Hiwin D1-N Series Assembly And Commissioning Instructions Download

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Assembly and

Commissioning Instructions

D1-N Servo Drive Amplifier

with EtherCAT® and

Safe Torque Off (STO) Safety Function

Version: 1.05
As of: 05.10.2015

Summary of Contents for D1-N Series

Page 1: ...Assembly and Commissioning Instructions D1 N Servo Drive Amplifier with EtherCAT and Safe Torque Off STO Safety Function Version 1 05 As of 05 10 2015 ...

Page 2: ...2 78 90 77654 Offenburg E Mail support hiwin de Technical customer service Tel 49 0 781 9 32 78 77 These assembly and commissioning instructions are protected by copyright The written consent of HIWIN GmbH is required for reproduction publication in part or in whole modification or abridgement of these instructions Subject to technical changes ...

Page 3: ...g with energised and live products 14 2 8 Safety notices regarding working with hot surfaces 14 2 9 Technical support 14 3 Product description 15 3 1 Order code 16 3 2 Type plates 17 3 3 Guidelines and standards 18 3 4 Scope of supply 18 3 5 Technical specification 19 4 Assembly 21 4 1 Assembling the drive amplifier 21 4 2 Dimensions 22 4 3 Switch cabinet assembly 25 5 Electrical connection 26 5 1...

Page 4: ...l axes and or external application of force 54 6 5 5 Unintended restart 54 6 5 6 Degree of contamination when using the safety function 54 6 5 7 Protected cable routing 55 6 5 8 Data for maintenance plans and safety calculations 55 6 5 9 Risk analysis 56 6 6 Examples of circuits for the STO function 56 6 7 Safety function certified by TÜV 58 7 EtherCAT 59 7 1 D1 N EtherCAT with CoE protocol 59 7 1...

Page 5: ...ors 124 9 2 3 Frequency analysis automatically adapting control parameters 128 9 2 4 Phase initialisation first commutation 133 9 2 5 SMCL tool 133 9 2 6 LM and TM with EnDat 2 2 135 9 3 Performance center controller parameter optimisation 137 9 4 First travel subject to control 139 9 4 1 Debounce time and Target radius in the Performance center 140 9 5 Using the scope functions 141 9 6 Controller...

Page 6: ... to run on and deleting it 169 11 Troubleshooting 172 11 1 Error codes and troubleshooting 172 11 2 Warnings and troubleshooting 175 11 3 Other errors and troubleshooting 178 12 Repair and replacement 178 13 Parts numbers and accessories 179 13 1 Item number for drive amplifier set 179 13 2 Item number for connector kit 180 13 3 Motor cables 181 13 4 Cables for encoder systems 182 14 Declaration o...

Page 7: ...1 Versions of this document 1 2 Information about the document These assembly and commissioning instructions are intended for planners devel opers and operators of machines and equipment in which Hiwin D1 N servo drive amplifiers are already integrated or are to be used They are also intended for peo ple who perform the following work on or with the D1 N transport assembly electrical connection in...

Page 8: ... amplifiers listed above are combined 1 6 Depiction of safety notices Safety notices are always indicated using a signal word and sometimes also a sym bol for the specific risk see section 1 7 The following signal words and risk levels are used in these instructions DANGER Direct danger Non compliance with the safety notices will result in serious injury or death WARNING Potentially dangerous situ...

Page 9: ...cal voltage Warning of magnetic fields Warning of hot surfaces Substance hazardous to the environment Table 1 2 Warning signs Signs giving orders Wear protective gloves Isolate before work Table 1 3 Signs giving orders Information Note Describes general information and recommendations Table 1 4 Information 1 8 Warranty and liability The General conditions of sale and delivery of HIWIN GmbH apply ...

Page 10: ...These instructions are protected by copyright The written consent of HIWIN GmbH is required for reproduction publication in part or in whole modification or abridgement of these instructions Windows is a registered trademark of the Microsoft Corp EnDat is a registered trademark of Dr Johannes Heidenhain GmbH Beckhoff TwinCAT and EtherCAT are registered and licenced trade marks of Beckhoff Automati...

Page 11: ...mponents The machine manufacturer is obligated to produce a risk assessment for the ma chine This is used as the basis for determining appropriate measures to prevent injury and damage to property resulting from unforeseeable movements The drive amplifiers of the D1 N series can be connected directly to single phase or three phase earthed industrial networks 110 230 V They must not be operat ed in...

Page 12: ...Spare parts and accessories not supplied by HIWIN are not checked for operation with HIWIN drive amplifiers and may restrict operational safety HIWIN assumes no liability for damage caused through use of non approved spare parts and accesso ries 2 3 Qualified trained staff The drive amplifiers may only be fitted integrated in superordinate systems start ed up operated and maintained by qualified t...

Page 13: ...d operated indoors The drive amplifiers should always be operated in conjunction with appro priate safety equipment zero contact protective equipment mechanical protective equipment etc This protective equipment must be designed installed and regularly checked in accordance with applicable national and international legislation and specifications 2 5 Safety notices regarding storing the drive ampl...

