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Xenus XSL™ User Guide 

P/N 

95-00286-000

 

Revision 7   
June 2008 

 

2004, 2005, 2006, 2007, 2008 

Copley Controls Corporation 

20 Dan Road 

Canton, MA 02021 USA 

All rights reserved 

Artisan Technology Group - Quality Instrumentation ... Guaranteed | (888) 88-SOURCE | www.artisantg.com

Summary of Contents for Xenus XSL

Page 1: ...service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE IN...

Page 2: ...Xenus XSL User Guide P N 95 00286 000 Revision 7 June 2008 Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 3: ...Xenus XSL User Guide This page for notes Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 4: ...ital Inputs to Connect Limit Switches 32 2 7 2 Diagram Sample Placement of Limit Switches 32 2 7 3 How the Amplifier Responds to Limit Switch Activation 32 2 7 4 Using Custom Output to Signal Limit Sw...

Page 5: ...tructions 60 4 1 1 Electrical Codes and Warnings 60 4 1 2 Grounding Considerations 60 4 1 3 Connector Locations 61 4 2 AC Mains J1 62 4 3 Motor J2 63 4 4 Regen Resistor J3 Optional 64 4 5 Logic Supply...

Page 6: ...agram 124 6 1 5 CAN Information and Status Bar 125 6 1 6 Choosing an Amplifier from a List of Amplifiers 125 6 1 7 Renaming an Amplifier 125 6 2 Manage Amplifier and Motor Data 126 6 2 1 Memory 126 6...

Page 7: ...ermal Considerations 169 D 1 Operating Temperature and Cooling Configurations 170 D 1 2 Heatsink and Fan Configurations 171 D 2 Heatsink Mounting Instructions 172 E Xenus Filter 173 E 1 Overview 174 E...

Page 8: ...3 Feedback XSL FC 10 197 H 5 Regen Resistor Specifications 198 H 5 1 XTL RA 03 XTL RA 04 Specifications 198 H 5 2 XTL RA 03 XTL RA 04 Dimensions 198 H 5 3 XSL RA 01 02 Discontinued Specifications 199...

Page 9: ...Corporation welcomes your comments on this manual See http www copleycontrols com for contact information Copyrights No part of this document may be reproduced in any form or by any means electronic o...

Page 10: ...ailure to heed this warning can cause equipment damage injury or death Using CME 2 or serial commands may affect or suspend CAN operations DANGER When operating the amplifier as a CAN node the use of...

Page 11: ...ltiplier See Position Mode and Position Loop p 24 Over Current fault See Fault Descriptions p 37 RS 232 multi drop serial control See Connecting for Serial Control p 183 New CAN addressing interface S...

Page 12: ...UCTION This chapter provides an overview of Copley Controls Xenus amplifier Contents include Title Page 1 1 Amplifier 12 1 2 CME 2 13 1 3 CMO CML 13 Artisan Technology Group Quality Instrumentation Gu...

Page 13: ...ication over a CAN network to perform torque velocity and position profiling interpolated motion and homing operations Multiple drives can be tightly synchronized for high performance coordinated moti...

Page 14: ...eliminated Motor data can be saved as ccm files Amplifier data is saved as ccx files that contain all amplifier settings plus motor data This makes it possible to quickly set up amplifiers by copying...

Page 15: ...Introduction Xenus XSL User Guide 14 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 16: ...equency 18 2 3 Commutation Modes 18 2 4 Feedback 18 2 5 Operating Modes 19 2 6 CANopen Operation 30 2 7 Limit Switches 32 2 8 Brake Operation 33 2 9 Status Indicators 34 2 10 Protection 36 2 11 Positi...

Page 17: ...olated Deriving internal operating voltages from a separate source enables the amplifier to stay on line when the mains have been disconnected for emergency stop or operator intervention conditions Th...

Page 18: ...R 5 Vdc DC BUSS DC BUSS L2 AMPLIFIER CHASSIS CONTROL SYSTEM ENABLE IN1 SIGNAL GND SIGNAL GND SHIELD J8 J7 J1 J2 FRAME SAFETY GROUND CONTROL SIGNAL GROUND REGEN REGEN SHIELD BRAKE 24 Vdc 24 Vdc GROUND...

Page 19: ...er provides traditional six step commutation When driving a DC brush motor the amplifier operates as a traditional H Bridge amplifier 2 4 Feedback 2 4 1 Encoder and Resolver Support The Xenus amplifie...

Page 20: ...internal current commands Basic Attributes of All Control Loops These loops and servo control loops in general share several common attributes Loop Attribute Description Command input Every loop is gi...

Page 21: ...for use in applications where there is a constant force applied to or required of the servomotor and the system must control this force Typical applications would be a vertical axis holding against gr...

Page 22: ...or is multiplied by this value Integral gain reduces the current error to zero over time It controls the DC accuracy of the loop or the flatness of the top of a square wave signal The error integral i...

Page 23: ...amplifier s internal function generator In position mode the velocity command is generated by the position loop Velocity Loop Limits The velocity command is limited based on the following set of para...

Page 24: ...s Scalar feature increases the resolution of the units used to express Vp and Vi providing more precise tuning This feature is used when tuning results in non scaled Vp or Vi values of 64 or less Such...

Page 25: ...et Position Velocity Command Trajectory Generator Position Loop Feedback Limits Max velocity Max accel Max decel Abort decel Position Proportional Gain Pp Velocity Feed Forw ard Vff Acceleration Feed...

