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20 Gear Drive, Plymouth Ind. Park, Terryville, CT 06786

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Tel: (860) 585-1254 Fax: (860) 584-1973 http://www.amci.com

SD4840EK User Manual

OTOR

AND

OWER

UPPLY

IZING

1.3 Torque and Power Curves (continued)

Figure T1.3 SM34-450 Torque and Power Curves

Figure T1.4 SM34-850 Torque and Power Curves

Summary of Contents for SD4840EK

Page 1: ...MICRO CONTROLS INC ADVANCED U s e r M anual Manual 940 0S310...

Page 2: ...ls and workmanship for a period of 18 months Within this warranty period AMCI shall at its option repair or replace free of charge any equipment covered by this warranty which is returned shipping cha...

Page 3: ...xer Move Input 16 Emergency Stop Input 16 Stop Jog or Registration Move Input 17 Capture Encoder Position Input 17 General Purpose Input 17 Available Discrete Output 17 Reference Introduction to the S...

Page 4: ...celeration Equations 42 Triangular S Curve Acceleration 42 Trapezoidal S Curve Acceleration 44 Determining Waveforms by Values 46 Chapter 4 Homing the SD4840EK Definition of Home Position 49 Position...

Page 5: ...inimum Spacing 84 Mounting the SD4840EK Module 84 I O Connector Pin Out 85 Power Wiring 85 Input Wiring 87 Cable Shields 87 Output Wiring 87 Encoder Wiring 88 Differential Wiring 88 Single Ended Wirin...

Page 6: ...TABLE OF CONTENTS SD4840EK User Manual ADVANCED MICRO CONTROLS INC 6 Notes...

Page 7: ...copy sections for use in other documents and you are allowed to add notes and annotations Manual Conventions Three icons are used to highlight important information in the manual NOTES highlight impor...

Page 8: ...es Homing the SD4840EK 49 Reference information on how to set the home position of the SD4840EK Configuration Data Format 53 Reference information on the format of the CANopen over Ether CAT CoE data...

Page 9: ...system is configured Each unit also supports the Distributed Clock DC functionality of the EtherCAT system This allows you to synchronize the start of moves across devices using the SYNC0 signal inst...

Page 10: ...Jog or Registration Move Input Start Indexer Move Emergency Stop Input General Purpose Input Conformance Markings The SD4840EK meets the requirements for the followingconformance markings when install...

Page 11: ...r Temp Heat Sink temperature exceeds 90 C 195 F Faults are reported in the Network Input Data and can be cleared through the Network Output Data Motor Current Programmable from 0 1 to 4 0 Arms in 0 1...

Page 12: ...SYNC0 signal Moves will begin within 25 microseconds of each other Jog Move Allows you to jog the motor in either direction based on an input bit from your host controller Relative Move Allows you to...

Page 13: ...omes active The 25 microsec onds is caused by the 20 kHz update frequency of the PWM drivers For the SD4840EK the minimum update time on the SYNC0 signal is two milliseconds If the task time is less t...

Page 14: ...r should hold a load against gravity but the Idle Current Reduction parameter is set to high the SD4840EK will issue a stall detection error if the load begins to fall Encoder Registration Move The en...

Page 15: ...standard motor performance For AMCI motors use a value of 5 as a starting point High induction motors often referred to as tin can steppers need a higher Current Loop Gain setting for normal operation...

Page 16: ...SD4840EK actually finds the Home sensor is described in chapter 4 Homing the SD4840EK starting on page 49 CW Limit Switch or CCW Limit Switch Each input can be defined as a CW or CCW Limit Switch When...

Page 17: ...rk data Available Discrete Output The SD4840EK has a single DC output that has a maximum rating of 30 Vdc at 20 mA The output can be configured to be a general purpose output or a Fault Output When co...

Page 18: ...There is a communications error between the main processor and the Ethernet co proces sor within the drive You must cycle power to the module to attempt to clear this fault EtherCAT Run LED The green...

Page 19: ...are based on the data format you choose when configuring the unit The default multi word format limits the Motor Position range from 32 768 000 to 32 767 999 If you choose the thirty two bit double in...

