ
JD
JU
OO
SSA
VP
SSA
VB
SSAT
P
SSAT
B
OSP
Set the Position Loop Proportional
Gain G
Decrease
the
Position
Loop
Proportional Gain G
Increase
the
Position
Loop
Proportional Gain G
Set the Torque Feedforward Gain
GT
Set the Velocity Feedforward Gain
GV
Set the Observer Inertia J
Decrease the Observer Inertia J
Increase the Observer Inertia J
Enable or disable use of the
Observer Velocity Estimate
Set Set-Point-Achieved Velocity
Set Set-Point-Achieved Velocity
Band
Set
Set-Point-Achieved
Torque
Percentage (as a fraction of PeakTorque of the motor servo-drive
combination)
Set Set-Point-Achieved Torque Band
Enable the Set-Point Achieved fuction
8.4.11 Diagnostics Commands
OTA
OTB
Set the internal process variable which
is to be displayed on analog Test Point
A:1. Torque
2. Commanded Velocity
3. Actual Velocity
4. Error Velocity
5. Reference Position
6. Actual Position
7. Error Position
8. Filtered Actual Velocity
9. Observer Estimated Velocity
10. Observer Estimated Error
11. Point Diagnostic Channel 1
Set the internal process variable which
is to be displayed on analog
Test Point B
1. Torque
2. Commanded Velocity
3. Actual Velocity
4. Error Velocity
5. Reference Position
6. Actual Position
OTP0
SFI
LFI
?B
?E
?F
?FL
?G
?H
?L
?LB
?LM
?LMR
?LR
?LRR
?M
?O
?P
?PF
?PR
?S
?V
7. Error Position
8. Filtered Actual Velocity
9. Observer Estimated Velocity
10. Observer Estimated Error
11. Point Diagnostic Channel 2
Zero reference the test point output
position display variable
Set Mode of Fault Indication
List Mode of Fault Indication
List the Power Amplifier heatsink
temperature
List the Encoder Position
List the present fault conditions
List the present latched fault
conditions.
NOTE:- the T200 front panel 7segment display shows all fault
conditions, which occurred up until this
command, is used. Use of this
command then clears the display of
such faults, if these faults are no longer
present.
Check Gravity Compensation Status
List the Fault History of the drive.
List the maximum allowed drive
phase current
List the bridge thermal current limit
List the motor thermal current limit
Check the average motor RMS
current over the last 28s (used for
applications sizing)
List the RMS thermal current limit
Check the average regeneration
power expended over the last 28s
List the motor windings temperature
Lists if the Point Extended I/O Card
is present or not.
List the present Motor Position
List Personality Plug Faults
List the present number of Motor
Revolutions travelled.
List the following T200 Status items:• Programmed Compensator type
• Programmed Reference
• Torque-Mode
• Disabling of Limit Switches
• Disabling of Thermal Protect
• Disabling of Manual Mode
• Indication of Break Released
• Enabling of use of the Velocity
Observer
List the present average velocity of
the motor
PAGE 8-13
T200 User's Manual
SECTION 8: HAND-HELD-TERMINAL INTERFACE
8.4.12 Warnings Commands
8.4.14 Local Mode Control Commands
STD
STS
SVL
SVT
RE
ORM
ORR
Set the position tracking dynamic
error band ∆, in %
For a P-position loop:
Position-Error =
Velocity/Position-G-Gain
If Position-Error > Velocity * ∆ / G
then a CAN warning is issued
Set the static loop warning position
error, in position increments. If the
position error exceeds this, then a CAN
warning is issued.
Set the warning level for the Velocity
7-segment warning
Set the Warning Time for the
Velocity 7-segment warning
Disable Regen Exceeded
Set Regen Exceeded Mode
Set Regen Resistor Resistance
OFA
OFD
OFI
OFN
OFNO
OFO
OFP
OFS
OFT
OFTO
8.4.13 CAN Configuration Commands
SCB
OCS
OGM
OGN
OHA
OHP
OHS
OL+
OLOLS
OMR
?C
SCB
SCR
OCM
T
PAGE 8-14
Set the CAN Baud Rate
Set CAN Position Scaling for the
Interpolation Mode
Set gearing M factor
Set gearing N factor
Set the home switch angle in
mechanical degrees
Set the home switch polarity
Set the home cycle speed
Set the software position counter
clockwise limits
Set the software position clockwise
limits
Enable/Disable the software limit
switches
Select the reference or actual as the
source of the Master Angle
Check CAN Status
Set the CAN Baud Rate in kBaud
Set the CAN-Communication Cycle
Period
Choose the CAN Mode
1. Profile Mode
2. Interpolation Mode
Invoke the Motion Control Menu
MB
MI
MO
MQ
MT
MV
Set the Function Generator
Acceleration
Set the Function Generator Duty
Cycle
Start the Function Generator (used
in position mode only, as set using
the ‘OC’command)
Set the Function Generator Speed
Amplitude
Set the Function Generator Speed
Offset
Stop the Function Generator (used
in position mode only, as set using
the ‘OC’command)
Set the Function Generator Period
Set the Function Generator
Position Traverse
Set the Function Generator Torque
Amplitude
Set the Function Generator Torque
Offset
Apply / Release the motor braka
Enable the T200 (the hardware
enable must already be conducting
current)
Disable the drive
Quick Stop the drive
Set the drive into Torque Mode
(ONLY functions if the drive is
already in velocity mode).
Set the drive into Velocity Mode
(ONLY functions if the drive is now
programmed to velocity mode, but
has been switched to torque mode
using the ‘MT’command)
8.4.15 Invert Output Polarity Commands
OIS
OIT
Invert System Ready Relay polarity
Invert Thermal Limit Active
Output polarity
SECTION 8: HAND-HELD-TERMINAL INTERFACE
T200 User's Manual
8.4.16 Thermal Protection Commands
IT
Set the IT Protection parameters:
• Ipeak
• Icont
• Max Time at Ipeak
OD
Disable the Thermal Protection
8.4.17 User-Calibration Commands
OI
OZ
RDCO
RDSO
RDGF
Set the Analog Input Offset on the
analog reference input
Zero the Analog Input Offset on the
analog reference input
Set the resolver interface Cosine
channel offset
Set the resolver interface Sine
channel offset
Set the gain matching coefficient
between the Sine and Cosine
channels of the resolver interface
PAGE 8-15
T200 User's Manual
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PAGE 8-16
SECTION 8: HAND-HELD-TERMINAL INTERFACE
SECTION 9: CAN INSTALLATION
T200 User's Manual
SECTION 9: CAN INSTALLATION
Version 37/00
PAGE 9-1
T200 User's Manual
SECTION 9: CAN INSTALLATION
TABLE OF CONTENTS
SECTION 9:
CAN INSTALLATION ................................................................................................................ 9-1
9.1
INTRODUCTION ......................................................................................................................................... 9-3
9.2
CAN CABLE WIRING ................................................................................................................................ 9-4
SECTION 9 TABLE OF FIGURES
Figure 9.1:- CAN Wiring and Termination ............................................................................................................ 9-4
Figure 9.2:- CAN-In/CAN-Out Connector (J2 and J3) Wiring.............................................................................. 9-5
PAGE 9-2
SECTION 9: CAN INSTALLATION
T200 User's Manual
9.1 Introduction
CAN is an abbreviation for the Controller Area Network. This is a high speed serial interface which was designed for
use in Automotive and Industrial applications.
The T200 provides two CAN Modes of operation:1. CAN Interpolation Mode:- The System Motion Controller transmits target positions at high data rates, and the T200
finely interpolates these positions to follow the target trajectory.
2. CAN Profile Mode. The System Motion Controller offloads complex motion calculations to the T200, which
provides the following functions:§ Point to Point Mode. The Control Computer transmits a target position, velocity and acceleration via the CAN
interface. The T200 generates a smooth trajectory to the target position using this data.
§ Gearing Mode. A 'master' T200 generates a 'Master-Angle' position reference at a high rate. One or many
T200 'slaves' receive this reference. These slaves multiple the 'Master-Angle' by a user programmed factor, and
use the result as their command position.
§ Camming Mode. Slave T200's simulate a mechanical cam with high precision. Slave T200's transform the
'Master-Angle' through a user defined cam shape, and use the result as their command position.
§ Velocity Mode. The T200 operates in velocity mode, with the command velocity and torque limit transmitted at
high speed via the CAN interface.
CAN Profile and Interpolation modes are described in detail in additional documents:1. CAN Protocol for Interpolation Mode and
2. CAN Protocol for Profile Mode
These documents are available on request from Moog Sales Outlets (See Section 11 for addresses and phone numbers).
Users are directed to read Section 2, Safety Instructions, before proceeding with installation.
PAGE 9-3
T200 User's Manual
SECTION 9: CAN INSTALLATION
9.2 CAN Cable Wiring
The CAN-In and CAN-Out ports at J2 and J3 of the T200 provide the means to daisy-chain the CAN cabling between
T200 units. Note:1. CAN lines must be terminated in a 120Ohm resistance, between the positive and negative terminals (CAN-High and
CAN-Low).
2. The CAN circuitry is isolated from the T200 logic power. An internal DC/DC – converter generates the supply
voltage for the isolated CAN interface.
Figure 9.1:- CAN Wiring and Termination
PAGE 9-4
SECTION 9:- CAN INSTALLATION
T200 User's Manual
Figure 9.2:- CAN-In/CAN-Out Connector (J2 and J3) Wiring
PAGE 9-5
T200 User's Manual
SECTION 9: CAN INSTALLATION
This page is intentionally left blank.
PAGE 9-6
SECTION 10: TROUBLE-SHOOTING GUIDE
SECTION 10:
C27095-001
T200 User's Manual
TROUBLE-SHOOTING GUIDE
PAGE 10-1
T200 User's Manual
SECTION 10: TROUBLE-SHOOTING GUIDE
How to use this Section
The table of contents below should help the user to understand problems and find solutions. The status of the T200
power status LED’s and 7-segment display is used as the starting point.
§ The user should check if a fault or warning code is displayed on the 7-segment display. If so the user can use the
table of contents below as a cross-reference to the appropriate troubleshooting section.
§ If no useful status, warning or fault code is present on the 7-segment display, then the user can check the 'Other
Problem Sources' section to find help on troubleshooting.
