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Infranor SMT-BD2, Manual

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Infranor SMT-BD2 Manual Download Page 49

 

 

SMT-BD2 

4 - SERVICE AND MAINTENANCE 

 
When exchanging an amplifier on a machine, proceed as follows:  
 
- Check that the new amplifier has the same hardware configuration as the old one,   
- Plug in the 

parameter EEPROM

 (or a copy of it) of the old amplifier on the new one, 

- Apply a zero speed input command and start the offset compensation procedure by means of the 

Offset 

button 

on the amplifier front panel.  
 

The new amplifier is configurated like the old one

.  

 

 

 

49

Chapter 7 - Fault finding

 

Summary of Contents for SMT-BD2

Page 1: ...SMT BD2 gb DIGITAL SERVO DRIVE FOR SINUSOIDAL BRUSHLESS AC MOTORS 1 SMT BD2 ...

Page 2: ...SMT BD2 2 SMT BD2 ...

Page 3: ... several hundreds of Volts may remain during a few minutes INFRANOR drives are conceived to be best protected against electrostatic discharges However some components are particularly sensitive and may be damaged Before handling the drives and particularly before any contact with the connectors the user himself must be earthed Place or store the drives on conducting or electrostatically neutral ar...

Page 4: ...SMT BD2 4 SMT BD2 ...

Page 5: ...tion 18 3 3 X1 connector for absolute single turn Sin Cos encoder configuration 19 3 4 X1 connector for other sin cos encoder configurations 20 4 X4 COMMAND CONNECTOR SUB D 25 POINTS MALE 21 4 1 Specification of the analog inputs outputs 22 4 2 Specification of the logic inputs outputs 23 5 X2 POSITION OUTPUT CONNECTOR SUB D 25 POINTS FEMALE 24 Specification of the TTL encoder output 24 CHAPTER 4 ...

Page 6: ... 10 I2 t fault 47 2 11 TRACKING fault 47 2 12 ADC fault 47 3 OPERATING PROBLEMS 48 3 1 Motor supplied but no torque 48 3 2 Motor does not move 48 3 3 Shaft locked eratic oscillations or rotation at maximum speed 48 3 4 Discontinuous motor rotation with zero torque positions 48 3 5 Motor drift with analog input command at zero speed 48 3 6 Loud crackling noise in the motor at standstill 48 3 7 Loud...

Page 7: ...dback provides smooth motor torque force control The SMT BD2 amplifier can be configurated for various encoder types feedback The appropriate encoder input configuration is selectable by jumpers With an incremental encoder only a motor phasing procedure must be executed at each amplifier power up before the motor enabling With an incremental encoder HES feedback from the motor the motor phasing pr...

Page 8: ...ed and radiated radioelectric disturbances CEI 801 2 3 4 regarding the immunity The 400 VAC version of the SMT BD2 amplifiers operating in the BF 400 rack which is equipped with the mains filter F400 35 or 70 has been approved for its conformity with the Electromagnetic Compatibility standards EN 55011 Group 1 Class A regarding the conducted and radiated radioelectric disturbances CEI 801 2 3 4 re...

Page 9: ...30 SMT BD2 220 70 240 70 25 30 35 SMT BD2 220 100 240 100 25 30 35 Authorized output currents for continuous current mode operation I2 t protection in limiting mode AMPLIFIER TYPE Urated Imax Arms Max authorized continuous current Arms of the amplifier Vrms 1 s WITHOUT FAN FAN TYPE 1 FAN TYPE 2 SMT BD2 220 04 240 4 4 2 SMT BD2 220 08 240 8 8 4 SMT BD2 220 12 240 13 8 6 SMT BD2 220 17 240 17 7 8 5 ...

Page 10: ...amplifier Vrms 1 s WITHOUT FAN FAN TYPE 2 SMT BD2 400 15 400 15 5 5 7 5 SMT BD2 400 30 400 30 8 15 SMT BD2 400 45 400 48 10 19 SMT BD2 400 60 400 60 not used 28 Authorized output currents for continuous current mode operation I2 t protection in limiting mode AMPLIFIER TYPE U rated Imax Arms Max authorized continuous current Arms of the amplifier Vrms 1 s WITHOUT FAN FAN TYPE 2 SMT BD2 400 15 400 1...

Page 11: ...e 5 V or 15 V supply voltage HES sequence error detection 1 Note 1 The maximum speed loop bandwidth value not only depends on the amplifier specification but also on the feedback encoder resolution and the motor mechanical load The lower the encoder resolution the lower the servo loop gains and the servo loop bandwidth to avoid any motor noise due to signal quantization effect The mechanical load ...

