Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
DC SERVO DRIVE
SERIES LD
DC Servo Control
Installation & Operating Manual
7/98
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Table of Contents
Section 1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Year 2000 Compliance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Limited Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1
Safety Notice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5
Model Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6
Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Servo Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Chassis Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Logic Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Bus Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Overvoltage Protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Adjustments, Testpoints, and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-10
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-11
Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-14
Section 2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Receiving & Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Location Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Installing the Servo Control Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1
Mount the Chassis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2
General Wiring Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3
Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
Electrical Noise Suppression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
Wiring Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4
Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5
Input Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6
Optional Input Signal Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6
Section 3
Start–up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Initial Potentiometer Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Start-up (Power On) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1
Adjustment Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2
MN1269
Table of Contents i
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 4
Troubleshooting and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Initial Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Resetting the Servo Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Servo Control Card Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3
Section 5
Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
Current (Torque) Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1
Emergency Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2
Appendix A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
Condensed Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
Appendix B . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
Jumper and Personality Module Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
Personality Module Current Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
Peak and Continuous Current Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-1
Record of “Set Up” Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
B-2
ii Table of Contents
MN1269
Section 1
General Information
Year 2000 Compliance
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
The motor control products listed below are manufactured or offered for sale by Baldor
Electric and are certified to be year 2000 compliant.
DC Motor Controls: Series BC100/200, BC19H, BC20H, LD, TSD, UM, UMH.
AC Motor Controls: Series ID10, ID1100, ID15H, ID15J, ID15V, ZD17H, ZD18H, ID21H,
ZD22H, SD23H, ZD24M, ZD25M, SD26M, BSC, DBSC, BTS, SBTS.
Position Controllers: PMC, SmartMove, NextMove.
Furthermore, year 2000 compliance means that the product will:
Not use dates or perform any date processing.
Date information is irrelevant to proper operation; and
There are no problems or issues to address to ensure continued and proper
operation of the product listed due to changes in century dates.
Limited Warranty
For a period of two (2) years from the date of original purchase, BALDOR will
repair or replace without charge controls and accessories which our
examination proves to be defective in material or workmanship. This
warranty is valid if the unit has not been tampered with by unauthorized
persons, misused, abused, or improperly installed and has been used in
accordance with the instructions and/or ratings supplied. This warranty is in
lieu of any other warranty or guarantee expressed or implied. BALDOR
shall not be held responsible for any expense (including installation and
removal), inconvenience, or consequential damage, including injury to any
person or property caused by items of our manufacture or sale. (Some
states do not allow exclusion or limitation of incidental or consequential
damages, so the above exclusion may not apply.) In any event, BALDOR’s
total liability, under all circumstances, shall not exceed the full purchase
price of the control. Claims for purchase price refunds, repairs, or
replacements must be referred to BALDOR with all pertinent data as to the
defect, the date purchased, the task performed by the control, and the
problem encountered. No liability is assumed for expendable items such as
fuses.
Goods may be returned only with written notification including a BALDOR
Return Authorization Number and any return shipments must be prepaid.
MN1269
General Information 1-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Safety Notice:
This equipment contains high voltages. Electrical shock can cause serious or fatal injury.
Only qualified personnel should attempt the start–up procedure or troubleshoot this
equipment.
This equipment may be connected to other machines that have rotating parts or parts
that are driven by this equipment. Improper use can cause serious or fatal injury. Only
qualified personnel should attempt the start–up procedure or troubleshoot this equipment.
PRECAUTIONS:
WARNING: Do not touch any circuit board, power device or electrical
connection before you first ensure that power has been
disconnected and there is no high voltage present from this
equipment or other equipment to which it is connected. Electrical
shock can cause serious or fatal injury. Only qualified personnel
should attempt the start–up procedure or troubleshoot this
equipment.
WARNING: Be sure that you are completely familiar with the safe operation of
this equipment. This equipment may be connected to other
machines that have rotating parts or parts that are controlled by
this equipment. Improper use can cause serious or fatal injury.
Only qualified personnel should attempt the start–up procedure or
troubleshoot this equipment.
WARNING: Be sure all wiring complies with the National Electrical Code and all
regional and local codes. Improper wiring may result in unsafe
conditions.
WARNING: Be sure the system is properly grounded before applying power.
Do not apply AC power before you ensure that grounds are
connected. Electrical shock can cause serious or fatal injury.
WARNING: Before servicing this control, allow at least five (5) minutes after AC
power is disconnected to allow capacitors to discharge. Electrical
shock can cause serious or fatal injury.
WARNING: Improper operation of control may cause violent motion of the
motor shaft and driven equipment. Be certain that unexpected
motor shaft movement will not cause injury to personnel or damage
to equipment. Peak torque of several times the rated motor torque
can occur during control failure.
WARNING: Motor circuit may have high voltage present whenever AC power is
applied, even when motor is not rotating. Electrical shock can
cause serious or fatal injury.
WARNING: A DB Resistor may generate enough heat to ignite combustible
materials. To avoid fire hazard, keep all combustible materials and
flammable vapors away from brake resistors.
Continued on next page.
1-2 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 1
General Information
MN1269
Caution:
To prevent equipment damage, be certain that the electrical service
is not capable of delivering more than the maximum line short
circuit current amperes listed for the control rating.
Caution:
To prevent equipment damage, be certain that the input power has
correctly sized protective devices installed as well as a power
disconnect.
Caution:
Avoid locating control immediately above or beside heat generating
equipment, or directly below water or steam pipes.
Caution:
Avoid locating control in the vicinity of corrosive substances or
vapors, metal particles and dust.
Caution:
The X and Y Axis motors may tend to run away, out of control, if the
tach wires are reversed. If the axis moves in the wrong direction,
the motor wires are reversed. If, however, reversing the leads
doesn’t stop a runaway motor, make sure the T (Tachometer)
potentiometer is not full counterclockwise.
General Information 1-3
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Introduction
The Baldor “LD” Series Servo Control (see Figure 1-1) is a multi axis pulse width
modulated (PWM), high performance servo control designed to be used with DC brush
type permanent magnet servomotors. This transistorized servo control is a key
component in motion control applications, providing not only converted DC power to the
motor, but also precisely controlling current and velocity at the motor. Its compact design
requires very little enclosure space, while its modular configuration makes servicing easy.