TABLE OF CONTENTS
TROUBLE-SHOOTING GUIDE................................................................................................................................ 10-1
10.1
INTRODUCTION...............................................................................................................................................10-4
10.2 POWER STATUS LED'S NOT ILLUMINATED ..................................................................................................10-5
10.2.1
Fault Type: Mains-Applied LED is not lighting (T200-X10 ONLY) ..................................................... 10-5
10.2.2
Fault Type: DC-Bus-Active LED is not Lighting................................................................................... 10-6
10.2.3
Fault Type: Regen-Active LED always lighting (T200-X10 ONLY)..................................................... 10-6
10.3 SEVEN-SEGMENT DISPLAY STATUS...............................................................................................................10-7
10.3.1
Fault Type: 7-Segment Display does not Illuminate...............................................................................10-7
10.3.2
Status Type: 'P' constantly on 7-segment Display................................................................................... 10-7
10.4 'F' SYMBOL FOLLOWED BY NUMBER ON SEVEN-SEGMENT DISPLAY (FAULTS) .........................................10-8
10.4.1
Fault Type: F1 (Phase Overcurrent) on 7-segment Display....................................................................10-8
10.4.2
Fault Type: F2 (DC-Bus Overvoltage) on 7-segment Display................................................................ 10-9
10.4.3
Fault Type: F3 (Fuse Fault) on 7-Segment Display..............................................................................10-10
10.4.4
Fault Type: F4 (PSU Heatsink Overtemperature) on 7-Segment Display ............................................10-11
10.4.5
Fault Type: F5 (Power Amplifier Over-temperature) on 7-segment Display .......................................10-11
10.4.6
Fault Type: F6 (Motor Over-Temperature) on 7-Segment Display ...................................................... 10-12
10.4.7
Fault Type: F7 (Internal Software Fault) on 7-Segment Display.......................................................... 10-13
10.4.8
Fault Type: F8 (Resolver Fault) on 7-segment Display........................................................................10-13
10.4.9
Fault Type: F9 (Internal DC/DC Fault) on 7-segment Display............................................................. 10-14
10.5 'U' SYMBOL FOLLOWED BY NUMBER ON SEVEN-SEGMENT DISPLAY (WARNINGS) .................................10-15
10.5.1
Warning Type: U1 (a.c. Mains has not been applied) on 7-Segment Display ......................................10-15
10.5.2
Warning Type: U2 (Motor Temperature Warning) on 7-Segment Display ..........................................10-16
10.5.3
Warning Type: U3 (Power Amplifier Warning) on 7-Segment Display...............................................10-17
10.5.4
Warning Type: U4 (Position Error Warning) on 7-Segment Display ................................................... 10-18
10.5.5
Warning Type: U5 (Velocity Error Warning) on 7-Segment Display .................................................. 10-19
10.5.6
Warning Type: U6 (External Regen Resistor Warning) on 7-segment Display ...................................10-20
10.5.7
Warning Type: U7 (CAN Communications Warning) on 7-segment Display......................................10-21
10.5.8
Warning Type: U8 (Limit Switches Warning) on 7-segment Display.................................................. 10-22
10.5.9
Warning Type: UA (Quick-Stop Warning) on 7-segment Display....................................................... 10-23
10.5.10 Warning Type: Ub (Stepper or Inc. Encoder Warning) on 7-segment Display ...................................10-24
10.5.11 Warning Type: Dot (Thermal Limit Warning) on 7-segment Display ................................................10-25
PAGE 10-2
SECTION 10: TROUBLE-SHOOTING GUIDE
T200 User's Manual
10.6 OTHER PROBLEM SOURCES ........................................................................................................................ 10-26
10.6.1
Problem: T200 will not enable ............................................................................................................. 10-26
10.6.2
Problem: T200 is Enabled, but will not move the Axis........................................................................ 10-27
10.6.3
Problem: T200 Movement is not Smooth............................................................................................. 10-28
10.6.4
Problem: Excessive Audible Noise from the Motor............................................................................. 10-29
10.6.5
Problem: Motor Shaft rotates in the Wrong Direction ......................................................................... 10-30
10.6.6
Problem: No ESM Position Feedback from the T200 .......................................................................... 10-31
PAGE 10-3
T200 User's Manual
SECTION 10: TROUBLE-SHOOTING GUIDE
10.1 Introduction
The following tables list typical system, controller, and motor troubleshooting conditions. A list of possible cause(s) is
given for each condition. For some conditions, there are multiple possible causes which are generally listed in order of
increasing complexity or decreasing likelihood for the stated conditions. A list of check/correct action recommendations
are listed below each possible cause(s).
The T200 provides extensive diagnosis of fault conditions and warnings, as well as high power status information. This
diagnostic information is intended to aid in the troubleshooting of applications and controller problems. The following
sections explain why high power status LED are illuminated, and what problem sources can cause faults and warnings to
be displayed on the 7-segment display. Additional diagnosis information is provided for other sources of faults.
WARNING: Do not attempt to repair or make internal adjustments to the controller or
power supply. Lethal voltages are present and changes to factory calibration can result
in serious equipment and/or personnel risk and void the equipment warranty. All faulty
items of this equipment must be returned to Moog Service Centres for maintenance and
repair.
PAGE 10-4
SECTION 10: TROUBLE-SHOOTING GUIDE
T200 User's Manual
10.2 Power Status LED's not Illuminated
Section 3.19 T200 User Visual Indications outlines the functionality of the power status LED's on the T200. The
following is list of problem sources and corrective actions when these LED's fail to illuminate, or in the case of the
REGEN-ACTIVE LED, is constantly illuminated.
10.2.1
Fault Type: Mains-Applied LED is not lighting (T200-X10 ONLY)
Table 1: Causes of Mains Applied LED not illuminated
Cause
a.c. Mains Power
disconnected from
T200 TB2 Connector
Check/[Correction]
§ Single phase or three phase a.c. mains plant supply is available [Switch-on plant a.c.
mains power if safe to do so]
§ a.c. Mains Input Circuit Breaker conduction status. [Switch circuit breaker to
conduction if safe to do so]
§ Repeated Earth Leakage Circuit Breaker trips. The T200 can have earth leakage
currents up to 10mA per phase, if no isolation transformer is used. [Use an Earth
Leakage Circuit Breaker with a trip level of higher than 30mA. Alternatively install an
isolation transformer to remove nuisance earth leakage currents.]
§ IF PRESENT, check a.c. Mains Conducted Emissions Filter wiring and misconnections [Check single phase filter wiring against recommended wiring practise]
§ Optional a.c. mains contactor is closed (user option to supply this) [Check user control
circuits and interlocks which may prevent the mains contactor from closing. Check
interlock systems which use the T200s' System Ready Relay fault status indication
output]
§ Transformer termination mis-wired or not connected [Check the wiring of the usersupplied transformer]
a.c. Mains Voltage
too Low
Magnitude of a.c. Mains voltage Line to Line at TB2. a.c. voltage should be in range 100V
r.m.s. to 255Vr.m.s. [a.c. Voltage may be too small to drive the T200 internal power
electronics circuitry, without tripping fast bus discharge circuitry. Ensure that the a.c.
mains voltage magnitude is within the range listed above].
PAGE 10-5
T200 User's Manual
10.2.2
SECTION 10: TROUBLE-SHOOTING GUIDE
Fault Type: DC-Bus-Active LED is not Lighting
Table 2: Causes of DC-Bus-Active LED not lighting
Cause
Check/[Correction]
a.c. Mains not
Applied (T200-X10
Units ONLY)
Regeneration Fuse
Blown (T200-X10
Units ONLY)
Check Mains Applied LED status. If this is not lit then the DC-Bus-Active LED cannot be
illuminated. [Corrections as per Fault Type: Mains-Applied LED is not lighting (T200-X10
ONLY)]
Check for F3 Fault on the 7-segment display that indicates that the internal regeneration
resistor fuse is blown.
Repeated a.c. mains power-on cycles within a short period will cause repeated softstart
cycles. These will eventually cause the fuse to be blown.
WARNING: The T200 should never be opened. Consult Moog
Applications Engineering for help on replacement of the fuse.
[Reduce the frequency of power-on/off cycles to be less than one cycle every 4.5 seconds.
Alternatively reduce the number of T200-X00's (units without integral High-Power PSU)]
which are connected to the T200-X10 (unit with integral High-Power PSU).]
Too Many T200-X00
Units Connected to
DC-Bus
DC-Bus Fuse Blown
in T200-X10
Too many T200-X00 Units connected to the T200-X10 unit will cause the softstart
mechanism to malfunction. Note that a maximum of 4 T200-X00 units can be connected to
a T200-X10 unit [Reduce the number of T200-X00's (units without integral High-Power
PSU) which are connected to the T200-X10 (unit with integral High-Power PSU)].
The DC-Bus Active LED does not light in T200-X00's, but does light in T200-X10's.
[Check the DC-Bus wiring interconnect to all connected T200-X00 units, as outlined in
Section 3. In particular check that the DC-Bus wiring from the T200-X10's TB3 connector
has not been reversed in polarity when connected to the T200-X00's TB2 connector, or that
DC+ and DC- terminals have not been connected to PE (protective earth). ]
WARNING: The T200 should never be opened. Consult Moog
Applications Engineering for help on replacement of the DC-Bus output
fuse.
10.2.3
Fault Type: Regen-Active LED always lighting (T200-X10 ONLY)
Table 3: Causes of Regen-Active LED constantly illuminated
Cause
Logic Backup Power
is Applied, a.c.
Mains Voltage is
NOT Applied
PAGE 10-6
Check/[Correction]
Same checks and corrections as Fault Type: Mains-Applied LED is not lighting (T200-X10
ONLY)
SECTION 10: TROUBLE-SHOOTING GUIDE
T200 User's Manual
10.3 Seven-Segment Display Status
The following section deals with T200 7-segment display status conditions. These are conditions that indicate to the user
a particular T200 state. They may or may not indicate real problems with the unit. For example, if the 7-segment display
is not illuminated, then there is no high voltage or logic backup power applied to the T200.
10.3.1
Fault Type: 7-Segment Display does not Illuminate
The 7-segment display will always illuminate when sufficient logic power is available in the T200. Logic power is
derived from the high voltage DC-Bus, or the 24V d.c. or 120V a.c. mains input.
