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XtrapulsCD1-a

Chapter 7 - Troubleshooting



Check the value of the

Motor parameters

in the

Advanced Functions

menu and execute the

AUTO-

PHASING

command again, with unloaded motor, if necessary (see chapter 6, section 3).

2.4 - DISCONTINUOUS MOTOR ROTATION WITH ZERO TORQUE POSITIONS



Check the connection of the 3 phase cables between motor and drive.

2.5 - MOTOR DRIFT WITH ANALOG INPUT COMMAND AT ZERO SPEED



Check that the input command wiring between the controller and the drive is complying with 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

command.

2.6 - LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL



Check that the motor-drive-controller ground connections are complying with the recommendations of chapter



Check that the CV speed input command wiring between controller and drive are complying with the

recommendations of chapter 4 and check the shield connection of the resolver cables on motor side and drive
side.

2.7 - LOUD NOISE IN THE MOTOR AT STANDSTILL AND WHEN RUNNING



Check the rigidity of the mechanical transmission chain between motor and load (backlash and elasticity in the

gears and couplings).



Execute the

AUTOTUNING

command again by choosing a lower bandwidth (

Medium

Low



If the problem remains, renew the

AUTO-TUNING

procedure by activating the antiresonance filter

(

Filter = Antiresonance

2.8 - POSITION CONTROL NOT POSSIBLE WITH THE NC



Check for the presence of the A, B and Z signals on the drive X2 connector by turning manually the motor

shaft and check the wiring between NC and drive.



Check the counting direction of the NC with regard to the polarity of the speed input command. If there is a

reversal, use the

Reverse Movement

function in the

VISUAL DRIVE SETUP

software to recover a correct

operation.

3 - SERVICE AND MAINTENANCE

When exchanging an drive on a machine, proceed as follows:



Plug the

parameter EEPROM

(or a copy of it) of the old drive on the new one.



Apply a zero speed input command on the CV input and start the automatic

offset compensation

procedure

by means of the push-button on the drive front panel.

The new drive is now configured like the old one

Summary of Contents for XtrapulsCD1-a Series

Page 1: ...1 Digital drive for AC sinusoidal brushless motors XtrapulsCD1 a ...

Page 2: ...s the right to change any information contained in this manual without notice INFRANOR April 2016 All rights reserved Issue 8 16 ESD INFORMATION Electro Static Discharge INFRANOR drives are conceived to be best protected against electrostatic discharges However some components are particularly sensitive and may be damaged if the drives are not properly stored and handled STORAGE The drives must be...

Page 3: ...D dp 16 5 560 15 5 FASTENING 16 5 1 XTRAPULS CD1 a 230 I 16 5 2 XTRAPULS CD1 a 400 1 8 TO 7 2 A 16 5 3 XTRAPULS CD1 a 400 14 16 5 4 XTRAPULS CD1 a 400 30 45 70 AND 90 A 16 6 MULTIAXES CABINET MOUNTING 17 6 1 XTRAPULS CD1 a 230 I 17 6 2 XTRAPULS CD1 a 400 1 8 TO 7 2 A 17 6 3 XTRAPULS CD1 a 400 14 17 6 4 XTRAPULS CD1 a 400 30 45 70 AND 90 A 17 CHAPTER 3 INPUTS OUTPUTS 18 1 CONNECTORS LOCATION 18 1 1...

Page 4: ... AND UL FUSE RATINGS 33 3 4 XTRAPULS CD1 a 230 I DRIVE CONNECTION DIAGRAM WITH PROTECTIONS BY UL FUSES 34 3 5 XTRAPULS CD1 a 400 I DRIVE CONNECTION DIAGRAM WITH PROTECTIONS BY UL FUSES 35 3 6 CONNECTION EXAMPLE FOR A UL COMPLIANT MULTIAXIS APPLICATION 36 CHAPTER 5 PARAMETER SETTING 37 CHAPTER 6 COMMISSIONING 38 1 DRIVE STANDARD CONFIGURATION 38 2 FIRST POWERING OF THE XTRAPULS CD1 A DRIVE 38 2 1 V...

