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Chapter 2 - Commissioning

XtrapulsCD1-pm - User manual

Chapter 2 - Commissioning

WARNING

During the machine adjustments, some drive connection or parameterization errors may involve

dangerous axis movements. It is the user's responsibility to take all necessary steps in order to

reduce the risk due to uncontrolled axis movements during the operator's presence in the

concerned area.

– COMMISSIONING OVERVIEW

The various stages of a first positioner commissioning are described below:

Both operation stages are:

The positioner parameters are accessible via:

- the serial link and the PC parameterization software,
- or by the PKW of the PROFIBUS DP.

CAUTION !
Do not make the drive parameterization by means of both PC software and Profibus at the same time.

SERVO CONTROL ADJUSTMENT

(chapter 2 section 8)

MOTOR ADJUSTMENT

(chapter 2 section 7)

CONFIGURATION

(chapter 4 section 2)

PROFIBUS COMMUNICATION

(PROFIBUS communication profile

manual)

- Current regulator adjustment.
- Definition of the current limitations and of the I

t protection.

- Adjustment of the motor control parameters.
- Speed limitation definition.
- Rotation direction.

- Adjustment of the servo control parameters according to the
load.

- Definition of the resolution.
- Limit switches.
- Following error.

PROFIBUS operation mode :
- Communication start between PLC and positioner.

PROGRAMMATION

(chapter 4 section 3)

PROFIBUS OPERATION

(PROFIBUS communication profile

manual)

- Sequences programmation.

PROFIBUS operation mode :
- "Operational" phase: sequences execution by Profibus.

Summary of Contents for XtrapulsCD1-pm

Page 1: ...1 XtrapulsCD1 pm User manual PROFIBUS POSITIONER ...

Page 2: ...2 XtrapulsCD1 pm User manual Windows is a registered trade mark of MICROSOFT CORPORATION STEP7 is a registered trade mark of SIEMENS ...

Page 3: ...utes after power down before handling the amplifiers a residual voltage of several hundreds of volts may remain during a few minutes ESD INFORMATION ElectroStatic Discharge INFRANOR amplifiers are conceived to be best protected against electrostatic discharges However some components are particularly sensitive and may be damaged if the amplifiers are not properly stored and handled STORAGE The amp...

Page 4: ...ategory Waste management Packaging Cardboard Recyclable waste Waste disposal centre collection point of recyclable waste Documents Paper Recyclable waste Waste disposal centre collection point of recyclable waste Mechanics Metal Recyclable waste Waste disposal centre metal collection point Heatsinks Metal Recyclable waste Waste disposal centre metal collection point Electronical boards and compone...

Page 5: ...NEAR MOTOR 13 7 5 MAXIMUM APPLICATION SPEED 13 7 6 CONFIGURATION OF THE THERMAL SENSOR 13 7 7 I2t PROTECTION 14 8 SERVO LOOP ADJUSTMENT 15 8 1 REGULATOR PARAMETERS 15 8 2 LOOP ADJUSTMENT WITH A VERTICAL LOAD 16 9 ROTATION COUNTING DIRECTION 16 10 PARAMETER SAVING 16 11 MOTOR PHASING AT POWER ON 17 12 INCREMENTAL ENCODER OUTPUTS 17 13 POSITION LOOP SETUP 18 14 APPLICATIONS WITH THE SECOND SENSOR IN...

Page 6: ... 40 1 DIAGNOSTICS 40 1 1 XtrapulsCD1 pm FAULT LEDs 40 1 2 FAULT RESET 40 2 FAULT FINDING 40 2 1 SYSTEM FAULT 40 2 2 NON STORED FAULTS 40 2 3 STORED FAULTS 40 3 OPERATING PROBLEMS 45 3 1 MOTOR DOES NOT MOVE 45 3 2 MOTOR SUPPLIED BUT NO TORQUE 45 3 3 SHAFT LOCKED ERATIC OSCILLATIONS OR ROTATION AT MAXIMUM SPEED 45 3 4 DISCONTINUOUS MOTOR ROTATION WITH ZERO TORQUE POSITIONS 45 3 5 LOUD CRACKLING NOIS...