Table 4: Causes of 7-Segment Display not illuminated
Cause
Check/[Correction]
High Power source
has not been applied
The high voltage a.c. mains or the high voltage d.c. bus power is not available at TB2.
[Check the availability of high power by checking the status of the Mains-Applied and the
Bus-Active LED's]
24Vd.c. or 120Va.c.
Backup Power not
Applied
24V Backup Power
Reversed
10.3.2
24V d.c. or 120Va.c. Logic backup power availability. [Check the presence of the user
supplied backup power source]
The 24V d.c. power source pins have been reversed. [Check the polarity of the connection of
the 24Vd.c. inputs power connection on TB5. Note that the input has a resetable fuse. When
the polarity is corrected, the fuse will return to the conduction mode.]
Status Type: 'P' constantly on 7-segment Display
The 7-segment display will always illuminate when sufficient logic power is available in the T200. Logic power is
derived from the high voltage DC-Bus, or the 24V d.c. or 120V a.c. mains input.
Table 5: Causes of Constant 'P' on 7-segment Display
Cause
Check/[Correction]
Motor has not been
Configured
The motor has not been correctly configured. [Check Section 4.2 on how to configure a
standard or non-standard motor in the T200. Configure the motor, set-up the appropriate
control configuration in the T200 and save the configuration to the non-volatile storage.]
Incorrect Software
Configuration
The T200 software has been configured in a mode which does not allow it to continue
without risk of damage to the T200, the motor or the load. [Upload the motor configuration
using the WinDrive File-Configuration Upload command. Fax or email the uploaded .log
configuration file to the Moog Application Engineers.]
PAGE 10-7
T200 User's Manual
SECTION 10: TROUBLE-SHOOTING GUIDE
10.4 'F' Symbol Followed by Number on Seven-Segment Display (Faults)
The following section deals with fatal T200 faults. These are fault conditions, which cause the T200 to immediately
remove high power from its power amplifier. If the fault condition has not been removed, then the T200 cannot generate
torque in the motor.
10.4.1
Fault Type: F1 (Phase Overcurrent) on 7-segment Display
The F1 fault is displayed when a motor phase over-current has occurred. The T200 disabled itself immediately when the
fault occurred.
Table 6: Causes of F1 on 7-segment Display
Cause
Short Circuit on
Motor Phase
Check/[Correction]
There is a short circuit from one of the motor phases (U, V, W on TB8) to one of the other
phases, to the DC-Bus terminals (DC+ and DC- on TB3) or to Protective Earth.
[Check the wiring and remove the short circuit]
Incorrect Motor
Configured in
Software
Incorrect Current
Loop Gain
PAGE 10-8
An incorrect motor has been configured, and motor over-current occurs, especially during
a high deceleration movement of the motor. [Check the motor nameplate and configure
the correct motor in the T200 per Section 4.2 of this manual. If the motor is a non-Moog
motor then check that all of the motor parameters have been entered in the WinDrive
dialog box (see Section 7.10.1.2 or Section 8.2.3)]
The current loop gain is not sufficient for adequate control of phase currents, if the motor
is a non-Moog motor. [Check the motor parameters (Section 7.10.1.2), and fax or email
these to Moog Applications Engineering for calculation of current loop gain for the nonMoog motor.]
SECTION 10: TROUBLE-SHOOTING GUIDE
10.4.2
T200 User's Manual
Fault Type: F2 (DC-Bus Overvoltage) on 7-segment Display
The F2 fault is displayed when the DC-Bus voltage exceeds 400V d.c. The T200 disabled itself immediately when the
fault occurred.
Table 7: Causes of F2 on 7-segment Display
Cause
Internal
Regeneration
Resistor not
adequate
Load Deceleration is
Excessive
Load Returning too
much Power
High Line Voltage/
Incorrect
Transformer Tap
Check/[Correction]
The internal regeneration resistor is not adequate to dissipate the kinetic energy returned
from the load, when the motor decelerates, or has to hold an overrunning or vertical axis
with a heavy load.
[Install an external regeneration resistor as detailed in Section 3.13.]
The deceleration of the load is excessive, and regenerative energy is returned too fast for
the regeneration resistor to dissipate. [Decrease the deceleration rate programmed in the
motion control system. Alternatively use an external regeneration resistor.]
As above the load returns too much power. Check the continuous regeneration energy
return, using the Hand-Held Terminal '?LRR' command. [If a vertical load is carried, a
counterbalance may be needed. Alternatively a larger sized T200, with extra regenerative
power capability may be required. See Section 3.13 for ratings.]
The line voltage at TB2 is too high. Measure the a.c. mains voltage at TB2 of the T200X10 (unit with integral PSU).
Check the step down transformer, to see if the tap off the secondary side of the transformer
is at the correct position.
[Install a step down transformer.
OR
Correct the transformer wiring.]
PAGE 10-9
T200 User's Manual
10.4.3
SECTION 10: TROUBLE-SHOOTING GUIDE
Fault Type: F3 (Fuse Fault) on 7-Segment Display
The F3 fault is displayed when either the internal regeneration resistor fuse (ONLY on T200-X10 units) or the DC bus
fuse or both fuses have blown. If the drive is enabled the T200 decelerates and disables itself immediately when the fault
occurs. The controller cannot be enabled if it is disabled when the fault occurs.
Table 8: Causes of F3 on 7-segment Display
Cause
Excessive Rate of
Power Cycling
Check/[Correction]
Repeated a.c. mains power-on cycles within a short period will cause repeated softstart
cycles. These will eventually cause the fuse to be blown.
WARNING: The T200 should never be opened. Consult Moog
Applications Engineering for help on replacement of the fuse.
[Reduce the frequency of power-on/off cycles to be less than one cycle every 4.5 seconds.]
Too Many T200-X00
Units Connected
•
Too many T200-X00 units connected to the T200-X10 unit will cause the softstart
mechanism to malfunction. Note that a maximum of 4 T200-X00 units can be
connected to a T200-X10 unit. This will cause the Internal Regeneration Resistor fuse
to blow.
•
The T200-X00 connected to the T200-X10 draw too much current from the DC bus
during normal operation. This will cause the DC bus fuse to blow.
[Reduce the number of T200-X00’s (units without integral High-Power PSU) which are
connected to the T200-X10 (unit with integral High-Power PSU).]
Load Returning too
much Power
DC Bus Daisy Chain
connection
mis-wired
As above the load returns too much power. [If a vertical load is carried, a counterbalance
may be needed. Alternatively a larger sized T200, with extra regenerative power capability
may be required. See Section 3.13 for ratings.]
If the DC Bus Daisy Chain connection is mis-wired (i.e. the two wires have been swapped),
excessive current will be drawn from the DC bus output prior to where the mis-wiring
occurred. This will cause the DC bus fuse to blow.
[Correct the wiring of the DC bus daisy chain.]
PAGE 10-10
SECTION 10: TROUBLE-SHOOTING GUIDE
10.4.4
T200 User's Manual
Fault Type: F4 (PSU Heatsink Overtemperature) on 7-Segment Display
The F4 fault is displayed when the High Power PSU Heatsink Temperature is excessive. The T200 decelerates and
disables itself immediately when the fault occurs.
Table 9: Causes of F4 on 7-segment Display
Cause
Check/[Correction]
Too Many T200X00's Connected
Too many T200-X00 (units without integral PSU) have been connected to the T200-X10
(unit with integral high power PSU).
[Install another T200-X10 to share the DC-Bus power generation load.]
Heatsink Fan Failure
One or more of the integral fans has failed. If possible to do safely, check that these fans
are circulating air. [If internal cooling fans have failed, return the unit to Moog].
The ambient temperature may be too high in the cabinet. [Check that the ambient
temperature does not exceed 55°C.]
10.4.5
Fault Type: F5 (Power Amplifier Over-temperature) on 7-segment Display
The F5 fault is displayed when the power amplifier heat-sink temperature is excessive. The T200 decelerates and
disables itself immediately when the fault occurs.
Table 10: Causes of F5 on 7-segment Display
Cause
Ambient
Temperature Too
High
Heatsink Fan Failure
Check/[Correction]
The T200 is rated for a maximum ambient temperature of 55°C. The ambient temperature
may exceed that in certain cases. Measure the ambient temperature in the T200 cabinet
[Provide improved outside air circulation in the cabinet.]
One or more of the integral fans has failed. If possible to do safely, check that these fans
are circulating air.
[If internal cooling fans have failed, return the unit to Moog.]
Excessive Static
Load
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement Duty
Cycle Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the T200.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement]
T200 Undersized
The T200 is not rated to handle the current duty cycle required by the application. Use the
?LMR Hand Held terminal command to measure the motor phase r.m.s. current. Check is
this very near the rating of the T200.
[Install a T200 with the correct current rating if this is available.]
PAGE 10-11
T200 User's Manual
10.4.6
SECTION 10: TROUBLE-SHOOTING GUIDE
Fault Type: F6 (Motor Over-Temperature) on 7-Segment Display
The F6 fault is displayed when the motor temperature is too high (at or greater than 155°C). The T200 decelerates and
disabled itself immediately when the fault occurs.
Table 11: Causes of F6 on 7-segment Display
Cause
Check/[Correction]
Inadequate Thermal
Contact between
Motor and Mounting
The motor is rated to operate with a maximum temperature rise of 100°C above ambient,
when operated at its rated continuous power level. This depends upon suitable thermal
contact between the motor and its mounting. Check the amount of physical contact between
the motor and the surrounding mounting metalwork.
[Provide improved thermal conduction between the motor and its mounting if possible.]
Inadequate cooling
airflow over the
motor.
Excessive Static
Load
There is inadequate cooling airflow over the motor.
[If possible, duct extra airflow from a cool ambient area over and around the motor.]
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement Duty
Cycle Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the motor.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement]
Motor Undersized
The motor is not rated to handle the current duty cycle required by the application. Use the
?LMR Hand Held terminal command to measure the motor phase r.m.s. current. Check if
this very near the rating of the motor.
[Install a motor with a high current rating if this is suitable for the application]
Ambient
Temperature too
High
PAGE 10-12
The ambient air temperature is too high around the motor. Check the ambient air
temperature.
[Extra airflow around the motor using fans or air-conditioning, if possible.]
