indel servo-drives manual · ch-8332 russikon 12 rev. 2.15 21.05.2004 controller manual for indel...

Indel Servo-DrivesManual

Revision 2.15

Copyright September 2004 by Indel AG, All Rights Reserved

CH-8332 Russikon 2

Rev. 2.15 21.05.2004 Controller Manual for Indel Servo-Controllers

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Index0. Introduction ................................................................................................................... 6

0.1 Types of controllers ........................................................................................................................ 6

0.2 Notes on Safety .............................................................................................................................. 7

0.3 Brief Description ............................................................................................................................. 8

0.4 Tools ................................................................................................................................................ 9

Part I ...............................................................................................10

1. Technical Data ............................................................................................................. 11

1.1 Dimensions INFO-SAC................................................................................................................... 11

2. Hardware installation of the controller ...................................................................... 12

2.1 EMC ................................................................................................................................................12

2.2 Wiring .............................................................................................................................................12

2.2.1 Wiring details ...................................................................................................................................122.2.2 Pin-Out ............................................................................................................................................142.3.3 Serial Interface ................................................................................................................................16

3. Software Installation ................................................................................................... 17

3.1 Registry-Editor ............................................................................................................................... 20

3.2 Installation with laptop (serial target) .........................................................................................21

4. ACS-Show ................................................................................................................... 22

4.1 Visualisation with ACS-Show ....................................................................................................... 22

4.2 Layout of ACS-Show .....................................................................................................................23

4.3 Motor Konfiguration ...................................................................................................................... 25

4.3.1 File Handling (File) ...........................................................................................................................254.3.2 Motor Flags (File) .............................................................................................................................264.3.3 Motor Data (Motor) ...........................................................................................................................284.3.4 PID-Parameter (PosCtrl) ..................................................................................................................304.3.5 Current Control (CurrentCtrl) ............................................................................................................. 33

4.4 Controller Configuration ...............................................................................................................34

4.5 Logger ............................................................................................................................................35

4.5.1 Configuration of the Logger ..............................................................................................................354.5.2 Logging data ....................................................................................................................................364.5.3 Measured Values .............................................................................................................................37

4.6 Test ................................................................................................................................................. 38

4.6.1 Trapezoid Controller ......................................................................................................................... 384.6.1 Current / PWM .................................................................................................................................38

4.6 Debug .............................................................................................................................................39

4.6.1 Software and Parameter download ...................................................................................................39

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5. Flash-Prom Updates ................................................................................................... 40

5.1 Parameter and Software updates ................................................................................................40

5.1.1 Burn Files to Flash-PROM ...............................................................................................................415.1.2 Save Motor- and Controller Constants into a file ............................................................................... 415.1.3 Copy Parameters from RAM into Flash-PROM .................................................................................415.1.4 Information ......................................................................................................................................425.1.4 Version and Help .............................................................................................................................425.1.5 Automated Flash-PROM Updates .................................................................................................... 42

5.2 Updates with Laptop .....................................................................................................................43

6. Trapezoid Controller ................................................................................................... 44

6.1 ACS-Show ......................................................................................................................................44

6.2 Win-Show ......................................................................................................................................44

6.2.1 Guideline for Trapeze- and S-Profile ................................................................................................. 456.2.2 Controlling constants .......................................................................................................................456.2.3 Actual values ...................................................................................................................................466.2.4 Status of axis .................................................................................................................................. 466.2.5 Driving commands, VRG_BEF .........................................................................................................466.2.6 Standardization, VRG_FLG..............................................................................................................476.2.7 Mode, VRG_TST .............................................................................................................................476.2.8 Standard factors ..............................................................................................................................486.2.9 Error messages ............................................................................................................................... 48

Part II..............................................................................................49

7. Start-up of AC-Servo Motors ...................................................................................... 50

7.1 Motor parameters ..........................................................................................................................50

7.2 Motor Temperature sensor ...........................................................................................................51

7.3 Test wiring of the Resolver ...........................................................................................................51

7.4 External Enable .............................................................................................................................52

7.5 Number of Pole Pairs ....................................................................................................................52

7.6 Verify direction of rotation ............................................................................................................52

7.7 Resolver Offset Callibration.......................................................................................................... 53

7.8 Stromregler abgleichen ...............................................................................................................547.8.1 Default Werte .................................................................................................................................. 547.8.2 Adjustment of closed-loop current controller ....................................................................................55

7.9 Adjustment of PID Parameters .....................................................................................................56

7.9.1 Optimisation with Ziegler-Nichols .....................................................................................................567.9.2 Procedure to adjust a PID-Controller ................................................................................................56

7.10 Adjustment of pre-hold values .....................................................................................................60

7.11 Adjust Resolver Filter ....................................................................................................................60

7.12 Fine-Tuning of Ke, Rs and Ls ....................................................................................................... 61

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8. Trouble Shooting ........................................................................................................ 62

8.1 Link Problems................................................................................................................................62

8.2 Pollution .........................................................................................................................................62

8.3 Intermediate Circuit Voltage ........................................................................................................63

8.4 Load ...............................................................................................................................................64

8.5 PID-Parameter ............................................................................................................................... 65

8.6 Disturbances .................................................................................................................................. 66

8.7 Prehold values ..............................................................................................................................67

8.8 Wrong standardisation..................................................................................................................68

8.9 Wrong Ke .......................................................................................................................................69

8.10 Wrong Resolver Offset ..................................................................................................................70

8.11 Coordinated axes ..........................................................................................................................72

Appendix .........................................................................................73

A Further documents ..................................................................................................... 73

B Online Documentation ................................................................................................ 73

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0. IntroductionWelcome to the world of digital controllers!

This manual will open you the seven seals of the digital controllers, and make you familiar with the IN-DEL tools.

In the first part you become aquainted with tools for startup, testing and so forth.

The second part examines the regulation of the PID parameter sets intensively and the Indel standardcontroller for trapezoidal profiles and reverse curves.

A further focal point is programming the controller from MS Visual BASIC or MS Visual C++ .

In the appendices, references to subsequent documents and online documentation are listed.

The manual is concluded with an extensive index.

0.1 Types of controllers

This manual refers to the INDEL controller types:

Stand Alone Controller

INFO-SAC 2.5A, 5A, 16A, 32A

19" Rack stile

INFO-HCSr 2.5A, 5A, 16A, 32A

INFO-ACSr 6A, 10A, 20A, 30A

with the associated power unit INFO-ACPr.

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0.2 Notes on Safety

TermsIn the following text, the term "Module" refers to the AC Servo-controller and the associated powercomponents as well as control components which have an operating voltage of over 50V AC.

Specialist personnelOnly qualified specialst personnel are allowed to carry out work such as handling, installation, start-up and maintenance.

DocumentationBefore installation and start-up, please read the present documentation. Incorrect handling of the Mo-dules may lead to personal injury or property damage. Always observe the technical data and the in-formation provided on the connection conditions.

ESDThe Modules contain electrostatically endangered components which might be damanged by impro-per treatment. Discharge your body before touching the Modules. Avoid contact with highly insulatingmaterials (synthetic fibers, plastic film, etc.). Place the Modules on a conductive base.

Live componentsDuring operation, keep all covers and cabinet doors closed. If you touch live components, you mayrisk death or serious injuries or property damage.Never disconnect the electrical connections of the Modules while they are energized and never with-draw rack boards from the rack while they are energized. In the worst case, this may cause electricarcs, injuring persons and damaging contacts.

DeactivationControl and power connections may be live even if a motor is not turning. After the operating voltagehas been switched off, residual voltages may remain present during several minutes. Measure the in-termediate circuit voltage and wait until the voltage has dropped below 50V.

InquiriesThese notes on safety do not claim to be complete. Should you have any inquiries, please call us.(Phone +41 (0)44 956 20 00)

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0.3 Brief Description

Controller typesFour variants of the INFO-SAC are available. In addition to the specified nominal current, the servo-controllers can be operated during 5s with the current IMAX 5S.