The “LD” Series can be used with many types of position controllers due to its
standardized ±VDC signal input.
Figure 1-1 “LD” Series Servo Control (2 Axis Package)
1-4 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Features
The Baldor “LD” Series switching concept enables the user to operate with the highest
possible bandwidth with reduced switching losses, ripple current, EMI and RFI. Servo
Control cards are field replaceable.
Note: “LD” and “UM” series cards are NOT interchangeable.
The “LD” chassis and Servo Control card combination provides protection features and
status indicators including:
Voltage Error (VE)
Excess Current (EC)
Thermal Protection (EC)
Ground Fault (GF)
Surge Current (SC) and Short Circuit Protection
Logic Voltage Status (MV, PV) or (–15V, +15V)
Bus Voltage Status (PB) or (BUS)
AC Input Voltage Status (AC)
Other standard features include:
20 kHz “Inaudible” Switching
Test Points – to aid during set up
Jumper Settings – allow easy tailoring for specific applications
“Personality Module” – for custom current settings
Decoupled current sense – for monitoring current (absolute or actual value)
EC Latch or Foldback – selectable response to overcurrent condition
Left Limit – Overtravel Limit
Right Limit – Overtravel Limit
Interlock – used to shut down output to motor
External reset line
Push button reset
Phoenix style detachable screw terminals
Each Servo Control can be configured for:
Velocity mode operation with tachometer
Current mode operation
Differential or single ended signal inputs
MN1269
General Information 1-5
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Model Information
Model descriptors that describe key parameters of each unit specify the “LD” Series
Servo Control and Chassis. The “LD” Series Servo Control cards can be configured with
chassis to support up to four (4) axes at 160 VDC.
Figure 1-2 Identification
1-6 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Functional Description
Power Supply
The “LD” Servo Control consists of (1) a power supply, (2) a velocity control amplifier and
(3) fault logic circuitry. The functional concepts are detailed below.
The power supply of a PWM bridge normally acts as a low output impedance voltage
source. However, if an analog signal representing motor current is applied to the front
end of the amplifier together with a current command, the impedance of the PWM bridge
then becomes high. These high impedance bridges exhibit a unique characteristic
referred to as current sourcing. That is, motor current and therefore motor torque
becomes proportional to commanded input current.
Current Sense Coupler The current sense coupler within the power amplifier serves as the current loop feedback
mechanism. The unit isolates the high voltage motor signal from the low level control
circuitry.
Switching Configuration
The power amplifier contains a transistor bridge consisting of 2 limbs each containing 2
main switches. These switches enable a limb output to be connected alternately from the
minus bus to the plus bus. Both limb output signals or motor lines are normally zero with
respect to the minus bus. However, if current is commanded as described above, the
average voltage on only one of the limbs will increase while the other limb remains
connected to the minus bus. This switching configuration is referred to as the lower
circulation method.
Velocity Control Amplifier (VCA)
The high gain front–end velocity control amplifier accepts a speed command (Signal) and
a tachometer voltage (Tach) through the input connector. The VCA clamped error signal
(C adjustment) is applied to the power amplifier as a current command.
Excess Current Limit
The long–term current clamp senses motor current and responds to overload conditions
beyond rated output. If the comparator is tripped, it disables the drive, lights the Excess
Current (EC) indicator and pulls the interlock line “low” (if P4 is in latch position).
Surge Current Sensor
The surge current sensor pulls the interlock line low internally if the peak output current is
exceeded. Once stopped, the drive must be cleared by connecting the reset line to
common momentarily (reset switch) or by interrupting logic power for 2 seconds.
Overheat Sensor
A thermal switch with significant hysteresis attached to the heatsink sets the EC (Excess
Current) latch if the heatsink temperature exceeds a preset level. The latch operates the
EC fault indicator. The fault condition is cleared after the heatsink temperature returns to
normal and a reset is given.
Left Limit, Right Limit
Limit switches are typically mounted on machinery to restrict the load from moving into
catastrophic over–travel conditions. Limit switch polarity of the voltage on this line is the
same as that on the signal pin of the input connector. The motor is wired such that
movement produces a positive voltage on NIML (Non–Inverting Motor Line) with respect
to IML (Inverting Motor Line). Therefore, a positive input signal will cause the axis to
move in a rightward direction. The limit switch leads are then wired confidently to the
appropriate pins of the input connector.
Decoupled Current Sense
The Decoupled Current Sense (DCS) pin is isolated from the high voltage motor lines.
Therefore, motor current is evaluated safely by connecting an oscilloscope or voltmeter to
the DCS pin of the input connector and common (TP1).
Tachometer Filter
MN1269
The tachometer filter rejects tachometer commutator noise by reducing the tach path
bandwidth so that the high gain velocity control amplifier can be responsive yet reject
tach noise.
General Information 1-7
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Specifications
Standard Chassis & Power Supply Assemblies
Output:
Rated Bus Voltage (VDC)
Rated Continuous Current (A)
Positive Logic 15VDC (A)
Negative Logic 15VDC (A)
LD2160
27
1.0
1.0
LD4160
50
1.0
1.0
LD2115
105-125
1
Prewired
LD4115
105-125
3
115 (1 phase)
LD2250
4000
195
220
LD4500
8000
195
220
LD20-50
14
LD40-50
20.6
9
10.5
7.25
13
10.5
7.25
Input:
Nominal Bus Input (VAC 50/60Hz)
Bus Input Range (VAC 50/60Hz)
Number of Phases
Nominal input for Fan & Logic Supply (VAC 50/60Hz)
Overvoltage Protection:
Continuous Rating (W)
Peak Rating (W)
Clamp Rating (V)
Shutdown Point Typical (V)
General:
Operating Temperature (°C)
Weight (lbs.)
Footprint (inches)
Length
Width
Height
Notes:
1. An isolation transformer is not required for “LD” controls (115VAC, 1phase).
2. For LD-4, the power requirements cannot be met by 115VAC 1phase input power. It is recommended that a
230VAC input power be used with an isolation transformer to provide 115VAC 3 phase input power for an LD-4.