Page 26: ...olled by a variety of external sources analog voltage or digital inputs CAN network or over an RS 232 serial connection using ASCII commands The amplifier can also function as a stand alone motion con...

Page 27: ...10 Vdc velocity command that had to control 1000 rpm CCW to 1000 rpm CW Scale would be set to 2000 rpm for a 10 Vdc input and Offset set to 5V After this a 0 Vdc input command would be interpreted as...

Page 28: ...t Amplifier Output 50 Duty Cycle The command can be inverted so that increased duty cycle commands negative output and vice versa 100 Duty Cycle Format Two Wire One input takes a PWM waveform of fixed...

Page 29: ...en using digital or analog command inputs the trajectory generator can be disabled by setting the Max Accel limit to zero Note that when using the CAN bus serial bus or CVM Control Program setting Max...

Page 30: ...ring Quadrature Format In quadrature format A B quadrature commands from a master encoder via two inputs provide velocity and direction commands as shown below B Input Velocity Command A Input The rat...

Page 31: ...the amplifier is programmed with a velocity a direction and acceleration and deceleration rates When the amplifier is enabled the motor accelerates to the set velocity and continues at that speed Whe...

Page 32: ...Each node must have a unique and valid seven bit address Node ID in the range of 1 127 Address 0 is reserved and should only be used when the amplifier is serving as a CME 2 serial port multi drop gat...

Page 33: ...fier Response to Active Positive or Negative Limit Switch Current Velocity Amplifier prohibits travel in positive or negative direction Travel in the opposite direction is still allowed Amplifier stat...

Page 34: ...p Sequences Disabling the amplifier by a hardware or software command starts the following sequence of events The motor begins to decelerate at Abort Deceleration rate in position mode or Fast Stop Ra...

Page 35: ...CAN Xenus REGEN FDBCK 24V BRAKE RTN 2 9 2 Amplifier Status Indicator Operation Amplifier status indicator color blink codes are described below Color Blink Code Meaning Not illuminated No 24 Vdc power...

Page 36: ...peration Indicator State Diagram Blinking green Pre operational 200 ms off 200 ms green Steady green Operational off green Single flash green Stopped green 200 ms off 1 second Physical Bus Status Sing...

Page 37: ...DANGER After the cause of a non latched fault is corrected the amplifier re enables the PWM output stage without operator intervention In this case motion may re start unexpectedly Configure faults a...

Page 38: ...the internal 5 Vdc supply used to power the feedback Resolver or analog encoder not connected or levels out of tolerance Encoder power returns to specified voltage range Feedback signals stay within...

Page 39: ...hen the position error reaches the programmed fault threshold the amplifier immediately faults The following error fault can be disabled For detailed information see Following Error Fault Details p 39...

Page 40: ...ing Error Fault The clearing of a non latched following error depends on the amplifier s mode of operation Issuing a new trajectory command over the CAN or serial bus will clear the fault and return t...

Page 41: ...velocity When the position or velocity error exceeds the programmed tracking window value a status word bit is set The bit is not reset until the error remains within the tracking window for the progr...

Page 42: ...terface or by the digital inputs CAN interface When operating as a CAN node the amplifier takes command inputs over a CANopen network CAN communications are described in the next section 2 12 2 CME 2...

Page 43: ...ription AMP Enable LO Enables with clear faults When the input is low amplifier enables PWM output stage Amplifier clears faults on the low to high transition of the input When input is high the ampli...

Page 44: ...nput is high motion stops but the amplifier remains enabled Any position or velocity commands received while the input is active are ignored In position mode upon activation of the input the motor wil...

Page 45: ...true output state The general purpose outputs require an external fly back diode to be installed across any inductive loads such as relays that are connected to them The brake output OUT4 is describe...

Page 46: ...ched faults DANGER Associating a fault with a latched custom configured output does not latch the fault itself After the cause of a non latched fault is corrected the amplifier re enables without oper...

Page 47: ...set as described in Velocity Loop Limits p 22 Velocity Outside of Tracking Window Difference between target and actual velocity has exceeded the window See Tracking Window Details p 40 Position Outsi...

Page 48: ...an external resistor known as a regen resistor when the voltage rises too high 2 15 3 Regen Circuit Components The amplifier provides an internal transistor that is used in combination with an externa...

Page 49: ...Operational Theory Xenus XSL User Guide 48 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 50: ...Digital Outputs 52 3 10 Brake Output 53 3 11 Encoder Power Supply Output 53 3 12 Primary and Secondary Encoder Inputs 53 3 13 Analog Encoder Inputs 53 3 14 Hall Switch Inputs 54 3 15 Resolver Interfa...

Page 51: ...m 3 3 Power Output Model XSL 230 18 XSL 230 18 R XSL 230 36 XSL 230 36 R XSL 230 40 XSL 230 40 R Peak Current 18 Adc 12 7 Arms 36 Adc 25 5 Arms 40 Adc 28 3 Arms Peak Current Time 1 Second Continuous C...

Page 52: ...XSL 230 18 R XSL 230 36 XSL 230 36 R XSL 230 40 XSL 230 40 R Continuous Power 2 kW 4 kW Peak Power 5 kW 10 kW Minimum Resistance 30 15 Minimum Resistor Wattage 25 W 50 W Turn On Voltage 390 Vdc Turn O...