Page 5: ... 49 2 8 POSITION CONTROL NOT POSSIBLE WITH THE NC 49 3 SERVICE AND MAINTENANCE 49 CHAPTER 8 APPENDIX 50 1 HARDWARE ADJUSTMENTS 50 2 ADJUSTMENT TO VARIOUS RESOLVER TYPES 51 3 ADJUSTMENT TO VARIOUS MOTOR TYPES 51 3 1 MOTOR THERMAL SENSOR 51 3 2 I2 t PROTECTION 52 3 3 ENCODER COUNTING PROTECTION 53 3 4 POSITION FOLLOWING PROTECTION 54 4 USE OF THE LIMIT SWITCH INPUTS 54 5 USE OF THE CV0 INPUT 55 6 US...

Page 6: ...only a motor phasing procedure must be executed at each drive power up before the motor enabling With an incremental encoder Hall Effect Sensors HES feedback the motor phasing procedure is no more necessary and the servo motor can immediately be enabled after the drive power up With an absolute single turn muti turn or linear encoder using the ENDAT or HIPERFACE communication protocols and fitted ...

Page 7: ... regarding immunity Standard to be applied to the electrical equipments of industrial machines EN 60204 1 2 3 REFERENCE TO THE STANDARDS UL LISTING XtrapulsCD1 a series have been cULus listed according to UL508C and UL840 regarding the insulator This product was evaluated to the Third Edition of UL508C the UL Standard for Power Conversion Equipment for the UL Listing USL the CSA Standard for Indus...

Page 8: ...230 7 5 7 5 3 75 44 3 75 6 A 5 kA yes CD1 a 230 10 5 10 5 5 25 55 5 25 6 A 5 kA yes CD1 a 230 16 5 16 5 8 25 66 8 25 9 A 5 kA yes Maximum room temperature 40 C 1 2 XTRAPULS CD1 a 400 I DRIVE Mains operating power supply voltage 400 to 480 VAC 10 15 3 TN or TT system with earthed neutral point 50 60 Hz Phase Ground voltage must be balanced Isolated auxiliary supply voltage 24 VDC 15 320 mA Motor ph...

Page 9: ... Mains filter on power supply Integrated in the drive XtrapulsCD1 400 90 exception EMC capacitors integrated Common mode choke not integrated Recommended filter F 400 70 90 Common mode filter on auxiliary supply Integrated in the drive Position sensor Transmitter resolver Absolute single turn encoder ERN1085 or compliant Incremental encoder TTL or SinCos signals Incremental encoder Hall Effect Sen...

Page 10: ...ncy 200 kHz Resolution 500 to 106 ppr Interpolation factor 1024 Absolute single turn Sin Cos encoder Heidenhain ERN 1085 or compliant Maximum signal frequency 200 kHz Resolution 2048 or 512 ppr Interpolation factor 1024 PULSE and DIRECTION input Re configuration of the encoder input for stepper motor emulation Line receiver RS 422 Maximum pulse frequency 1 MHz Resolution 200 to 106 pitch revolutio...

Page 11: ...840 regarding the insulator This product was evaluated to the Third Edition of UL508C the UL Standard for Power Conversion Equipment for the UL Listing USL the CSA Standard for Industrial Control Equipment C22 2 N 14 10 for the Canadian UL Listing CNL Temperature storage 20 C to 70 C operation 5 C to 40 C From 40 C on the rated currents must be reduced of 3 per additional C Max temperature 50 C Al...

Page 12: ...12 Chapter 2 Specifications XtrapulsCD1 a 2 BLOCK DIAGRAM ...

Page 13: ...rances 19 V 24 VDC 29 V 24 V LED is unlit LED is lit NOTE The power stage error includes the following faults power supply overvoltage internal switch protection short circuit between motor phases or between motor phase and earth drive overtemperature on XtrapulsCD1 a 400 I only fan system error PWM control error power stage supply error braking system error The detail of the Power stage fault can...

Page 14: ...14 Chapter 2 Specifications XtrapulsCD1 a 4 DIMENSIONS 4 1 XTRAPULS CD1 a 230 I 4 2 XTRAPULS CD1 a 400 1 8 TO 7 2 A 4 3 XTRAPULS CD1 a 400 14 4 4 XTRAPULS CD1 a 400 30 45 70 AND 90 A ...