SECTION 10: TROUBLE-SHOOTING GUIDE
10.4.7
T200 User's Manual
Fault Type: F7 (Internal Software Fault) on 7-Segment Display
The F7 fault is displayed when an internal software error has occurred. The T200 disabled itself immediately when the
fault occurred.
Table 12: Causes of F7 on 7-segment Display
Cause
Check/[Correction]
Software MisConfiguration
The software error should rarely if ever occur. It is due to a critical mis-configuration of
the software which causes improper operation of the software (e.g. divide by zero
exception to occur)
[Upload the software configuration using the WinDrive File, Configuration-Upload
command, to a .log file. Email or fax a copy of this .log file to Moog Applications
Engineering. Completely reconfigure the T200 from motor configuration onwards in order
to bring the T200 back into operation.]
10.4.8
Fault Type: F8 (Resolver Fault) on 7-segment Display
The F8 fault is displayed when a resolver position transducer error has occurred. The T200 disabled itself immediately
when the fault occurred.
Table 13: Causes of F8 on 7-segment Display
Cause
Resolver Cable
Disconnected, or
Mis-Wired
Non-Moog Resolver
Type Used
Check/[Correction]
The resolver cable is either not connected, has been wired incorrectly, or has become
disconnected or broken.
[Check the wiring of the resolver cable. Ensure that it is wired as per Figure 3.33, Table
3.8.]
The user has connected the T200 to a non-Moog motor, whose resolver electrical
characteristics do not match those expected by the T200.
[Contact Moog Applications Engineering with a description of the resolver parameters.]
Resolver Bad
Faulty resolver in the motor. Remove all power from the T200. Swap the motor if possible
with another known good motor and check is a resolver fault present with the known
motor.
[Return motor to Moog.]
PAGE 10-13
T200 User's Manual
10.4.9
SECTION 10: TROUBLE-SHOOTING GUIDE
Fault Type: F9 (Internal DC/DC Fault) on 7-segment Display
The F9 fault is displayed when a internal analogue power supplies are below acceptable voltage levels. The T200
disabled itself immediately when the fault occurred.
Table 10: Causes of F9 on 7-segment Display
Cause
Check/[Correction]
Internal DC/DC Error
The internal DC/DC which generates ±15V supplies has malfunctioned.
[This error should never occur. Return the T200 unit to the factory or sales outlet
immediately for analysis, and a report on the cause of the problem.]
PAGE 10-14
SECTION 10: TROUBLE-SHOOTING GUIDE
T200 User's Manual
10.5 'U' Symbol Followed by Number on Seven-Segment Display (Warnings)
The following section deals with T200 warnings. These are usually fault conditions which do not require that the T200
immediately remove high power from its power amplifier. However some of these warning conditions will cause the
T200 to servo-stop and disable.
10.5.1
Warning Type: U1 (a.c. Mains has not been applied) on 7-Segment Display
The U1 Warning is displayed when a.c. Mains power has not been applied on T200-X10 units, OR the Power-RDY
digital input has not been activated on T200-X00 units. The T200 cannot generate torque in the motor when U1 is
present.
Table 14: Causes of U1 on 7-Segment Display
Cause
A.C. Mains Power
has not been applied
(T200-X10 units
ONLY)
Power Ready digital
input has not been
activated (T200-X00
units ONLY)
Check/[Correction]
The high voltage a.c. mains is not available at TB2. Check the availability of high power
by checking the status of the Mains-Applied and the Bus-Active LED's.
[Check using Section a.c. Mains Power disconnected from T200 TB2 Connector, that the
mains can be safely reconnected to TB2.]
Check the status of the Power Ready digital input. This can be done by using the
WinDrive, Drive, Drive-Status menu item.
[Check that the PWR-RDY digital input on J1 of this T200-X00, has been driven by the
PWR_RDY± relay output on TB4 of a T200-X10 which supplies DC-Bus high voltage to
this T200-X00.]
PAGE 10-15
T200 User's Manual
10.5.2
SECTION 10: TROUBLE-SHOOTING GUIDE
Warning Type: U2 (Motor Temperature Warning) on 7-Segment Display
The U2 warning is displayed when the motor temperature exceeds 130°C. The T200 can generate reduced torque in the
motor when U2 is present.
Table 15: Causes of U2 on 7-Segment Display
Cause
Check/[Correction]
Inadequate Thermal
Contact between
Motor and Mounting
The motor is rated to operate with a maximum temperature rise of 100°C above ambient,
when operated at its rated continuous power level. This depends upon suitable thermal
contact between the motor and its mounting. Check the amount of physical contact between
the motor and the surrounding mounting metalwork.
[Provide improved thermal conduction between the motor and its mounting if possible.]
Inadequate cooling
airflow over the
motor.
Excessive Static
Load
There is inadequate cooling airflow over the motor.
[If possible, duct extra airflow from a cool ambient area over and around the motor.]
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement Duty
Cycle Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the motor.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement]
Motor Undersized
The motor is not rated to handle the current duty cycle required by the application. Use the
?LMR Hand Held terminal command to measure the motor phase r.m.s. current. Check if
this very near the rating of the motor.
[Install a motor with a high current rating if this is suitable for the application]
PAGE 10-16
SECTION 10: TROUBLE-SHOOTING GUIDE
10.5.3
T200 User's Manual
Warning Type: U3 (Power Amplifier Warning) on 7-Segment Display
The U3 warning is displayed when the power amplifier internal heatsink temperature comes within about 10°C of its
fault temperature. The warning may only signify that the T200 is being used close to its thermal limits. The T200 can
generate torque in the motor when U3 is present.
Table 16: Causes of U3 on 7-Segment Display
Cause
Ambient
Temperature Too
High
Heatsink Fan Failure
Check/[Correction]
The T200 is rated for a maximum ambient temperature of 55°C. The ambient temperature
may exceed that in certain cases. Measure the ambient temperature in the T200 cabinet.
[Provide improved outside air circulation in the cabinet.]
One or more of the integral fans has failed. If possible to do safely, check that these fans
are circulating air.
[If internal cooling fans have failed, return the unit to Moog.]
Excessive Static
Load
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement Duty
Cycle Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the T200.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement.]
T200 Undersized
The T200 is not rated to handle the current duty cycle required by the application. Use the
“?LMR” Hand Held terminal command to measure the motor phase r.m.s. current. Check if
this value is greater than or above the rating of the T200.
[Install a T200 with a high current rating if this is available.]
PAGE 10-17
T200 User's Manual
10.5.4
SECTION 10: TROUBLE-SHOOTING GUIDE
Warning Type: U4 (Position Error Warning) on 7-Segment Display
The U4 Warning is displayed when the T200 position error exceeds the user-programmed range (see Section 6.6.3 for an
overview of position error monitoring). The T200 can generate torque in the motor when U4 is present.
Table 17: Causes of U4 on 7-Segment Display
Cause
Loop Tuning not
Adequate
Check/[Correction]
The loop tuning will determine the amount of position error which occur during a specific
movement. Increase the gains in the loop if possible.
[The P and I gains need to be set appropriately for the load (see Section 6.6.3, Velocity
Loop Tuning). In certain cases the velocity observer can be used to significantly increase the
value of these gains (see Section 6, Velocity Observer Tuning and Usage).
The G gain needs to be set (see Section 6.6.3, Position Loop Tuning).
Advanced Tuning for T200 Applications which use the CAN interface - In CAN systems the
velocity feedforward term GV should be set to 1 to decrease the position loop error. In
certain systems the torque feedforward term GT should be set equal to the combined
motor + load inertia, to decrease position error during the acceleration and deceleration
phases.]
Programmable
Torque and Velocity
Limits too Low
Drive has been
placed in Manual
Mode
The user configures the manual and automatic velocity limits, for the application at hand.
These limits may be set too low.
[Increase the velocity and torque limits, when ensuring the safe operation of the machine.]
The drive has been commanded into manual mode, either through the AUTO-MAN digital
input on J1, or through the CAN interface.
[Check why the T200 has been forced into manual mode:
Check the wiring of the AUTO_MAN input.
Check the safety status of the machine control system.]
Analog Torque Limit
is Active
Excessive Static or
Dynamic Load
The analog torque limit is an analog interface which allows dynamic limiting of torque.
[If the input is not used, then short the SAIN+ and SAIN- pins at the J1 connector.]
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement's DutyCycle is Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the T200.
[Decrease the torque necessary during the movement, by reduction of the acceleration and
deceleration, and/or the frequency of the movement.]
PAGE 10-18
SECTION 10: TROUBLE-SHOOTING GUIDE
10.5.5
T200 User's Manual
Warning Type: U5 (Velocity Error Warning) on 7-Segment Display
The U5 Warning is displayed when the T200 velocity error exceeds the user-programmed range (see Section 6.6.2 for an
overview of velocity error monitoring). The T200 can generate torque in the motor when U5 is present.
Table 18: Causes of U5 on 7-Segment Display
Cause
Loop Tuning not
Adequate
Check/[Correction]
The velocity loop tuning will determine the amount of velocity error, which occurs during
a specific movement. Increase the gains in the loop if possible.
[The P and I gains need to be set appropriately for the load (see Section 6.6.2, Velocity
Loop Tuning). In certain cases the velocity observer can be used to significantly increase
the value of these gains (see Section 6.6.2, Velocity Observer Tuning and Usage).]
Programmable
Torque and Velocity
Limits too Low
Drive has been
placed in Manual
Mode
The user configures the manual and automatic velocity limits, for the application at hand.
These limits may be set too low.
[Increase the velocity and torque limits, when ensuring the safe operation of the machine.]
The drive has been commanded into manual mode, either through the AUTO-MAN digital
input on J1 or through the CAN interface.
[Check why the T200 has been forced into manual mode:
Check the wiring of the AUTO_MAN input
Check the safety status of the machine control system.]
Analog Torque Limit
is Active
Excessive Static or
Dynamic Load
The analog torque limit is an analog interface, which allows dynamic limiting of torque.
[If the input is not used, then short the SAIN+ and SAIN- pins at the J1 connector.]
The machine bearings or other parts may have become seized or severely worn. This can
cause extra friction or load torques.
[Check the freedom of rotation of the load, including bearing wearing and load alignment.]
Movement's DutyCycle is Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the T200.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement.]
PAGE 10-19
T200 User's Manual
10.5.6
SECTION 10: TROUBLE-SHOOTING GUIDE
Warning Type: U6 (External Regen Resistor Warning) on 7-segment
Display
The U6 warning is displayed when the thermal rating of the external regeneration resistor has been exceeded. The T200
can generate torque in the motor when U6 is present.