Page 53: ...ll up or pull down to internal 5 Vdc Input Voltage Range General Purpose High speed 0 V 28 Vdc 0 V 12 Vdc Logic Low Input Voltage 1 35 Vdc Logic High Input Voltage 3 65 Vdc Scan Time 333 Sec RC Filter...

Page 54: ...ltage Range 7 Vdc Differential Input Threshold 0 2 Vdc Differential Input Impedance 121 Maximum Frequency 5 MHz Line 20 Mcount sec Function Incremental or analog encoder or resolver required for sinus...

Page 55: ...o maximize feedback Reference Max Current 100 mA Max RPM 10 000 Function Incremental or analog encoder or resolver required for sinusoidal commutation and position or velocity modes of operation Type...

Page 56: ...d Position PVT and Homing Node Address Selection 16 position rotary switch on front panel OR programmable digital inputs OR stored in flash memory OR combination of above Bus Termination External 121...

Page 57: ...Considerations p 169 3 23 Mechanical and Environmental Size 7 55 in 191 8 mm X 5 57 in 141 5 mm X 2 57 in 65 3 mm Weight Without Heat Sink With Heat Sink XSL HL With Heat Sink XSL HS 3 0 lb 1 36 kg 4...

Page 58: ...Xenus XSL User Guide Specifications Copley Controls Corp 57 3 24 Dimensions Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 59: ...Specifications Xenus XSL User Guide 58 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 60: ...tle Page 4 1 General Wiring Instructions 60 4 2 AC Mains J1 62 4 3 Motor J2 63 4 4 Regen Resistor J3 Optional 64 4 5 Logic Supply Brake J4 65 4 6 RS 232 Serial Communications J5 66 4 7 CAN Bus J6 67 C...

Page 61: ...or disconnecting of cables while the amplifier has 24Vdc and or mains power applied is not recommended Failure to heed this warning may cause equipment damage 4 1 2 Grounding Considerations Primary G...

Page 62: ...nd must be connected to the control system signal ground The amplifier signal ground is not connected to earth ground internal to the amplifier Therefore the control system signal ground can be connec...

Page 63: ...endation Recommended fuse type Class CC 600 Vac rated Ferraz Shawmut ATDR Littelfuse CCMR Bussman LP CC or equivalent AC Mains Wiring Diagram Single Phase Amplifier L1 L2 Fuses L1 Line L2 Neut Earth G...

Page 64: ...tor and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 Ground Motor frame ground and cable shield 2 W Phase W output of amplifier 3 V Phase V output of ampli...

Page 65: ...Function 1 Regen DC Bus to one side of regen resistor 2 N C No connection 3 Regen Collector of regen transistor to one side of regen resistor 4 N C No connection 5 Ground Enclosure ground and cable sh...

Page 66: ...Wire Insertion Extraction Tool Wago 231 131 Standard connector and tool are included in connector kit XSL CK or XSL CA Pin Description Pin Signal Function 1 RTN 24 Vdc return 2 Brake Return or low si...

Page 67: ...le connector is shown below 1 2 3 4 5 6 Pin Description Pin Signal Function 1 N C No connection 2 RxD Receive data input from computer 3 Signal ground Power supply ground 4 Signal ground Power supply...

Page 68: ...Ground 0 V V 4 No connection 5 Pass though to second connector no internal connection 6 CAN_SHLD Pass though to second connector no internal connection 7 CAN_Gnd Ground 0 V V 8 CAN V Pass through to s...

Page 69: ...C style Plug assembly Molex 52316 2611 Boot cover Molex 52370 2610 28 AWG Back shell 3M 10326 52F0 008 standard Molex 54331 0261 rugged Standard solder style connector included in Connector Kit PN XSL...

Page 70: ...ndant Dedicated Inputs p 70 High Group 4 12 IN11 Programmable Standard Group 4 13 OUT1 14 OUT2 15 OUT3 General purpose programmable outputs 16 Encoder A 17 Encoder A 18 Encoder B 19 Encoder B 20 Encod...

Page 71: ...Direction IN10 Direction Input IN9 Count Up Position Up Down IN10 Count Down IN9 Channel A Position Quadrature IN10 Channel B Digital Inputs Wiring Diagram Amplifier J7 9 J7 10 J7 11 J7 12 J7 26 J7 2...

Page 72: ...ode required for inductive loads Secondary Encoder Interface Diagram J7 18 Amplifier Typical Circuit J7 Motion Controller or Position Encoder A A B B X X Frame Gnd J7 16 J7 17 J7 19 J7 20 J7 21 J7 1 5...

Page 73: ...style Plug assembly Molex 52316 2011 Boot cover Molex 52370 2010 28 AWG Back shell 3M 10320 52F0 008 standard Molex 54331 0201 rugged Standard solder style connector included in Connector Kit PN XSL...

Page 74: ...U 12 Digital Hall V OR Resolver R1 Output 13 Digital Hall W OR Resolver R2 Output Standard Xenus Motor Hall switch inputs Resolver Xenus Resolver outputs 14 Digital Input IN5 Motor over temperature s...

Page 75: ...r Case Ground 5 Vdc Typical Circuit To Encoder Output 5 V 400 mA 2 2 K 1 K 22 p 22 p 121 1 K A B X Index B A A B X Gnd Hall Switch Wiring Diagram J8 11 J8 12 J8 13 J8 1 J8 3 J8 10 Typical Circuit 5 V...