Page 7: ... by means of micro switches accessible by the operator 1 1 PROFIBUS MODE WITH SOFTWARE ADDRESSING This mode is activated by the 00 micro switches selection This operation mode is fully compliant with the CD1 p positioner The positioner Profibus address is saved into a non volatile memory EEPROM This EEPROM can be modified via Profibus message Set_Slave_Add by a Profibus master of class 2 The new a...

Page 8: ...enerally proportional to the current amplitude Speed loop Speed regulator Allows the motor speed control with a speed input command Position loop Position regulator Allows the motor position control Positioner Positioner with position loop and trajectory generator that allows positioning Trajectory generator Generates a speed profile acceleration step speed deceleration that allows positioning sta...

Page 9: ... Do not make the drive parameterization by means of both PC software and Profibus at the same time SERVO CONTROL ADJUSTMENT chapter 2 section 8 MOTOR ADJUSTMENT chapter 2 section 7 CONFIGURATION chapter 4 section 2 PROFIBUS COMMUNICATION PROFIBUS communication profile manual Current regulator adjustment Definition of the current limitations and of the I2 t protection Adjustment of the motor contro...

Page 10: ...F Stand alone Mode without VT100 Drive used in Positioner mode via inputs START STOP IN1 to IN6 X1111110 7E Stand alone Mode with VT100 Drive used in Positioner mode via inputs START STOP IN1 to IN6 Possible use of a VT100 terminal X Cursor unused Remark The positioner automatic procedure for the commissioning phase autophasing autotuning cogging torque acquisition cannot be started in the stand a...

Page 11: ...tor over one revolution or one pole pitch on linear motors If the HES error is displayed switch off the amplifier and check the following points before switching it on again The Hall effect sensors HES must be correctly connected on the amplifier X3 connector if 60 Hall sensor types are used check the various wiring combination of the HES signals for finding the right wiring order Check for the co...

Page 12: ...trapulsCD1 pm amplifier range allows the detection of pulse counting errors and immediately disables the amplifier for reasons of security The encoder counting protection checks that the number of encoder pulses between to successive Z marker pulses or R reference signals is equal to the value of the Motor encoder resolution parameter multiplied by the one of the Zero mark pitch parameter The enco...

Page 13: ...x speed parameter value is changed all speed set point values are scaled accordingly 7 6 CONFIGURATION OF THE THERMAL SENSOR According to the selected position feedback sensor of the motor the thermal sensor is entering either the X1 connector resolver or the X3 connector encoder 7 6 1 SELECTION OF THE SENSOR TYPE The motor can be equipped either with a CTN sensor ohmic resistance decreasing tempe...

Page 14: ...m If the RMS current I2 t has not dropped below 85 of the rated current within 1 second the I2 t error is released and the amplifier disabled otherwise the blinking is inhibited t3 in the diagram When the amplifier output RMS current I2 t reaches the rated current value the I2 t limits the amplifier output current at this value t2 in the diagram Diagram of the amplifier output current limitation i...

Page 15: ...release of the blinking display t1 t0 and before limitation at the rated current t2 t0 is calculated the same way as in the Fusing mode 8 SERVO LOOP ADJUSTMENT 8 1 REGULATOR PARAMETERS The Autotuning procedure identifies the motor and load specifications and calculates the speed position loop parameters In P and PI speed mode only the speed loop gains are calculated In PI2 speed mode the proportio...

Page 16: ...ted manually Set the Feedforward speed 1 gain value at 1 in order to avoid a high following error value 8 2 LOOP ADJUSTMENT WITH A VERTICAL LOAD In the case of an axis with vertical load proceed as follows Select the Limiting current limitation mode Initialize the speed loop gains corresponding to the unloaded motor execute therefore the Autotuning procedure with the motor uncoupled from its mecha...

Page 17: ...r or the encoder parameter value The analog output on the X2 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 is OK In the Profibus mode the Phasing OK can be checked by the master controller PNU 897 In the Software control mode via the serial link the state of the Ph...

Page 18: ...p menu Check that Enable second sensor feedback is not selected in order to use the motor position sensor resolver or encoder for feedback Set the Position resolution parameter according to the desired position scaling of the load in order to display the position in the load units as described below Position resolution number of desired load position increments for one motor revolution Ex one moto...