3. Line power limitations with 1 phase prevents the chassis and drives from delivering full continuous rated output
power.
1-8 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Servo Control Card
Output:
Rated Bus Voltage (VDC nominal)
Rated Continuous Current (A)
Current Limit Adjust (A)
Peak Current Adjust (A) (maximum time 1.5 seconds)
Peak Current Adjust (A)
Switching Frequency (kHz)
Form Factor
Minimum Inductance (mH)
Frequency Response (kHz)
LD3015HS
160
15
5-15
30
0-30
20
1.01
2.0
2.5
Input:
Signal Input 〈±VDC) See note 2.
Drift (mV/°C)
Overall Gain (A/V min)
LD3015HS
5 to 15
10
0-6000
Auxiliary input:s
LD3015HS
See note 3.
Impedance (k ohms)
20
Power Requirements:
Logic
+15VDC (mA)
–15VDC (mA)
Bus range (VDC)
LD3015HS
180
55
148-176
General:
Weight (lbs.)
Operating Temperature (°C)
LD3015HS
1.4
0-50
Notes:
1.
RMS current limit is a built–in function that turns off or folds back the servo control if the continuous current is exceeded
for an extended period of time. The (EC) fault indicator identifies the condition.
2.
Input signal (S) can be differential or single ended while the auxiliary (A) and tachometer (T) signals are single ended
for all models.
3.
The Left Limit, Right Limit and external Reset auxiliary input signals are connected through normally open (NO)
contacts while the external status I/0 signal is provided through a bi–directional Interlock. The current sense signal
(DCS) is provided as an analog representation of current. For information on usage, refer to Section 2.
MN1269
General Information 1-9
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
General Description
A typical Baldor “LD” Servo Control like that shown in Figure 1-3 can contain from 1 to 4
servo control cards and a chassis assembly. The chassis assembly includes a Logic
Power Supply, Bus Power Supply, Overvoltage Protector, Fans and miscellaneous
hardware.
Servo Control Card
The servo control card is a circuit board, which translates bus voltage and velocity
information into an output for the servomotor with a defined velocity and direction.
Chassis Assembly
The chassis assembly provides the mounting plate for the servo control cards as well as
the power supplies.
Logic Power Supply
The logic power supply converts the 115 VAC input to a ±15 VDC for operating the servo
control electronics and provides a fused ground fault protection circuit. Four green status
LED’s are also provided to verify the presence of +15 VDC (PV), –15 VDC (MV), AC for
fans and logic (AC), and DC Bus voltage (PB or BUS).
Bus Power Supply
The bus power supply converts the 115 VAC input voltage into a DC voltage, which is
controlled within the servo control to power the servomotor.
Overvoltage Protector The standard configuration contains an overvoltage protector, which dissipates (shunts)
excess bus voltage developed during rapid deceleration to prevent damage to the servo
control. The overvoltage protector is fused to protect against catastrophic conditions.
Adjustments, Testpoints, and Indicators
The servo control card contains six set–up adjustments and four (4) red fault indicators
for flexibility and troubleshooting (see Figure 1-4.) The logic power supply has four green
status indicators which when lit show the presence of AC and DC power to the chassis.
Figure 1-3 Example of a LD2–02S
1-10 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Adjustments
Each servo control card contains six (6) potentiometers located on the top left side of the
unit. The location of each potentiometer is provided in Figure 1-4.
Auxiliary (A)
(A) pot is used to adjust the gain of an optional single ended input voltage between ±10
VDC. The effect of changing the gain enables the installer to vary the motor speed for a
given signal input voltage.
Signal (S)
(S) pot is used to adjust the gain of a single ended or optionally configured differential
input voltage between ±10 VDC. The effect of changing the gain enables the installer to
vary the motor speed for a given signal input voltage.
Tachometer (T)
(T) pot is used to adjust the tachometer circuit gain. The effect of changing the gain
enables the installer to vary the overshoot or stiffness of a motor as it is commanded to
change speeds.
Response (R)
(R) pot is used to adjust the overall velocity loop gain. The effect of changing the gain
enables the installer to vary the stiffness of the velocity loop to minimize the overshoot of
the axis when responding to a step input voltage.
Current Limit (C)
(C) pot is used to attenuate the peak current output to the servomotor. This can
effectively reduce the overall RMS current in applications, which are subjected to
constant acceleration and deceleration changes.
Balance (B)
(B) pot is used to compensate for the digital to analog offset errors. This will allow for fine
tuning the zero speed when the input device is installed and there is no signal–input
voltage to the servo control.
Figure 1-4 Adjustment and Indicators
MN1269
General Information 1-11
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Optional Adjustments
Each servo control contains six jumper settings and a personality module that can be
used to custom tailor the module to the application (for location see Figure 1-4).
Underlined positions indicate the factory default settings.
P1
P2
P3
P4
P5
P6
Right position (pins 1 and 2) when normally opened switches are used.
Left position (pins 2 and 3) when normally closed switches are used.
Right position when using a differential input.
Left position for single ended input.
Right position for reading actual current (+ or –) on the DCS current monitor.
Left position for the absolute value. (always positive)
Right position for EC (Excess Current) latch function
Left position for current foldback mode, where current is limited to a lower fixed
level.
(See Appendix B)
A factory installed resistor (P5) which is on–board the personality module. This
is to ensure that the servo control will not function without the personality module in the socket.
Left position for velocity mode operation.
Right position for current mode and for use in positioning applications with
Personality Module
The personality module has 3 after factory adjustable settings (for location, see Figure
1-4). With the appropriate 1 % resistor soldered into the socket, peak current, RMS
current, and the foldback level can be adjusted. Motor compensation values are also on
this module, allowing custom compensation on specialty motors. These components are
already appropriate for Baldor DC servomotors. For a description of the current settings,
see Appendix B.)
Set Up Testpoints
Six testpoints have been added to help with set up and the replacement of a card. Once
a card is set up, the potentiometer’s resistance can be measured and recorded for future
reference. Other cards can be preset to these values minimizing the need to set up each
card on the particular piece of equipment.