Table 19: Causes of U6 on 7-segment Display
Cause
External
Regeneration
Resistor Continuous
Rating Exceeded
Check/[Correction]
The T200 monitors the external regeneration resistor load cycle to check if its continuous
rating is exceeded. Check using the Hand Held Terminal's ?LRR command what is the
average power dissipation in the external resistor. Compare this number against the ratings
provided in Section 3.13.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement.]
PAGE 10-20
SECTION 10: TROUBLE-SHOOTING GUIDE
10.5.7
T200 User's Manual
Warning Type: U7 (CAN Communications Warning) on 7-segment Display
The U7 warning is displayed when the CAN interface has malfunctioned. The T200 will servo-stop, apply the brake if
present, and then disable when U7 occurs.
Table 20: Causes of U7 on 7-segment Display
Cause
CAN Cable
Disconnected
Check/[Correction]
CAN cable pin(s) have become disconnected, resulting in a break in CAN
communications.
[Check the CAN cable wiring, as per Section 9.]
Master Control
System Malfunction
Check that the master control computer has power-up correctly, and that it has started its
CAN communications process.
[Start the System Motion Controller, as required.]
CAN Parameters
Incorrect
The CAN Parameters Baud-Rate, Communication-Cycle-Period, Actual Window Time and
Command Window Time have to be set appropriately, and at the same values in all T200's
which communicate on the same CAN cable. The Node-ID's also have to be set correctly
to a unique number for each node.
[See Section 9 for an overview of suitable values for these parameters. ]
Excessive Noise on
CAN Cable
There is excessive noise interference on the CAN Cabling. Check:
§ Recommended cable type or equivalent type is used. Cable with characteristic
impedance of 120Ohms is recommended.
§ CAN Cable Termination with 120Ohms, at the physical extremities of the cabling
ONLY.
§ Connection of all pins, especially the GND and Cable-Shield connections, at all
connected end of the cabling.
§ CAN Cabling Routing, if alongside high current cabling
[Ensure there is only two termination resistors, at the physical end of the cabling
Correct mis-wiring.
Route cables away from motor power or other cables, which carry high currents if
possible.]
Software
Configuration Error
The Software has been mis-configured, with parameters, which are unachievable.
[Review Section 9, and re-configure the T200 correctly.]
PAGE 10-21
T200 User's Manual
10.5.8
SECTION 10: TROUBLE-SHOOTING GUIDE
Warning Type: U8 (Limit Switches Warning) on 7-segment Display
The U8 warning is displayed when the Limit Switches (digital inputs on J1) have been activated, and they have not been
disabled through software control. The T200 can still generate torque when the limit switches have been activated.
Table 21: Causes of U8 on 7-segment Display
Cause
Limit Switches not
Disabled
Check/[Correction]
The application does not require that the limit switches are used.
[Disable the Limit Switches using the WinDrive or Hand Held Terminal interface (‘OL’
command.)
OR
Hardwire the digital inputs, to always conduct current, such that they are never activated.]
Axis has run into
Forbidden Area
The application requires that the limit switches are used. The axis has activated the limit
switches because its has exceeded its allowed work zone.
[Reposition the axis using a homing or other absolute position referencing scheme. Restart
the work cycle.
OR
Change the position of the limit switches if these are incorrectly positioned.]
Limit Switches
broken or
disconnected
PAGE 10-22
The Limit Switch may be broken. Move the axis in a working zone and verify that the
switch deactivates.
[Replace the switch or the wiring.]
SECTION 10: TROUBLE-SHOOTING GUIDE
10.5.9
T200 User's Manual
Warning Type: UA (Quick-Stop Warning) on 7-segment Display
The UA warning is displayed when the servo-stop function is active, ONLY IF the Reference Source is the CAN
interface, in Interpolation Mode.
Table 22: Causes of UA on 7-segment Display
Cause
Quick-Stop digital
input has been
activated
Check/[Correction]
Check the activity state of the Quick-Stop Digital input. This input is otherwise known as
PROG_SPD_0 of J1, which has the alternative use of Quick-stop when the Reference
Source is CAN.)
[To check for a problem:
§ Correct the Quick-Stop digital input wiring
§ Correct the event which caused the quick-stop to be triggered e.g. opened robot cage.]
Master Controller
has commanded a
servo-stop
Check the activity state of the master control system's emergency stop.
[Correct the event which caused the quick-stop to be triggered e.g. opened robot cage.]
PAGE 10-23
T200 User's Manual
10.5.10
SECTION 10: TROUBLE-SHOOTING GUIDE
Warning Type: Ub (Stepper or Inc. Encoder Warning) on 7-segment
Display
The Ub warning is displayed when the incremental encoder or stepper motor interface cable is disconnected. The T200
can still generate motor torque when Ub is displayed.
Table 23: Causes of Ub on 7-segment Display
Cause
J5 Cabling Mis-wired
or Disconnected
Stepper Interface or
Incremental Encoder
not Connected
RS422 Interface
voltage levels
inadequate
Check/[Correction]
The pins at J5 have been mis-wired or the cabling to J5 has become disconnected
[Check the wiring requirements in Section 3.16.]
The stepper motor command generation unit or incremental encoder has become
disconnected.
[Plug in the stepper interface or incremental encoder.]
The voltage levels are inadequate. Check:
§ Recommended cable type or equivalent type is used. Cable with characteristic
impedance of 120Ohms is recommended.
§ Cable Termination of 120Ohms is already provided in the T200. Ensure that no extra
termination was provided by the user.
§ Connection of all pins, especially the GND and Cable-Shield connections, at all
connected end of the cabling.
§ Use a driver with a higher voltage drive capability at the user's control computer end.
PAGE 10-24
SECTION 10: TROUBLE-SHOOTING GUIDE
10.5.11
T200 User's Manual
Warning Type: Dot (Thermal Limit Warning) on 7-segment Display
The Dot warning is displayed when the T200 current demand exceeds the thermal current limit that was derived from a
variety of sources. The T200 can generate torque in the motor when Dot is present.
Table 24: Causes of Dot on 7-segment Display
Cause
Motor 'ThermistorPresent' Parameter
Incorrectly
Configured
Motor Thermally
Limited
Power Amplifier
Thermally Limited
R.M.S. Current Level
exceeded
Check/[Correction]
The T200 has been configured for a non-Moog motor. The user must tell the T200 if the
motor uses a Negative Temperature Coefficient (NTC) Thermistor. This parameter may
have been mis-configured.
[Using the 'SNM' command on the Hand Held Terminal, to change the polarity of the
Motor-Thermistor Present flag. Alternatively via the Win-Drive motor icon, non-standard
motor entry, change the polarity of the Motor-Thermistor tick box.]
Check Fault Type: F6 (Motor Over-Temperature) on 7-Segment Display, for possible
sources of thermal limiting due to the motor.
Check Fault Type: F5 (Power Amplifier Over-temperature) on 7-segment Display, for
possible sources of power amplifier thermal limiting.
The T200 provides self protection for connectors and other internal devices (See Section 6,
Cabling and Interconnect Protection Scheme for an explanation).
[See Excessive Load, Movement Duty Cycle is Excessive under Section Warning Type:
U6 (External Regen Resistor Warning) on 7-segment Display.]
External
Regeneration
Resistor Continuous
Rating Exceeded
The T200 monitors the external regeneration resistor load cycle to check if its continuous
rating is exceeded. Check using the Hand Held Terminal's ?LRR command what is the
average power dissipation in the external resistor. Compare this number against the ratings
provided in Section 3.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement.]
Movement Duty
Cycle Excessive
The acceleration and deceleration of the movement, as well as the frequency of movement
may be excessive for the motor.
[Decrease the duty cycle, by reduction of the acceleration and deceleration, and/or the
frequency of the movement.]
Motor Undersized
The motor is not rated to handle the current duty cycle required by the application. Use the
?LMR Hand Held terminal command to measure the motor phase r.m.s. current. Check if
this is very near the rating of the motor.
[Install a motor with a high current rating if this is suitable for the application.]
PAGE 10-25
T200 User's Manual
SECTION 10: TROUBLE-SHOOTING GUIDE
10.6 Other Problem Sources
The T200 diagnostics will not identify all problem sources. The following is a list of faults that do not necessarily result
in T200 diagnostics messages.
10.6.1
Problem: T200 will not enable
The T200 can be enabled only if all faults have been removed, high power is present, AND if the digital input ENABLE
on J1 is activated simultaneously. The E symbol on the 7-segment display indicates that the T200 is enabled.
Table 25: Causes of T200 not enabling
Cause
A.C. Mains or D.C.
Bus not present on
TB2
ENABLE input on J1
not activated
Check/[Correction]
A.C. Mains or high voltage D.C. Bus voltage has not been applied.
[See Section Fault Type: Mains-Applied LED is not lighting (T200-X10 ONLY) and
Section Fault Type: DC-Bus-Active LED is not Lighting.]
T200 cannot be enabled without activation of the ENABLE input. Check the status of the
ENABLE input using the WinDrive, Drive, Drive-Status menu item is possible. Otherwise
check the status of the digital input using a voltmeter or other means, between
I_COMMON and ENABLE.
[Check the wiring at J1-ENABLE and I_COMMON.
Activate the ENABLE digital input, typically by commanding the master control to enable
the T200. If using the T200 in standalone 'Point' mode, then activate user supplied safety
circuitry to activate the T200 ENABLE.]
T200 Software not
Configured
Fault Present
The T200 software has not been configured correctly.
[Review Section 5 for a Quick-Start, and Sections 6, 7 and 8 for a detailed overview of
set-up procedures. Save the parameter set to non-volatile storage.]
Faults are present. Check the 7-segment display for indication of the faults.
[Correct the fault and try to re-enable.]
PAGE 10-26
SECTION 10: TROUBLE-SHOOTING GUIDE
10.6.2
T200 User's Manual
Problem: T200 is Enabled, but will not move the Axis
The motor cannot move the axis, though the T200 is already applying high voltage to the motor.
Table 26: Causes of T200 not moving
Cause
Command Source
set to 0
Limit Switches
activated
Brake Applied
Check/[Correction]
The T200 command source is not commanding a movement!