Page 19: ... load if the load position must be displayed in mm with a resolution of 1 m choose Position resolution 3302 Decimal number 3 and Unit mm Remark In the second sensor feedback configuration the servo loop stability is affected by a wrong Position resolution parameter value Set at 0 the value of the Position deadband parameter This parameter is only useful in applications with high transmission backl...

Page 20: ...ion Setup menu Check that Enable second sensor feedback is not selected Set the Position resolution parameter according to the desired position scaling of the load in order to display the position in the load units as described below Position resolution number of desired load position increments for one motor shaft revolution Enter the desired Decimal number and the Unit for the position display E...

Page 21: ... stator teeth For a given motor the cogging can be easily evaluated by simply moving the motor manually when the amplifier is disabled The Cogging compensation option available in the XtrapulsCD1 amplifier range allows cancelling the motor cogging effects for specific applications where torque accuracy or force accuracy higher than 1 is required XtrapulsCD1 amplifiers must be factory set for getti...

Page 22: ...emory the EEPROM error is displayed and the Enable cogging torque compensation function is disabled Note 2 When exchanging an amplifier on an axis the file of the adjustment parameters PAR as well as the cogging torque file COG corresponding to the motor must be uploaded once again in the amplifier Note 3 When exchanging the motor or when disassembling the resolver sensor the acquisition procedure...

Page 23: ...account after the end of the former sequence This signal can be disabled before the end of the sequence STOP This input stops the motor with the deceleration given by the JOG motion parameters IN1 to IN6 These inputs allow defining in natural binary code the number of the sequence to be executed Sequence control configuration The activation of the START input will execute the sequence defined by t...

Page 24: ...us Various triggering types BEGIN SPEED POS HOLD END These outputs can be triggered only once per programmed sequence 2 LIMIT SWITCHES ADJUSTMENT The limit switch inputs are inputs for a proximity sensor that stops the motor with maximum deceleration When both limit switches are correctly placed on the motor travel they are a protection for the machine in case of incorrect movement The limit switc...

Page 25: ... be modified by the serial RS 232 link PC parameterization software The new address must be saved in the EEPROM and the positioner must be switched on again in order to get the new address operational or by a Profibus class 2 master device The address modification is only possible when the bus is not running In this case the address will be automatically saved in the positioner EEPROM and will be ...

Page 26: ... inputs START STOP IN1 to IN6 can be activated either via the PROFIBUS or by using the hardware inputs on the X2 connector The inputs source configuration is saved in the amplifier EEPROM In the Profibus operation mode all logic outputs SEQ POS SPEED OUT1 to OUT8 can be read via PROFIBUS 2 POSITIONER CONFIGURATION 2 1 POSITION SCALING Position resolution defines the number of position increments f...

Page 27: ...r threshold parameter value When the measured position error is exceeding the following error threshold the position following error is released This configuration is used for applications requiring the smallest possible following error When Relative to dynamic model is selected the following error protection is operating as described below The measured position error value is continuously compare...

Page 28: ...The brake off delay value must be higher than the amplifier servo loop response time Note The brake ON and OFF delays are not valid for the stand alone operation mode ENABLE input desactivation and fault reaction defines the amplifier behaviour when the ENABLE input is desactivated or when an amplifier fault is triggered When Switch off is selected the amplifier is immediately disabled and the mot...

Page 29: ...14 value is not considered Analog input reversal when this command is selected there is no limitation for 0 Volt on the analog input and full limitation for 10 Volts When this command is not selected full limitation is for 0 Volt Note 1 The cut off frequency value for the low pass filter on the analog input is defined by the parameter Analog Input low pass filter in the Controller parameters windo...

Page 30: ...e second sensor input for electronic gearing or second sensor feedback applications Reverse position when selected this command allows reversing the counting direction on the second sensor input Pulse interpolation this command is selected when the second sensor is a SinCos encoder type 2 9 PROFIBUS COMMUNICATION Address defines the software address 1 to 125 for the Profibus software adressing ope...

Page 31: ...delay time in ms at the end of the positioning For a SPEED sequence this parameter defines the motor running time in ms at the speed set point value If this parameter value exceeds 16000 ms then a sequence stop condition can be used to leave the speed control sequence For a TORQUE sequence this parameter defines the torque holding time in ms when the torque set point value has been reached If this...