Page 20: ...ates Absolute coordinates treat the Target Position as an actual position on the machine Note that you must setthe Home Position on the machine before you can run an Absolute Move See Home Position on...

Page 21: ...quick change in velocity at the beginning or end of the acceleration phase Figure R2 1 Constant Acceleration Additional information including example move calculations can be found in section 3 Calcul...

Page 22: ...ng Speed The motor then accelerates at the programmed Acceleration Value until the speed of the motor reaches the Programmed Speed Both the Acceleration Value and the Programmed Speed are programmed w...

Page 23: ...areaffected by this command The section Basic Move Types starting on page 24 describes each move type in detail including if the move is affected by this command Immediate Stop Command When this comm...

Page 24: ...stop When stopped successfully the SD4840EK will set a Hold State bit in the input data table The Relative Move can be restarted with the Resume Move command from the network data or the move can be...

Page 25: ...ving to calculate relative posi tions If you are controlling a rotary table you can drive the table to any angle without hav ing to calculate the distance to travel For example an Absolute Move to 180...

Page 26: ...CW limit switch is active This allows you to move off of an activated end limit switch As shown below a Jog Move begins at the programmed Starting Speed accelerates at the programmed rate to the Progr...

Page 27: ...example it is possible to start a clockwise Jog Move while the CCW Limit Switch is active CW CCW Registration Move Similar to a Jog Move a Registration Move will travel in the programmed direction as...

Page 28: ...ve Input in its active state will result in a move of Minimum Registration Distance Programmed Number of Steps You toggle the Hold Move control bit in the Network Output Data The SD4840EK responds by...

Page 29: ...the Resume Move bit or abandon the held move by starting a new one The use of the Hold Move and Resume Move bits is explained in the Controlling Moves In Progress section starting on page 35 Immediate...

Page 30: ...enter a segment that segment s programmed acceleration and deceleration values are used to change the speed of the motor 8 The blend segment must be long enough for the acceleration or deceleration po...

Page 31: ...you the ability to string multiple relative moves together and run all of them sequentially with a single start condition Like a Blend Move a Dwell Move is programmed into the SD4840EK as a series of...

Page 32: ...nd enter Command Mode Controlled Stops The move completes without error You toggle the Hold Move control bit in the Network Output Data When this occurs the SD4840EK decelerates the move at the decele...

Page 33: ...Program_Assembled bit in the Network Output Data 2 The SD4840EK responds by setting both the In_Assembled_Mode and Waiting_For_Assembled_Segment bits in the Network Input Data 3 When the host detects...

Page 34: ...to program a second move and run it as an Indexed Move type then you must have a 0 1 transition on the move command bit before the new parameters are accepted The easiest way to accomplish this is by...

Page 35: ...red New Acceleration Deceleration and Programmed Speed parameters can be written to the SD4840EK while a Jog Move is in its hold state If these parameters are accepted without error the move can be re...

Page 36: ...progress which allows you to adjust the tracking speed and position of the motor How It Works The SD4840EK always uses 4X decoding when counting pulses from the encoder If you set both of your ELGear...

Page 37: ...lse is not used to correct the encoder position once per turn so you can actually program the Motor Steps Turn to any value you want within its valid range For example if your encoder outputs 4 096 pu...

Page 38: ...MOVE PROFILES SD4840EK User Manual ADVANCED MICRO CONTROLS INC 38 Notes...

Page 39: ...ed For the smoothest transition from the starting speed the starting speed should be equal to the square root of the acceleration in steps sec2 For example if the choose acceleration is 20 000 steps s...

Page 40: ...needed to accelerate and decelerate 250 002 199 982 449 984 steps If a move with the above acceleration deceleration starting speed and programmed speed has a length greater than 449 984 steps the SD4...

Page 41: ...ezoidal Profiles you must first determine the number of counts that you are running at the Pro grammed Speed This value DP below is equal to your DA and DD values subtracted from your total travel You...

Page 42: ...ble accelerations the starting speed does not have to be equal to the square root of the pro grammed acceleration value Variable acceleration provides smooth transitions at the beginning and end of th...

Page 43: ...programmed acceleration value to keep the accelera tion time the same If your constant acceleration value is the maximum your system will allow then using S curve accelerations will lengthen the time...