INFO-SAC 2.5A 5A 16A

INOM

2.5ARMS

5ARMS

16ARMS

IMAX 5s

7.5ARMS

15ARMS

35ARMS

UCC

3 x 110 ... 400VAC 3 x 110 ... 400VAC 3 x 110 ... 400VAC

INFO-HCSr 2.5A 5A 16A 32A

INOM

2.5ARMS

5ARMS

16ARMS

32ARMS

IMAX 5s

10ARMS

15ARMS

35ARMS

70ARMS

UCC

525VDC 525VDC 525VDC 525VDC

Integration in the INFO-LinkThe AC servo-controllers are systematically integrated in the INFO-Link. Analog interfaces and asyn-chronicities between the field bus master and the controller are eliminated.

All parameters are read and written via the INFO-Link or via a serial connection using tools and areavailable throughout the network.

PID parameter setsThe different PID parameter sets are freely available to the user. The parameter sets are simultane-ously active, allowing load changes to be optimally accommodated.

Example: PID parameter set 1 for upward stroke with load; parameter set 2 for downward stroke wit-hout load; parameter set 3 for stand-by with reduced current input. In addition to the PID parameters,it is possible to specify pilot controls (boosters) for velocity and acceleration.

Computing powerThe PowerPC 403-66MHz performs the following taks at a clock rate of 12kHz:

- PID position controller, velocity control, active current control- Power factor compensation- Encoder correction (incremental transmitter)- Limitation for: I

MAX, I

2t , controller, motor temperatures

- Logger of 6 freely selectable parameters such as rotary speed, active current,path error, target/actual velocities, etc.

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Position registrationSynchronous motors require a resolver for position registration. The resolution of the resolver is 12 ...16-Bit. 16-Bit precision can only be achieved at standstill.

Asynchronous motors require either a resolver or an incremental transmitter for position registration.For uncontrolled rotary speed operation, no actual value registration is necessary.

The incremental transmitter may also be used as an additional encoder. The measurement value canif required also be included directly in the control algorithm, or be used as an independent measuredvariable.

Operational reliabilityVarious quantities of the AC servo-controller are continuously monitored in order to ensure maximumoperational reliability. Short-circuit stoppages prevent shorts to motor or ground. In the individual pha-ses, quick-action current cutouts protect the motor and the output stage.

These become active when the drive is jammed or is stopped abruptly. The motor and the output sta-ge are monitored for overtemperature. The motor temperature can be measured as required by meansof a bimetal switch (digital) or via an NTC in the motor (voltage value).

0.4 Tools

Various tools facilitate work with the AC servo controllers:

- The program "ACS show" is available for the configuration and adjustments of the controllers.An extensive logger is also constituent from "ACS show".The program "Win-Show" is now included into ACS-Show. Axes can be moved with it. Commandsand operating modes of the Indel standard controller can be adjusted manually.

- In order to load in series configuration files and to burn into the Flash PROM the program"ACSUpdate.exe" is used.

- All the tools are network-compatible. The logger, installed on the coordination post, can recordaxis outlines of a machine in production.

- The "Variable Explorer" provides a survey of all variables registered in the system.

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Part IHardware installation of the controller

Software installation of the controller

ACS-Show - configuration, set up and axis movement

ACS-Flash - updating controller data

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1. Technical Data1.1 Dimensions INFO-SAC

60.00 mm

ø 9.00

5.20

Material:Alublech 2.5mm,beidseitig chromatiert

285.00 mm

6.00

7.00

30.00

5.00

10.00

30.00

75.00 mm

ø 9.00

5.20

285.00 mm

7.00

37.50

5.00

10.00

37.50

Material:Alublech 2.5mm,beidseitig chromatiert

Dept= 168mmINFO-SAC 2.5A INFO-SAC 5A INFO-SAC 16A

19.006.00

52.00

285.00

99.60

10.00

104.00

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2. Hardware installation of the controllerPlease visit our website for technical documentation of our servo-controllers:

http://www.indel.ch/download

2.1 EMC

Pleace refer to our document "Wiring_Guidelines.pdf". If all the suggestions and rules specified inthese Guidelines are carefully observed, there will be a high degree of probability that the product willachieve CE conformity without any additional expenditures and at minimized cost, and that it will berobust when exposed to interference at the customer’s site.

2.2 Wiring

2.2.1 Wiring details

Board supplyFor the board supply, a 3-phase rectifier without electrolytic capacitor is sufficient. To avoid trouble,however, we recommend an electrolytic capacitor of 4'700 ... 10'000mF.The rack must be provided with a power line filter, immediately after entry of the power supply.

Screening linesThe signals of the resolver are extremely susceptible to interference; therefore the resolver must beinstalled with a twisted-pair and screened cable.

The incremental transmitter and the serial interface as well as the motor cables must always be con-nected with screened lines!

BondingAlways connect all screens at both ends. To avoid undesirable discharge currents through the scree-ning, it may be necessary to provide a binding conductor, especially with large distances or differentsupplies.

Screen barThe control cabinet must be provided with a screen bar to which all screened cables are connected.Metallic connectors with all-round contacting of the screen are also suitable for cable entries.

ConnectorsInterruptions in the resolver and motor cables at the cabinet entries etc. should be implemented usingmetallic connectors and not terminal connections.

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CoolingAll INFO-SAC controllers are provided with a built-in fan. Despite this, an additional fan must be in-stalled inside the cabinet to dissipate the exhaust heat.

Between the individual SAC controllers, observe a clearance of at least 1cm.

The fan is operated at a temperature of 37.5°C with 25% power, at 50°C 100%.

Motor temperatureThe motor temperature can be measured as required by a bimetal switch (T-switch) or using an NTC(MTemp).

Sensor leads in the motor cablesIf the leads of the bimetal switch are located in the motor cables, these must be wired to connectorsPh 2.

Sensor leads in the resolver cableIf the leads of the bimetal switch or of the NTC are located in the resolver cable, these must be wiredto connector Ph 2. (insulation class!)

It the temperature is measured with an NTC resistor, the T-Switch on connector Ph2 mustbe shortened.

FilterThe 24V supply must be provided with a filter, as well as the 3 x 400V AC to connector Ph1. The opti-mal filter may have to be determined by a measurement for line-bound emission, as the radiated inter-ference depend, among other things, on the motor cable length.

GroundingThe casing of the INFO-SAC board is grounded. Take care to ensure that the casing is connected tothe mounting plate so that good conduction exists. (EMC and heat dissipation). As the resolver ismounted directly onto the motor, this motor transmitter combination must must always be grounded,as otherwise the transmitter electronics will be exposed to interference.

Further documentationSee also INDEL wiring guidelines and INDEL design guidelines.

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2.2.2 Pin-Out

Pin-Out of installation material:

Signal Print: HCS-SIG

Pic. 2.3.1 Connector Board for signals "HCS-SIG"

Controller Board for: HCS-P4, HCS-P10, HCS-P10-x2

Stromschiene

W 4

+T

-T

1

2

V

U

3

1

2

Erde

Insert M3

Stecker 2PhoenixMDKDS 5/2-6.35

Stecker 1PhoenixMKDSP 10

Anschlusseite

4x D=3

Insert M3

+T

-T

1

2

3

4W

V

1

2U

Erde



Anschlusseite 4xD=3

Pic. 2.3.2 Connector Board for Motor "HCS-P4", "HCS-P10"

0V

+Temp

+Sin+Ref

+Cos

Sh

J-2

0V-Act

-I_Red0V

J-1

D-Sub, WeibchenDistrelec0966 151 6502

Anschlusseite SH-In1

-A-B

Stromschiene

Doppelstock-ZugfederPhoenixMKKDSN 1,5/3-5,08

11 5V

A,B,NM,5V,0V,Sh

-Temp-Cos

5-Ref-Sin

9

St-21

12

141618

131517 +B

+A

+In1

6

J-3

ExtEn+I_Red

910

Stecker 1

2468

57

31

24V

+Act24V

0V

+24V

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Power-Supply Board: HCP-P10, HCP-P10-x2

Anschlusseite

Erde

-Ballast

W

Insert M3

V

+Ballast

U

6

PhoenixMKDSP 10

3

4

5

St-1

1

2

Stromschiene

4xD=3

Pic. 2.3.3 Connecting Board for power supply"HCP-P10"

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2.3.3 Serial Interface

RS232-InterfaceCommunication to the Servo-Controller is done via serial interface or via INFO-Link.