Page 32: ...l otherwise the motor will be stopped after the braking Reset Load the position reset value in the position counter at the home position Homing procedure diagram If Switch 1 and Zero 1 or Home 1 the speed can be reversed by the switch detection or by a limit switch In the configuration Switch 0 and Zero 1 if the limit switch in the searching direction is activated at the homing sequence starting t...

Page 33: ...hout stopping the deceleration ramp of the first sequence is 0 Note For a small displacement when the programmed motion speed value cannot be reached the motion speed profile is modified according to the Profile limit parameter selection When Constant time is selected the trajectory acceleration and deceleration are reduced and the profile is calculated according to the programmed acceleration and...

Page 34: ...peed set point value until the current rises up to the limit value defined in percentage of the Maximum current parameter value The motor running direction depends on the sign of the speed set point When the current limitation is reached the amplifier is holding this current during the time interval defined by the Delay time parameter If the Delay time exceeds 16000 ms the torque holding time is i...

Page 35: ...nd sensor position master up to the output position value The output position value is equal to the gearing sequence start position the distance parameter value When the output position is reached the motor is stopped according to the deceleration parameter value If the deceleration parameter value is set at 0 the next sequence is immediately executed The acceleration and deceleration times parame...

Page 36: ...ted the programme will be the following Sequence 1 Start of sequence 1 then connection to sequence 2 parameter Next sequence First execution of sequence 2 then connection to sequence 1 parameter Jump Execution of sequence 1 then connection to sequence 2 parameter Next sequence Second execution of sequence 2 then connection to sequence 3 parameter Next sequence Execution of sequence 3 then end of t...

Page 37: ...ivated The inputs can be used either as a sequence start condition or as a sequence stop condition When Stop is desactivated the logic inputs are used as a sequence start condition for any sequence type The Stop selection allows the use of the logic inputs as a sequence stop condition A sequence stop condition is only valid for a SPEED or TORQUE sequence when the delay time value is higher than 16...

Page 38: ...ecution according to the limitation value if Enable speed modulation is selected For the HOME SPEED and TORQUE sequences the programmed speed is limited over the whole sequence execution according to the limitation value at the sequence start When Enable analog input is selected the limitation is provided by the analog input voltage value If Enable analog input command is not selected the limitati...

Page 39: ... 5 Parameterization by Profibus 39 XtrapulsCD1 pm User manual Chapter 5 PROFIBUS communication For the commissioning of the PROFIBUS communication please see manual XtrapulsCD1pm PROFIBUS Communication Profile ...

Page 40: ... of the CD1updater software Check for no conducting dust that may involve short circuits on the amplifier logic board 2 2 NON STORED FAULTS 2 2 1 BUS FAULT Profibus This fault is only displayed when the Profibus communication is interrupted The fault is cancelled as soon as the communication is restored 2 2 2 UNDERVOLT FAULT If the fault occurs at the positioner commissioning Check that the power ...

Page 41: ...ree during the procedure If the BUSY fault is continuously displayed after the execution of the COGGING TORQUE ACQUISITION procedure the procedure has failed because of an external cause and the cogging torque acquisition is not valid Check that the ENABLE input is activated Check that the limit switch inputs are not activated Check that the encoder is providing one marker pulse per motor revoluti...

Page 42: ... correct resolver type with regard to the amplifier specifications Check the connections between the resolver and the amplifier 2 3 6 R D C FAULT If the failure occurs when starting the amplifier Check for the correct resolver type with regard to the amplifier specifications If the failure occurs during the operation Check that the connections between the resolver and the amplifier are complying w...

Page 43: ...ans of the parameter Zero mark pitch set at 0 For a linear motor with only one marker pulse over the whole motor travelling range the parameter Zero mark pitch must be set at 15 In this case the encoder counting protection is checking that the measured encoder position has always got the same value when the marker pulse is activated no position measurement drift Note In the TTL incremental encoder...

Page 44: ...ou must check the various wiring combinations to find the right wiring order Check for the correct HES supply voltage value Check for the correct Motor encoder resolution parameter value Check that the HES amplifier motor ground connections and shield answer the requirements of chapter 4 of the XtrapulsCD1 pm Installation Guide For the Absolute single turn Sin Cos encoder configuration Check that ...