Page 14: ...tes before touching live parts e g contacts threaded bolts etc or breaking connections For your own safety measure the voltage in the intermediate circuit and wait until it has fallen below 40 VDC 2 8 Safety notices regarding working with hot surfaces WARNING The surface of the drive amplifier may reach temperatures in excess of 50 C There is therefore a risk of burns The housing must not be touch...

Page 15: ...system also suited to use in time critical motion control applications The D1 N supports the CoE CANoverEthernet protocol and can therefore be inte grated in any EtherCAT master controller which supports this protocol Further more the D1 N works according to the standardised drive profile CiA 402 and can therefore be easily integrated into the TwinCAT control software of Beckhoff as an NC axis In ...

Page 16: ...16 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 3 1 Order code Figure 3 1 Order code for D1 N ...

Page 17: ... There is also another type plate on the front of the device which states the type designation and the device s serial number Figure 3 2 Type plate right hand side of device Figure 3 3 Type plate front Number Description 1 Type designation of drive amplifier 2 HIWIN item number 3 Serial number of device 4 Barcode 5 Electrical properties of the device 6 CE compliant 7 Compliance Functional Safety S...

Page 18: ... IEC 61508 2010 SIL 3 IEC 62061 2005 SILcl 3 IEC 61800 5 2 STO UL Standard UL508C E164620 CSA Standards C22 2 No 14 Table 3 2 Guidelines and standards 3 4 Scope of supply The scope of supply may vary depending on the configuration ordered Before in stallation please check whether all the ordered components have been supplied and whether the goods are damaged If the goods are damaged please contact...

Page 19: ...5 500 mA Analogue encoder Sin Cos 1 VPP Z Z differential max input frequency 1 MHz Digital encoder TTL A A B B Z Z differential only for 13bit encoder max input frequency 5 MHz HIWIN resolver Option EnDat2 2 Standard Hall sensors Digital A B C 120 offset Encoder output Encoder output buffered Forwarding of incoming encoder signals incl quadrupling max 18 000 000 Incr s RS422 differ ential Encoder ...

Page 20: ...ted Brake control 24 VDC max 1 A Capture input Reaction time 7 ns Input PCP CAM output Reaction time 7 ns Output PT 5 VDC DC Bus Overvoltage HV 404 VDC HV 800 VDC Undervoltage HV 60 VDC HV 158 VDC Brake resistor Connection Internal 50 Ω 150 W and or external External only Activation threshold HV 390 VDC HV 735 VDC Deactivation threshold HV 380 VDC HV 695 VDC Tolerance 5 Cooling External heatsink N...

Page 21: ...s drive amplifier has to be mounted on a hard surface and is only mounted us ing the mounting holes provided These are designed for size M4 screws Refer to chapter 4 2 page 22 onwards for the precise dimensions Assembly procedure Produce appropriate mounting holes on the assembly surface if not al ready present Clean assembly surface and position drive amplifiers on it Screw in retaining bolts and...

Page 22: ...22 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 4 2 Dimensions All measurements are in millimeters Figure 4 1 Dimensions of D1 N 09 D1 N 18 ...

Page 23: ...Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 23 183 Figure 4 2 Dimensions of D1 N 36 ...

Page 24: ...24 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 Figure 4 3 Dimensions of D1 N 90 ...

Page 25: ...ng of the drive amplifier Conductive screws should be used for this purpose The assembly surface may have to be treated to produce a low ohm electrical connection between the housing and assembly plate in the switch cabinet The following minimum spacing must be observed when assembling several drive amplifiers Figure 4 4 Minimum spacing in switch cabinet ...

Page 26: ...ay be live even if the motor is not moving Never discon nect the electrical connections of motors and drive amplifiers when live In the worst case scenario electric arcs may form causing personal injury and damage to contacts After disconnecting the drive amplifiers from the supply voltages wait at least five minutes before touching live parts e g contacts threaded bolts etc or breaking connection...

Page 27: ... sup plied Figure 5 1 provides an overview of all connections on the D1 N drive amplifi er Figure 5 1 Overview of electrical connections X1 mains connection X13 EtherCAT option X2 brake resistor connection X5 parameterisation interface X6 inputs outputs connection X7 input STO X8 output STO X9 motor temperature sensor X4 control voltage and brake connection X3 motor connection X10 digital encoder ...

Page 28: ... 10 2015 A diagram showing all electrical connections on the D1 N can be seen in Figure 5 2 Please note that the wiring of the inputs and outputs on the X6 connector is shown as NPN switching in this overview Figure 5 2 Diagrammatic overview of electrical connections NPN ...

Page 29: ...ier Pin Name 1 L3 2 PE 3 L2 N 4 L1 Table 5 1 X1 mains connection The D1 N does not have an integrated mains filter A suitable mains filter not in cluded in scope of supply must therefore be provided in order to operate the drive amplifier A distinction is made between the single and three phase mains con nection on the D1 N 5 2 1 1 phase mains connection with mains filter Figure 5 3 1 phase mains ...