Page 76: ...ring Diagram J8 12 J8 13 J8 18 J8 19 J8 1 Frame Gnd Resolver Case Ground REF REF COS COS R1 R2 S2 S4 Amplifier J8 J8 16 J8 17 SIN SIN S3 S1 Motor Over Temperature Wiring Diagram 10 K 4 99 K pull up pu...

Page 77: ...Wiring Xenus XSL User Guide 76 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 78: ...ier Configuration 93 5 8 1 Digital Inputs 93 5 8 2 Standard Digital Outputs 95 5 8 3 Custom Digital Outputs 96 5 8 4 Save Input Output Changes 96 5 8 5 Fault Latching 97 5 8 6 Regen Resistor 98 5 9 Co...

Page 79: ...with power OFF DANGER Do not make connections to motor or drive with power applied Failure to heed this warning can cause equipment damage injury or death Spinning motor with power off may damage ampl...

Page 80: ...on CME 2 5 2 2 4 When prompted save the CME2 zip file to the folder chosen or created in Step 5 2 2 1 The folder should now contain a file named CME2 zip 5 2 2 5 Extract the contents of the zip file...

Page 81: ...not been selected the Select Devices screen appears 5 2 4 2 If the CME 2 Main screen appears instead of Select Devices choose Tools Communications Wizard 5 2 4 3 From the Available Devices list on th...

Page 82: ...the Selected Devices list 2 Choose a Baud Rate for that port 3 Repeat for each selected port 5 2 4 6 Click Next to save the choices and open the Serial Ports Settings Review screen or click Cancel to...

Page 83: ...6 J1 L1 L2 L3 Earth line power power OFF 5 3 1 3 Secure the motor 1 Make sure motor is securely fastened 2 Make sure that no load is connected to the motor 5 3 1 4 Apply 24 Vdc to the amplifier s J4 c...

Page 84: ...dware disable and may be used to disable the amplifier 5 3 2 1 Verify CME 2 installation and serial port configuration 5 3 2 2 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows des...

Page 85: ...n Modes p 18 Halls Type Select Hall type None Digital Analog used with Copley Controls ServoTube motors Hall Phase Correction If checked will enable error checking between Hall switches and encoder ba...

Page 86: ...remental Incremental encoder on J7 Analog Analog encoder on J8 Low Frequency Analog Copley ServoTube motor on J8 Resolver Resolver version only Resolver on J7 Position Encoder Select type and source o...

Page 87: ...Data folder in the CME 2 installation folder 4 The default installation folder is C Program Files Copley Motion CME 2 MotorData 5 Extract the contents of the zip file to the same location 6 The folder...

Page 88: ...d by torque constant motor s peak current limit Range 0 001 to 1 000 Nm Default 0 0001 Nm Continuous Torque The continuous torque that the motor can produce Used with the torque constant to calculate...

Page 89: ...e The continuous force that the motor can produce Used with the force constant to calculate continuous current Range 0 00001 to 1 000 N Default 0 00001 N Velocity Limit Maximum speed of the motor Used...

Page 90: ...k channel J8 or both It can also operate in certain modes without encoders or resolvers A dual feedback setup is shown below The amplifier receives feedback from an incremental motor encoder through t...

Page 91: ...coder turns to position encoder turns 5 6 2 4 If using a brake then proceed to Brake Stop Optional p 91 Else proceed to Calculate p 92 5 6 3 Linear Motor Feedback Setup Options 5 6 3 1 Click the Feedb...

Page 92: ...p 33 5 7 2 Procedure 5 7 2 1 Click the Brake Stop tab 5 7 2 2 Enter the following options Option Description Brake Stop Delay Time Range of accepted values 0 to 10 000 mSec Brake Activation Velocity R...

Page 93: ...nd Torque or Force Constant Correct them if needed If the Motor Feedback values were correct but the peak current limit continuous current limit or velocity loop velocity limit values are not optimal...

Page 94: ...tes input is used as a CAN address bit 5 8 1 2 Enter the following options Option Description Pull up 5 V Internally pulls the group of inputs up to internal 5 V Pull down Internally pulls the group o...

Page 95: ...bits A high input will inhibit motion in positive direction POS Limit LO Inhibits A low input will inhibit motion in positive direction Reset on LO HI Transition A low to high transition of the input...

Page 96: ...is detected Faults p 36 Brake Active High Output goes high to activate the brake Brake Active Low Output goes low to activate the brake Brake Operation p 33 PWM Sync Output OUT1 only The PWM synchron...

Page 97: ...the output 5 8 3 4 To optionally latch the selected events select Latch Output For more information on latching see Non Latched and Latched Custom Outputs p 45 5 8 3 5 Click OK to save changes to vola...

Page 98: ...pectedly Configure faults as latched unless a specific situation calls for non latched behavior When using non latched faults be sure to safeguard against unexpected motion Failure to heed this warnin...

Page 99: ...n resistors supplied by Copley Controls Custom Resistor User supplied resistor See Regen Resistor Sizing and Configuration p 153 5 8 6 3 Click OK to save regen settings to flash memory and close the R...

Page 100: ...Position mode position change counts or mm produced by 10 Vdc of input Range 0 to 1 000 000 000 counts Default 1 Revolution of a rotary motor or 1 pole pair distance for a linear motor For more inform...