Page 15: ...200 dp 33 280 AND dp 16 5 560 dp 16 5 560 Connection of the braking resistor dp 16 5 560 on pins 1 and 3 of the braking resistor connector DIMENSIONS dp 50 200 dp 100 100 and dp 200 100 dp 33 280 dp 16 5 560 A 157 mm 290 mm 290 mm B 145 mm 278 mm 278 mm C 83 mm 83 mm 57 mm D 52 mm 57 mm 145 mm ...

Page 16: ...apter 2 Specifications XtrapulsCD1 a 5 FASTENING VERTICAL MOUNTING IS MANDATORY 5 1 XTRAPULS CD1 a 230 I 5 2 XTRAPULS CD1 a 400 1 8 TO 7 2 A 5 3 XTRAPULS CD1 a 400 14 5 4 XTRAPULS CD1 a 400 30 45 70 AND 90 A ...

Page 17: ...17 XtrapulsCD1 a Chapter 2 Specifications 6 MULTIAXES CABINET MOUNTING 6 1 XTRAPULS CD1 a 230 I 6 2 XTRAPULS CD1 a 400 1 8 TO 7 2 A 6 3 XTRAPULS CD1 a 400 14 6 4 XTRAPULS CD1 a 400 30 45 70 AND 90 A ...

Page 18: ...ted to X1 6 Shield connection The shield must have a 360 connection on the connector metal cover This connection can be completed by connecting the wires to pin 1 2 TC thermal sensor If thermal switch connected to X1 7 S1 cosine Resolver connector 3 S3 cosine Resolver connector 8 S4 sine Resolver connector 4 S2 sine Resolver connector 9 R2 reference Resolver connector 5 R1 reference Resolver conne...

Page 19: ...rrent input command for Imax with CI input active 15 GND I GND reference of the earthed drive 3 I limit current limitation I Analog input for external max current limitation 0 to 10 V for 100 to 0 of Imax 11 Analog output O 10 V resolution 8 bit load 10 mA linearity 2 low pass filter 170 Hz programmable output signal Channel 1 of the digital oscilloscope current speed or position or Phasing OK out...

Page 20: ... The input voltage corresponding to level 1 is between 18 V and 30 V 3 3 SPECIFICATION OF THE AOK RELAY OUTPUT Relay contact open if any fault except for the Undervolt fault Pmax 10 W with Umax 50 V and Imax 100 mA 100K 16K 100K 100K 16K X2 17 CV 100K X2 16 CV 1nF 1nF 20K X2 15 GND X2 3 ILIM 10K X2 25 GND 18K 100K 2 2nF 10K Logic input 100 nF 0 V 5 V 8 2 k 100 kΩ 10 kΩ ...

Page 21: ... encoder marker pulse Z 19 Channel A Differential input of the encoder channel A 6 Channel A Differential input of the encoder channel A 20 Channel B Differential input of the encoder channel B 7 Channel B Differential input of the encoder channel B 8 5 V Encoder supply voltage 300 mA max current 21 GND Encoder supply GND 11 HALL U Hall sensor input signal phase U 24 HALL V Hall sensor input signa...

Page 22: ...Cos encoder reference pulse R 14 Channel A Differential input of the Sin Cos encoder channel A 1 Channel A Differential input of the Sin Cos encoder channel A 15 Channel B Differential input of the Sin Cos encoder channel B 2 Channel B Differential input of the Sin Cos encoder channel B 8 5V Encoder supply voltage 300 mA max current 21 GND Encoder supply GND 11 HALL U Hall sensor input signal phas...

Page 23: ... R Differential input of the Sin Cos encoder reference pulse R 14 Channel A Differential input of the Sin Cos encoder channel A 1 Channel A Differential input of the Sin Cos encoder channel A 15 Channel B Differential input of the Sin Cos encoder channel B 2 Channel B Differential input of the Sin Cos encoder channel B 16 Channel C Differential input of the Sin Cos encoder channel C 3 Channel C Di...