Test Point
TP1
TP2
TP3
TP4
TP5
TP6
Reset Button
1-12 General Information
Description
Common
“A” Pot Wiper Resistance
“S” Pot Wiper Resistance
“T” Pot Wiper Resistance
“R” Pot Wiper Resistance
Tach monitor (measures actual tach voltage)
A momentary push button (SW1) is mounted on the top of the servo control card next to
the adjustment potentiometers (for location, see Figure 1-4). This allows you to restart
(reset) a control that has shut down.
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Fault Indicators
Each servo control card contains four (4) red fault indicators located on the top left side of
the unit (for location see Figure 1-4). Each fault is a latch type function (unless in
Foldback Mode) where the servo control card will not function when tripped. A reset must
be done in order to restart the servo control. Refer to Section 4 – Troubleshooting for
detailed information on solving fault problems.
Voltage Error (VE)
The purpose of the (VE) indicator is to identify either excess bus voltage detected by the
overvoltage protector or insufficient logic voltage at the servo control.
Excess Current/Overtemperature (EC)
The purpose of the (EC) indicator is to identify either excess RMS current or over
temperature condition.
Ground Fault (GF)
The purpose of the (GF) indicator is to identify if current is flowing at or leaking to ground
potential in either the motor or servo control.
Surge Current (SC)
The purpose of the (SC) indicator is to identify a peak current draw, which exceeds the
rating of the servo control.
Status Indicators
The logic power supply on the chassis has four (4) green status indicators (see Figure
1-5) which when lit verify the presence of the +15 VDC, –15 VDC, AC for fans and logic,
and Bus voltage (DC).
Figure 1-5 Status Indicators
MN1269
General Information 1-13
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Tools
There are a few basic tools recommended to install the “LD” Servo Control.
Recommended Tools
Slotted screw driver, medium size
Slotted, very small screw driver (or pot adjustment
tool
Phillips, screw driver medium large with 8” long
shank (required if replacing or adding servo control
cards
Phillips, screw driver medium
Crescent Wrench (6” or 8”)
VOM meter
Description and Use
Terminal strips, chassis and possibly transformer
Potentiometer adjustment and screw terminal
connections
Add or remove modules
Input connections to AC bus power
Disassemble packaging from chassis
Testing continuity, verifying Voltage, current,
polarity, etc.
A number of other common tools are recommended in order to do a proper job i.e. solder iron, solder,
crimp tools, wire stripper, etc.
1-14 General Information
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 2
Installation
Receiving & Inspection
Location Considerations
Baldor Controls are thoroughly tested at the factory and carefully packaged for shipment.
When you receive your control, there are several things you should do immediately.
1.
Observe the condition of the shipping container and report any damage
immediately to the commercial carrier that delivered your control.
2.
Remove the control from the shipping container and remove all packing
materials. The container and packing materials may be retained for future
shipment.
3.
Verify that the part number of the control you received is the same as the part
number listed on your purchase order.
4.
Inspect the control for external physical damage that may have been sustained
during shipment and report any damage immediately to the commercial carrier
that delivered your control.
5.
If the control is to be stored for several weeks before use, be sure that it is
stored in a location that conforms to published storage humidity and
temperature specifications.
The location of the control is important. It should be installed in an area that is protected
from direct sunlight, corrosives, harmful gases or liquids, dust, metallic particles, and
vibration. Exposure to these can reduce the operating life and degrade performance of
the control.
CAUTION: Avoid locating control immediately above or beside heat generating
equipment, or directly below water or steam pipes.
CAUTION: Avoid locating control in the vicinity of corrosive substances or
vapors, metal particles and dust.
Several other factors should be carefully evaluated when selecting a location for
installation:
1.
For effective cooling and maintenance, the control should be mounted on a
smooth, non-flammable vertical surface.
2.
At least two inches top and bottom clearance must be provided for air flow.
Installing the Servo Control Card
This procedure is to be followed only if the Servo Control Cards have not been mounted
to your chassis. If the cards are already installed, skip this procedure and continue with
Mount the Chassis.
MN1269
1.
Prepare to mount the card by loosening the two phillips head machine screws
located on base of chassis (see Figure 2-1).
2.
Open the shipping carton, remove the card enclosed in plastic, anti–static
protective bag.
3.
Remove the card from the bag and slip the module’s slotted tabs under the
screw heads.
4.
Tighten the screws moderately with a long phillips head screwdriver.
5.
Repeat the mounting procedure for each card.
6.
On the prewired chassis cable harness, grasp the large connector (female “Bus
Connector”) and plug it into the row of pins (J6) at the upper right corner of the
card near the fan (see Figure 2-1). Take care to ensure proper alignment as
there is only one correct position .
7.
Grasp the small connector (4 socket female “Logic Connector”) from the same
harness and plug it into J5 (see Figure 2-1). Again make sure it is properly
aligned on the 4 pins.
Installation 2-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Figure 2-1 Installing the Module
Mount the Chassis
2-2 Installation
1.
Remove the shipping base by taking off the four nuts and bolts at the corners of
the chassis.
2.
Select an appropriate mounting location that meets the vapor, vibration and
particle avoidance requirements stated in General Precautions in section 1.
3.
Lay out the hole pattern according to the dimensions of your chassis. Refer to
Appendix A for dimensions.
4.
Cut any wiring openings needed in the cabinet, debur the edges, and bolt the
chassis securely within the equipment enclosure. Use one of the mounting
bolts to attach a ground strap to earth ground.
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
General Wiring Considerations Care should be taken to see that all interconnecting wiring is sized and installed in
conformance with the National Electrical Code (NEC) or Canadian Electrical Code (CEC)
and other applicable local codes.
To minimize electrical interference problems, interconnecting wires should be arranged in
groups. As a minimum, two groups should be used; (1) high current, high voltage power
wiring such as main power input, 115 VAC for fans, relays, contactors, etc. DC wiring for
motor power and (2) low level signal wiring such as input speed commands, tachometer
feedback, inhibit/enable signals, etc. It is recommended that wire groups be separated
by at least one foot, or run in separate grounded conduits. All wiring should be kept as
short as possible.