Page 101: ...the load inertia and peak current Min 0 Default 0 5 x velocity loop Accel Limit value Max Decel Maximum trajectory deceleration Max value may depend upon the load inertia and peak current Min 0 Defaul...

Page 102: ...100 duty cycle Range 0 to 100 000 rpm mm sec Default Maximum Velocity value PWM Input Type One wire 50 or two wire 100 with direction Options Invert PWM input Inverts the PWM logic Allow 100 output O...

Page 103: ...and another takes each pulse as a negative step command Quadrature A B quadrature commands from a master encoder via two inputs provide velocity and direction commands Increment position on Rising Edg...

Page 104: ...k current Min 0 Default 0 5 x velocity loop Accel Limit value Max Decel Maximum trajectory deceleration Max value may depend upon the load inertia and peak current Min 0 Default 0 5 x velocity loop Ac...

Page 105: ...ress sources Switch Inputs and Programmed Value The address is the sum of the values from these sources 5 9 4 5 For each source selected perform the additional steps described below Source Steps Comme...

Page 106: ...amage injury or death Notes Do not connect a load to the motor before performing Auto Phase procedure Always connect the motor using the same configuration Wire properly and consistently Connections a...

Page 107: ...wer 5 10 2 3 Click Auto Phase to open the Auto Phase Motor Direction Setup screen 5 10 2 4 Move the motor in the direction you wish to be considered positive The Actual Position value on the screen sh...

Page 108: ...rent loop oscillation evidenced by an audible high frequency squeal during auto phasing 5 10 2 8 For a R version of Xenus with a resolver skip to 5 10 2 11 5 10 2 9 For a standard version Xenus click...

Page 109: ...the screen and save values to flash memory OR to close the screen without saving changes click Cancel 5 10 2 14 If the Auto Phase algorithm does not produce desired results try adjusting the Auto Pha...

Page 110: ...Setup If motor direction setup step failed 5 10 4 1 Check Encoder or resolver power and signals 5 10 4 2 Verify that the encoder is differential Contact factory if encoder is single ended 5 10 4 3 Che...

Page 111: ...options as needed Options Description Peak Current Limit Used to limit the peak phase current to the motor Max value depends upon the amplifier model Min value continuous limit I 2 T Time Limit Sets...

Page 112: ...ions Function Generator Tab Excitation Square Wave Amplitude 10 of continuous current setting Frequency 100 Hz Settings Tab Channel 1 Commanded current green Channel 2 Actual current white 5 11 2 4 Ve...

Page 113: ...obtained 5 11 2 7 Press Stop to stop the function generator 5 11 2 8 On the Main screen click Save to Flash 5 11 2 9 If the amplifier is to be operated in current mode skip the velocity and position l...

Page 114: ...ply in position mode Deceleration Limit Maximum deceleration rate Max value may depend upon load inertia peak current Min value 1 Does not apply in position mode Tracking Window Tracking Time See Trac...

Page 115: ...elocity value Frequency 5 Hz Settings Tab Channel 1 Limited velocity green Channel 2 Actual velocity white 5 12 2 4 Verify that the Amplitude value is not excessive for the motor 5 12 2 5 Click Start...

Page 116: ...ssed to the velocity loop In dual encoder systems the multiplier s initial value is calculated based on the ratio of motor encoder turns to position encoder turns See Rotary Motor Feedback Setup Optio...

Page 117: ...lect the Profile tab 3 On the Settings tab make sure that Auto Setup is checked Auto Setup automatically sets the following options Profile Tab Move Relative Type Trap Distance 2000 counts Reverse and...

Page 118: ...profile Often a velocity feed forward Vff value of 16384 100 provides best results 1 Click in the Vff field and adjust the value 2 Click Start after each adjustment to test the new value on a new pro...

Page 119: ...um Acceleration Deceleration Maximum acceleration deceleration of the profile The deceleration is set to be the same as acceleration Maximum Jerk The value of jerk set during the calculate procedure p...

Page 120: ...om connector J1 5 14 2 3 Attach load 5 14 2 4 Reconnect AC power to connector J1 5 14 2 5 Re tune velocity and position loops if applicable 5 14 2 6 On the Main screen click Save to Flash 5 14 2 7 On...

Page 121: ...Quick Setup with CME 2 Xenus XSL User Guide 120 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 122: ...6 4 4 Control Functions 133 6 4 5 Jog Mode 133 6 5 Scope Tool 134 6 5 1 Scope Tool Overview 134 6 5 2 Function Generator and Profile Tabs 135 6 5 3 Scope Settings 136 6 5 4 Scope Tool Controls 139 6...

Page 123: ...ol Panel p 131 Auto Phase Opens Auto Phase tool Auto Phase p 105 Scope Opens Scope Scope Tool p 134 Error Log Opens Error Log Error Log p 142 Amplifier Properties Displays basic amplifier properties S...

Page 124: ...mmunications Wizard Starts sequence of prompts to set up serial port Serial Port Setup p 80 Communications Log Opens Communications Log Communications Log p 143 Download Firmware Starts sequence of pr...

Page 125: ...ton not present when amplifier programmed to use CVM Control Program for Control Loop Input Otherwise the button will be labeled with one of the following CAN Configuration Digital Position Inputs Fun...

Page 126: ...an amplifier CME 2 automatically attempts to connect to the amplifier on that port on CME 2 startup If as shown at center below multiple PC serial ports have been set up for communications with multip...