Check:
•
Analogue command voltage wiring to REF+ and REF- is intact.
•
Voltages between REF+ and REF- on J1 are non-zero.
•
If using a function generator that the acceleration, velocity, torque and/or position
commands are non-zero.
•
If using CAN, Stepper Interface that the master control computer commands a
movement.
•
If using the Digital Inputs Reference, that the Reference Velocities have been set-up.
See Section Warning Type: U8 (Limit Switches Warning) on 7-segment Display
The T200 brake is released only if the BRK_IP digital input is activated. If the CAN
Reference Source is used, the CAN software MUST also be commanded through the CAN
interface to release the brake.
[Release the brake by activation of the BRK_IP input on J1.
If a CAN system then release the brake via the master control computer.]
Torque Limits Too
Low
The user may have programmed too low torque limits to overcome static friction and load
stiffness (stiction). Check the present power mode of the T200 using the WinDrive, Drive,
Drive Status menu to see if the AUTO_MAN input box is ticked. (If the AUTO_MAN
input box is ticked, then the T200 is in Automatic mode). Check the Limits, Manual Mode
Disable tick-box to check if Manual Mode has been disabled.
[If safe to do so, then the user can disable Manual Mode. Alternatively he can activate the
AUTO-MAN mode such that the T200 is placed in Automatic Mode.
The Torque and Velocity Limits in the Limits dialog box should be increased if it is safe to
do so.]
Motor is
Disconnected
Fault Present
The motor is not connected at all to the T200.
[DISABLE the T200. Remove all power from the T200 and wait 5 minutes before
attempting re-connection. Reconnect the motor power cable to TB8. Re-apply power to
the T200. Re-enable and try again to move the axis.]
Faults are present. Check the 7-segment display for indication of the faults.
[Correct the fault and try to re-enable.]
PAGE 10-27
T200 User's Manual
10.6.3
SECTION 10: TROUBLE-SHOOTING GUIDE
Problem: T200 Movement is not Smooth
The motor moves, but the movement is not smooth.
Table 27: Causes of T200 lack of smoothness
Cause
Motor Phase(s)
Disconnected
Motor not mounted
correctly.
Check/[Correction]
A loss of a motor phase will cause a non-smooth torque to be applied to the motor.
[Disable the T200. Remove all power from the T200 and wait 5 minutes before attempting
re-connection. Check the motor power cable connections to TB8. Re-apply power to the
T200. Re-enable and try again to move the axis.]
The motor may not be mounted correctly, such that it moves with respect to its mounting
flange during the movement.
[Disable the T200. Remove all power from the T200 and wait 5 minutes before attempting
re-connection.
Check the motor mounting arrangements. Tighten all mounting
attachments and screws, bolts etc. so that motor movement is not restricted or impossible.
Re-apply power to the T200. Re-enable and try again to move the axis.]
Motor or Load
Bearings damaged
Mechanical
Resonance
The motor or load bearings may have become worn or damaged.
[Check the motor and load bearings with all power removed. If the motor is damaged,
return it to Moog.]
The mechanic elements of the coupling between motor and load, and the load itself, may
be flexible.
[Consult Moog Applications engineering for guidance on tuning.]
Shaft Misalignment
The motor and load shafts may be mis-aligned.
[Correct the alignment problem.]
Motor Damage
The motor resolver transducer may be damaged or faulty. The motor phases may have
partial or total short circuits.
[Return the motor to Moog.]
Coupling Damage
The coupling between the Moog motor and the load may be damaged. For example,
gearwheel teeth may be broken off.
[Replace the coupling mechanism.]
PAGE 10-28
SECTION 10: TROUBLE-SHOOTING GUIDE
10.6.4
T200 User's Manual
Problem: Excessive Audible Noise from the Motor
The motor movement is somewhat acceptable, but there is unacceptable high frequency noise from the motor.
Table 28: Causes of Noise in the Motor
Cause
Check/[Correction]
Control Loop
Gains are too
High
Retune the velocity and position loop gains, so that these are lower in value to reduce the effects
of noise. [The P and I gains need to be set at lower values which are still appropriate for the load
(see Section 6.6.2, Velocity Loop Tuning). The G gain may need to be reduced (see Section 6.6.3,
Position Loop Tuning).
Excessive
Noise Pickup
on the
Resolver
Position
Sensor Cable
Low noise content on the resolver position feedback signals is critical for good servoperformance. Check the display of velocity on an analogue test point TP2 or using the WinDrive
data-logger. Note that about 10RPM of noise is normal because of Analogue to Digital conversion
accuracy and other quantisation effects. [Check the following:
§ [Ensure that all resolver cable wires are properly connected at J6 of the T200. (see Section
3.14 for pinouts).
§ Ensure that the resolver cable shield is connected at both the motor to Protective Earth and
the T200 end to the chassis via a J6 as detailed in Section 3.14.
§ If the resolver cable run from the motor is alongside the motor power cable, try to separate
the cable runs wherever possible.]
T200 Chassis
is not well
earthed
Ensure that the connection between the T200 Chassis and Protective Earth is as low resistance
(and impedance) as possible.
[Use a braided wire, or low AWG wire to connect the T200 chassis to Earth. A PE connection
point is provided at the top right hand side of the T200's front panel (see Section 3.4 for a diagram
of the Front Panel) to augment the TB2 PE connection point.
Alternatively use a high conductivity common metal mounting panel for all T200's, so that there is
a good low impedance conduction path for high frequency noise away to Protection Earth. For
best results resistance should be less than 0.1Ohms to Protective Earth from the T200 chassis.]
Motor Body is
not well
earthed
High frequency currents flow in the motor internal windings. The motor body should be
connected to a metallic path to Protective Earth, to conduct high frequency capacitively-coupled
noise generated in the motor, which would otherwise flow in motor power cables lines and
shields.
[Ensure that the motor has a low resistance path to Protective Earth, with the motor power cable
disconnected. For best results resistance should be less than 0.1Ohms to Protective Earth from the
motor's metallic body.]
Motor Power
Cable shield
not well
Terminated
Damaged
Motor
Bearings
For best noise shielding results, the motor cable shield should be connected at BOTH ends of the
cable (to the T200 chassis through the PE connection or through the EMC bracket as shown in
Section 3.14.5, and to the motor body at the motor end).
If the motor shield cannot be connected at the motor end, then the EMC bracket should be used, as
shown in Section 3.14.5 and 3.14.6.
Remove all power from the T200. If possible remove the motor from the machine and check the
motor can rotate freely by hand, if the motor does not have a brake. Check if there is radial play in
the motor shaft with respect to the motor housing.
[Return the motor to Moog for repair.]
PAGE 10-29
T200 User's Manual
10.6.5
SECTION 10: TROUBLE-SHOOTING GUIDE
Problem: Motor Shaft rotates in the Wrong Direction
The motor movement is reversed in direction from that desired.
CAUTION: Reversal of the direction of rotation can lead to positive feedback and
runway conditions of control loops, as part of the system control loop is closed
outside of the T200. Ensure that the direction of rotation is well understood before
changing polarity of rotation.
Table 29: Causes of Direction Reversal
Cause
Check/[Correction]
ROT_DIR digital
Input activated
The rotation direction has been activated, which reverses the polarity of the analog input
command, and the digital references velocities. Check the polarity of the ROT_DIR input
using the WinDrive Drive, Drive-Status menu item.
[Change the state of the ROT_DIR digital input to reverse the motor.]
Swapped REF±
differential analog
input pins
ESM Polarity
reversed
The polarity of rotation can be changed by swapping the cable connections to the REF+
and REF- inputs.
When the ESM Channel A leads Channel B, as shown in Section 6.9 Encoder Simulation
Function, the motor rotates in a clockwise direction as described in Section 6.2 T200
Conventions. If A+ and A- are swapped (similarly for B+ and B-) inadvertently by the
user, then Channel B will appear to lead Channel A when viewed by the user.
[Check all ESM cable wiring to ensure proper of wiring.]
Motor Wiring
Reversal
The motor phase wiring may be swapped. Remove all power from the T200. Check the
motor phases wiring against Figure 3.32 and Table 3.7.
[Correct the wiring.]
PAGE 10-30
SECTION 10: TROUBLE-SHOOTING GUIDE
10.6.6
T200 User's Manual
Problem: No ESM Position Feedback from the T200
The motor moves but the encoder simulation feedback does not appear to move.
Table 30: Causes of no ESM Feedback
Cause
No user-supplied
external 5V Power
Supply
Mis-wiring or
Disconnected Cable
Check/[Correction]
The RS422 type outputs on the T200 are isolated from the T200 control section. A usersupplied 5V must be available to supply power to the isolated side of these RS422 drivers.
[See Section 6.9 Encoder Simulation for a description of the wiring and a block diagram.]
[See Section 6.9 Encoder Simulation for a description of the wiring and a block diagram.]
PAGE 10-31
T200 User's Manual
SECTION 10: TROUBLE-SHOOTING GUIDE
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PAGE 10-32
SECTION 11: USER INFORMATION
SECTION 11:
C27095-001
T200 User's Manual
USER INFORMATON
PAGE 11-1
T200 User's Manual
SECTION 11: USER INFORMATION
TABLE OF CONTENTS
USER INFORMATON.................................................................................................................................................11-1
11.1
TECHNICAL SUPPORT ....................................................................................................................................11-3
PAGE 11-2
SECTION 11: USER INFORMATION
T200 User's Manual
11.1 Technical Support
Technical support for Windrive and Moog Brushless DC Motor Drive products is available by contacting MOOG at one
of the following addresses: -
Europe and Asia
MOOG GmbH
Hanns-Klemm-Strasse 28
71034 Boeblingen
GERMANY
phone: +0049 - 7031 - 622 -0
fax:
+0049 - 7031 - 622 - 100
North America
MOOG INC / Industrial Controls Division
Seneca and Jamison Roads
East Aurora, NY 14052
USA
phone: +001 - 716 - 655 - 3000
fax:
+001 - 716 - 687 - 4870
PAGE 11-3
T200 User's Manual
SECTION 11: USER INFORMATION
This page is intentionally left blank.