As a general rule, use only wires of adequate size for their length and current being
carried. Specific recommendations for each major group follows. For critical
applications, finer subdivision into wire groups of like functions is advised.
Power Wiring
All power wiring for the cooling fans, motor power and input power connections should be
no less than 16 AWG gauge or equivalently rated wire. It is suggested that power wires
be run as twisted pairs, i.e., twist the wire carrying current with the same wire returning
the current. Twisting the wires will reduce radiated electrical noise. In systems
particularly sensitive to electrical noise, use of shielding for the motor power wiring might
be considered.
Grounding
Proper grounding helps guard against electrical shock to personnel and can reduce the
effects of electrical noise interference. Each chassis/power supply assembly should be
grounded. One mounting bolt can be used to attach a ground wire. The chassis ground
wire should have a green or green with yellow stripe insulation. In addition to the chassis
grounds, the cabinet which houses the equipment should have a separate connection
direct to earth ground on the power distribution panel.
The system ground should be designed in a tree fashion with individual ground wires
converging to a single earth ground point. Ground wires should be short and large
enough to carry the maximum short circuit current rating of the circuit, as determined by
the fuse rating on the incoming power. Consult local governing codes for compliance with
safety regulations before finalizing the grounding system.
MN1269
Installation 2-3
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Signal Wiring
All signal wiring and limit circuit wiring need not be larger than 22 AWG gauge. Signal
circuits, including the tachometer, should employ twisted, shielded pairs. Proper
termination of shielded cables is important to avoid creating ground loops or otherwise
degrading the noise immunity of the servo package. Cable shields should be terminated
at one end only. The other end should be left floating but insulated by electrical tape or
some other means to prevent contact with any metallic part. In most applications,
satisfactory noise immunity will be realized with the signal line shields terminated at the
respective signal input points. Note: Always reference the shield to the low side of the
signal wires which the shield is to protect. Earthing or grounding the shield does little
good unless the signal is also referenced to the same point. It is important to maintain
the continuity of cable shields through any intervening connector and/or terminal blocks.
Try to minimize the length of unshielded cable at these points.
Electrical Noise Suppression
Electrical noise suppression requires a thorough system design using a combination of
good grounding practices, shielded cable, cable separation and suppressors. The
customer must provide suppression of transient voltages in his equipment, which may
occur when interrupting current to an inductive load.
Wiring Instructions
Power Wiring
Wire the unit according to the National Electrical Code (NEC) as well as your local
requirements. Motor power and AC input wiring should be appropriate for the continuous
rated current for the motor being used.
The connections and the wiring can vary between chassis depending on the user’s
requirements and the terminal strip options chosen.
Note: Refer to the drawing in Appendix A before connecting the unit and integrating
it into the system.
Note: LD-2 units have screw type terminals for L1 and L2.
LD-4 units have screw type terminals for L1, L2 and L3.
Figure 2-2 Power Wiring
2-4 Installation
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Power Wiring Continued
1.
2.
3.
4.
5.
Connect the negative lead (black wire) from the first servomotor to terminal 1 on
the 12 position terminal block (see Figure 2-2).
Connect the positive lead (red wire) from the first servomotor to terminal 2 on
the 12 position terminal block (see Figure 2-2).
For the second axis servomotor, connect the negative lead (black wire) to
terminal 3; and the positive lead (red wire) to terminal 4. Repeat this procedure
for any other axes (Refer to drawing in Appendix A).
Do not at this time connect any AC power to the chassis.
Wire the AC power input to the screw–type terminals on the rear of the chassis
as shown in Figure 2-2. Do not connect any AC power at this time. Phasing is
not critical on the bus power input. For LD-2 units, use the two terminals
marked L1 and L2 and connect 115VAC 1 phase power. For LD-4 units, use
the three terminals L1, L2, and L3 and connect 3 phase power.
Signal Wiring
1.
2.
3.
Connect the positive (+) side tachometer lead wire (of the first servomotor) to
the Tach input (pin 5) on the 18 position Phoenix style input signal connector
(see Figure 2-3).
Connect the negative (–) side tachometer lead wire (of the first servomotor) to
the Tach input (pin 6) on the 18 position Phoenix style input signal connector
(see Figure 2-3). Tie the tachometer cable shield to pin (11) common.
Continue connecting remaining tachometer lead wires for other axes (Refer to
drawing in Appendix A).
Figure 2-3 Input Signal Wiring
4.
Differential Command input
The “LD” Series Servo Control is configured to operate using a differential
command input signal. To utilize differential input, jumper P2 (see Figure 2-3)
must be in its right position (pins 1 to 2). This is the normal position as shipped.
The Servo Control Signal pot (S) will be used to scale the differential voltage
input.
5. Connect the input velocity command signal to pin 1 and its return to pin 4.
Note: Do not apply voltage at this time.
6. Verify the first axis tachometer signal by rotating the first axis motor shaft by
hand while monitoring the tach test points with a VOM. Connect the black lead
of the VOM to test point TP1 and the red to TP6. When rotating the motor shaft
in a clockwise direction (facing the shaft), the VOM should read positive.
MN1269
Installation 2-5
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Input Wiring Connections
Left Limit, Right Limit
(Pins 8 & 9 for Normally Open, 17 & 18 for Normally Closed)
When the Left or Right limit is pulled to common (for normally open switches), output is
inhibited in that direction. This function disables the control and the motor will coast to a
stop. This function can be used for an axis overtravel limit to prevent further operation in
the inhibited direction, but it does allow the drive to back out of the limit. Jumper P1 on
the servo control allows you to select either normally open or normally closed limit inputs.
The normal position as shipped is P1 jumper right (pins 1 to 2). If normally closed
switches are to be used, then this circuit must be first activated by placing jumper P1 in
the left position (pins 2 to 3).
Note: If P1 is in the left position and limit switches are not used in the application,
the control will assume the switch has opened and disable its output in that
direction, unless the right and left limits (pins 17 & 18) are tied to common.
Optional Wiring
Single Voltage Input (pin 4 to 2)
The servo control can be configured to operate using a single ended positive or negative
voltage command input signal. Move jumper P2 from its right position to its left position
(pin 2 to 3).