Page 30: ...mains connection with mains filter Figure 5 4 3 phase mains filter HIWIN recommends the mains filter described in Table 5 3 for the D1 N s 3 phase mains connection Filter Schaffner FN3258 7 45 Maximum continuous voltage 30 480 277 VAC Operating frequency AC up to 60 Hz Rated currents 7 A at 50 C 7 7 A at 40 C Rated power 4 kW Leakage current at 400 V AC 50 Hz 33 mA Overvoltage protection 2 kV IEC ...

Page 31: ...be dissipated via a brake resistor Figure 5 5 contains a diagram of the intermediate circuit in the D1 N Figure 5 5 Intermediate circuit The devices D1 N 09 D1 N 18 and D1 N 36 are fitted with an internal brake re sistor of 50 Ω 150 W The D1 N 90 does not have an internal brake resistance Should high levels of dynamism mean that the D1 N s internal brake resistor is insufficient an additional brak...

Page 32: ...32 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 Figure 5 6 Possible connections on X2 Pin Name 1 DC 2 RGS 3 RGP 4 DC Table 5 4 X2 brake resistor connection ...

Page 33: ...mbly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 33 183 5 3 1 Brake resistor calculation 5 3 2 DCbus capacity of D1 N servo drives D1 N 09 940uF D1 N 18 940uF D1 N 36 1880uF D1 N 90 940uF ...

Page 34: ...nterference can be eliminated only when the motor cable is shielded The motor cable shielding must be connected over a large area to the assembly plate e g Figure 5 7 Figure 5 7 Shield terminal ATTENTION The motor cable without output filter must not exceed a length of 15 m If longer cables are used suitable filters must be fitted to effectively dampen any voltage peaks which arise ...

Page 35: ...A For brakes requiring other voltages or higher currents we would recommend a relay or optocoupler circuit see Figure 5 8 Figure 5 9 and Figure 5 10 You will find more information about the brake configuration in section 8 6 Pin Name Function 1 24 V 24 VDC control voltage 2 BRK Brake connection 3 BRK Brake connection 4 RTN GND 24 VDC Table 5 6 X4 control voltage and motor brake connection Figure 5...

Page 36: ...015 Figure 5 10 Brake control via relay 5 6 X5 parameterisation interface A standard USB interface is provided to set pa rameters for and commission the drive amplifier This takes the form of a mini type B USB bush on the X5 connector Figure 5 11 X5 parameterization interface ...

Page 37: ...igital input 4 programmable 11 I5 Digital input 5 programmable 12 I6 Digital input 6 programmable 13 I7 Digital input 7 programmable 14 I8 Digital input 8 programmable no function with EnDat 2 2 15 I9 Digital input 9 programmable no function with EnDat 2 2 16 I10 Digital input 10 programmable no function with EnDat 2 2 17 COM Selection of switching characteristics for digital inputs I1 to I10 see ...

Page 38: ...ATTENTION Please only use shielded cables for all cables carrying encoder signals This minimises the effect of perturbation and avoids incorrect motor responses 5 7 1 Wiring variants for step direction input on X6 The step direction input on the D1 N can process both differential signals and sin gle ended signals The step direction input must be wired on the X6 connector according to the signal ty...

Page 39: ...ction without external resistor 5 7 2 Switching characteristics of digital inputs on the X6 The switching characteristics of the digital inputs can be defined by their wiring on the X6 connector Either PNP or NPN characteristics can be selected See the dia grams below Figure 5 15 PNP I O switching characteristics ...

Page 40: ...40 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 Figure 5 16 NPN I O switching characteristics ...

Page 41: ...nate controller via the X6 connector Figure 5 17 shows the wiring needed for this Figure 5 17 Encoder output wiring 5 7 4 Wiring of analogue input on X6 The D1 N s analogue input can be used to specify analogue 10 VDC speed and torque nominal values The input has a 12 bit resolution Figure 5 18 shows the wiring of the analogue input on the X6 connector Figure 5 18 Wiring of analogue input ...

Page 42: ...can be found in chapter 6 from page 46 onwards X7 Pin Name Function 1 SF1 Safety input 1 This input deactivates the final stage 2 SF2 3 SF2 Safety input 2 This input deactivates the final stage 4 SF2 5 MO Status feedback contact of STO function 6 MO X8 Pin Name Function 1 SF1 Safety input 1 This input deactivates the final stage 2 SF2 3 SF2 Safety input 2 This input deactivates the final stage 4 S...

Page 43: ...ture sensor For motor temperature monitoring the D1 N provides the option of evaluating both PTC resistors and NTC resistors The temperature sensors are connected to the X9 connector Pin Name Function 1 T Thermal protection contact 2 T Thermal protection contact Table 5 9 X9 motor temperature sensor ...