Page 44: ...ion multiplied by the time it is applied This is shown graphically in figure R3 5 as the area of the blue rectangle In order for the Trapezoidal S curve acceleration to reach the same speed in the sam...

Page 45: ...rations calculating the percentage increase in time is shown in figure R3 6 The time added to the acceleration phase is equal to the time spent increasing the acceleration during the phase As shown in...

Page 46: ...e of 20 and the second a value of 400 Triangular or Trapezoidal S curve accelerations are always symmetrical We ll use this fact to calculate the profile up to one half of the change in speed At that...

Page 47: ...t acceleration period is 2 0 1336 0 7672 or 34 8 of the entire phase Sm 30 000 steps sec 2 15 000 steps sec Sm midpoint of change in speed J 100j a j Ja 100 J Acceleration Jerk parameter j physical je...

Page 48: ...CALCULATING MOVE PROFILES SD4840EK User Manual ADVANCED MICRO CONTROLS INC 48 Notes...

Page 49: ...ind Home command begins searching by rotating the motor shaft in the clockwise direction when the motor is wired as shown in this manual and ends when the home sensor triggers while the SD4840EK is ro...

Page 50: ...ou configure as a Home Input will function as a hardware home proximity sensor Using this feature is com pletely optional Homing Profiles The CW Find Home command is used in all of these examples The...

Page 51: ...the proximity input has not made a 0 1 transition 4 Deceleration towards the Starting Speed when the proximity input Backplane bit or Home Input transitions from its inactive to active state The axis...

Page 52: ...the axis with an error if both overtravel limits are activated while the unit is trying to find the home position Figure R4 3 Profile with Overtravel Limit 1 Acceleration from the configured Starting...

Page 53: ...ncing resonance problems with this feature enabled disable this feature and test the machine again Bit 13 Enable_Stall_Detection 0 disables motor stall detection 1 enables motor stall detection Only v...

Page 54: ...ections Bits 8 7 6 5 4 3 2 1 0 Function Available On 0 0 0 General Purpose Input The input is not used in any of the functions of the SD4840EK but it s status is reported in the Network Data This allo...

Page 55: ...bling Stall_Detection will cause a error if the encoder is not enabled The Use_Encoder must equal 1 Table R5 3 Configuration Word 0 Bits Set These Bits To To Make These Settings 15 14 13 12 11 10 9 8...

Page 56: ...a is read from the Ether CAT Slave Controller ESC When set to 1 the SD4840EK will synchronize the move to the SYNC0 output of the system s Distributed Clock This allows you to synchronize moves over m...

Page 57: ...f this featureis completely optional and you can leave the Current Loop Gainat its default setting of 1 for standard motor performance AMCI motors should use a Current Loop Gain value of 5 High induct...

Page 58: ...e Current Loop Gain setting by 10 to 20 The goal is to eliminate the sound from the motor Refer to the documentation for your programming software to learn how to set the Current Loop Gain using the C...

Page 59: ...rk Output Data used to command the SD4840EK and the format of the Network Input Data that contains the responses from the device The parameter names of the input and output data are defined by the dev...

Page 60: ...These bits are used to program the seg ments of an Assembled Move before the move can be run Their use is explained in the Assembled Move Programming section of this manual starting on page 33 Bit 10...

Page 61: ...clockwise direction A full explanation of homing can be found in the Homing the SD4840EK reference chapter starting on page 49 Bit 4 Immediate_Stop When set to 1 the SD4840EK will stop all motion with...

Page 62: ...is started when the Run Assem bled Move bit CMD_word1 Bit 13 makes a 0 1 transition When this bit equals 1 a Dwell Move is started on the transition The direction of a Blend Move is controlled by the...

Page 63: ...normal relative or absolute moves A full description of an Encoder Registration Move can be found starting on page 14 Bits 1 0 Current_Key1 and Current_Key0 These bits can be used to set the motor cur...

Page 64: ...tarting Speed and 2 999 999 Acceleration UINT Acceleration Steps sec ms 1 to 5000 Deceleration UINT Deceleration Steps sec ms 1 to 5000 Motor_Current UINT Motor Current 0 1 amps 0 to 40 0 0 to 4 0 amp...