Page 127: ...licks the appropriate Save to Flash button or closes the screen Flash and Volatile Includes all user entered data represented on other screens such as gains limits and I O faults and regen settings In...

Page 128: ...data management tools at the bottom of the Motor Feedback screen shown below affect only user entered data that is represented on the Motor Feedback screen Motor Feedback Data Management Tools The mot...

Page 129: ...S 232 Serial Communications J5 p 66 6 2 4 2 Start CME 2 by double clicking the CME 2 shortcut icon on the Windows desktop 6 2 4 3 On the Main screen click Restore amplifier data from disk 6 2 4 4 When...

Page 130: ...to the Firmware Image folder in the CME 2 installation folder The default installation folder is C Program Files Copley Motion CME 2 FirmwareImage The folder should now contain a file named Xenus_Fir...

Page 131: ...eck marks to select whether to save to disk flash both or neither 2 Click OK to save data and continue to select a firmware image or click Cancel to continue without saving data 3 If Save Data to Disk...

Page 132: ...put s Red indicates one or more enable inputs are inactive Software Enable State of the software enable Red indicates the amplifier is disabled by software POS Limit State of the positive limit switch...

Page 133: ...variable from the list Disabled disables the display Other options represent the following amplifier values Actual Current Commanded Current Limited Position Actual Velocity Commanded Velocity Analog...

Page 134: ...following mode specific options Mode Option Description Torque Current applied to the motor Limited by current loop Continuous Current Warning Unloaded motors may depending on torque setting ramp up i...

Page 135: ...ures for performing basic activities with the scope To Run a Function Generator Move 1 Click on the Function Generator tab 2 As required adjust Function Generator settings scope tool settings gains li...

Page 136: ...d Selected Control Loop Excitations Available Current Sine Wave Square Wave Step Forward Step Forward and Reverse and Impulse Velocity Sine Wave Square Wave Step Forward Step Forward and Reverse Posit...

Page 137: ...ble The categories and variables are listed below Category Trace Variable Category Trace Variable Disabled Channel disabled no associated variable Position Commanded Position Limited Position Actual P...

Page 138: ...acement of the trigger event on the screen Value is not configurable for Immediate Function Generator or Move Start trigger types Left for optimal viewing of events following the trigger Middle for op...

Page 139: ...Auto Scale and Zoom The Scope automatically scales the display axes to optimally display all channels To zoom in one area of a trace hold the left mouse button and drag a box around the area of intere...

Page 140: ...epresented on these tabs can also be accessed through the screens used to configure the control loops and the digital position input Changing a value in the Scope tool automatically updates the value...

Page 141: ...mode the Position Params tab can be used to set position loop parameters Set Zero Position sets the amplifier s actual position count to zero For more information on the other settings see Position a...

Page 142: ...lation folder For instance c Program Files Copley Motion CME 2 ScopeData To save trace data 1 Generate the trace you wish to save 2 In the Oscilloscope window click the Save to Disk icon When prompted...

Page 143: ...tents of this tab are not refreshed automatically as new events occur The contents are refreshed only when the tab is displayed or when Refresh is clicked Frequency Type description and frequency of e...

Page 144: ...the exception of status messages are recorded in the log Enable Event Status Logging When checked status messages are included in the log Filter Get Variable Cmds When checked Get Variable commands ar...

Page 145: ...Virtual Amplifier screen b a b 6 7 2 3 To open a virtual amplifier from an existing amplifier file skip to Step 6 7 2 4 now To create a new virtual amplifier file based on a virtual amplifier template...

Page 146: ...o control the current vector rotation command the motor forward or reverse using the buttons shown here NOTE Some motors have bearings stiction so helping the motor with mechanical force is acceptable...

Page 147: ...ccurs when the needle is between indicators 30 degrees as shown below 2 If the needle and Hall states do not track properly use the Hall Wiring list box shown below to swap the amplifier s Hall wire c...

Page 148: ...ate of vector rotation then reduce the Increment Rate or increase the Current 6 8 3 6 Verify that Fwd moves motor forward If not toggle Motor Invert Output setting 6 8 3 7 Verify actual position count...

Page 149: ...mutation mode the encoder is highly suspect 1 Verify the differential encoder signals 2 Verify proper twisted shielded cable with good grounding 3 Disable the amplifier and move the motor manually to...

Page 150: ...wing steps in Quick Setup with CME 2 p 77 have been performed Prerequisites Basic Setup Motor Setup Amplifier Configuration Command Input Auto Phase 6 9 2 2 Click Current Loop to open the Current Loop...

Page 151: ...oach that would be used by a trained technician as described below 1 Sets Cp and Ci to zero and then adjusts Cp and Ci for optimal values 2 Uses a frequency sweep to determine the small signal current...

Page 152: ...edium values selected by default are appropriate for most applications 2 Optionally choose how to save Save Cp and Ci to Flash or Keep Cp and Ci in RAM only 3 Click OK to save the values as chosen and...

Page 153: ...so used when moving to an offset position Slow Velocity The velocity used to find a switch edge index pulse or hard stop Accel Decel The acceleration and deceleration rate used during homing Offset Th...

Page 154: ...the optimal resistor characteristics would be for a given application For an overview of regeneration and regen resistors see Regen Resistor Theory p 47 The contents of this chapter include Title Pag...