Page 44: ...gue encoders and EnDat 2 2 HIWIN resolvers Pin Signal 1 A SIN SIN1 2 B COS COS1 3 Z Index SIN2 4 FLT n c AGND 5 5 VDC 5 VDC 5 VDC 6 A SIN SIN1 7 B COS COS1 8 Z Index SIN2 9 Hall A n c COS2 10 Hall B n c COS2 11 Hall C DX Data REF 12 n c DX Data REF 13 n c CLK Clock Index 14 n c CLK Clock Index 15 GND GND GND Table 5 10 X10 X11 X12 encoder connection To avoid EMC faults in the encoder signal the en...

Page 45: ...ng the two RJ45 bushes at the X13 slot the D1 N can be integrated in an EtherCAT network and communicate with an EtherCAT master You will find a de tailed description of the EtherCAT function in chapter 7 Connector Function IN Connector for incoming EtherCAT cable OUT Connector for forwarding EtherCAT cable Table 5 11 X13 EtherCAT ATTENTION For firmware versions 9 055 and later the rear port the o...

Page 46: ... does not have to be interrupted in the process Fur thermore there is no monitoring for standstill Both IEC61800 5 2 and IEC 60204 1 describe various stop categories for machines and systems The stop categories described below can be undertaken with the D1 N Stop category 0 Stopping by immediately 200 ms cutting off the energy to the machine s drive elements This means that an uncontrolled stop is...

Page 47: ...ion has been reset Inputs SF1 and SF2 must be reset to High for this to happen Connections DSF and DSF on the X6 connector must then be connected with one another for 1 second to again enable the STO function The final stage remains blocked if just one of the two outputs has a High status or if the activation time window between the two inputs is exceed ed The error message is automatically acknow...

Page 48: ...and DSF connections on the X6 connector can also be used to deactivate the STO function How ever these two connections must not be perma nently connected with one another during normal operation of the D1 N Figure 6 3 X6 DSF and DSF bridged For regular checks of the STO safety function when operating the D1 N on a su perordinate controller the connector wired for normal operation at X7 and or X8 m...

Page 49: ...8 Pin Name Function 1 SF1 Safety input 1 This input deactivates the final stage 2 SF2 3 SF2 Safety input 2 This input deactivates the final stage 4 SF2 5 MO Status feedback contact of STO function 6 MO Table 6 2 Safety inputs connection at X7 and X8 Low status 3 to 3 VDC High status 10 to 30 VDC Max input current per safety input 5 mA Debounce time 1 ms Time window for activating safety inputs SF1...

Page 50: ...ff On On On Feedback contact of the STO function MO Closed Open Table 6 4 Logic for activation of the STO function The response time of the STO function between activation of inputs SF1 and SF2 and activation of the safety function is 10 ms response time 6 ms To prevent the STO function from activating when not wanted e g due to OSSD signals at the safety inputs signal interrupts lasting 6 ms are ...

Page 51: ...een DSF and DSF at X6 for 1 second Motor is energised Deactivate SF1 and SF2 at the same time D1 N delivers error message E06 motor may be disconnected and motor is de energised Reactivate SF1 and SF2 and establish connection between DSF and DSF at X6 for 1 second Motor is energised To test the function of the safety inputs SF1 and SF2 with 24 VDC the fol lowing power supply can be used If disabli...

Page 52: ...52 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 6 4 1 Timing diagram for activating the STO function Figure 6 6 Timing diagram for activating the STO function ...

Page 53: ... relevant timing for energising the motor 6 5 Preconditions for using the safety function DANGER Electric shock due to incorrect use The STO Safe Torque Off safety function does not result in electrical isolation The DC intermediate circuit voltage is still present even after the safety function has been activated Therefore use a suitable switch to cut off the mains voltage to achieve a voltage fr...

Page 54: ... two safety inputs SF1 and SF2 The two safety inputs are controlled using a standard safety module with safe time delay 6 5 3 Parking brake behaviour When the STO safety function is triggered the braking delay for motors with a parking brake is not effective because when the STO function is active the motor cannot produce any braking torque to bridge the time until the parking brake is closed Chec...

Page 55: ...nd this check must be performed at regular intervals The interval between the individual checks depends on the result of the risk analysis for the entire system The minimum interval is 1 year High Demand Mode according to IEC 61508 Use the data listed below to produce your maintenance plan and for your safety calcu lations Lifetime of the safety function STO IEC 61508 Years 20 SFF IEC 61508 Safe F...

Page 56: ...for the STO function Undertaking a category 0 stop To undertake a category 0 stop no separate safety module is needed A corre sponding example circuit is shown in Figure 6 8 Figure 6 8 Example of circuit for stop category 0 When the emergency stop button is pressed a category 0 emergency stop is per formed Via safety inputs SF1 and SF2 the safety function is activated and the final stage therefore...

Page 57: ...the motor enable at D1 N is removed via the Q1 output of the safety module single channel not monitored As a result the motor is decelerated with the Dec Kill and Smooth factor parameters Once the delay time set on the safety module has passed the STO safety function is activated via the safety module s Q3 and Q4 outputs and the limit stage therefore deactivated No more energy can therefore be sup...