Use the servo control Signal (S) pot to scale the single voltage input. Rotate (A) pot full
counterclockwise.
Current Monitor Interface (Pins 7 & 11).
Decoupled Current Sense (DCS) is an analog representation of servo control current.
Using an oscilloscope, the output current can be viewed. An analog output voltage of 1
volt peak to peak represents approximately 1/10 of peak current. If you have a
LD3015HS servo control card and your DCS voltage is 1.5V peak, amplifier output
current is:
30 amps peak 1/10 x 1.5 = 4.5 amps output
OR
3 x DCS voltage = output current (for LD3015)
Figure 2-4 Optional Input Signal Wiring
2-6 Installation
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Figure 2-5 Optional Input Signal Wiring
Interlock (Pin 10)
The interlock is bidirectional. That is, it can be pulled to common internally to disable the
output stage of the control or externally to accomplish the same disabling function (see
Figure 2–5). The internal pull down function occurs as a result of:
High bus or low bias voltage. (VE Indicator ON)
Ground Fault current. (GF Indicator ON)
Excessive I2T current or overtemperature (in latch mode). (EC indicator ON)
Excessive bus surge current. (SC Indicator ON)
The interlock function can be used to tie multiple servo control cards together thus locking
all cards together. If wired in this configuration and a fault condition occurs on one axis
card, all other cards will also be interrupted. An Emergency E–stop could also be wired
to the interlock line, upon switch closure the output stages of all servo control cards will
be disabled (i.e., motors will coast to a stop with no holding torque). See Section 5 for
additional information on Emergency Stop.
Reset (Pin 15)
The reset line is used to externally reset the servo control. When the reset signal is tied
to common temporarily and then released, the control will be enabled (restarted) if a fault
condition is not present. If activated, the reset line will totally disable the servo control
card. The reset button (SW1) (a momentary switch) was added for your convenience and
will provide the same results.
+15 VDC/–15 VDC (Pins 12 & 13)
This is an available logic power source with a 50 mA maximum load which can be used to
support external devices or can be used with a voltage divider network to provide the
signal input to the servo control card.
MN1269
Installation 2-7
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
2-8 Installation
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 3
Start-up
Overview
The start-up information provided in this section contains the procedures necessary to get
each axis running and properly tuned using the 6 adjustment potentiometers on the servo
control. Each axis should be started up independently to insure that catastrophic
problems do not cause damage to the equipment. It is further recommended that the
load is not connected to the servo control until you are familiar with the control.
Initial Potentiometer Settings
Potentiometer
A (Auxiliary)
S (Signal)
T (Tachometer)
R (Response)
C (Current Limit)
B (Balance)
Position
Fully counterclockwise
Fully counterclockwise
Fully clockwise
Fully counterclockwise
One turn clockwise
Leave as shipped
Condition
Off
Off
Low
Low
Low
Center
Note: All pots have a 15 turn range and are without a hard stop. You may hear a
‘click’ when the end is reached.
Start-up (Power On)
MN1269
To minimize the potential damage to the machine during power up, disconnect all axis
except the first (X-axis).
1.
Apply the 115 VAC to the AC power input.
2.
Observe that the fan starts and 4 of the green LED’s on the logic power supply
(+15V, –15V, AC, and ”BUS”) illuminate.
3.
Observe that the servomotor on number 1 axis (X) did not rotate. If the
servomotor runs up to a high speed at an uncontrolled rate, reverse the
tachometer or motor power leads.
Startup 3-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Adjustment Procedure
Caution:
The X–Axis motor may tend to run away, out of control, if the tach
wires are reversed. If the axis moves in the wrong direction, the
motor wires are reversed. If, however, reversing the leads doesn’t
stop a runaway motor, make sure the T (Tachometer) potentiometer
is not full counterclockwise.
1.
Apply a signal step input command between 0 and 10 VDC at positions 1 and 4
on the signal input connector. (Suggest 5 VDC input voltage)
2.
Slowly turn the (S) Signal pot 4 turns in the clockwise direction observing that
the motor shaft rotates at a reasonably controlled rate.
3.
Slowly turn the (C) Current pot 4 turns in the clockwise direction (motor shaft
speed may increase and stabilize). If the X axis motor shaft runs to a high or
uncontrolled rate, reverse the tach wires coming to the signal input connector.
4.
If the X axis motor shaft rotates in the wrong direction for a given polarity of the
signal input voltage, reverse both the tachometer wires along with the red and
black motor power wires on the terminal block.
5.
If connected, verify that the Left and Right limit switches properly inhibit the axis
travel in the direction defined. The normally open limits are activated when tied
to common.
6.
Slowly turn the (S) pot clockwise to increase the motor shaft speed to full
speed.
7.
If a high output voltage tachometer is used, it may be necessary to turn the (T)
pot a few turns counterclockwise to achieve the desired speed.
8.
Slowly turn the (C) pot to the full clockwise position if the servo control’s peak
current is less than the rated peak current of the motor. If the peak motor
current is less than that of the servo control, a reduced current MUST be
maintained.
Note: The following 5 steps (9 through 13) are to be followed in setting up each axis
before connecting the servo motors to the equipment. The following
procedure should also be used after the equipment has been installed with a
load and control applied for the final fine tuning.
9.
Slowly turn the (R) pot in the clockwise direction until the axis becomes
unstable and then turn the pot back one turn in the counterclockwise direction.
This adjustment is best done with a step input command.
10. If the motor shaft rotates with the signal input voltage at zero; slowly turn the (B)
pot to eliminate any motor shaft rotation.
11. If the motor shaft overshoots when stopping, turn the (T) pot in the
counterclockwise direction being careful not to turn to full counterclockwise.
Full counterclockwise on the (T) pot may cause the motor shaft speed to
become uncontrollable.
12. The (S) pot can now be adjusted to optimize the maximum response for the
given signal input voltage range.
13. Repeat the wiring instructions in Section 2 of this manual and the Start-up
procedure in this section for each servo motor and servo control card.
3-2 Startup
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 4
Troubleshooting and Maintenance
Overview
This troubleshooting section describes the symptoms of possible malfunctions along with
information needed to check and correct the causes of a fault. Using the four LED fault
indicators on the Servo Control Card and a VOM can identify most of the faults.