RS-232 Stecker Kabel 9-Pol-SteckerServo Regler am PC, Laptop

Pin 5 GND Schirm Pin 5

Pin 2 Rx Eingang ← Pin 3

Pin 3 Tx Ausgang → Pin 2

Pin 6 DSR Eingang ← Pin 4

Pin 4 DTR Ausgang → Pin 6

Caution: laptop usersObserve the following sequence when connecting a laptop computer to the INFO-SAM:

1. Isolate the power supply of the laptop so that it is only supplied with powerfrom the accumulator.

2. Connect the INFO-SAM and the laptop by appropriate serial cables.3. Reconnect the power supply.

Reason: As a result of the electrical isolation of the transformer, the laptop power supply is raised toa potential of 110V (providing the laptop is supplied via the mains). Because there is no assurancewith conventional SUB-D connectors that the shield will contact before the signal lines,there is a riskof potential equalization taking place via the signal ground line. This will destroy the relevant SIOchannel.

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3. Software InstallationStart the file „Main.pdf“ on the CD-ROM to install the IMD - Indel Master Desk.Click onto „IMD-Installation“ and follow the instructions.

This installation contains:- INCO-Server- ACS-Show- ACS-Update

If you use floppy discs start "a:\ACSSetup.exe" on the first disc.

Choose the language and the directory where you like to install the ACS-tools.

Abb 3.1.1 (ACS-Setup)

If you have choosen "Custom", the following dialog apeers:

Abb 3.1.2 (ACS-Setup)

1

2

3

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INCO-ServerCommunication between fieldbus or ACS-Controller and PC.

ACS-ShowConfiguration of motor and controller data, Logger,firmware updates, axes moving

ACS-UpdateInstallation of ACS-Update. Tool to update of motor and controller dataas well as firmware updates. (Console program 96kByte)

"Standard" installs all components.

Choose a target:

Remote-PC Any Target, located in a network Power-PC Master Target is a local PowerPC-Master (INFO-PPC) PCI-Master Target is a local PowerPC-Master (INFO-PCI, -PCI2) NET-Master Target has a Ethernet-Interface (INFO-SAM, IMP-MAS2) INCO-Sio Target is a local, connected with a serial cable:

− Serieal interface: INFO-SIO− AC-Servo controller: INFO-ACSr− Stand Alone Master: INFO-SAM

INFO-Master Target is a local INFO-Master (INFO-PCM) IPS Target is a local IPS-System with serial cable PC-Master Target is a local Fieldbus (EXT-MAS)

If you work with a laptop (serial cable) or with a Stand Alone Master, choose the"INCO-SIO" target

If you work with a PowerPC Maser card, choose the "Power-PC Master" target.No other target can communicate with an INFO-ACSr controller.

It is possible to define more targets later. (With the "INCO-Registry")

4

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Choose a Target Name:

Any name without blank character and a maximum of 20 characters is allowed.5

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3.1 Registry-Editor

Choose "Yes" to start the INCO-Server Registration.

Abb 3.1.5

Registry-Editor: The address switch on the fieldbusmaster card (INFO-PPC, INFO-PCM,INFO-MAS) and the address at the directory "Setup" must be identical.

Abb 3.1.6

For the PowerPC master the addresses "CE00" or "D000" are vaild.

For serial targets only the COM-Port must be defined, all other entries should not be changed.Choose a target and type "Register" to build new targets.

Reboot your computer.

6

7

8

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3.2 Installation with laptop (serial target)

If you work with a laptop, e.g. to update motor or controller parameter or to download and burn newsystem software, use the following settings for your "INCO-Sio" Target:

Pic 3.2

Important!

Choose a free COM-Port of your PC or laptop. The INCO-Server must bestarted to communicate with the target.

For older INFO-ACS Controllers the Baud-Rate must be set to 57'600. The newer controllersINFO-HCSr, INFO-SAC have 115'200 Baud.

Older INFO-ACS Controllers need Slave-Number 1. See INCO-Registry.

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4. ACS-Show4.1 Visualisation with ACS-Show

Precenditions:

- Start INCO-Server- 24V power supply for INFO-ACSr- Register serial or PowerPC target.- Active link if you work with a PowerPC Master- Install ACS-Show

ACS-Show is the interface between ACS-Controller and user. ACS-Show contains a large range offunctions:

- Configuration of motor and controller parameter- Adjustment of the 3 PID parameter sets- Logger- Parameter and Firmware updates- Test- und debug functions e.g. adjust relover offset- Script Language for moving commands

To increase user-friendliness the program is fit out with a context sensitive help function.If you stay for 1 sec. on the field "ErrorCount: 0" a text apears "Double click to clear the INFO-LinkErrorCounter".

ACS-Show is network compatible. The logger, installed on the operation center, records profiles froma machine out in the plant.

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1

2

73

6

4

5

4.2 Layout of ACS-Show

ACS-Show is devided into 5 directories (1) each with 2 ... 4 sub-directories (2):

MotorConfig, CtrlConfig, Logger, Test, Debug

Pic 4.1.1

(3) Error-Message ACS-Show

(4) TargetAll targets are listed in this pull-down menu.

Important! After a Link-Down of the INFO-Link or after a disconnection of the communication,the Target must be re-selected.

(5) Actual Values

ErrCnt:The Error-Counter counts broken telegrams transmitted over the fieldbus. A few brokentelegrams per day are allowed. If the counter increases permanentely there is a problem withthe link that must be recovered.

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UCC: [V] Intermediate Circuit Voltage (7)

The limits of UCC can be set by the user. Code of the diagnostic LEDs of Servo-Controller:

Power Supply 3x230V 3x400V= E Link Voltage less than 200V 480V

= E Link Voltage greater than 400V 800V

= W Link Voltage less than 270V 500V

= OK Link Voltage between 271...400V 501...800V(Optimal operation mode)

Temp: [°C]Temperature of the controller

up to 60°C Warning: Controller "warm"up to 75°C Warning: Controller "hot"; Current limitation to "I

NOM"

up to 80°C Error: Controller "overheated"

Motor Temp: [°C]Temperature of the motor. If a temperature-switch is connected through the resolver cable,the value MotorTemp shows a value of -89°C it the switch is opened. If the switch is closedthe value shows +191°C.

Speed: [U/min]Actual value of revolution speed

Position: [Inc]Distance

Wheel_Position: [Inc]Position of the measuring wheel.

I_torque: [A]Actual value of current I torque (all three phases)

I2t: [%]Value of power loss in the motor.

Fan: [%]Load of the ventilator. The ventilator starts at a temperatur of 37.5°C with a duty cycle of 25%,at 50°C the duty cycle is 100%

Power ON/OFFSet controller Active / Inactive.

(6) Errors:The last error is shown here. Click on the text to get a possible cause.

(7) Link StatusThe green LED shows "Link-Ok" or "Communication ok" in case of serialcommunication If the communication breaks, the target must be re-selected (4)

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4.3 Motor Konfiguration

All motor parameters are placed in the directory "MotorConfig"

- Parameter for current loop.- 3 different PID-Parameter sets- Physical data such as inductance- File handling of motor config files „*.cpf“ files

4.3.1 File Handling (File)

Burn Values to Target:If the user changes parameters with ACS-Show, the parameters are stored only inside theRAM of the controller. If you like to store it definitely, you need to burn them."Burn Values to Target" If you do not burne the values, then you will loose the themafter loss of power.

Motor Select:8 different motors can be stored.

Flag:Operating mode of the controller.

Filename:Filename of the parameter file.

File Notes:Notes belonging to the motor. The file notes are not strored inside the controller!

Save to File:Save motor parameter into a file with ending "*.CPF"

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4.3.2 Motor Flags (File)

0x04 External Zero-MarkFlag = 0: Resolver Zero-Mark is activatedFlag = 1: External Zero-Mark from encoder or cam is activated. (Input 1)

0x08 Motor rotating directionFlag = 0: Rotation direction not changedFlag = 1: Rotation direction changed

Important: U, V, W must be wired correct!

0x20 Adaptive Ke DisableFlag = 0: Adaptive Ke enabled.Flag = 1: Adaptive Ke disabled.

0x40 Temperatur compensation for Ke and Rs disabledFlag = 0: Temperatur compensation for Ke and Rs enabled. This function is needed if a

KTY-temperatur sensor is used for measuring motor temperature.Flag = 1: Temperatur compensation disabled. The temperature compensation must be

disabled if a bi-metal switch is used for measuring motor over temperature.