Page 24: ...corresponding X3 connector pin functions are described below PIN FUNCTION REMARKS 19 PULSE Differential input of the PULSE channel 6 PULSE Differential input of the PULSE channel 20 DIR A Differential input of the DIR channel 7 DIR Differential input of the DIR channel others reserved SPECIFICATION OF THE PULSE AND DIRECTION SIGNALS X3 1 2 13 X3 14 15 25 20K 120R 20K 20K 20K Uref X3 3 4 X3 16 17 2...

Page 25: ...10 pins male connector with 10 16 mm pitch Female connectors supplied in 2 parts 7 pins female pins 1 to 7 and 3 pins female pins 8 to 10 for the motor Fastening torque of the connector screws 0 5 Nm PIN SIGNAL I O FUNCTION DESCRIPTION 1 RB O Power feedback during the motor deceleration with high inertia and speed CD1 a 230 I 100 Ohms 100W dp 100 100 CD1 a 400 1 8 to 7 2 200 Ohms 100W dp 200 100 C...

Page 26: ...apulsCD1 a Chapter 4 Connections 1 CONNECTION DIAGRAMS 1 1 XTRAPULS CD1 a 230 I DRIVE For the UL certified connection see chapter 4 section 3 4 The protection on source side of both 24 V and power supplies must be made by the user ...

Page 27: ... 4 section 3 5 for the UL compliant connection The protection on source side of both 24 V and power supplies must be made by the user 1 3 SERIAL LINK CONNECTION PC Serial port 360 shield connection Sub D 9 pins female Sub D 9 pins female RxD 2 TxD 3 GND 5 5 GND 2 RxD 3 TxD CD1 a X5 ...

Page 28: ...ep the drive on during i e a long 3 days week end or during a mains cut off without losing the machine initialization This backup method is very interesting for saving the machine initialization as well as the axis position even when moving with the mains switched off An ASCII command allows sending the axis position to the digital host system 1 5 CONNECTION EXAMPLE FOR A MULTIAXIS APPLICATION ...

Page 29: ...ed only if these loops have a very low impedance 0 1 Any shield that is not used as a conductor can be connected at both ends under the condition to be connected over 360 at both ends by means of metal links in order to ensure the shield continuity The preferred reference potential must be the earth Cables with low potential should never run in the proximity of power lines If there is a potential ...

Page 30: ...S SHIELD CONNECTION RULE The shield should never be interrupted or corrupted over the whole cable length NOTE When the 360 shield connection is made by means of a collar it is not necessary to connect a cable on the appropriate pin of the SUB D connector ...

Page 31: ...t must be connected at one end to the GND pin of the connector on the drive side with a connection as short as possible Check that the voltage drop in the power supply lines of the encoder cable is complying with the technical specifications of the encoder The voltage drop value for a given cable is calculated as follows 10 40 6 mm S mA I m L V U C with U voltage drop in volts Lc cable length in m...

Page 32: ...Heating of the power module the motor and the cable High overvoltage on the motor windings involving a shortening of their life time The reactance reduces the undesirable effects on motor and drive but it may be quite heated This requires an appropriate cooling 2 5 INPUT COMMAND AND SERIAL LINK CABLES The analog input command signal CV requires a pair twisted and shielded cable The shield must hav...

Page 33: ...iliary supply input protected by a 4 A UL listed fuse 3 3 POWER SUPPLY AND UL FUSE RATINGS The fuse type recommended for motor applications is class RK5 The maximum short circuit power of the mains must not exceed 5000 Arms at a voltage of 480 V when protected by a UL fuse of type RK5 and A60Q40 for 400 70 and 400 90 ratings On XtrapulsCD1a 400 I drives the fuse ratings must be the following CD1 a...

Page 34: ...ding to the table in section 3 3 of this chapter IMPORTANT The installer of the drives has to use a UL listed quick connect for ground connection 0 250 inches or 6 35 mm wide nominal Field wiring terminals must use copper conductors only Torque value for field wiring terminals according to the Recognized terminal block used ...

Page 35: ...ding to the table in section 3 3 of this chapter IMPORTANT The installer of the drives has to use a UL listed quick connect for ground connection 0 250 inches or 6 35 mm wide nominal Field wiring terminals must use copper conductors only Torque value for field wiring terminals according to the Recognized terminal block used ...

Page 36: ...36 Chapter 4 Connections XtrapulsCD1 a 3 6 CONNECTION EXAMPLE FOR A UL COMPLIANT MULTIAXIS APPLICATION ...