Page 58: ...ime sampling time as described below T smooth factor 8 sampling time Max dec speed T Example Smooth factor 100 sampling time 16 000 speed 400 mm s T 100 8 16000 0 05s Max dec 400 mm s 0 05 s 8000 mm s 6 7 Safety function certified by TÜV The integrated safety function STO Safe Torque Off of the D1 N meets the re quirements of IEC61800 5 2 and has been certified by TÜV Nord Figure 6 10 Seal of TÜV ...

Page 59: ... profile DC synchronous synchronisation methods distributed clock jitter 1 µs Communication cycle time 62 5 µs 16 kHz CiA 402 operation modes The following modes are supported Cyclic Synchronous Position Mode Cyclic Synchronous Velocity Mode 7 1 1 Integration of a D1 N in a TwinCAT project These instructions describe only the settings needed to operate the D1 N at a Beckhoff controller Basic knowl...

Page 60: ...T network must be wired correctly see section 5 11 Figure 7 1 Scanning available devices The message stating that not all available devices can be detected automatically must be acknowledged with OK When all devices have been scanned successfully the input mask depicted in Fig ure 7 2 appears Normally an EtherCAT master with links to slaves is preselected automatically This dialog must be confirme...

Page 61: ...re linked automati cally for this NC axis Figure 7 4 depicts a device that has been integrated correct ly Figure 7 4 Completely linked device Automatically adding a drive s NC axis also configures most of the basic parame ters Only the following parameters need then be configured for operating the axis 7 1 4 Setting the axis resolution The scaling factor for the NC axis must be adjusted to the Lig...

Page 62: ...s 7 1 5 Setting the maximum speed The Lightening limits for speed and acceleration serve to monitor movements and hence contain the maximum dynamic response This limit should be entered analogously for the NC axis Figure 7 6 Figure 7 6 Defining dynamic response limits The limits defined here should always equal the values entered in Lightening However also smaller values may be selected ATTENTION ...

Page 63: ...is greatly simplifies the setting of controller parameters CPU 1 0 GHz or more RAM 512 MB or more Free hard disk memory At least 50 MB Connections USB port Operating system Win 2000 Win XP Win 7 Monitor resolution At least 1024 768 pixels Table 8 1 PC requirements 8 1 Installation of the software To install the Lightening commissioning software run the Setup exe file The desired installation locat...

Page 64: ...d to be installed confirm this message and install the driver This is the driver for the USB interface of the D1 N which is essential to operation Successful installation is confirmed by the following dialogue Figure 8 2 End of installation Lightening is now installed in full and can be launched via the following desktop icon Figure 8 3 Lightening desktop icon ...

Page 65: ...n is complete Lightening can be started If Lightening was already open at the time of driver installation the COM port may not be available This problem can be remedied by restarting the software Now open the Tools tab in the menu and select Communication Setup Figure 8 4 Communication setup All connection parameters for communicating with the device can be set in the following dialogue All import...

Page 66: ...ier D1 N 15 10 2015 Figure 8 5 Setting the communication parameters Confirm your selection with Apply and Close If the connection has been estab lished successfully it will look like this in the status bar Figure 8 6 Confirmation of connection in the status bar ...

Page 67: ...e confirmed with the Enter button other wise the change does not take effect Example Figure 8 7 Original value Highlight field and enter new desired value Figure 8 8 New value not confirmed Confirm value entered with the Enter button Figure 8 9 New value confirmed and active ATTENTION All changes are written to the RAM and are lost once the drive amplifier is reset restarted To permanently save ch...

Page 68: ...ctions Servo amplifier D1 N 15 10 2015 The following screenshot shows the main operating interface of the Lightening software Figure 8 11 Main operating interface Variable rapid access Errors and warnings Device status Main operating toolbar ...

Page 69: ... mode Auto phase center motor commissioning with setup of commutation settings and direction of counting Performance center interface for drive procedure for commissioning and controller tuning Advanced gains menu for setting the controller parameters and set ting filters Application center settings for homing backlash compensation error mapping and resolver Protection center limit value settings ...

Page 70: ...ollection recording of parameter values in real time Scope oscilloscope for evaluating travel behaviour and controller set ting Encoder test tune testing encoder function at analogue sine cosine en coders PDL device s own programming language for simple processes Loop constructor display and adaptation of control circuit structure Reset Amplifier device restart Upgrade Downgrade firmware loading o...

Page 71: ...er parameters from file to drive amplifier Write parameters from drive amplifier RAM to drive amplifier flash save permanently in drive amplifier CAUTION If the Save parameters from amplifier RAM to flash button is pressed while the motor is energised moving the drive amplifier initiates a quick stop Dec Kill and de energises the motor 8 3 4 Reset Clicking on the Reset symbol yellow square trigger...

Page 72: ... In this example the lack of a power supply to the drive amplifier is reported 8 3 7 Variable rapid access The setting of user units can be adapted in this area using the Position Units drop down list Depending on the drive used different units are provided for linear and rotary systems The other drop down lists can be used to clearly view any drive parameters The units for e g speed and position ...