0x80 Encoder FeedbackFlag = 0: Feedback from ResolverFlag = 1: Feedback from encoder, can be used together with "0x04" external zero mark.

0x100 Asynchronous-MotorFlag = 0: Synchronous MotorFlag = 1: Asynchronous Motor

0x200 Speed controlFlag = 0: PID-Controller acts as a position controller.Flag = 1: PID-Controller acts as a speed controller.

0x400 Encoder directionFlag = 0: Rotation direction of measuring wheel not changedFlag = 1: Rotation direction of measuring wheel changed

0x800 Scaling factor for measuring wheelFlag = 0: No measuring wheelFlag = 1: Slip correction is calculated as following:

Slip = Weel / Motor * 100 - 100

"Ctrl.Actual.MotorSlip" shows actual slip.

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0x1000 Current reduction ModeFlag = 0: Position ControlFlag = 1: Output Ired (LED "Output") is set. The current controller limits current to Ired.

0x2000 Missing Ext-EnableFlag = 0: If external Enable is missed, no error is shown.Flag = 1: If external Enable is missed, an error is shown, controller can not be

switched "active".

0x4000 Torque modeFlag = 0: Position ControlFlag = 1: Controller acts as a current controller. Output Ired (LED "Output") is set.

0x10'0000 1-Phase, 3-Phases Power SupplyFlag = 0: 3-Phases Power Supply (3x400V)Flag = 1: 1-Phase Power Supply , e.g 230V (valid only for SAC-Controller)

0x20'0000 Temperatur-SensorFlag = 0: Motor Temperature-Sensor: KTY-84, e.g. for siemens motors, range up to 199°C.Flag = 1: Motor Temperatur-Sensor: KTY-110, e.g. for Lenze motors, range up to 130 °C.

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4.3.3 Motor Data (Motor)

PolePair: Number of pole pairs of motor.

ResolverPolePair:Number of pole pairs of resolver.

Rs: [ΩΩΩΩΩ] Resistor of coil (Phase-Phase)

Ls: [mH] Inductance of coil (Phase-Phase)

Ke: [V] (EMK) [Vrms/1000Umin]

Pic 4.3.1

INOM: [ARMS]Nominal current of the motor

IMAX: [ARMS]Maximum current of the motor.

IRED: [ARMS]Current for operating mode "Current reduction". If this mode is activated, the controllerlimits the current to "I

RED".

In this mode the controller software reduces the maximum current to "IRED"

insted of "I

MAX".

Default value of "IRED" is "I

NOM".

This operating mode is designed to set up axes. The power of the motor is reduced because ofthe reduced current. Damages in case of crashes can be avoided.

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If the power at "Reduced Current" is too few, the error "Too many increments"appears. In case of cold lubricant more power (current) is needed to move axes.

The yellow LED "Output" at the Servo-Controller indicates themode "Reduced Current". "Reduced Current" must be set at machine software.

Resolver_Offset: [Inc]The angle between mechanical zero-position of the resolver and electrical zero-position ofthe rotor is called resolver offset.If the resolver offset is adjusted very well, the efficiency of the motor can be increased.

Speed_Max: [U/min]Maximum allowed speed of the motor.

Umin_10V: [U/min]Maximum revolution speed of the controller, equals 10V.

LinkSamplingRate:Sampling rate of the controller algorithm of the trajectory. This value is needed to calculate theinterpolation of set values sent by the fieldbusmaster.

The servo-controllers use 8 ... 12kHz sampling rate, the fieldbusmaster uses 250Hz ... 10kHzsampling rate.

Temp_Warm:At this temperature (80°C) a warning "Motor Temp warm" is set.

Temp_End:At this temperature (120°C) a error "Motor Temp max." is set.

Inputs:Filter constant for digital inputs.

kT_ExtEn:Software filter for external enable (10ms).

kT_ExtDis:Delay between turning off external enable and switching off motor power. This time is neededto decelerate the motor after emergency stop.

Measure Wheel:Second channel to get an actual postion.

MotorToWheel:Gearratio of the measure wheel.

kP:Proportional value of PID contoroller for measure wheel correction. If no measure wheel isconnected kp is set ot zero.

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4.3.4 PID-Parameter (PosCtrl)

The INFO-ACSr servo controller is equipped with a modifiable PID controller. It contains 3 indepen-dent parameter sets.Two pre-hold values are added to the desired value. One derivative action gain depends on the veloci-ty, the second depends on the acceleration.

The pre-hold values are pure desired values they don't affect the controlling argorithm and they don'taffect the stability of the closed loop. All tree PID-Parameter sets are completely independent formeach other and are active at the same time. The default using of the PID-Sets are: Forward, Back-ward, and Stand-by.

Forward - Backward (4,5)With the forward and backward PID-Set alternation of stress can be considered.

Pic. 4.1.2

PID-ParameterIf you change the PID-Parameters they will be changed only in the RAM of the controller. To savethem permanentely they must be burned into the Flash-Prom with "Burn Values to Master"If you don't burn the parameters into the Flash-Prom they get lost after power off.

To burn parameters into the Flash-Prom set the controller inactive.

V

Standby Forward Backward

Speed

PID-Parameter Set

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kT_Speed:This filters work like a RC-Filter for the resolver input. Disturbances on the resolver line can bereduced with this software filter. The maximum time is about 2 ... 3 ms. If this values aregreater, the system will lose its dynamic.

Pic 4.1.3

HoldToStand-by: [s]At the end of a driven profile the controller switches to "Hold-Mode". After the time "HoldToStandby" the controller turns into "Stand-by-Mode". At "Stand-by-Mode" the Stand-byparameter-set works. With this function the servo drive can be set into a low-power mode.

Pos_Int_Max:Limitation of Integral-Part of PID-Controller. (Position Controller)

I_Hold:Prehold value for "hanging loads" with "I_Hold" a constant current is added to theset value.

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Units of PID-Parameter

Value Unit Description

kP FactorA/Inc Regeldifferenz Proportional coefficientkI ms Integral coefficientkD ms Differenzial coefficient

phvSpeed FactorA/v Pre-hold velocityphvAcc ms Pre-hold acceleration

A: AmpereInc: Incrementv: Velocity

PID-Parameter-Sets

Parameter-Set Pre-Hold Description

Forward v, a ForwardBackward v, a BackwardStandby Hold

v: Velocitya: Acceleration

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4.3.5 Current Control (CurrentCtrl)

Current controllerSee chapter "7.8 Adjustment of Current Controller"

Pic 4.3.4

I_Int_MaxLimitation of Integral-Part of PI-Controller. (Current Controller)Dimensioning: I_Int_Max = 3 mal IMAX

Overload protectionTo protect overload of the motor, the power dissipation of the motor is integrated. The heatgiven away over the housing and cooling system is subtracted. The result of the subtraction isshown as a value in percent and must be below 100%.

Equivalent circuit:

I2t [%]Result of the overload protection.

I2t_up: [s]Time constant of the heating up.

I2t_down: [s]Time constant of the cooling system

Rth zuP zu

Rth weg

P weg

Motor

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4.4 Controller Configuration

All parameter in this chapter depends on the hardware setup of the motor controller. Non of this para-meter shall be changed. In case of changing any parameter the controller can be damaged.

Controller parameter Files are named as following: "Name.CPF" (3)

Typ (1)The Type is the individual description of the parameter file

Burn Values to Master (2)If you change parameters they will be changed only in the RAM of the controller. To save them per-manentely they must be burned into the Flash-Prom with "Burn Values to Master". If you don'tburn the parameters into the Flash-Prom they get lost after power off.

To burn parameters into the Flash-Prom set the controller inactive.

Pic 4.4.1

All adjustments of controller parameter are done at Indel AG. Never change any kind ofcontroller parameter without consultation of Indel AG. If new controller parameters are loadedinto a Servo Controller, callibration data get lost and the servo controller must be returnedto Indel AG.

1

2

3

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4.5 Logger

4.5.1 Configuration of the Logger

Channel Config (1)Each of the 6 channels can be set by the user.

Delay (2)The sampling rate of the ACS-Controller is 12kHz. The logger saves 1358 samples of each channel atmaximum. It isn't necessary to get 12 samples every ms.Delay = 11 means: 1 time mesure, 11 times drop out

Pic 4.5.1

1

2

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1

2

4

5

7

8

9

10

4.5.2 Logging data

(1) Switch on/off channels

By clicking on a channel you can switch it on and off. After switching on or off you need toReload the data.