Page 12: ...Logic outputs Relay contact Umax 50 V Imax 100 mA Pmax 10 W Power ready closed if power OK Amp ready closed if amplifier OK Phasing OK closed if motor phasing OK incremental encoder without HES Idyn open if I2 t warning threshold is reached Monitor outputs 2 channels ANout1 ANout2 10 V full scale 12 bit resolution Programmable output signals on the digitizing oscilloscope Channel 1 and Channel 2 c...

Page 13: ... Ref Speed Supply voltages Position Pulses counter Speed controller Drive parameters Vector control Current Ref Current limitation Current loops PWM power stage Current Mes Motor phases Power supply Aux supply The PR8 and PR10 connectors are not accessible for direct wiring they are plugged on the BM20A single axis rack or on the multiaxes BF rack according to the SMT BD2 amplifier housing see cha...

Page 14: ... 220 70 and 220 100 current rating amplifiers 5 z Power supply undervoltage Undervolt z 5 5 z Motor overtemperature C Motor 5 5 5 z Hall Effect Sensors or Sin Cos commutation channels error HES z z 5 z Analog to Digital Conversion error ADC 5 z z 5 Speed following error Tracking z z z 5 Fault of the amplifier parameter storage EEPROM 5 z 5 5 Amplifier automatic procedure Busy 5 5 blinking display ...

Page 15: ... see Hardware adjustments in chapter 5 1 AMPLIFIER TYPE F1 F2 Power Logic SMTBD2 220 04 to 12 10 AT 1 A SMTBD2 220 17 and 30 15 AT 1 A SMTBD2 220 45 20 AT 1 A SMTBD2 220 60 20 AT 1 A SMTBD2 220 70 1 A SMTBD2 220 100 1 A 3 2 2 Fuse protection for the 400 VAC amplifier version F2 Control of the average DC current of the logic board supply see Hardware adjustments in chapter 5 1 AMPLIFIER TYPE F2 Log...

Page 16: ...ER CONNECTORS LED Faults display X1 Encoder sensor X5 Serial link X2 Encoder output X4 Command BP Offset 2 X5 SERIAL LINK CONNECTOR Sub D 9 points male PIN FUNCTION REMARKS 5 0 Volt GND shield connection if no 360 connection possible on the connector 3 TXD Transmit data RS 232 2 RXD Receive data RS 232 6 TXH Transmit data RS 422 7 TXL Transmit data RS 422 8 RXL Receive data RS 422 9 RXH Receive da...

Page 17: ... the encoder channel A 10 Channel A Differential input of the encoder channel A 3 Channel B Differential input of the encoder channel B 11 Channel B Differential input of the encoder channel B 5 5V Encoder supply voltage 400 mA max current 4 GND Encoder supply GND 12 TC Motor thermal sensor input 10 mA max load current 13 GND Motor thermal sensor GND 6 7 8 reserved 14 15 reserved Encoder input spe...

Page 18: ...annel A 3 Channel B Differential input of the encoder channel B 11 Channel B Differential input of the encoder channel B 5 5V Encoder supply voltage 400 mA max current 4 GND Encoder supply GND 14 HALL U Hall sensor input signal phase U 6 HALL V Hall sensor input signal phase V 7 HALL W Hall sensor input signal phase W 15 15V Hall sensors supply voltage 50 mA max current 12 TC Motor thermal sensor ...

Page 19: ...Channel B Differential input of the Sin Cos encoder channel B 11 Channel B Differential input of the Sin Cos encoder channel B 6 Channel C Differential input of the Sin Cos encoder channel C 14 Channel C Differential input of the Sin Cos encoder channel C 8 Channel D Differential input of the Sin Cos encoder channel D 7 Channel D Differential input of the Sin Cos encoder channel D 5 5V Sin Cos enc...

Page 20: ...MENTAL SIN COS ENCODER HES CONFIGURATION The Incremental Sin Cos encoder HES configuration Heidenhain 1Vcc Sin Cos encoder or compatible is selected according to the following COM and COD jumpers setting see chapter 5 section 1 Hardware adjustments COD B5 B4 B2 B1 COM B3 COD B5 B4 B2 B1 COM B3 60 HES type 120 HES type A wrong jumper configuration may damage the encoder and amplifier electronics Th...

Page 21: ...h CI input inactive Maximum speed value for 10 V 10 V current input command with CI input active full amplifier current rating Imax for 10 V 10 ANout1 monitor O 10 V resolution 12 bits load 10 mA 2 ANout2 monitor O 10 V resolution 12 bits load 10 mA 11 0 Volt analog outputs Programmable output signals on the digitizing oscilloscope Channel 1 and Channel 2 current ref IDC current mes ID IQ IMES I2t...