Page 73: ... five tabs in the configuration center for setting the motor type motor encoder any Hall sensors the operation mode and the connected voltage EtherCAT devices come with an additional tab for the addressing First the parameters are set for the motor used There are three motor types to choose from AC servo linear motor torque motor each with or without EtherCAT functions When using a HIWIN motor the...

Page 74: ...or used should be entered Figure 8 16 Configuration center AC servo motor without CoE When using a toothed belt axis the spindle pitch corresponds to the circumference of the driving belt wheel feed constant If a HIWIN AC servo motor has been selected the matching encoder is automati cally selected If using a non HIWIN motor all motor parameters must be taken from the motor manufacturer s manual a...

Page 75: ...re 8 17 Configuration center AC servo encoder without CoE The Linear Resolution field shows the system resolution calculated from the motor and encoder data The Encoder Output area is only of importance if the drive amplifier creates an encoder signal for e g communicating the position to an external device such as a controller The Buffered Encoder renders the position of the drive amplifier as a ...

Page 76: ...he Hall Sensor tab contains all settings for commutating the motor with Hall sensors If this function is activated there is no commutation finding when the drive amplifier is restarted Both digital and analogue Hall sensors are available Figure 8 18 Configuration center AC servo Hall sensor without CoE ...

Page 77: ...ternal controller Depending on the device type present not all operation modes are available Oper ation modes with I O control are not available for devices with an EtherCAT inter face Vice versa devices without an EtherCAT interface cannot be taken into Ether CAT operation mode Stand Alone Mode The nominal values for speed acceleration and position are generated in the drive amplifier Figure 8 19...

Page 78: ...on Pulse Up Pulse Down and Quadra ture A B I can be selected here Electronic gear signal scaling can also be un dertaken This reflects the ratio of motor increments output counts to input puls es at controller end The position specification can be connected via High Speed Pulse Input or Low Speed Pulse Input For the precise input specifications refer to chapter 5 7 1 Figure 8 20 Configuration Cent...

Page 79: ...terface X6 Here the nominal value can be supplied via the analogue input or via a digital input using PWM Figure 8 21 Configuration center velocity mode The Dead band is an area around the stationary point in which small signals in the mV range do not trigger movement in order to compensate for any zero point deviations Figure 8 22 Definition of dead band ...

Page 80: ...l value can be supplied via the analogue input or via a digital input using PWM The setting is made in the same way as in Velocity mode Figure 8 23 Configuration Center force torque mode AC servo connected voltage Selection The last tab lists the drive s connected voltage Figure 8 24 Configuration Center drive selection without CoE Connect the 24 and 48 VDC supplies via X2 plugs see Table 5 4 ...

Page 81: ... window for checking purposes Changes compared with the data from the drive amplifier s RAM are highlighted in red To transfer the data confirm with the Send to RAM button Figure 8 25 Parameter data set check The motor and encoder settings are now saved in the drive amplifier s RAM For permanent storage the changes still need to be transferred to the flash memory otherwise all changes will be lost...

Page 82: ...of the HIWIN linear motor types In this example only the weight of the moved drive masses need be set Figure 8 26 Configuration Center LM motor without CoE If a non HIWIN motor is used all motor parameters must be taken from the motor manufacturer s manual and entered in the corresponding fields Customized Lin ear with these parameter settings can be added to the motor database ...

Page 83: ... encoder manufacturer s manual must be entered Figure 8 27 Configuration center LM encoder without CoE The Encoder Output area is only of importance if the drive amplifier creates an encoder signal for e g communicating the position to an external device such as a controller The Buffered Encoder renders the position of the drive amplifier as a digital signal With an Emulated Encoder there is a sig...

Page 84: ...he Hall Sensor tab contains all settings for commutating the motor with Hall sensors If this function is activated there is no commutation finding when the drive amplifier is restarted Both digital and analogue Hall sensors are available Figure 8 28 Configuration center LM Hall sensor without CoE ...

Page 85: ...controller De pending on the device type present not all operation modes are available Opera tion modes with I O control are not available for devices with an EtherCAT inter face Vice versa devices without an EtherCAT interface cannot be taken into Ether CAT operation mode Stand alone mode The nominal values for speed acceleration and position are generated in the drive amplifier Figure 8 29 Confi...

Page 86: ...se Up Pulse Down and Quadra ture A B I can be selected here Electronic gear signal scaling can also be un dertaken This reflects the ratio of motor increments output counts to input puls es at controller end The position specification can be connected via High Speed Pulse Input or Low Speed Pulse Input For the precise input specifications refer to section 5 7 1 Figure 8 30 Configuration Center pos...

Page 87: ...interface X6 Here the nominal value can be supplied via the analogue input or via a digital input using PWM Figure 8 31 Configuration Center velocity mode Dead band is an area around the stationary point in which small signals in the mV range do not trigger movement in order to compensate for any zero point devi ations Figure 8 32 Definition of dead band ...