Page 155: ...f the motor windings A 1 1 2 For rotary motor applications gather this additional information 1 Load inertia seen by the motor 2 Inertia of the motor A 1 1 3 For linear motor applications gather this...

Page 156: ...ated by the Motor Calculate the amount of energy dissipated by the motor due to current flow though the motor winding resistance using the following formulas Pmotor 3 4 Rwinding F Kt 2 Where Pmotor Po...

Page 157: ...tor in joules Ereturned Energy delivered back to the amplifier from the motor in joules Eamp Energy that the amplifier will absorb in joules A 1 8 Calculate Pulse Power of Each Deceleration that Excee...

Page 158: ...ak and continuous currents as well as the peak current time must be taken into consideration for proper fuse selection The duration of the peak current is the deceleration time Tdecel associated with...

Page 159: ...t Damage to the external regen resistor may result from incorrect values entered Damage to the amplifier may result if an incorrect resistance value is entered Failure to heed this warning can cause e...

Page 160: ...thin the range described Click Next for Step 4 A 2 2 6 Click Next for Step 5 A 2 2 7 Review the configuration A 2 2 8 Click Finish to save the configuration to volatile and flash memory and close the...

Page 161: ...Regen Resistor Sizing and Configuration Xenus XSL User Guide 160 Copley Controls Corp This page for notes Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 162: ...maximum amount of time that the peak current can be applied to the motor before it must be reduced to the continuous limit or generate a fault This chapter describes the algorithm used to implement th...

Page 163: ...the output current Sampling Frequency The value of the I2 T Accumulator Variable is incrementally increased for output currents greater than the Continuous Current Limit and is incrementally decreased...

Page 164: ...s best understood through an example For this example a motor with the following characteristics is used Peak Current Limit 12 A I2 T Time Limit 1 S Continuous Current Limit 6 A From this information...

Page 165: ...ws that the actual output current follows the commanded current Note that the current is higher than the continuous current limit setting of 6 A Under this condition the I2 T Accumulator Variable begi...

Page 166: ...nt Because the actual current is less than the continuous current the I 2 T Accumulator Variable value begins to fall incrementally The I 2 T Accumulator Variable value continues to fall until at appr...

Page 167: ...I 2 T Time Limit Algorithm Xenus XSL User Guide 166 Copley Controls Corp This page for notes Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 168: ...f high frequency resonance Low Pass 2 Pole Butterworth The Butterworth filter is a maximally flat low pass filter This second order two pole filter has a damping ratio of 0 707 and produces no peaking...

Page 169: ...Velocity Loop Filters Xenus XSL User Guide 168 Copley Controls Corp This page for notes Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 170: ...cteristics heatsink options and heatsink mounting instructions Contents include D 1 Operating Temperature and Cooling Configurations 170 D 1 2 Heatsink and Fan Configurations 171 D 2 Heatsink Mounting...

Page 171: ...30 36 XSL 230 36 R Mains 120 Vac Mains 240 Vac Continuous Output Current Adc No Heatsink Standard Heatsink Low Profile Heatsink w fan Low Profile Heatsink or no Heatsink w fan Standard Heatsink w fan...

Page 172: ...No Fan With Fan 4 25 in Fan Low Profile Heatsink No Fan With Fan 4 25 in Fan Standard Heatsink No Fan With Fan 4 25 in Fan Select a 4 25 inch square fan that supplies forced air at a minimum rate of...

Page 173: ...D 2 2 Place the phase change material on the amplifier taking care to center the phase change material holes over the heatsink mounting holes D 2 3 Mount the heatsink onto the amplifier taking care t...

Page 174: ...this chapter include Title Page E 1 Overview 174 E 2 XSL FA 01 Edge Filter Specifications 175 E 3 Thermal Considerations 175 E 4 XSL FA 01 Edge Filter Dimensions 176 E 5 XSL FA 01 Edge Filter Wiring 1...

Page 175: ...actor of 3 substantially reducing noise in the system Copley Controls amplifiers typically have a 150 ns rise time high frequency component in the MHz range Thus the edge filter can increase rise time...

Page 176: ...ates below maximum temperature values and thus requires no cooling fan When used with XSL 40 amplifiers running continuous currents greater than 12 Adc the XSL FA 01 should be cooled with an external...

Page 177: ...176 Copley Controls Corp E 4 XSL FA 01 Edge Filter Dimensions The following diagram shows the mounting dimensions of the XSL FA 01 Edge Filter Artisan Technology Group Quality Instrumentation Guarante...

Page 178: ...can cause equipment damage injury or death Risk of electric shock DANGER High voltage circuits on Xenus J1 J2 and J3 and on Filter J1 and J2 are connected to mains power Failure to heed this warning...

Page 179: ...Xenus J2 Edge Filter J2 connects to the motor J2 J1 U V W U V W FROM AMPLIFIER TO MOTOR CNTRL J4 J3 J2 J1 STATUS RS232 CAN ADDR J5 S1 J6 J7 J8 FDBCK 24V BRAKE RTN REGEN U V W L1 L2 L3 CAN Xenus REGEN...

Page 180: ...sis ground and cable shield 2 Phase W Phase W input from amplifier 3 Phase V Phase V input from amplifier use for DC motor connection 4 Phase U Phase U input from amplifier use for DC motor connection...