Page 22: ...UTPUTS X4 17 CV X4 16 CV SMT BD2 10 KΩ 10 KΩ 10 KΩ 10 KΩ 10 KΩ 20 KΩ 20 KΩ 10 KΩ 10 nF 10 nF 10 nF 22 nF 22 nF 20 KΩ 22 nF X4 3 ILIM X4 15 AGND SMT BD2 1 KΩ 20 KΩ 1 KΩ 20 KΩ X4 11 AGND X4 2 ANout2 10 KΩ 10 KΩ X4 10 ANout1 22 Chapter 3 Inputs outputs ...

Page 23: ... X4 pins 23 24 25 is not connected to the 0 V of the SMT BD2 amplifier module X4 pin 12 X4 1 4 7 14 20 X4 23 24 25 4 1 KΩ 10 nF 100 KΩ 5 V TLP281 SMT BD2 I O I O jumper closed When the I O jumper is closed the 0 V of the optoisolated inputs X4 pins 23 24 25 is connected to the 0 V of the SMT BD2 amplifier module X4 pin 12 SMT BD2 15 V PRME15015 BZW04P85B X4 5 8 18 X4 6 9 19 23 Chapter 3 Inputs Out...

Page 24: ...ferential output of the encoder channel A 5 Channel B O Differential output of the encoder channel B 5 V 20 mA max 6 Channel B O Differential output of the encoder channel B 7 25 0 V O 8 to 24 reserved The programmable encoder ouput Division ratio Output resolution Input resolution is only valid for the A and B channels The Marker Z channel is not modified by this parameter value SPECIFICATION OF ...

Page 25: ... V CV0 CI AOK PhOK Idyn 0 V FC FC X4 17 16 15 1 14 20 7 4 18 5 8 19 6 9 25 12 13 RACK U V W V W L1 L2 L3 13 12 14 6 7 15 13 10 2 11 3 9 1 5 4 X1 COM B5 B4 B3 B5 B4 B3 B5 B4 B3 SMT BD2 5 V U V W 15 V U CONTROLLER Encoder input DAC output ENABLE Logic I Os 0 V I O 24 V I O 24 V I O I O I O jumper open GND GND GND or or ENCODER GND THERMAL POWER SUPPLY MOTOR Reset GND GND GND SENSOR HALL EFFECT SENSO...

Page 26: ...1 L2 L3 13 12 10 2 11 3 9 1 14 6 X1 COM B5 B4 B3 SMT BD2 C U 7 8 5 4 C D D 5 V CONTROLLER Encoder input DAC output ENABLE Logic I Os 0 V I O 24 V I O 24 V I O I O I O jumper open GND GND GND ENCODER SIN COS THERMAL POWER SUPPLY MOTOR Reset GND GND SENSOR The I O jumper must be open for getting the X4 connector I Os optoisolation the I O 0 V X4 pins 23 24 25 is disconnected from the 0 V of the SMT ...

Page 27: ...7 kOhm 4 7 kOhm 4 7 kOhm 4 7 kOhm 4 7 kOhm FC FC ENABLE CV0 CI Pont I O fermé GND RAZ I O Le pont des I O doit être fermé pour que le 0 V des E S X4 pins 23 24 25 soit connecté au 0 V du module variateur SMT BD2 1 3 CONNEXION DE LA LIAISON SERIE RS 232 Reprise de blindage sur 360 3 TxD 2 RxD 5 GND GND 5 TxD 3 RxD 2 Port série PC SMT BD2 X5 Sub D 9 pts femelle Sub D 9 pts mâle 27 Chapitre 4 Connexi...

Page 28: ...have a metallic collar allowing a 360 shield connection Motor cables must be shielded to avoid common mode effects Encoder and HES cable must also be shielded 2 3 INPUT COMMAND AND SERIAL LINK CABLES The analog input command signal CV requires a pair twisted and shielded cable The shield must have a 360 connection via metallic collars at both ends If the shield is connected by means of a pig tail ...

Page 29: ...d because the connector box is metallic This solution does not exactly meet the EMC requirements but it is acceptable Motor connector box Metallic or metal plated plastic SUB D pin package 360 shield ensured by the tightening clamp The fastening screws must be tightened in order to ensure the shield continuity on the amplifier housing INFRANOR amplifier SUB D connector W V U L1 L2 U W N V X X NOTE...