3

(2) AutoscaleAutoscale of all channels

(3) Move Cursor Left, Move Cursor RightMovement of the cursors

(4) Zoom between CursorZoom in the screen between cursors

(5) Referenz ON/OFFSwitching on and off the reference curve. After switching on or off the curve click reload.

(6) ReloadLoad log-data from controller memory or refresh log-data if it is loaded from file.

(7) Save to ReferenceThe actual log-data are used as reference curve.

(8) Save to FileSave Log-Data to file.

6

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(9) Load FileLoad Log-Data from file.

(10) Text windowIf you save logger data to file some additional information are saved too:

- Date- Target name- Motor Type- Controller Type- Revision of ACS-Show and System.s-File

This information is shown in the text window after "Load File"

4.5.3 Measured Values

Typically the following measured values are useful:

Set Speed Waves Set Voltage Waves

UCC Pos_Err UCC SpeedReq_Speed Pos_Err_Int U_Torque I_ReaktiveSpeed I_Torque U_Reaktive I_Torque

UCC [V]Link voltage

Req_Speed [U/min]Required revolution speed

Speed [Inc/T]Actual revolution speed

U_Reactive [V]Reactive voltage

U_Torque [V]Active Voltage

Pos_Err [Inc]Position Error

Pos_Err_Int [Inc]Integrated position error. (I-Part of PID-Controller)This value is needed to adjust "phvSpeed" und "phvAcc".

I_Torque [A]Active Current (3-phases)

I_Reaktive [A]Reactive Current (3-Phases)

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4.6 Test

4.6.1 Trapezoid Controller

Please refer to chapter 6 "Trapezoid Controller"

Abb 4.7.1

4.6.1 Current / PWM

In this window the resolver-offset is adjusted, please refer to chapter 7.7 "Resolver callibration"

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4.6 Debug

4.6.1 Software and Parameter download

ACS-Update is used to download Firmware, Motor- and Controller parameter.Always "Reset Master" after download.

Pic 4.4.1

"Burn File(s) to Master" without any sign at "Burn" shows the Releas of the system-file andboth parameter files.

Make a sign at "Burn" for all files you like to burn into the flash-prom of the target. Use the button"Burn File(s) to Target" to start the procedure.

If the sign "-A" is marked, ACS-Show burns the file in any case. If "-A" is not marked, a versioncheck is done befor burning. The file is burned only if it has a newer revision than the file inside theservo-controller.

See also chapter 5. "Flash-PROM Updates"

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5. Flash-Prom UpdatesAdditional to the controller software the INFO-ACS Controller needs two configuration files:

Controller Software System.s

Motor Parameters File.cpf

Controller Parameters File.chf

The motor parameters contain the PID-Parameters, physical constants such asohmic resistor, inductance, and so forth.

The controller parameters consist of constants of the IGBT-Final stage, balance data of current mea-surement and so forth.(Controller-Data files can be requested at Indel AG)

Software and parameter updates can be burned into the Flash-Prom of the controller either with theprogram "ACS-Show" or with the DOS-Program "ACSUpdate.exe"

Flash-Prom updates can be burned to remote-targets network-wide.

"ACSUpdate.exe" is designed for automatic updates to entire machines or systems with more thanone controller.

5.1 Parameter and Software updates

Requirements:- INCO-Server must be started- 24V Power supply for INFO-ACSr- Serial Target or Power-PC-Master must be registered- Link must be active, if you do not communicate via serial target- ACSUpdate.exe

The program "ACSUpdate.exe" is located in the directory "..\imd\bin"."ACSUpdate.exe" is a DOS-Program. Open a DOS-Box to start it.Structure of the command line:

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5.1.1 Burn Files to Flash-PROM

The files (motor- and controller parameter, software) are sent to the target with command lines.ACSUpdate.exe checks for the file extensions, the sequence is not important. The program compa-res the version number of the existing file inside the Flash-Prom with the software to be loaded befo-re burning. The release to be loaded is always burned with the extension [-a]; without extension itis only burned if the file to be burned has a later release number.

c:\ACSUpdate TargetName [*.s][-a] [*.cpf][-a] [*.chf][-a]

Example:Burn the Controller Software "system.s", the Motor Constants "motor.cpf" and the ControllerConstants "controller.chf" into the Flash-PROM. The Target is Axis 0 of a Power-PC-Master.

C:\ACSUpdate PPC\Axis0 system.s motor.cpf controller.chf

Burn only the Controller Software "system.s" into the Flash-PROM. Burn it always no matter if it isa new or an old software release. The Target is an ACS-Controller connected via serial interface of thePC.

C:\ACSUpdate INFO-ACS a:\acs\update\system.s -a

5.1.2 Save Motor- and Controller Constants into a file

Motor- and Controller Constants are saved to disk with the extension [s]. The filename of the motorconstants must end with [*.cpf]. The filename of the controller constants must end with [*.chf].

c:\ACSUpdate TargetName [*.cpf][-s] [*.chf][-s]

Example:Save the motor- and controller parameters into a file. The Target is a ACS-Controller connected to aserial interface of the PC. It is located in a network.

C:\ACSUpdate Remote_ACS motor.cpf-s controller.chf-s

5.1.3 Copy Parameters from RAM into Flash-PROM

The extensions [-h] and [-p] burn the actual controller- and motor parameters from RAM of theACS-Controller into the Flash-PROM.

c:\ACSUpdate TargetName [-p] [-h]

Example:Burn motor- and controller parameters into Flash-Prom. Target is an ACS-Controller connected to aStandAlone Master.

C:\ACSUpdate SAM/AXIS0 -p -h

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5.1.4 Information

The extension [-i] compares the version of software inside the Flash-PROM of the controller withthe File to be loaded. The command shows if an update is necessary.No files are burnt to Flash-PROM with thes command!

c:\ACSUpdate TargetName [*.s][-i] [*.cpf][-i] [*.chf][-i]

5.1.4 Version and Help

C:\ACSUpdate -V shows actual version of controller software.C:\ACSUpdate -? shows a brief help.

5.1.5 Automated Flash-PROM Updates

To make quick Flash-Prom updates in large machines and entire systems with more than one ACS-Controller the ACSUpdate.exe program works with a Config File.The Config File contains all commands to update several ACS-Controllers."ACSUpdate.exe" with Config Files works network-wide. The extension [-a] can be added to theconfig-file too. The file extension of the Config File must be "*.cfg"!

C:\ACSUpdate [*.cfg] [-a]

Content of the Config-File

; Local PowerPC-Master, Axis 0,1,2,3PPC/AXIS0 system.s axis0.cpf 6_A.chfPPC/AXIS1 system.s axis1.cpf 10_A.chfPPC/AXIS2 system.s axis2.cpf 10_A.chfPPC/AXIS3 system.s axis3.cpf 20_A.chf

; PPC-Master located in a Network, Axis 0,1Remote_PPC/AXIS0 system.s axis4.cpf 6_A.chfRemote_PPC/AXIS1 system.s axis5.cpf 10_A.chf

; Remote ACS-Controller connected to serial interfaceRemote_ACS system.s axis6.cpf 6_A.chf

Example:Work out the Config File above:

C:\ACSUpdate ACSConfig.cfg

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5.2 Updates with Laptop

Precondition:- INCO-Server must be started- 24V Power supply for INFO-ACSr- Serial Target must be registered- Important note below- Programs "ACSUpdate.exe" or "ACS-Show.exe"

If you work with a Laptop to burn Flash-Proms you consider to the following chapters:(Usage of the programm "ACS-Show")

"3.2 Laptop Installation""4.2 ACS-Show start up""4.7.1 Load Software and Parameters"

or use the DOS-Program "ACSUpdate.exe". To execute updates the ACS-Controller needs only a24V Power Supply and a serial connection to the laptop.An active Link ("Trans.exe" executed) is not necessary for serial communication.ImportantThe following Sequence must be maintained when connecting a Laptop-Computer to the INFO-ACSr:

1. Interrupt mains of the Laptop, so that it is supplied by theAccumulator only.

2. Connect INFO-ACS and Laptop with the corresponding serial Cable.3. Replug Power Unit.

Reason: By means of the Transformer's galvanic Separation, the Laptop-Supply is increased to a Po-tential of 110V (provided that the Laptop is supplied via the 230V-mains). Since there is no guaranteefor the conventional SUB-D Connectors, that the Shield is contacted before the Signal-Lines, there isa real Danger that the Potential Equalization occurs via the Signal-Ground-Line. As a consequencethis leads to the destruction of the relevant SIO Channels.