Unless the cause of a malfunction is obvious and readily correctable, replace the servo
control card with a new one. This will get the system running most quickly and reduce
equipment down time.
Under no circumstances should you modify or replace any components. This could
compound the problem as well as voiding the warranty.
If a problem develops in a system that was previously operating well, do not make any
adjustments without first diagnosing the cause or causes. To arbitrarily readjust the unit
will only compound the problem.
Work from the four LED indicators and from the troubleshooting table in this section.
Initial Checks
Begin your troubleshooting with a systematic and complete check of power lines and
input signals to the servo control.
WARNING: Do not touch any circuit board, power device or electrical
connection before you first ensure that power has been
disconnected and there is no high voltage present from this
equipment or other equipment to which it is connected. Electrical
shock can cause serious or fatal injury. Only qualified personnel
should attempt the start–up procedure or troubleshoot this
equipment.
WARNING: Do not remove cover for at least five (5) minutes after AC power is
disconnected to allow capacitors to discharge. Electrical shock can
cause serious or fatal injury.
1. Check input speed command signals. Determine that they reach the servo
control input connector.
2.
Check the external limit switches if used to determine that they are functioning
properly.
3.
Check the 115 VAC power to determine that it is correct.
4.
Check for open fuses and circuit breakers.
5.
Check for correct jumper positions.
6.
Check for damaged control or equipment wiring.
7.
Check for loose or broken terminals.
8.
Check for abnormally hot components.
9.
Check for burned insulation or components.
Resetting the Servo Control To reset a servo control with a fault, the following procedure must be performed.
1.
Check over the servo control and wiring for obvious problems.
2.
Review the following troubleshooting table for a possible explanation of the
cause and corrective action to be taken.
3.
Reset the axis by either taking the reset line on the signal input connector and
touching it to common and releasing, or depressing the reset button.
Note: Remove incoming AC power before changing AC fuse. To gain access to
change fuse, press fuse holder cover to the side and lift up. Install new fuse
and press cover down securely to re–seat fuse cover, noting that it snaps
back in place. Re–apply incoming AC power.
MN1269
Troubleshooting and Maintenance 4-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Fault
Symptom
No torque in one direction.
No output in either direction.
N/A
Motor runs at uncontrolled
speeds
Oscillation in motor seen as
instability or rocking of motor
shaft. Motor may have
growling sound.
Motor exhibits a “dead zone“
when responding to a signal
input.
Low output voltage from logic
power supply.
VE
Bus Voltage too high.
RMS current output is
exceeded.
Overtemperature on servo
control.
EC
GF
Current flow is detected at
ground potential
Rated peak current has been
exceeded.
SC
4-2 Troubleshooting and Maintenance
Corrective Action
Check left or right limit switch wires to ensure that they are not tied to
common.
Verify that the proper limit switches are used.
Verify P1 position
Check interlock and reset wires to ensure that they are not tied to common.
Perform set–up procedure and verify all connections. Observe if all 4
green LED’s are lit on logic supply.
If all 4 LED’s are not lit, perform start–up procedure in Section 3 and
recheck all steps.
If only (bus) LED is lit, check AC logic fuse on top of unit to verify it is good
and set in the holder.
Verify P1 jumper is not missing.
Verify that the servo control is not set for current mode.
Verify P6 position.
Verify that (T) pot is not set full CCW. Reverse tach leads and verify that
tach voltage is present at signal input connector when motor is running.
Refer to Start-up and Adjustment
Procedures for proper setting of (R) and (T) pots.
Verify that the bus voltage is sufficient for the motor.
Verify that inductance is not overly high (see specifications in Section 1
). Refer to Start-up procedures for proper setting of (R) pot.
Check incoming power to logic power supply and verify that it is in specified
range. If in range, disconnect any external load on logic power and
reset servo control.
Check fuse on shunt regulator.
Recheck voltage and if problem still exists, disconnect power to each servo
control individually and isolate which servo control is drawing excess
current.
Check to ensure (T) pot is turned too far CCW.
Check axis for instability (oscillation). Correct by turning (R) pot CCW.
If not instability, look for high tach noise (over 5% p–p) by using an
oscilloscope. If noise is present, check tach shielding.
If overloading is suspected, a larger servo control may be required.
Contact your supplier for alternatives.
Verify that air circulation is present. Check for overload using oscilloscope
on the DCS line to determine current to motor. 1V is approximately 1/10
of the peak rated output current. If not overloaded, unit should be
returned for repair.
Can be caused by a short to ground. Remove armature connections and
check for short to ground. If none exists, remove servo control and reset
unit. If problem is resolved, servo control should be returned for repair.
Verify that motor has sufficient inductance (see Section 1.5.2). Reset servo
control and see if problem immediately reappears. If so, check for short
in motor. If motor is not shorted, unit has an internal short and should be
returned for repair.
If upon resetting servo control, the unit does not fault, cycle equipment
while watching for a fault during acceleration. If fault occurs, increase the
acceleration time, reset and cycle until problem is eliminated.
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
WARNING: Do not touch any circuit board, power device or electrical
connection before you first ensure that power has been
disconnected and there is no high voltage present from this
equipment or other equipment to which it is connected. Electrical
shock can cause serious or fatal injury. Only qualified personnel
should attempt the start–up procedure or troubleshoot this
equipment.
WARNING: Do not remove cover for at least five (5) minutes after AC power is
disconnected to allow capacitors to discharge. Electrical shock can
cause serious or fatal injury.
Maintenance
The only periodic maintenance required on the servo control is an occasional inspection
for accumulated dust or dirt on the heat sinks and circuit boards. Heat sinks must be kept
clean for maximum cooling efficiency. Also, shop dust in some environments tends to be
electrically conductive and can cause servo control malfunction.
1.
If cleaning is needed, carefully vacuum loose dirt or use dry compressed air.
2.
Remove power and ensure that bus capacitor voltage has bled down before
checking connections.
3.
Periodically check all connections and fasteners for tightness.
Servo Control Card Replacement
MN1269
1.