Page 88: ...ue mode The drive amplifier receives the nominal force torque value via I O interface X6 Here the nominal value can be supplied via the analogue input or via a digital input using PWM The setting is made in the same way as in Velocity mode Figure 8 33 Configuration Center force torque mode ...

Page 89: ...uctions Servo amplifier D1 N 15 10 2015 89 183 AC servo drive The last tab lists the drive s connected voltage Figure 8 34 Configuration Center drive selection without CoE Connect the 24 and 48 VDC supplies via X2 plugs see Table 5 4 ...

Page 90: ...w window for checking purposes Changes compared with the data from the drive amplifier s RAM are highlighted in red To transfer the data confirm with the Send to RAM button Figure 8 35 Parameter data set check The motor and encoder settings are now saved in the drive amplifier s RAM For permanent storage the changes still need to be transferred to the flash memory otherwise all changes will be los...

Page 91: ... of the HIWIN torque motor types In this example only the drive s mass inertia moment need be set Figure 8 36 Configuration Center TM motor without CoE If a non HIWIN motor is used all motor parameters must be taken from the motor manufacturer s manual and entered in the corresponding fields Customized Torque with these parameter settings can be added to the motor database ...

Page 92: ... encoder manufacturer s manual must be entered Figure 8 37 Configuration center TM encoder without CoE The Encoder Output area is only of importance if the drive amplifier creates an encoder signal for e g communicating the position to an external device such as a controller The Buffered Encoder renders the position of the drive amplifier as a digital signal With an Emulated Encoder there is a sig...

Page 93: ...l Sensor tab contains all settings for commutating the motor with Hall sensors If this function is activated there is no commutation finding with motion when the drive amplifier is restarted Both digital and analogue Hall sensors are available Figure 8 38 Configuration Center TM Hall sensor without CoE ...

Page 94: ...controller De pending on the device type present not all operation modes are available Opera tion modes with I O control are not available for devices with an EtherCAT inter face Vice versa devices without an EtherCAT interface cannot be taken into Ether CAT operation mode Stand alone mode The nominal values for speed acceleration and position are generated in the drive amplifier Figure 8 39 Confi...

Page 95: ...se Up Pulse Down and Quadra ture A B I can be selected here Electronic gear signal scaling can also be un dertaken This reflects the ratio of motor increments output counts to input puls es at controller end The position specification can be connected via High Speed Pulse Input or Low Speed Pulse Input For the precise input specifications refer to section 5 7 1 Figure 8 40 Configuration Center pos...

Page 96: ...interface X6 Here the nominal value can be supplied via the analogue input or via a digital input using PWM Figure 8 41 Configuration Center velocity mode Dead band is an area around the stationary point in which small signals in the mV range do not trigger movement in order to compensate for any zero point devi ations Figure 8 42 Definition of Dead band ...

Page 97: ...ue mode The drive amplifier receives the nominal force torque value via I O interface X6 Here the nominal value can be supplied via the analogue input or via a digital input using PWM The setting is made in the same way as in Velocity mode Figure 8 43 Configuration Center force torque mode ...

Page 98: ... Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 AC servo drive The last tab lists the drive amplifier s connected voltage Figure 8 44 Configuration Center drive selection without CoE ...

Page 99: ...w window for checking purposes Changes compared with the data from the drive amplifier s RAM are highlighted in red To transfer the data confirm with the Send to RAM button Figure 8 45 Parameter data set check The motor and encoder settings are now saved in the drive amplifier s RAM For permanent storage the changes still need to be transferred to the flash memory otherwise all changes will be los...

Page 100: ...15 8 4 4 Motor parameterisation with EnDat 2 2 encoder If an encoder with EnDat 2 2 protocol is connected the configuration center detects this automatically and there is no other encoder in the selection window Figure 8 46 Configuration Center Example LM encoder with EnDat 2 2 ...

Page 101: ...osition If desired values for position errors and speed errors above which a warning is to be output can also be set under Warning Windows These warnings do NOT however stop motor movement if the values are exceeded Note The selection menu provided for Position Units can be used to define the desired unit for your input 8 5 1 Homing Regardless of the method selected the speed Faster Speed and Slow...

Page 102: ...en the position is set the motor is energised for the greatest pos sible accuracy Figure 8 49 Homing method 3 Method 2 Move at Faster Speed in the positive direction Move up to the hard stop until End stop current is reached On reaching this decelerate stop and move at Slower Speed in the neg ative direction until the next index pulse is reached End stop current defines the current limit when the ...

Page 103: ...se is reached End stop current defines the current limit when the drive moves to the end limit Time defines the time during which the set End stop current is active Figure 8 51 Homing method 1 End stop current is given in peak and not effective amperes Method 1 Move at Faster Speed in the negative direction Move until the negative hard switch outputs a rising edge On reaching this decelerate stop ...

Page 104: ... Figure 8 53 Homing method 2 Method 7 Move at Faster Speed in the positive direction Until the home sensor outputs a rising edge On reaching this decelerate stop and move at Slower Speed in the neg ative direction until the next index pulse Figure 8 54 Homing method 7 Method 8 Move at Faster Speed in the positive direction Until the home sensor outputs a rising edge On reaching this decelerate sto...