Page 37: ...nfranor com for downloading the VISUAL DRIVE SETUP software WARNING The auto tuning procedure should be executed by the PC in control mode and at standstill If the auto tuning procedure must be executed with the drive controlled by the analog command input CV the value of the input command MUST be 0 Volt It is the user s responsibility to take all necessary steps in order to reduce the risk due to...

Page 38: ...undings and 360 shield connections 2 2 SWITCH ON THE 24 VDC SUPPLY The green front panel ON Led must light up The Undervolt fault must be displayed The AOK relay contact pins 18 and 19 of X2 is closed It is then possible to control the power relay according to the recommendations of Chapter 4 section 1 Connection diagrams Connection according to X8 sticker 2 3 SWITCH ON THE 230 VAC OR 400 VAC SUPP...

Page 39: ...ter value is correct If the motor HES are not working correctly select the appropriate Incremental encoder type without HES in the Feedback configuration menu and start the drive commissioning in this configuration If the motor is using an absolute single turn Sin Cos encoder Heidenhain ERN 1085 or compliant check that the ENABLE input is disabled and the drive turned on and move the motor manuall...

Page 40: ...ections in Digital speed input command mode If necessary readjust the speed regulator parameters by means of the Stability button 3 4 PARAMETERS ADJUSTMENT TO A LINEAR MOTOR The Motor encoder resolution parameter is calculated as described below The motor Maximum speed parameter value in rpm is calculated according to following formula The linear speed value in m s is calculated according to follo...

Page 41: ...EPROM 3 7 MOTOR PHASING AT POWER UP In the Incremental encoder configuration without HES the motor Phasing procedure must be executed according to the following diagram at each drive power up The analog output on the X3 connector can be configured in the Setup menu of the VISUAL DRIVE SETUP software in order to get the Phasing OK output signal output voltage from 0 V to 10 V when the motor phasing...

Page 42: ...GEARING APPLICATION The software gearing application requires the use of the drive second position sensor for measuring the displacements of the master axis If the motor is equipped with a resolver select the encoder type for the input of the second sensor in the Encoder input configuration part of the Position sensor configuration window When using a master SinCos encoder adjust the Position scal...

Page 43: ...he master axis check the CV0 input It must be disabled If there is a loud noise in the motor during the axis motion set at 0 the Feedforward acceleration gain If using a SinCos master encoder check also that the Pulse interpolation command is enabled in the Second sensor window If the motion direction is not correct select the Reverse position command in the Second sensor window or the Reverse mov...

Page 44: ... execution of the AUTO TUNING function the procedure has failed because of an external cause and the calculated parameters are wrong Check that the ENABLE input is open Check that the limit switch inputs are not active Then check that the motor shaft is free during the procedure If the BUSY fault is continuously displayed after the execution of the OFFSET COMPENSATION function the offset is exceed...

Page 45: ...3 inputs of the X9 connector If the failure occurs during the operation Check the braking system during the deceleration phases Check the sizing of the braking resistor with regard to the motor deceleration phases Check the drive current cycle with regard to the current table see chapter 2 section 1 Check for no short circuit in the motor wiring and at the motor terminals Check for no short circui...

Page 46: ...per revolution Check that the Motor encoder resolution and the Zero mark pitch parameter values are correct Check that the number of encoder pulses between two successive Z marker pulses is equal to the Motor encoder resolution value multiplied by the Zero mark pitch parameter value If this condition is not fulfilled the encoder counting protection must be disabled in order to cancel the Counting ...

Page 47: ...meter must be set at 15 In this case the encoder counting protection is checking that the encoder measured position has always got the same value when the R reference signal is activated no position measurement drift Remark In the Sin Cos encoder configuration without HES the motor Phasing procedure must be executed again after a Counting fault release 1 11 HES FAULT For the Incremental encoder HE...

Page 48: ...e value of the parameter Speed following error threshold is complying with the operation cycle If necessary increase the value of this parameter Drive in POSITION MODE The FOLLOWING ERROR fault corresponds to a following error of the position loop Check that the load is adjusted to motor and drive types Reduce the accelerations decelerations Check that the axis is not positioned on a mechanical st...