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6. Trapezoid Controller6.1 ACS-Show

With the software "ACS-Show" you can set-up and run all servo-axis. No code must be written.The Indel-Standard-Controller works as a trapezoid controller with S-Curves.

Pic 6.1.1 ACS-Show

Choose an axis out of the pull-down menue "Targets"

6.2 Win-Show

The software "Win-Show" works like the part above of ACS-Show. Use the Win-Show program forServo-Controllers, DC- and Stepper-Motor-Controllers.

Abb 6.1.2 Win Show

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6.2.1 Guideline for Trapeze- and S-Profile

These values can also be changed during operation.

vrg_s Distance to drive [degree, m, mm]

vrg_v Speed to drive [degree, m, mm/sec]

vrg_a Acceleration [degree, m, mm/sec2]

vrg_b Deceleration [degree, m, mm/sec2]

vrg_scu S-Curves share in % [%]

vrg_syn Synchronization position, i.e. after a synchronization the actual position of the synch-point will be set to vrg_syn.

6.2.2 Controlling constants

The control weights can be indicated separately for S (distance) and V (speed) as well as for RUN(axis running) and STOP (axis stoped). The value 1.0 means that 1 INC error causes 1 DAC-Bit cor-rection. These values can be fixed definitely only during Start up.

krg_vr Controlling weight for speed with axis running. If Indel Servo controllers are used thisvalue must be set at zero!

krg_vh Controlling weight for speed when axis is standing. If Indel Servo controllers are usedthis value must be set at zero!

krg_sr Controlling weight for distance error with axis running.Typical krg_sr = 1 for Servo controllers.

krg_sh Controlling weight for distance error when axis is standing. Typical krg_sh = 1 or 2 forthe Servo controllers.

kmx_se It concerns the maximum allowed distance error in INC (difference between ACTUAL -and CALCULATED position). If this value will be exceeded during drive, the controllergoes automatically on Emergency-Stop.

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6.2.3 Actual values

Display of the actual position in the measurement unit set in your configuration (degrees, meter ormillimetre).

S_ERR Actual divergence of position in INC (difference between Actual – and Calculated posi-tion). If this number will increase during drive more than

kmx_se: then the controller will go to Emergency-Stop and Bit 0 will be set in the error-flag “err_flag”.

V_ERR (only in simulation mode) actual divergence of speed in INC/gradation (difference be-tween ACTUAL – and CALCULATED speed).

DAC Actual DAC value in volt.

6.2.4 Status of axis

Status of axis

axs_sta Bit 0: Zero Mark

6.2.5 Driving commands, VRG_BEF

Various driving commands can be set off with this command.

Start 0x81h Under consideration of vrg_v, vrg_a and vrg_b drive toposition vrg_s (with F7 this function is directly accessible).

Neues V/A 0x82h Accelerate / decelerate to new speed vrg_v

Synch 0x83h Under consideration of vrg_v, vrg_a und vrg_b drive to position vrg_s.During drive inspect appearance of a synch impulse (Zero-Mark). If asynch impulse appears the ACTUAL position is set to vrg_syn andslowed down normally otherwise the error flag has is set on synch error.

Start Pull 0x84h Follow the guideline position vrg_s. As the controlling always immediate-ly attempts to reach vrg.s (without driving a ramp), the chosen stepsshould not be too large (driving error if distance error is too big). Themaximum acceleration of the motor has to be taken into considerationas well. This mode can be used to drive e.g. curves.

Stop 0x88h Slow down the driving axis under consideration of vrg_b to zero (with F8this function is directly accessible).

Not Stop 0x89h Slow down the driving axis with immediate effect (without braking ramp)to zero. (Emergency-Stop)

POS=0 0x8Ah Standardize angle to 0 ... 359°, according chapterstandardization.

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POS=0 0x8Bh Set ACTUAL position to 0.

POS=VRG_SYN 0x8Ch Set ACTUAL position to VRG_SYN

Toggle Drive under consideration of vrg_v, vrg_a and vrg_b to position vrg_s,await ‘Delay’ ms, set vrg_s = -vrg_s and start again at the beginning.Repeat this until process aborted.

PToggle Drive under consideration of vrg_v, vrg_a und vrg_b to position vrg_s,await ‘Delay’ ms and drive again the same distance. Repeat this untilprocess aborted (with F9 this function is directly accessible).

Delay With this point the waiting period in ms can be adjusted between twodriving commands at ‘Toggle’ and ‘PToggle’.

6.2.6 Standardization, VRG_FLG

The master always standardizes the ACTUAL position automatically as soon as STOP is reached.Because of the standardization no increments will be lost (no sum error, also if after every drivestandardized to 0.0).

No 0x00h After every drive the position stays as it is.

Angle 0x01h The angle will be standardized to 0..359°.

Set to zero 0x02h After every drive the actual position will be set to 0.0.

Endless 0x03h From start command it will be driven to the next stop with VRG_V, re-gardless how large vrg_s is (Tip: vrg_s must be enough for the accelera-tion ramp otherwise the endless drive will not be active).

Round 0x04h Angle round up to 365°.

6.2.7 Mode, VRG_TST

With the mode of operation you decide how the controlling behaves.

Inactiv 0x00h The controlling for this axis is switched off.

Activ 0x80h The complete range of the controlling (inclusive error monitoring) is acti-vated.

A. o. F. 0x81h Active without errors. The controlling is activ but does not goto Emergency-Stop if driving error.

Simulation 0x82h The motor will be simulated. This is only a set value output.

DAC/INC 0x83h The controlling for this axis is switched off. You can use the DAC re-spectively the incremental input for your own purposes.

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6.2.8 Standard factors

knf_dac This factor serves the internal conversion of actual speed to DAC-Bits. It is calculatedby the configuration.

knf_s This factor serves the conversion of your guidelines V, S, A, B, to Inc. It is also calcu-lated by the configuration.

knf_e

knf_tim Sampling rate: 0 = 4 ms1 = 2 ms2 = 1 ms3 = 0.5 ms

6.2.9 Error messages

Error of axis. As long as this byte has not been deleted, no new commands can be accepted.

err_flg 00h ok

Bit 0=1 → Distance error. anz_ser is greater than kmx_se -> OFFBit 1=1 → Could not be synchronizedBit 2=1 → The axis card is not operating correctly.Bit 3=1 → External controller error

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Part II

Initial start-up of the servo-controller

Adjustment of PID-Parameter

Trouble-shooting

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7. Start-up of AC-Servo MotorsFor the initial start-up the motor should be operated without load. The operator needs to see the engi-ne shaft.

The start-up is done with the tool "ACS-Show". Please go through this manual step by stepin detail. If any part is done not correctly the motor will not run perfectly.

7.1 Motor parameters

Take the values from motor data-sheet.

1. Go to "MotorConfig; Motor" in ACS-Show.

2. Rs Resistor phase-phase: Rs = 2 * Rstr

3. Ls Inductance phase-phase: Ls = 2*Lstr

4. Ke VRMS/1000Umin

4a. If it is not sure that the values for Rs, Ls, Ke are correct, please verify theparameters: see chapter 7.12

5. Inom in ArmsImax in ArmsIred in Arms Ired = Inom (default)

6. Speed_Max Maximum revolution speed (mechanical)

7. Umin_10V Maximum revolution speed of the regulation, equals +- 10VThis value must be the same as in the configuration in IMD

8. LinkSamplingRate Sampling rate of the regulation in the fieldbusmaster. This valuemust be the same as in the configuration in IMD

9. Temp_Warn At this temperature a warning "Motor warm" appears.

10. Temp_End At this temperature an error appears.

11. BurnToFlashProm, SaveToFile, Filename without spaces!

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7.2 Motor Temperature sensor

1. Connect Motor and Resolver cables to the controller.

2. Turn on 24V power supply.Do not turn on 3 x 400V!

3. If the temperature sensor (Resistor) is located in the resolver line, MotorTempmust show a value between 20 ... 30 °C.The connector pins +T, -T at the motor connector must be shortened.