Page 45: ...hat the power supply is on Check the motor connection Check the logic wiring of the signals FC FC and ENABLE Check that the positioner is enabled 3 2 MOTOR SUPPLIED BUT NO TORQUE Check that the Maximum current and Rated current parameters have no zero value 3 3 SHAFT LOCKED ERATIC OSCILLATIONS OR ROTATION AT MAXIMUM SPEED Check the resolver or encoder wiring on the amplifier connector as well as t...

Page 46: ...ses If after power on the operator wants to start a positioning sequence whereas sequence 0 is a homing sequence that is not yet executed A start condition has been defined for this sequence and is not fulfilled One or two limit switches are activated 4 SERVICE AND MAINTENANCE When exchanging a positioner on a machine proceed as follows Check that the new positioner has got the same voltage and cu...

Page 47: ...uired Feedforward speed 1 gain KF1 defines the feedforward speed amplitude corresponding to the speed input command This term allows reducing the following error during the motor acceleration and deceleration phases Its value is set at 1 after the auto tuning procedure if a following error as small as possible is required It can then be modified by the user if required Feedforward speed 2 gain KF2...

Page 48: ...forward gain values are set at 0 and the motor position is lagging with regard to the position reference value during the whole motor displacement 2 USE OF THE SERIAL LINK 2 1 OVERVIEW Specifications of the serial link 8 data bits 1 stop bit no parity 19200 baud The parameters can be sent to the amplifier by an ASCII terminal using the instructions list given in this section Each instruction is co...

Page 49: ...is no sequence executed The sequence must exist Unit The unit of the position value is defined by position resolution and decimal number parameter values for the display in the PC software However via the ascii instruction the position value must be sent without the decimal point Example position resolution 5000 decimal number 3 unit mm If the user wants to set a value 100 mm to sequence 3 the ins...

Page 50: ...uence is executed The sequence must exist Unit Millisecond Range 16 ms 16000 ms Note The parameters acceleration time and deceleration time define the time with regard to the maximum speed parameter value When the motion speed is lower than the maximum speed the trajectory acceleration and deceleration times are proportionally reduced Remark The parameter modification takes effect immediately but ...

Page 51: ...ns Enable and Run signals are activated Note Unit See modify position of a sequence Speed absolute move Instruction DS Defines the speed for an absolute movement MP Parameters Speed Conditions Note This parameter is saved in the positioner memory When the maximum speed parameter value is changed this parameter value is scaled accordingly Unit rpm Acceleration absolute move Instruction DA defines t...

Page 52: ...d Note This command is not operating in the Stand alone operation mode Software Disable Instruction AR Parameter No parameter Condition Positioner in local mode Profibus operation mode selected and Profibus control desactivated Note This command is not operating in the Stand alone operation mode 3 USE OF THE VT 100 TERMINAL A VT 100 terminal can be connected to the serial link of the amplifier X5 ...

Page 53: ...programmed speed 3 To start a sequence the operator enters the number of the sequence to be executed 4 To move until a position the operator enters the position and moves the motor until this position 3 2 2 POSITION DISPLAY The arrow keys allow moving the motor Jog or Jog when the ENABLE signal is activated The key allows the operator getting back to the main menu In this window the operator can s...

Page 54: ... or the torque of a given sequence in the same way The previous sequence modifications can be saved in the positioner memory as follows 3 2 4 EXECUTION OF A SEQUENCE When the positioner is not executing any sequence and when the ENABLE signal is activated the operator can enter the number of a sequence to be executed MODIFY SPEED Sequence 1 Speed 1øøø Speed _ RUN SEQUENCE Sequence _ MODIFY SEQUENC...

Page 55: ...iting 4 Homing time out 5 EEPROM cogging checksum 6 EEPROM parameters writing 10 I t 11 Position counting 12 Position following error 13 Bus error 14 Busy procedure error 20 Power overvoltage 21 24 Vdc out of range 22 Phase earth short circuit 23 Braking resistor 24 Fan 25 Holding brake 28 Hall effect sensors Com channel 30 IGBT 32 Position sensor 33 Motor overtemperature 35 Power voltage initiali...

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