Remove power and ensure that the bus capacitor voltage has bled down.
DO NOT short capacitor with a screwdriver or clip lead.
2.
Measure capacitor voltage with a voltmeter or wait for 3 minutes for capacitor to
bleed off.
3.
Disconnect both of the module top edge connector by holding printed circuit
board while pulling connector away from board.
4.
Disconnect the signal–input connector in the same fashion.
5.
Loosen the chassis mounting screws (module heatsink brackets are slotted)
and slide module out from chassis.
Troubleshooting and Maintenance 4-3
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
4-4 Troubleshooting and Maintenance
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Section 5
Special Functions
Current (Torque) Mode
The “LD” can be configured for current mode operation by moving jumper P6 to its right
position (pins 1 to 2). This current mode operation is useful in applications where
commanded motor torque must be proportional to a voltage at the signal input. Since
torque is proportional to motor current, constant current must be provided to the motor to
develop constant torque. The current mode operation differs from standard operation in
that the velocity loop is basically disabled (gain is reduced from 6000 A/V to
approximately 6 A/V). The remaining current loop controls the output current proportional
to the input voltage (VCS).
Typical applications requiring current mode operation are:
Web controls
Brake applications
Bolt tightening
Current mode operation is useful if a programmable motion controller is precisely
controlling the velocity loop. In this configuration tachometer feedback is not required.
To convert a velocity control amplifier to a current amplifier (Refer to Figure 5-1).
1.
Move the P6 jumper to its right position (pins 1 to 2).
2.
The T pot must be rotated fully counter–clockwise.
3.
The S pot should be set fully clockwise.
Note: if the A pot is used, set full clockwise and the S pot counter–clockwise.
Figure 5-1 Servo Control Card
MN1269
Special Functions 5-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Emergency Stop
In some applications, a requirement may exist to positively disconnect a motor in the
event of an emergency (E) stop.
A suggested approach using a relay with 4 sets of contacts could be applied as shown in
Figure 5-2, providing a power disconnect of motor and servo control in the event of an E
stop.
Figure 5-2 Power Contactor for Positive Disconnect
5-2 Special Functions
MN1269
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Appendix A
Condensed Installation Instructions
Step 1
Become familiar with the equipment. You should have:
1.
Servo Control Cards of the type and quantity you have ordered, mounted to the
chassis.
2.
Chassis Assembly which also includes:
– Logic power supply (bias supply)
– Overvoltage protector (shunt regulator)
– Bus power supply
In addition to the above you will find an Installation and Operating Manual and input
connector which are attached to the servo control cards.
Step 2
Read the Installation and Operating Manual.
It contains detailed installation and start up procedures and drawings pertaining to your
equipment. Specific CAUTIONS must be adhered to so that equipment or personnel are
not damaged or injured.
Step 3
Mount the Chassis Assembly.
WARNING: Do not apply power until all connections are made, connections are
checked and the safety precautions in Sections 1 are read and
understood.
Step 4
Connect the Motors.
1.
Connect motor armature leads to the motor output terminals on the chassis
assembly. Refer to Figure A-1.
2.
Connect the tachometer leads to the input connector A1, pins 5 and 6. See
input connector Installation Drawing. Be sure that the armature and tach are
connected to the same axis.
Step 5
Connect Power to the Chassis Assembly.
Connect the power source to the input terminals. Use caution when connecting 115VAC
to LD-2 (one input power units) and LD-4 (two input power units). Refer to Figure A-1.
Step 6
Refer to Section 3 for Start Up and Adjustment instructions.
MN1269
Appendix A-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Figure A-1 Series “LD” Installation Drawing
115VAC 1 phase input bus
power for LD-2.
115VAC 3 phase input bus
power for LD-4.
A-2 Appendix
MN1269
Appendix B
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Jumper and Personality Module Settings
Personality Module Current Settings Refer to Figure B-1.
The personality module allows you to calibrate the servo control. Resistors can be
soldered to the module to select the upper limit values of the following:
Peak Current
Continuous Current
Foldback Current (LD3015HS)
Peak and Continuous Current Levels
Adding a resistor reduces the set values from the specifications in Section 1.
Figure B-1
R96
C25
R97
C26
R98
C27
Foldback Current Level (LD 3015HS)
Foldback Current
(Amps)
5
7
9
11
13
15
Feedback Resistance
(Ohms)
453
715
1.0K
1.37K
1.82K
2.43K
Peak / Continuous Current Levels
Peak
Ipeak (Amps) RP (Ohms)
30
OPEN
28
14.0k
26
8.87k
24
6.19k
22
4.64k
20
3.57k
18
2.74k
16
2.15k
MN1269
Continuous
I rms (Amps)
RR (Ohms)
15
OPEN
14
475k
13
97.6k
12
59.0k
11
31.6k
10
23.2k
9
16.2k
8
11.3k
Appendix B-1
Servo Systems Co. • 115 Main Road • P.O. Box 97 • Montville, NJ, 07045-0097
(973) 335-1007 • Toll Free: (800) 922-1103 • Fax: (973) 335-1661
www.servosystems.com
Record of “Set Up” Configuration
It is highly recommended that a record be kept of the set up details for future reference.
This will come in quite handy for new units, field replacements, and diagnostic aid.
Using recorded values from similar set–ups will reduce installation time, and service can
be conducted faster. These charts provide a common diagnostic communication tool for
the builder or system integrator.
Jumper
P1
Jumper Function
Normally closed limit circuit.
Jumper Identification
ON
P2
Differential Input
OFF
P3
Current monitor value DCS
Absolute
P4
EC Fault Function
Foldback
P6
Amplifier Loop Mode
Velocity
Potentiometer Settings
POT
TP
Auxiliary Input
A
2
Signal Input
S
3
Tach Gain
T
4
Response
R
5
321
321
321
321
321
OFF
ON
Actual
Latch
Current
Axis
#1
#2
#3
#4
Measure ohm readings for the four compensation potentiometers and record them in the
chart above. Take your resistance measurements between common (TP1) and the
appropriate pot test point.
Note: Power down the servo control and disconnect the signal input connector
before making any measurements.
B-2 Appendix
MN1269