Limit switch is located in the resolver line.If the motor is equipped with a limit switch, MotorTemp shows a value of about -89 °C if theswitch is closed and +191°C if the switch is opened.The connector pins +T, -T at the motor connector must be shortened.

The "Flag" at "MotorConfig; File" must be set to 0xh40. Ke, Rs temperaturecompensation disabled. Now the temperature compensation of Rs, Ke is disabled.

If the temperature switch is located in the motor-lines, it must be connected to +T, -T!

7.3 Test wiring of the Resolver

Standardised forward rotation is clock wise from the backward of the motor.

Motor turns forwardPhase 1,2,3 to U,V,WResolver COS and SIN

Motor turns backwardRückwärts, CCW (Counter-Clock-Wise)Phase 2,1,3 to U,V,WResolver change +- of COS do not change +- of SIN

1. Turn the motor shaft clock wise by hand.

2. The value "Resolver" at "Test; Current/PWM" must count upward.

3. If the resover counts downward: change +- of COS do not change +- of SIN.

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7.4 External Enable

1. External Enable ExtEn must be connected to 24V.For more details see hardware documentation of Servo-Controller.

2. The green LED ExtEn on the front of the servo-controller must light.

7.5 Number of Pole Pairs

1. Use motor without load.

2. Change to "Test; Current/PWM" in ACS-Show.

3. Flag = 4 "Motor field turns 1/sec" (→ electrical rotating field turns 360° per second)4. Set U_torque to 1 ... 10V. Start at 1V and watch I_torque!

Operate the servo-controller in simulation mode. Use F3 (inactive), F5 (simulation)If the motor does not turn at 10V, check wiring.

Bei Number of Pole Pairs 1 motor turns 1 U/sPPz 2 1/2 U/sPPz 3 1/3 U/sPPz 4 1/4 U/s

7.6 Verify direction of rotation


2. Flag = 4 Motor field turns 1/sec (→ Rotating field turns 360° per second)

3. Set U_torque to 1 ... 10V. Operate the servo-controller in simulation mode.Use F3, F5. The motor must turn forward (clock wise)!

Change Motor direction:Change to "MotorConfig; File" With Flag = 0xh08 (Change Motor Direction)it is possible to change the motor direction without changing wiring.The resolver offset must not be changed.

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7.7 Resolver Offset Callibration

The resolver offset is an angle between mechanical zero position of the resolver and the zero positionof the electrical field.

If the resolver offset is adjusted very well, the motor has a better efficiency.

1. Motor and resolver must be connected correctly.


3. The motor must turn without mechanical load

4. Turn on external enable.Input 0, green LED "Ext.En" at servo-controller lights.

5. Set Flag = 1 Current Test Mode

6. Enter a reactive current of about 1/20 INENN at "I_Reactive". Run the controller in simulationmode. Use F3, F5. If the motor is turning, the resolver-offset is wrong. Turn off with F3.

7. Change resolver offset until the motor does not turn any more.

8. If you have found a resolver offset where the motor does not turn any more, increase reactivecurrent "I_Reactive" to IMAX.Turn on the power only for a short time of about 0.5 seconds!!

9. Verify if the right resolver offset has been found.

10. Flag = 2 Voltage Test Mode

11. Set U_torque to 1 ... 10V. Run the controller in simulation mode. Use F3, F5. The motor mustturn clock-wise (forward). If the motor does not turn forward a wrong resolver offset has beenfound (There is more than one)

12. Do not forget to copy the resolver-offset to the motor-parameters:"MotorConfig; Motor" "ResolverOffset".

13. Set all flags, currents and voltages back to zero.

14. BurnToFlashProm, SaveToFile

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7.8 Stromregler abgleichen

7.8.1 Default Werte

1. Change to "MotorConfig; CurrentCtrl"

2. Default setting for closed-loop current controller

Active CurrentkPq = 5 (3 ...8)kIq = 0.8 (0.5 ... 0.8)

Reactive CurrentkPd = 5 (3 ...8)kId = 0.8 (0.5 ... 0.8)

3. I2tup, I2tdown See chapter 4.3.5 "Current Controller"

4. I_Int_Max = 3 * IMAX

5. 3x400V 3x230V

Ucc_Min 480V 200V Ucc < Ucc_Min: ErrorUcc_Ok 500V 270V Ucc < Ucc_Ok: Warnung

Ucc_Ok < Ucc < Ucc_End OkUcc_End 800V 400V Ucc > Ucc_End: Error


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7.8.2 Adjustment of closed-loop current controller

Logger settings:1. Trigger Slope: Until Error#Reload2. Delay 0 -> logger works with 8 ... 12 kHz (measue 1 time, suspend 0 time)

Procedure1. Change to "MotorConfig; CurrentCtrl"

kPq, kIq = 0kPd, kId = 0

2. Change to "Test; Current/PWM" in ACS-Show.I_reacive = In/4

3. Flag = 1 Current Test Mode

4. Change to "MotorConfig; CurrentCtrl"Increase kP slowly until current starts to oscillate with constant amplitude:Enter kP to kPq, kPd, set controller into simulation mode, reload logger,set controller inactive, ...

Pic 7.8.1 Adjustment of current controller

5. Get values from grafic above:Tk = 0.6 ms critical periodkPkr = 15 critical kP

kP = 0.45 * kPkr kPq, kPd = 0.675kI = 0.85 * Tk kIq, kId = 0.510ms


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7.9 Adjustment of PID Parameters

To get the PID-Parameters the motor needs to be operated with its load.

7.9.1 Optimisation with Ziegler-Nichols

First the control path will be operated with a P-Controller. The P-Value gets increased until the controlpath starts to oscillate with a constant amplitude.

With the critical P-Value (kP krit) and the periode (Tk) all other PID-Parameters are calculated.

Controller I-Value D-Value P-Value

P - - 0.5 * kP krit

PD - 0.125 * Tk 0.8 * kP krit

PI 0.85 * Tk - 0.45 * kP krit

PID 0.5 * Tk 0.125 * Tk 0.6 * kP krit

7.9.2 Procedure to adjust a PID-Controller

1. Change to "MotorConfig; PosCtrl" in ACS-Show.

2. Default-Parameters:

kT_Speed = 1ms Resolver-Filter timeHoldToStandbyTime = 100ms

PID standby = 0 set all parameters to zeroPID forward = 0 set all parameters to zeroPID backward = 0 set all parameters to zero

3. Start with: forward = INOM / 50

Example Motor with INOM

= 2.4 A -> kP = 0.05

4. Change to "Test; Trapezoid Controller".Use this ramp:

VRG_S = 360°VRG_V = 600 °/S (100 U/min)VRG_A = 5000 °/S2VRG_B = 5000 °/S2VRG_SCU = 0%

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It is also possible to use a ramp that is more steep e.g. 50'000 °/s2.This activates the natural frequency oscillation of the control path.

Please refer to the motor data sheet! Do not stress the load to much.

Start the ramp drive with simulation mode F3, F5. Start moving with F7.If the motor oscillates to much stop immediately with F3 (inactive) or F8 (Stop) andchoose a smaller value for kP.

This specifications are for gear 1:1.

5. Increase "kP PID forward" until the oscillation during the constant drive has constantamplutide. -> Use Logger!

Pic 7.9.1 Critical P-Value kP krit

See Pic 7.9.1: this is critical p-value "kP krit", measure the periode of the oscillation,this time is "Tk".

Pic 7.9.1 kP to high

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6. Use the folowing calculation to get kP, kI, and kD :

kP = 0.6 * kPkritkI = 0.5 * TkkD = 0.12* Tk

Example: kP = 0.6 * 0.13 = 0.78kI = 0.5 * 54 = 27 mskD = 0.12 * 54 = 6.48 ms

Pic 7.9.3 First aproximation of the PID-Parameters

7. Increase kp continuously. With a higher kP, the position error gets lower. The curve getssmoother. Now use a faster ramp:

VRG_S = 3'600°VRG_V = 6'000 °/S (1000 U/min)VRG_A = 50'000 °/S2VRG_B = 50'000 °/S2VRG_SCU = 0%

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8. Repeat step 6 and 7 until the curve fits the following points:- Req_Speed and Speed are congruent.- After driving the ramp ANZ_S and VRG_S are the same value +- 1%.- No oscillation of current and position error.