Page 30: ... memory 16 bit ADC option CT BD2 option Power fuse power board Only for the 220 VAC range Logic fuse power board I O Inputs 0 V reference Motor thermal sensor type Encoder signal Commutation signal Serial link selection B RS 232 standard C RS 422 option Parameters EEPROM Undervolt fault inhibition Encoder marker pulse disable enable Drive address selection Motor thermal sensor adjustment 5 V suppl...

Page 31: ... A B CA C14 RA CA C14 RA CA C14 RA PW PV PU Power board adjustment for amplifier types 220 70 A and 220 100 A A and B OPEN with auxiliary supply A and B CLOSED without auxiliary supply 31 Chapter 5 Adjustable functions ...

Page 32: ... for 220 04w to 220 17w SMT BM 20 A single axis rack Braking resistor jumper closed BF rack Braking resistor jumper open NOTE This braking resistor system selection is only available on w referenced amplifiers Braking system selection on SMT BD2 220 04w to 220 60w 32 Chapter 5 Adjustable functions ...

Page 33: ... easy modification of all amplifier parameters Please see Web site www infranor fr for downloading the Visual Drive Setup software Minimum requirements for the PC Processor Pentium Operating system WINDOWS 95 98 WINDOWS NT Graphics adapter Windows compatible colour SVGA with resolution 800x600 or 1024x768 Drives 3 5 disk drive hard disk with 6 MB free space Main memory at least 8 MB Interface One ...

Page 34: ... fault inhibition jumper in position JK Undervolt fault enabled Serial link communication jumper in position B RS 232 protocol Drive address selection jumpers in position OFF address 0 selected Encoder signal jumpers COD in position B1 TTL incremental encoder configuration Encoder marker pulse jumper in position ZM encoder marker pulse enabled Commutation signal jumpers COM in position B3 incremen...

Page 35: ...ifier configuration is the following MN jumper closed and OP jumper open The triggering threshold adjustment for the PTC thermal sensor is made by means of the PSTH components as described below PSTH D 14 3 kΩ PSTH B 28 kΩ PSTH A 3 x RPTC 120 C in kΩ RPTC 120 C ohmic value of the PTC thermal sensor resistor at 120 C the default adjustment is RPTC 120 C 3 kΩ with PSTH A 10 kΩ 1 4 2 NTC thermal sens...

Page 36: ...motors the adjustment of the current loops according to the amplifier current rating and to the inductance between the motor terminals is made as follows 15 A and 30 A amplifier current ratings Calculation of G 0 8 x Amplifier current rating A x Inductance between phases mH If G 60 current loop jumpers x3 on B3 position If 60 G 100 current loop jumpers x3 on B2 position If G 100 current loop jumpe...

Page 37: ... B3 B3 B2 B2 BL 115 B3 B3 B2 B2 B2 BL 141 B2 B2 B2 B1 B1 BL 142 B3 B3 B2 B2 B1 BL 143 B3 B2 B2 B1 B1 B1 BL 144 B2 B2 B2 B1 B1 B1 For other motors the adjustment of the current loops according to the amplifier current rating and to the inductance between the motor terminals is made as follows 4 A 8 A 12 A and 17 A amplifier current ratings Calculation of G 1 4 x Amplifier current rating A x Inducta...

Page 38: ...der feedback cable between the motor and the amplifier X1 connector Connect the X4 command connector the Enable input must be open the FC and FC limit switches inputs must be connected and closed and the analog input command CV must be open or short circuited Connect the serial link RS 232 between the PC and the amplifier X5 connector Switch on the PC and the monitor and then start the WINDOWS int...

Page 39: ...ing combinations to find the right wiring order The commutation signal jumpers COM are correctly set according to the HES type The HES supply voltage value is correct The Motor encoder resolution parameter value is correct If the motor HES are not working correctly select the following COM jumpers setting to run the motor without the HES devices B5 B4 COM B3 In this case a motor phasing procedure ...

Page 40: ...e transmission between motor and load backlashes and elasticities in gears and couplings If necessary renew the Auto tuning procedure by selecting a lower bandwidth Bandwidth Medium or Low If the problem remains renew the Auto tuning procedure by activating the Antiresonance filter The Auto tuning procedure should be executed in Software control mode and Off position selected If the Auto tuning pr...

Page 41: ... in order to reduce the risk due to uncontrolled axis movements during the operator s presence in the concerned area Test the motor running in both directions with a low digital speed reference value If required adjust with more accuracy the speed loop response stability by means of the Stability gain buttons or by means of the adjustable gain values Go back to the motor standstill position before...