Page 181: ...s Motor Case Ground J2 2 J2 1 J2 3 J2 4 Filter J2 2 J2 1 J2 3 J2 4 J1 4 J1 3 J1 2 J1 1 J1 5 E 5 7 Diagram Edge Filter Wiring with Brush Motor U V Brush Motor Case Ground Amplifier J2 2 J2 1 J2 3 J2 4...

Page 182: ...01 Xenus Edge Filter Connector Kit Model Qty Ref Description Mfr Model No 1 J1 Plug 5 position 5 0 mm female Wago 721 105 026 047 1 J2 Plug 4 position 5 0 mm female Wago 721 104 026 047 XSL FK 2 Inser...

Page 183: ...Xenus Filter Xenus XSL User Guide 182 Copley Controls Corp Artisan Technology Group Quality Instrumentation Guaranteed 888 88 SOURCE www artisantg com...

Page 184: ...ONNECTING FOR SERIAL CONTROL This chapter describes how to connect one or more amplifiers for control via the RS 232 bus on one of the amplifiers Artisan Technology Group Quality Instrumentation Guara...

Page 185: ...o after power up the amplifier must be reset or power cycled to make the new address setting take effect PC PLC or HMI for ASCII Control Serial COM port for RS 232 9pin D sub RJ11 Copley Amplifier wit...

Page 186: ...d to return to the proper location in Quick Setup with CME 2 The return point is Current Loop p 110 Contents of this chapter include G 1 ServoTube Setup and Configuration 186 G 1 1 ServoTube Basic Set...

Page 187: ...G 1 1 1 Click the Basic Setup button to display the Basic Setup screen G 1 1 2 Click ServoTube Setup G 1 1 3 Click Yes The software automatically sets motor and feedback options appropriate for the Se...

Page 188: ...the Manufacturer field choose Copley Motion Systems from the pull down list G 1 2 3 In the Series field choose STA or STB to match the ServoTube motor G 1 2 4 In the Model field choose the model numb...

Page 189: ...ut screen G 1 4 2 Verify that the inputs group containing IN5 is pulled up to internal 5 V and the IN5 function is set to Motor Temp HI Disables If the motor temperature sensor is wired to IN5 and the...

Page 190: ...Enable Input is not activated G 2 1 2 Apply power G 2 1 3 Click Auto Phase to open the Auto Phase Motor Direction Setup screen G 2 1 4 Move the motor in the direction you wish to be considered positi...

Page 191: ...the Analog Hall wiring setup The message area displays the messages Microstepping Test Complete Motor has been properly phased During microstepping a current vector is applied to the motor windings a...

Page 192: ...up step failed Check feedback power and sin cos signals Check shielding for proper grounding Trouble Shoot Motor Wiring Setup If motor wiring setup step failed Verify that amplifier is disabled Check...

Page 193: ...6 Verify that pressing forward button moves motor forward If it does not toggle the Motor Invert Output box setting G 2 2 7 Verify actual position count agrees with direction of rotation increasing co...

Page 194: ...Feedback Cable Color Codes 196 H 4 1 Wire Description Nomenclature 196 H 4 2 Control Cable XSL CC 10 196 H 4 3 Feedback XSL FC 10 197 H 5 Regen Resistor Specifications 198 H 5 1 XTL RA 03 XTL RA 04 S...

Page 195: ...ry fitted low profile heatsink XSL 230 40 R HS Xenus Servoamplifier 20 40 A with resolver feedback and factory fitted standard heatsink NOTE Heatsink kits may be ordered separately H 2 Accessory Model...

Page 196: ...Heatsink low profile 1 Heatsink thermal material XSL HL 1 Heatsink hardware mounting kit Heatsink Kit Standard Model Qty Description 1 Heatsink standard 1 Heatsink thermal material XSL HS 1 Heatsink h...

Page 197: ...et 14 OUT2 Signal Ground 2 Rev A B Tan White Rev C Orange 1b 8b Violet White 15 OUT3 Enable IN1 3 White Brown 2a 9a White Gray 16 Encoder A In Out GP Input IN2 4 Brown White 2b 9b Gray White 17 Encode...

Page 198: ...t 7 Orange White 4b 9b Gray White 17 Encoder Sin Input Encoder X Input 8 White Yellow 5a 10a Tan Brown 18 Encoder Cos Input Encoder X Input 9 Yellow White 5b 10b Brown Tan 19 Encoder Cos Input Signal...

Page 199: ...0 kW 1000 ms XSL 230 36 XSL 230 36 R XSL 230 40 XSL 230 40 R High Temperature Risk WARNING Setting Default Continuous Power for a standard Copley regen resistor to a value greater than the default of...

Page 200: ...e been replaced by models XTL RA 03 and XTL RA 04 Model Resistance Continuous Power Peak Power For Use With XSL RA 01 30 ohms 167 W 5 kW XSL 230 18 XSL 230 18 R XSL RA 02 15 ohms 200 W 10 kW XSL 230 3...

Page 201: ...00286 000 Revision 7 June 2008 2004 2005 2006 2007 2008 Copley Controls Corporation 20 Dan Road Canton MA 02021 USA All rights reserved Artisan Technology Group Quality Instrumentation Guaranteed 888...

Page 202: ...service in house repair center WE BUY USED EQUIPMENT Sell your excess underutilized and idle used equipment We also offer credit for buy backs and trade ins www artisantg com WeBuyEquipment REMOTE IN...

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