Pic 7.9.3 kP was increased until current starts to oscillate again.

9. Example: kP was increased up to 0.6 -> with this value current and positionerror are oscillating again

decrease kP to 80 ... 90% of the critical kP; kP = 0.5

10. The PID-Parameter for "PID standby" are calculated out of the arithmetic mean valueof forward and backward. For kP standby you can enter 1/2 of kP.

11. With this parameters the motor should run. For better efficiency a fine tuning must be done.The fine tuning needs a lot of experience. Please call us for assistance.

12. Until now, the controller was running in simulation mode. For fine tuning the motor must beoperated in "Aktive" (F4).

13. Burn the PID-Parameters into Flash-Prom "Burn Values to Target".Save the parameters into a file "Save Values to File".

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7.10 Adjustment of pre-hold values

phvSpeed:The Pre-hold vale for speed acts as a pre-hold value for current. Losses depending on speed are com-pensated.

1. Measure current during a drive with constant speed. Speed at maximum.

2. Calculation:

phvSpeed = Konst-Strom / Konst-v

Example:Constant drive with 3000 U/min at 6AphvSpeed = 6A / 3(1000)U/min = 6 / 3 = 2 A@Spd

3. The integrator (Pos_Err_int) should stay at a constant value during constant speed.Optimal: Pos_Err_int < 1000 Inc

phvAcc:PhvAcc adds a current to the set-value to apply the power for acceleration/deceleration.

1. Measure the current during an acceleration/deceleration drive:

Example12A for deceleration in about 250ms from 3000 to 0U/min

2. phvAcc = 12Arms / 3 (1000)U/min * 0.25sec = 12 / 3 * 0.25 = 1 A@acc

3. The integrator (Pos_Err_int) should be symetric during acceleration and deceleration.

7.11 Adjust Resolver Filter

kT_Speed:The D-Part of the PID-Controller causes noise. To reduce this noise "kT_Speed" can be used."kT_Speed" can be set to 1/10 of the period of Tk. If two frequences are present take the faster.Keep the value of "kT_Speed" at a minimum!

PIDd:If two frequences are present (eg. oscillation of belt 6ms, oscillation of mass 100ms) PIDd can beused. PIDd = Acceleration error, or D-Part of closed-loop speed controller.

Increase Kd in small steps. Find a compromise between oscillation and noise.

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7.12 Fine-Tuning of Ke, Rs and Ls

This fine-tuning is not strongly needed.

Use this fine-tuning to verify the values from the data-sheet to prevent failures.

If you have an application with heavy loads this fine-tuning is recommended.

The sequence is important.

Uq U Torque Active VoltageUd U Reactive Reactive Voltage

Iq I Torque Active CurrentId I Reactive Reactive Current

Iq_Int I Torque Integrator Integrator Active Current (Current controller)Id_Int I Reactive Integrator Integrator Reactive Current (Current controller)

1. Adjuste Resolver-Offset with Imax.

2. Set a value to Ke to get Iq_Int = 0 during maximum speed (constant drive)

Uq = Iq*Rs + wKe = Iq=0 = 0 + wKe -> only Ke-Error stays

3. Set a value to Pre-hold value for Resolver (phvAngle) to get Id_Int = 0 during maximum speed(constant drive)

Udd = Id*Rs + w(Ls*Iq) = Iq,Id=0 -> only Resolver-Error stays

(default value for phvAngle is 1, this tuning is not neccessary usually)

4. Set a value to Ls to get Id_Int = 0 during deceleration / acceleration. (symetric)

If Id_Int during accelertion is negative: Ls is too smallIf Id_Int during accelertion is positive: Ls is too large

5. Set a value to Rs to get Iq_Int = 0 during acceleration / deceleration.

The most important values are Resolver-Offset 1) and Ke 2)

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8. Trouble Shooting8.1 Link Problems

First check for Link-Problems. The Error Counter must not count!Rever to "INFO-Mess" to Light Power Measuring Tool

8.2 Pollution

Pic 8.2.1

Use dust filter for the cooling system. Too much dust and humidity cause shor circuits.

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8.3 Intermediate Circuit Voltage

Pic 8.3.1

Current is getting lower although the position error is increasing. Difference between actual and desi-red speed is getting higher.

Error The intermediate circuit voltage is to low

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8.4 Load

Pic 6.4.1

The maximum current is reached. The whole profile is driven with maximum current.

Error 1: Motor is overloaded.

At the cursor position the position error is about 270 increments. Increment errors above 256 are cutby the controller! For at least 30ms the maximum position error of 256 is reached. The cut positionerror is lost forewer, and the axis will stop behind the desired position!

Error 2: The max. position error KMX_SE is greater then themaximum of 200!

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8.5 PID-Parameter

Pic 8.5.1

PID-Parameter Set not optimiced.

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8.6 Disturbances

Disturbances on the resolver cables. I_Torque of less than 100mA causes position error of ±3 incre-ments. This error is cause too by a bad resolver input on the ACS-Controller.

Pic 8.6.1

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8.7 Prehold values

The prehold value phvSpeed is fairly to larg. The actual velocity is about 40U/min faster than requi-red speed. The controller can not compensate the to large phv. The position integrator Pos_Err_Int(pink) and the position error Pos_Err (gray) have reached their maximum.

Pic 8.7.1 Prehold values

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8.8 Wrong standardisation

In the IMD configuration for all axes the revolution at 10V and the samplingrate must be set. In all ser-vo controllers the same parameters must be configured as well. If this standardisation is not correctthe controller does not work ideal. If the parameters differ too much, the axis don't move. Possible er-rors are "Too many error increments" or "Imax reached".

Errors in standardisation can be detected at the curve "Req_Speed" (green curve). If the controllermust adapt the "Req_Speed" during the movement, the standardisaton of 10V is not correct.

Pic 8.8.1 Wrong standardisation

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8.9 Wrong Ke

The parameter Ke is to large. During break down, the motor gets to less working voltage.

See chapter 7.12 "Fine-Tuning of Ke, Rs and Ls"

Pic 8.9.1 Wrong Ke; Log with "Speed curve"

Pic 8.9.2 Wrong Ke; Log with currents and current integratorsPicture left: wrong Ke, Picture right: correct Ke

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8.10 Wrong Resolver Offset

The resolver offset is wrong. The axis can not run with maximal speed. If the resolver offset is not cor-rect, the reactive voltage gets calculated wrong. The axis runs into error "Imax reached".

See chapter 7.7 "Resolver Offset Callibration"

Pic 8.10.1 Wrong resolver offset; Log with voltage curvesPicture left: wrong offset, Picture right: correct offset

Pic 8.10.2 Wrong resolver offset; Log with speed curvesPicture left: wrong offset, Picture right: correct offset

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Pic 8.10.3 Wrong resolver offset; Log with speed curvesPicture left: wrong offset, Picture right: correct offset

Pic 8.10.4 Wrong resolver offset; Log with speed curves

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8.11 Coordinated axes

Picture. 8.11.2 shows the axes after callibration of PID-Parameters. Picture 8.11.1 shows movementof the same axes but now the axes is a slave of an other axes, it oscillates very much.

The slave axes must follow an axes with req_speed that oscillates to much (green curve).

The cause of this error is: The position of the master axes gets incremented over a long period oftime. The restricted resolution a the float-values results in a rounding problem.

Pic 8.11.1 Coordinated axes Pic 8.11.2 Axes after callibration

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Appendix

A Further documentsINCO-Server Documentation

Installation of the Developper Environment and ToolsDescription of all Functions of the INCO-Server

Hardware FolderDocumentation of all INFO-ModulesAddressing, Pin arrangement, Wiring examples, and so forth

INDEL Wiring-Directive:Rules for an EMC compatible wiring and installation in machines and systems.

INDEL Configuration GuidelineRules for an EMC compatible wiring of the INFO-Modules andof the rack boards

B Online DocumentationComplete documentation is available in the Internet under

http://www.indel.ch/

Select the page "download" and after this, "documentation". You can download thelatest version of documentation for free. All documents are PDF-Files.

http://www.indel.ch/

indel servo-drives manual · ch-8332 russikon 12 rev. 2.15 21.05.2004 controller manual for indel...

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