Page 65: ...e changed when the move is resumed ESI File Name Data Size Function Units Range CMD_Word0 UINT CMD_word0 16 0004 CMD_Word1 UINT CMD_word1 See pg 62 Position DINT Unused See Note Below Velocity UDINT U...

Page 66: ...1 UINT CMD_word1 See pg 62 Position DINT Unused See Note Below Velocity UDINT Unused See Note Below Acceleration UINT Unused See Note Below Deceleration UINT Unused See Note Below Motor_Current UINT U...

Page 67: ...Unused See Note Below Velocity UDINT Programmed Speed Steps Second Value between the configured Starting Speed and 2 999 999 Acceleration UINT Acceleration Steps sec ms 1 to 5000 Deceleration UINT De...

Page 68: ...i ous command ESI File Name Data Size Function Units Range CMD_Word0 UINT CMD_word0 16 0080 CMD_Word1 UINT CMD_word1 See pg 62 Bits 7 6 must equal 10 Position DINT Stopping Distance Steps 0 to 8 388 6...

Page 69: ...nto the two sixteen bit registers This code was written with TwinCAT software Motor_Current UDINT_TO_UINT nMRMDist Motor_Current stores the lower 16 bits Jerk UDINT_TO_UINT SHR nMRMDist 16 Jerk stores...

Page 70: ...d by the SD4840EK and can be any value including parameter values in the previ ous command Presetting the position will also reset the Move_Complete status bit in the Network Input Data ESI File Name...

Page 71: ...previ ous command ESI File Name Data Size Function Units Range CMD_Word0 UINT CMD_word0 16 0400 CMD_Word1 UINT CMD_word1 See pg 62 Set bit 10 to clear driver faults Position DINT Unused See Note Below...

Page 72: ...value including parameter values in the previ ous command ESI File Name Data Size Function Units Range CMD_Word0 UINT CMD_word0 16 4000 CMD_Word1 UINT CMD_word1 See pg 62 Position DINT Encoder Preset...

Page 73: ...12 of CMD_word0 set it will accept the block and reset bit 9 in STATUS_word0 When your program sees this bit reset it must respond by resetting bit 12 of CMD_word0 The SD4840EK will respond to this b...

Page 74: ...40EK has valid configuration data Bit 12 Command_Error 1 when an invalid command has been written to the SD4840EK This bit can only be reset by the Reset_Errors bit CMD_word0 Bit 10 Note that setting...

Page 75: ...hat it is ready to accept assembled move profile programming data Its use is explained in the Assembled Move Program ming section of this manual starting on page 33 Bit 7 Move_Complete Set to 1 when t...

Page 76: ...d to invalid values Parame ters that can be changed during a Jog Move are Programmed Speed Acceleration and Deceleration While in Electronic Gearing mode this bit is also set if the Numerator or Denom...

Page 77: ...nput Data See STATUS_word1 Format on page 76 for a full description of STATUS_word1 Once you have cleared the fault condition you can reset the Driver Fault with the following Command Block Reset Driv...

Page 78: ...COMMAND DATA FORMAT SD4840EK User Manual ADVANCED MICRO CONTROLS INC 78 Notes...

Page 79: ...e may allow you to use a lower current setting on the SD4840EK drive This lowers the I2R losses and the operating temperature of the motor which increases the motor s life 1 2 Determining Your Motor C...

Page 80: ...TOR AND POWER SUPPLY SIZING SD4840EK User Manual ADVANCED MICRO CONTROLS INC 80 1 3 Torque and Power Curves Figure T1 1 SM2340 130 Torque and Power Curves Figure T1 2 SM2340 240 Torque and Power Curve...

Page 81: ...CT 06786 Tel 860 585 1254 Fax 860 584 1973 http www amci com SD4840EK User Manual MOTOR AND POWER SUPPLY SIZING 81 1 3 Torque and Power Curves continued Figure T1 3 SM34 450 Torque and Power Curves Fi...

Page 82: ...nge Table T1 1 SM23 Suggested Power Supply Ratings Regeneration Back EMF Effects All motors generate electrical energy when the mechanical speed of the rotor is greater than the speed of the rotating...