PAGE 11-4
APPENDIX A: EMC TEST CONFIGURATION
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATIONS
C27095-001
PAGE A-1
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATION
TABLE OF CONTENTS
EMC TEST CONFIGURATIONS............................................................................................................................... A-1
APPENDIX A:- TEST CONFIGURATIONS FOR EMC-RELATED CE-COMPLIANCE ..................................................... A-3
Test Configuration 1: EMC Emissions: 3 Phase Power application. ....................................................................... A-3
Test Configuration 2: EMC Emissions: 3 Phase Power application. ....................................................................... A-3
Test Configuration 3: EMC Emissions: 3 Phase Power application. ....................................................................... A-4
Test Configuration 4: EMC Emissions: 3 Phase Power application. ....................................................................... A-5
Test Configuration 5: EMC Immunity: 3 Phase Power application......................................................................... A-5
Test Configuration 6: Supplementary EMC Emissions & Immunity: Single Phase Power Application................. A-6
Test Configuration 7: Supplementary EMC Emissions & Immunity: Single Phase Power Application................. A-7
Test Configuration 8: Supplementary EMC Emissions & Immunity: Single Phase Power Application................. A-7
Test Configuration 9: EMC Emissions & Immunity: 3 Phase Power application. .................................................. A-8
Single Phase Power Application: Line Filtering (Models T200-3XX, -4XX, -5XX). ............................................. A-9
PAGE A-2
APPENDIX A: EMC TEST CONFIGURATION
T200 User's Manual
Appendix A:- Test Configurations for EMC-related CE-Compliance
The T200 Series Motor Controllers are system components which must be installed in a correct manner to ensure that all
electromagnetic compatibility (EMC) requirements are met. The requirements of European Union (EU) EMC Directive:
89/336/EEC, as amended, must be met by all equipment, systems and installations into which the T200 Series Motor
Controllers are installed.
The T200 Series Motor Controllers have been tested for compliance with the EU EMC Directive in so far as they can be
regarded as single functional units. The T200 Series Motor Controllers have been tested in typical configurations and it
has been found that these configurations meet the essential requirements of the EU EMC Directive.
Test Configuration 1: EMC Emissions: 3 Phase Power application.
The configuration consisted of a Model T200-310 Drive and two Model T200-300 Drives. The Drives were connected to
Motors via 10m Motor Power and Motor Resolver shielded cables, terminated to chassis earth at each end. One T200300 had a motor brake option installed with cable connection to the MOTOR BRAKE port
All drives were driven by an external CANBUS (CAN) test computer connected via a 30m shielded cable to the T200310 Drive and daisy chained via the CAN IN and CAN OUT ports to the two T200-300 Drives. There was a Steward
type 28A2024-0A0 ferrite installed through 1.5urns on the 30m shielded cable at the T200-310 port.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There was a 3m shielded cable terminated in
characteristic impedances connected to the Power Ready port on the T200-310 Drive.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected by armoured cable to
the AC LINE IN port on the T200-310 Drive. The DC BUS voltage was daisy chained from the T200-310 Drive to the
two T200-300 Drives.
An optional 24Vd.c. control backup supply was connected to the 24Vd.c. control backup port of the T200-310 and
daisy-chained to the two T200-300's. A Steward 28A2024-0A0 ferrite was installed through 2.5turns on the external
24Vd.c supply cable at the T200-310 port. This external 24Vd.c. power supply was supplied from a connection to one
of the secondary phases of the 400:230Va.c. step down transformer.
All Drives were mounted onto an earthed metal panel mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 2: EMC Emissions: 3 Phase Power application.
The configuration consisted of a Model T200-410 Drive and Model T200-400 Drive. The T200-400 Drive had a T200
Personality Module option ( Moog p/n C09951) installed. The Drives were connected to Motors via 10m Motor Power
and Motor Resolver shielded cables, terminated to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive.
PAGE A-3
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATION
There was a 3m shielded cable terminated in characteristic impedances connected to the Power Ready port on the T200410 Drive. There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the
T200-410 Drive and the CAN OUT port on the T200-400 Drive and a daisy chain connection from the T200-410 CAN
OUT port to the T200-400 CAN IN port.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected by armoured cable to
the AC LINE IN port on the T200-410 Drive. The DC BUS voltage was daisy chained from the T200-410 Drive to the
T200-400 Drive.
An optional 24V d.c. external logic power supply was connected to the 24V DC LOGIC POWER port on the T200-410
Drive and daisy chained to the T200-400 Drive. This external 24 V d.c power was supplied from a power supply on the
equipment connected to one of the secondary phases of the 400:230 V a.c. step down isolation transformer.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 3: EMC Emissions: 3 Phase Power application.
The configuration consisted of a Model T200-510 Drive and Model T200-500 Drive. The T200-510 Drive had a T200
Point Extended I/O Card option (Moog p/n C09950) and external regen resistor option installed. The Drives were
connected to Motors via 10m Motor Power and Motor Resolver shielded cables, terminated to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There was a 3m shielded cable terminated in
characteristic impedances connected to the Power Ready port on the T200-510 Drive.
There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the T200-510
Drive and the CAN OUT port on the T200-500 Drive and a daisy chain connection from the T200-510 CAN OUT port
to the T200-500 CAN IN port. There was a 3m shielded cable terminated in characteristic impedances connected to the
Point Extended I/O option port on the T200-510 Drive. There was an in-line FairRite Type 0443164151 ferrite installed
at each end of this cable.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected by armoured cable to
the AC LINE IN port on the T200-510 Drive. The DC BUS voltage was daisy chained from the T200-510 Drive to the
T200-500 Drive. An optional external Regen resistor was connected via a 10m shielded cable to the EXT REGEN port
on the T200-510 Drive.
An optional 120V a.c. external logic power supply was connected to the 120 V AC LOGIC POWER port on the T200510 Drive and daisy chained to the T200-500 Drive. This external 120 V a.c power was supplied from a 230:120 V a.c.
step down isolation transformer on the equipment connected to one of the secondary phases of the 400:230 V a.c. step
down isolation transformer.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
PAGE A-4
APPENDIX A: EMC TEST CONFIGURATION
T200 User's Manual
Test Configuration 4: EMC Emissions: 3 Phase Power application.
The configuration consisted of a Model T200-410 Drive and Model T200-400 Drive plus a Model T200-510 Drive and
Model T200-500 Drive. The T200-400 Drive had a T200 Personality Module option ( Moog p/n C09951) installed. The
T200-510 Drive had a T200 Point Extended I/O Card option (Moog p/n C09950) and external regen resistor option
installed. The Drives were connected to Motors via 10m Motor Power and Motor Resolver shielded cables, terminated
to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There were 3m. shielded cables terminated in
characteristic impedances connected to the Power Ready ports on the T200-410 and T200-510 Drives.
There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the T200-410
Drive and the CAN OUT port on the T200-400 Drive and a daisy chain connection from the T200-410 CAN OUT port
to the T200-400 CAN IN port. There were 3m shielded cables terminated in characteristic impedances connected to the
CAN IN port on the T200-510 Drive and the CAN OUT port on the T200-500 Drive and a daisy chain connection from
the T200-510 CAN OUT port to the T200-500 CAN IN port.
There was a 3m shielded cable terminated in characteristic impedances connected to the Point Extended I/O option port
on the T200-510 Drive. There was an in-line FairRite Type 0443164151 ferrite installed at each end of this cable. The
Drives were connected to the Motors via 10m. Motor Power and Motor Resolver shielded cables terminated to chassis
earth at each end.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected independently by
armoured cable to the AC LINE IN ports on the T200-410 and T200-510 Drives. The DC BUS voltage was daisy
chained from the T200-410 Drive to the T200-400 Drive and from the T200-510 Drive to the T200-500 Drive. An
optional external Regen resistor was connected via a 10m shielded cable to the EXT REGEN port on the T200-510
Drive.
An optional 24V d.c. external logic power supply was connected to the 24V DC LOGIC POWER port on the T200-410
Drive and daisy chained to the T200-400 Drive. This external 24 V d.c power was supplied from a power supply on the
equipment connected to one of the secondary phases of the 400:230 V a.c. step down isolation transformer.
An optional 120V a.c. external logic power supply was connected to the 120 V AC LOGIC POWER port on the T200510 Drive and daisy chained to the T200-500 Drive. This external 120 V a.c power was supplied from a 230:120 V a.c.
step down isolation transformer on the equipment connected to one of the secondary phases of the 400:230 V a.c. step
down isolation transformer.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 5: EMC Immunity: 3 Phase Power application.
The configuration consisted of a Model T200-310 Drive and two Model T200-300 Drives plus a Model T200-410 Drive
and Model T200-400 Drive plus a Model T200-510 Drive and Model T200-500 Drive. The Drives were connected to
Motors via 10m Motor Power and Motor Resolver shielded cables, terminated to chassis earth at each end.
The Model T200-310 Drive and two Model T200-300 Drives were driven by an external CANBUS (CAN) computer
connected via a 30m shielded cable to the T200-310 Drive and daisy chained via the CAN IN and CAN OUT ports to
the two T200-300 Drives. There was a Steward 28A2024-0A0 ferrite installed through 1.5turns on the 30m shielded
PAGE A-5
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATION
cable of the T200-310 CAN-IN port. One T200-300 had a motor brake option installed with cable connection to the
MOTOR BRAKE port
The T200-400 Drive had a T200 Personality Module option ( Moog p/n C09951) installed. The T200-510 Drive had a
T200 Point Extended I/O Card option (Moog p/n C09950) and external regen resistor option installed.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There were 3m. shielded cables terminated in
characteristic impedances connected to the Power Ready ports on the T200-310, T200-410 and T200-510 Drives.
There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the T200-410
Drive and the CAN OUT port on the T200-400 Drive and a daisy chain connection from the T200-410 CAN OUT port
to the T200-400 CAN IN port. There were 3m shielded cables terminated in characteristic impedances connected to the
CAN IN port on the T200-510 Drive and the CAN OUT port on the T200-500 Drive and a daisy chain connection from
the T200-510 CAN OUT port to the T200-500 CAN IN port.
There was a 3m shielded cable terminated in characteristic impedances connected to the Point Extended I/O option port
on the T200-510 Drive. There was an in-line FairRite Type 0443164151 ferrite installed at each end of this cable.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected independently by
armoured cable to the AC LINE IN ports on the T200-310, T200-410 and T200-510 Drives. The DC BUS voltage was
daisy chained from the T200-310 Drive to the two T200-300 Drives, from the T200-410 Drive to the T200-400 Drive
and from the T200-510 Drive to the T200-500 Drive. An optional external Regen resistor was connected via a 10m
shielded cable to the EXT REGEN port on the T200-510 Drive.