Page 42: ...tch mm Encoder signal pitch µm 1 encoder signal pitch 4 counting increments The motor Maximum speed parameter value in rpm is calculated according to following formula Maximum speed rpm 60 x x Maximum motor speed m s 1000 Motor pole pitch mm The linear speed value in m s is calculated according to following formula Motor pole pitch mm 1000 Linear speed m s x X Motor speed rpm 60 42 Chapter 6 Commi...

Page 43: ...of the Auto tuning procedure the procedure has failed because of an external cause and the calculated parameters are wrong Check that the ENABLE input is activated Check that the limit switches inputs are not activated Check that the motor shaft movement is free during the procedure execution If the BUSY fault is continuously displayed after the execution of the Offset compensation procedure the o...

Page 44: ... is only valid on amplifiers with current ratings 220 70 and 220 100 2 6 POWER STAGE FAULT If the fault occurs when starting the amplifier Check the DC bus voltage and the terminal voltage of the power transformer secundary For the 220VAC version of the amplifier DC bus 370 VDC and V secundary 260 VAC For the 400VAC version of the amplifier DC bus 800 VDC and V secundary 480 VAC If the fault occur...

Page 45: ...connections on the amplifier connector X1 If the motor encoder is not providing a marker pulse channel output the amplifier marker pulse channel must be disabled in order to cancel the Encoder fault In this case the encoder marker pulse jumper ZM must be set in the disabled position as described below Encoder marker pulse disabled Encoder marker pulse enabled ZM ZM When the amplifier marker pulse ...

Page 46: ... between two successive Z marker pulses is an entire multiple of the Motor encoder resolution value If this condition is not fulfilled the encoder counting protection must be disabled in order to cancel the Counting fault The encoder counting protection can be disabled by disabling the encoder marker pulse by means of the ZM jumper see section 2 8 Encoder fault The encoder counting protection is c...

Page 47: ...hecking that the encoder pulse frequency is lower than 1 5 times the maximum encoder frequency The maximum encoder frequency is calculated into the amplifier according to the Motor encoder resolution parameter value and the Maximum speed parameter value In this case encoder pulse noise at a frequency lower than 1 5 times the maximum encoder frequency can involve uncontrolled motor movements that m...

Page 48: ...s to the recommendations of chapter 4 CV at diff low of the NC and 0 Volt cable Check the offset compensation and if necessary execute the Offset compensation procedure 3 6 LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL Check that the motor amplifier controller ground connections correspond to the recommendations of chapter 4 Check that the speed input command wiring between controller and amplif...

Page 49: ...me hardware configuration as the old one Plug in the parameter EEPROM or a copy of it of the old amplifier on the new one Apply a zero speed input command and start the offset compensation procedure by means of the Offset button on the amplifier front panel The new amplifier is configurated like the old one 49 Chapter 7 Fault finding ...

Page 50: ...nce must be kept when a stored fault is released on the amplifier and the power supply turned off it is necessary to have an auxiliary supply for the logic board which is independent from the power supply In this case the JK and KL jumpers of the logic board allow to inhibit or to release the Undervolt fault when the amplifier is turned on JK jumper closed and KL jumper open configuration If the a...

Page 51: ...n the value of the Rated current and Maximum current parameters This value is calculated as follows T max second t2 t0 4 x Rated current Maximum current 2 NOTE 1 The above formulas are valid as long as the Maximum current Rated current ratio is higher than 3 2 When the Maximum current Rated current ratio is close to 1 the calculated values of Tdyn and Tmax are quite below the real values For examp...

Page 52: ...rent value must be adjusted lower or equal to the Maximum authorized continuous current of the amplifier see Chapter 2 section 1 5 COGGING COMPENSATION OPTION The cogging torque in brushless permanent magnet rotating motors or the cogging force in brushless permanent magnet linear motors result from the interaction between the permanent magnets and the winding frame slots This disturbance is due t...

Page 53: ... shaft revolution renew the acquisition procedure Switch off the amplifier and couple the motor to the load Switch on the amplifier again enable the Cogging compensation command and execute the Save parameters to EEPROM procedure At the amplifier power up the cogging torque compensation is only effective after the detection of the first encoder marker pulse When changing either the motor the encod...

Page 54: ...ually for the reduction of the cogging force effects by moving the motor when the Cogging compensation command is activated and the amplifier enabled If some resistant points do remain over one complete motor travel renew the acquisition procedure Switch off the amplifier Then switch on the amplifier again enable the Cogging compensation command and execute the Save parameters to EEPROM procedure ...

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