Page 49: ...s on motor side and drive side 2 7 LOUD NOISE IN THE MOTOR AT STANDSTILL AND WHEN RUNNING Check the rigidity of the mechanical transmission chain between motor and load backlash and elasticity in the gears and couplings Execute the AUTOTUNING command again by choosing a lower bandwidth Medium or Low If the problem remains renew the AUTO TUNING procedure by activating the antiresonance filter Filte...

Page 50: ...apulsCD1 a Chapter 8 Appendix Chapter 8 Appendix 1 HARDWARE ADJUSTMENTS All hardware adjustments of the XtrapulsCD1 a drive module are located on the hardware location diagram below HARDWARE LOCATION DIAGRAM ...

Page 51: ...ameter allows entering the ohmic value kOhm of the sensor corresponding to the desired temperature value for the triggering of the T motor protection The Motor T warning threshold parameter allows entering the ohmic value kOhm corresponding to the desired temperature value for the warning of the T motor protection When the warning temperature is reached the fault is displayed on the drive front pa...

Page 52: ...tion before release of the blinking display is depending on the value of the parameters Rated current and Max current This value is calculated as follows T dyn second t1 t0 3 3 x Rated current A Max current A 2 The maximum current duration before limitation at the rated current is also depending on the value of the Rated current and Maximum current parameters This value is calculated as follows T ...

Page 53: ...ncoder resolution value multiplied by the Zero mark pitch parameter value The encoder counting protection is also checking that the encoder pulses frequency is lower than 1 5 times the maximum encoder frequency The maximum encoder frequency is calculated in the drive according to the Motor encoder resolution parameter value and the Maximum speed parameter value The Motor encoder resolution paramet...

Page 54: ...d speed gain 0 for getting a positioning without overshooting in Stepper motor emulation applications a very low threshold of the Following error threshold parameter can nevertheless be adjusted in order to detect the smallest error on the axis 4 USE OF THE LIMIT SWITCH INPUTS Response time 500 µs During the drive operation in speed mode CI logic input inactive or in torque mode CI logic input act...

Page 55: ...y contact as described in chapter 3 section 3 3 in order to allow the power voltage being switched on after the initialization phase Remark The Undervolt fault can be configured in the Setup menu of the VISUAL DRIVE SETUP software to open the AOK relay contact 7 USE OF THE RESET INPUT If the position initialization references must be kept when a stored fault is released on the drive or when the po...

Page 56: ...order to avoid oscillations of 1 encoder edge on channels A and B The value 4095 corresponds to 1 16 of the motor shaft revolution The Zero pulse origin shift parameter allows shifting the marker pulse position on channel Z with regard to the resolver zero position The value 32767 corresponds to one motor shaft revolution The marker pulse width is equal to 1 4 of the A and B channels period 11 USE...

Page 57: ...s This term allows reducing the viscous frictions effect during the motor acceleration and deceleration phases The gain value is equal to the damping gain value the viscous friction compensation term After the auto tuning procedure the feedforward speed 2 gain is set equal to the damping gain value if minimum following error is required The viscous friction compensation term can be calculated by m...

Page 58: ... during the entire motor displacement 13 DRIVE ADDRESSING VIA RS 232 The XtrapulsCD1 a drives allow a multi axis connection with a host PC via the RS 232 serial link according to following connection diagram The connection of the various units host PC and drives is made as a ring the transmission signal TxD of each unit is connected to the reception signal RxD of the next unit Each XtrapulsCD1 a d...

Page 59: ...r than 1 are required Xtrapuls CD1 drives must get the factory set cogging compensation option reference CD1a U I CT Check for the presence of the cogging compensation option CT CD1 in the VDSetup Hardware option menu In this case the Cogging torque compensation menu can be selected in the Servo loop module The cogging torque acquisition procedure is started by means of the Start button The motor ...

Page 60: ...the braking resistor is ALWAYS mounted outside It MUST be mounted out of range of heat sensitive and inflammable elements plastic cable sleeves etc For an optimum power feedback by the drives in a multiaxis application the DC bus DC and DC can be parallel connected see diagram in chapter 4 section 1 5 In this case the mains input must also be parallel wired in order to balance the current load ins...

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