Page 83: ...nting of all devices be sure that all debris metal chips wire strands tapping liquids etc is prevented from falling into the module Debris may cause damage to the module or unintended machine operatio...

Page 84: ...dditional air up through the modules or you can increase the space between the drives to limit mutual heat ing The SD4840EK has a bit in the network data that signals when the module is close to overh...

Page 85: ...or only The control electronics will remain powered and the drive will not lose its network connection This feature was incorporated into the design of the SD4840EK for customers that must remove powe...

Page 86: ...with an overall shield should be used for all power supply wiring to limit EMI The shield must be connected to the earth ground point used by the power supply These cables must be routed away from al...

Page 87: ...ground bus as the SD4840EK 2 6 Output Wiring The SD4840EK output is an optically isolated transistor that is capable of driving a typical PLC input Both ends are uncommitted so it can be wired as a si...

Page 88: ...with an overall shield The shield should be grounded at the end when the signal is gener ated which is the encoder end If this is not practical the shield should be grounded to the same ground bus as...

Page 89: ...grounded at the end when the signal is gener ated which is the encoder end If this is not practical the shield should be grounded to the same ground bus as the SD4840EK Figure T2 8 Single Ended Encod...

Page 90: ...ce will result 2 8 3 Connecting the Load Care must be exercised when connecting your load to the stepper motor Even small shaft misalignments can cause large loading effects on the bearings of the mot...

Page 91: ...IN rail If you connect the motor shields to the DIN Rail and the grounding connection from the DIN rail to the Grounding Bus fails over time then youwill eventually have a condition where electrical n...

Page 92: ...S INC 92 2 9 Connecting the Motor continued 2 9 2 Motor Wiring continued Figure T2 9 Motor Wiring 4 4 2 2 1 1 Eight Lead Parallel Connected 6 LEAD MOTOR Six Lead Series Connected 6 LEAD MOTOR Six Lead...

Page 93: ...cable should be used The Ethernet ports on the units are auto sense ports that will automatically switch between 10baseT and 100baseT depending on the network equipment they are attached to The ports...

Page 94: ...INSTALLING THE SD4840EK SD4840EK User Manual ADVANCED MICRO CONTROLS INC 94 Notes...

Page 95: ...40EK to the Project This section assumes that the TwinCAT software is in Config Mode 3 2 1 Scan for the SD4840EK 1 Attach the SD4840EK to the network and power up the device 2 At this point the device...

Page 96: ...hexadecimal value of CFG_word0 for your application 5 Once you set a parameter check the value of the STATUS_word1 register 6000 01 If the value has bit 13 set to 1 there is an error in your configur...

Page 97: ...s AT Q DINT nTargetVel AT Q UDINT nAccel AT Q UINT nDecel AT Q UINT nMtrCurr AT Q UINT nJerk AT Q UINT 0 Inputs nStatus0 AT I UINT nStatus1 AT I UINT nMotorPos AT I DINT nEncPos AT I DINT nTrappedEnc...

Page 98: ...5 Link Variable Names to I O Words continued 4 In the Attach Variable window that opens select the variable to link to the STATUS_word0 input word and click OK Figure T3 6 Change Link Pop up Menu 5 R...

Page 99: ...1 In the Solutions Explorer expand out System Tasks so that the tasks are visible Double click on the task assigned to the main PLC This task is typically named PlcTask In the windows that open note t...

Page 100: ...and select Add New Item 2 In the window that opens name the new task and select TwinCAT Task With Image as the Type Click the OK button to accept the values Figure T4 1 Create New Task 3 In the window...

Page 101: ...the name of the new variable to select it The information on the variable will appear in a pane Click on the Linked to button in this pane to open the Attach Variable window 8 Double click on the CMD...

Page 102: ...n 5 Click on the Advanced Settings button 6 Verify or set the following Cyclic Mode Enable checkbox is checked Sync Unit Cycle s is equal to the time of the correct task If not the variables are not l...

Page 103: ...edure If the value is less than 64 then the bit is not set This new value must be specified in the Startup tab in order to make the change permanent 4 Click on the Startup tab 5 Right click on the bla...

Page 104: ...LEADERS IN ADVANCED CONTROL PRODUCTS ADVANCED MICRO CONTROLS INC...

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