An optional 24V d.c. external logic power supply was connected to the 24V DC LOGIC POWER port on the T200-410
Drive and daisy chained to the T200-400 Drive. This external 24 V d.c power was supplied from a power supply on the
equipment connected to one of the secondary phases of the 400:230 V a.c. step down isolation transformer.
An optional 120V a.c. external logic power supply was connected to the 120 V AC LOGIC POWER port on the T200510 Drive and daisy chained to the T200-500 Drive. This external 120 V a.c power was supplied from a 230:120 V a.c.
step down isolation transformer on the equipment connected to one of the secondary phases of the 400:230 V a.c. step
down isolation transformer.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 6: Supplementary EMC Emissions & Immunity: Single Phase
Power Application.
The configuration consisted of a Model T200-310 Drive and two Model T200-300 Drives. The Drives were connected to
Motors via 10m Motor Power and Motor Resolver shielded cables, terminated to chassis earth at each end. One T200300 had a motor brake option installed with cable connection to the MOTOR BRAKE port
All drives were driven by an external CANBUS (CAN) computer connected via a 30m shielded cable to the T200-310
Drive and daisy chained via the CAN IN and CAN OUT ports to the two T200-300 Drives.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There was a 3m shielded cable terminated in
characteristic impedances connected to the Power Ready port on the T200-310 Drive.
PAGE A-6
APPENDIX A: EMC TEST CONFIGURATION
T200 User's Manual
Single phase input power was supplied via a Schaffner type FN 350-12-29 mains input line to the AC LINE IN port on
the T200-310 Drive. The DC BUS voltage was daisy chained from the T200-310 Drive to the two T200-300 Drives.
An optional 24Vd.c. control backup supply was connected to the 24Vd.c. control backup port of the T200-310 and
daisy-chained to the two T200-300's. A Steward 28A2024-0A0 ferrite was installed through 2.5turns on the external
24Vd.c supply cable at the T200-310 port. This external 24Vd.c. power supply was supplied from a connection to one
of the secondary phases of the 400:230Va.c. step down transformer.
All Drives were mounted onto an earthed metal panel mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 7: Supplementary EMC Emissions & Immunity: Single Phase
Power Application.
The configuration consisted of a Model T200-410 Drive and Model T200-400 Drive. The T200-400 Drive had a T200
Personality Module option ( Moog p/n C09951) installed. The Drives were connected to Motors via 10m Motor Power
and Motor Resolver shielded cables, terminated to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive.
There was a 3m shielded cable terminated in characteristic impedances connected to the Power Ready port on the T200410 Drive. There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the
T200-410 Drive and the CAN OUT port on the T200-400 Drive and a daisy chain connection from the T200-410 CAN
OUT port to the T200-400 CAN IN port.
Single phase input power was supplied via a Schaffner type FN 350-12-29 mains input line to the AC LINE IN port on
the T200-410 Drive. The DC BUS voltage was daisy chained from the T200-410 Drive to the T200-400 Drive.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 8: Supplementary EMC Emissions & Immunity: Single Phase
Power Application.
The configuration consisted of a Model T200-510 Drive and Model T200-500 Drive. The T200-510 Drive had a T200
Point Extended I/O Card option (Moog p/n C09950) and external regen resistor option installed. The Drives were
connected to Motors via 10m Motor Power and Motor Resolver shielded cables, terminated to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on all Drives:
Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type 0443164151 ferrite
installed at each end of the Axis Signal port cables for each Drive. There was a 3m shielded cable terminated in
characteristic impedances connected to the Power Ready port on the T200-510 Drive.
There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the T200-510
Drive and the CAN OUT port on the T200-500 Drive and a daisy chain connection from the T200-510 CAN OUT port
PAGE A-7
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATION
to the T200-500 CAN IN port. There was a 3m shielded cable terminated in characteristic impedances connected to the
Point Extended I/O option port on the T200-510 Drive. There was an in-line FairRite Type 0443164151 ferrite installed
at each end of this cable.
Single phase input power was supplied via a Schaffner type FN 350-12-29 mains input line to the AC LINE IN port on
the T200-510 Drive. The DC BUS voltage was daisy chained from the T200-510 Drive to the T200-500 Drive. An
optional external Regen resistor was connected via a 10m shielded cable to the EXT REGEN port on the T200-510
Drive.
All Drives were mounted onto an earthed metal panel, mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to cable routing on
machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Test Configuration 9: EMC Emissions & Immunity: 3 Phase Power application.
The configuration consisted of two Model T200-610 Drives. Both Drives had 8 ohm external regen resistor options
installed. The Number Two T200-610 Drive had a T200 Point Extended I/O Card option (Moog p/n C09950) and a
T200 Personality Module option ( Moog p/n C09951) installed. The Drives were connected to Motors via 10m Motor
Power and Motor Resolver shielded cables, terminated to chassis earth at each end.
There were 3m shielded cables terminated in characteristic impedances connected to the following ports on both Drives:
Power Ready port, Encoder port, ESM Out port, Serial port, Axis Signals port. There was an in-line FairRite Type
0443164151 ferrite installed at each end of the Axis Signal port cables for each Drive.
There were 3m shielded cables terminated in characteristic impedances connected to the CAN IN port on the Number
One T200-610 Drive and the CAN OUT port the Number Two T200-610 Drive. Each of these cables had an in-line
Steward Type 28A2024-0A0 ferrite installed at the Drive ports. There was a daisy chain connection from the Number
One T200-610 Drive CAN OUT port to the Number Two T200-610 Drive CAN IN port.
There was a 3m shielded cable terminated in characteristic impedances connected to the Point Extended I/O option port
on the Number Two T200-610 Drive. There was an in-line FairRite Type 0443164151 ferrite installed at each end of
this cable.
Input power was supplied via a 3 phase 400:230 V a.c. step down isolation transformer connected by separate armoured
cables to the AC LINE IN port on each T200-610 Drive. The external regen resistors (8 ohm ) were connected via 10m.
shielded cables to the EXT REGEN port on each T200-610 Drive.
An optional 24V d.c. external logic power supply was connected to the 24V DC LOGIC POWER port on the Number
Two T200-610 Drive and daisy chained to the Number One T200-610 Drive. This external 24 V d.c power was supplied
from a power supply on the equipment connected to one of the secondary phases of the 400:230 V a.c. step down
isolation transformer. There was a Steward Type 28A2024-0A0 ferrite installed through 2.5 turns on the supply cable at
the 24V DC LOGIC POWER port on the Number Two T200-610 Drive.
An optional 120V a.c. external logic power supply was connected to the 120 V AC LOGIC POWER port on the Number
One T200-610 Drive and daisy chained to the Number Two T200-610 Drive. This external 120 V a.c power was
supplied from a 230:120 V a.c. step down isolation transformer on the equipment connected to one of the secondary
phases of the 400:230 V a.c. step down isolation transformer. There was an in-line Steward Type 28A2024-0A0 ferrite
installed on the supply cable at the 120 V AC LOGIC POWER port on the Number One T200-610 Drive.
PAGE A-8
APPENDIX A: EMC TEST CONFIGURATION
T200 User's Manual
Both Drives were mounted onto an earthed metal panel mounted in turn onto an earthed equipment chassis frame. The
bare metal rear panel of each Drive enclosure was fixed in direct contact with the earthed metal panel on the equipment
chassis.
Output cables were grouped and routed along the chassis of the equipment frame in a manner similar to routing of cables
on machinery. The motor power and motor resolver cables were grouped together and installed in a fixed routing to the
motors. The output port cables, motor power and resolver cables, and power input cables had segregated routings.
Single Phase Power Application: Line Filtering (Models T200-3XX, -4XX, -5XX).
An a.c. power input Line Filter is required to be installed by the user in the a.c. power input supply lines. The following
power input Line Filter is recommended:
Type: FN 350-12-29, manufactured by Schaffner, Switzerland. ( Rated 12 A r.m.s.)
Care must be taken when installing the a.c. power input Line Filter to ensure that the ability of the filter to function
effectively is not degraded.
When installing the Line Filter, care must be taken to implement the following measures:
•
Install the Line Filter on an earthed metal panel. There must be continuous earth continuity with good HF
bonding between this panel and the panel on which the T200 Series Controllers are mounted. This must result in
continuous earth continuity with good HF bonding between the enclosure of the Line Filter and the enclosures of
the T200 Series Controllers.
•
Remove paint or other insulating materials and provide conductive corrosion protection at the mounting points
for the Line Filter. Secure the filter using conductive bolts and locking washers.
•
Locate the Line filter as close as possible to the T200 Power input connector. Total cable length from Line Filter
to the T200 Power input connector should not exceed 1 metre. Keep all cable lengths as short as possible and
route separately from other cables and conductors.
•
If using shielded or armoured cable for all connections from Line Filter to the T200 Power input connector, the
shields of these voltage supply cables should be earthed to Chassis Earth using a 180 degree metal clamp (P clip)
connection. Alternatively, if the cable is required to pass through an enclosure panel earthed to Chassis Earth, the
shield may be earthed to the panel by use of a 360 degree metal cable gland.
•
Ensure that the Line Filter is firmly connected to mains Earth and that the Protective Earth (PE) of the Line Filter
is correctly connected to the Protective Earth (PE) of the T200 Series Controllers. Ensure that there is good highfrequency (HF)bonding between enclosure of the Line Filter, T200 Series Controllers and Protective Earth (PE).
•
Ensure that input and output cables from the Line Filter are segregated as much as possible to prevent noise
coupling. ( See figures below ). It is essential that the input conductors to the Line Filter be completely
segregated from both the filter output conductors and all other cables and conductors in the installed product.
PAGE A-9
T200 User's Manual
APPENDIX A: EMC TEST CONFIGURATION
P Clip ( Cable shield connection to earth )
Output cable
Input cable
LINE
FILTER
Correct Input/Output Cable Routing
Output cable
Input cable
LINE
FILTER
Incorrect Input/Output Cable Routing
PAGE A-10
APPENDIX A:- EMC TEST CONFIGURATIONS
T200 User's Manual
This page is intentionally left blank.
PAGE A-11
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