Page 105: ...g this decelerate stop and move at Slower Speed in the neg ative direction until the home sensor logical 1 and the next index pulse is reached Figure 8 56 Homing method 9 Method 10 Move at Faster Speed in the positive direction Until the home sensor outputs a falling edge On reaching this move at Slower Speed in the positive direction until the next index pulse Figure 8 57 Homing method 10 ...

Page 106: ...ate and stop Move at Slower Speed in the positive direction Until the next index pulse is reached Figure 8 58 Homing method 11 Method 12 Move at Faster Speed in the negative direction Until the home sensor outputs a falling edge On reaching this move at Slower Speed in the negative direction until the home sensor logical 1 and the next index pulse is reached Figure 8 59 Homing method 12 ...

Page 107: ...aching this decelerate stop and move at Slower Speed in the posi tive direction until the home sensor logical 1 and the next index pulse is reached Figure 8 60 Homing method 13 Method 14 Move at Faster Speed in the negative direction Until the home sensor outputs a falling edge Move at Slower Speed in the negative direction Until the next index pulse is reached Figure 8 61 Homing method 14 ...

Page 108: ...suring systems that feature only one index mark single index Figure 8 62 Homing method 33 Method 34 Move at Slower Speed in the positive direction Until the index pulse is reached This method is intended for position measuring systems that feature only one index mark single index Figure 8 63 Homing method 34 Method 37 With this method the current position becomes the zero position Figure 8 64 Homi...

Page 109: ...ions Servo amplifier D1 N 15 10 2015 109 183 8 5 2 Backlash The accuracy for axes with backlash can be increased by means of backlash com pensation The backlash simply needs to be known in advance Figure 8 65 Application center backlash ...

Page 110: ... D1 N drive amplifier allows up to 16 000 position correction points to be stored directly in the drive amplifier The raw data for the correction points can be cap tured with a glass scale or laser interferometer for example Figure 8 66 Application center error map Figure 8 67 Example of an error map ...

Page 111: ...Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 111 183 Figure 8 68 Correction on a belt axis ...

Page 112: ...ning Instructions Servo amplifier D1 N 15 10 2015 8 5 4 Resolver Motors with resolver feedback can also be operated on the D1 N The resolver is learnt by clicking on the Start learning button Figure 8 69 Application center resolver ...

Page 113: ...thin certain limits The same applies to the speed The protection center therefore allows you to set limit values for these parameters The software limit switches sw limit can also be set here If the system is not allowed to exceed a particular speed range or the acceleration needs to be limited this can also be done in the protection cen ter 8 6 1 Protection Figure 8 71 Protection center protectio...

Page 114: ... used switch monitoring can be activated in this tab Figure 8 72 Protection center HW limit protection The relevant inputs for limit switches can be configured in the I O center See capture 8 7 8 6 3 Brake The Brake tab clearly shows all the parameters needed to configure the brake behaviour Figure 8 73 Protection center Brake ...

Page 115: ... is braked after the controller enable dis appears This delay can be changed in the performance center Attention This acceleration ramp also depends on the smooth factor vel_stop If the motor speed has fallen below this speed value the brake closes even if the time delMaxEnToBrk hasn t yet been reached delBrkToDis Time between the brake being activated and control being shut down The Set button ca...

Page 116: ...be configured and monitored Launch the I O center by clicking on the corresponding button in the main oper ating interface or the Lightening Conf Tune menu Figure 8 74 Launching I O center 8 7 1 Inputs Any function can be assigned to each input in the Inputs tab The logic of each input can also be inverted to undertake adaptation e g to the switch type used Figure 8 75 I O center inputs ...

Page 117: ...nput Please check that all con nected inputs are functioning correctly when commissioning The Set default button resets all I O settings to their default values Note If the Axis Enable function is not used this input must be inverted other wise a controller enable is not possible 8 7 2 Outputs The outputs of the D1 N are configured in the Outputs tab The status of each output is also shown in this...

Page 118: ...118 183 Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 Figure 8 77 I O center configuration of Ox ...

Page 119: ...burns may result from contact with the drive amplifier which is heated as the heat sink warms up Overview of basic commissioning steps Check motor encoder connection Disconnect motor cable Switch on device Enter motor and encoder parameters Check function of distance measuring system Permanently save settings save in flash memory De energise device Connect motor cable Switch on device Perform all ...

Page 120: ... the system can also be inverted The auto phase center is only needed when commissioning the first time SW method 1 and LSWIR are available for commutation finding These two methods are commutation findings with motion CAUTION Steps 1 Enable Axis in SM mode and 2 Drag the slider auto phase cen ter should be carried out each time the motor encoder or their cables are replaced Should the motor phase...

Page 121: ... the motor type and method selected The following screenshots show examples of possible structures Figure 9 2 depicts the interface for linear and torque motors Figure 9 3 is the startup interface for AC servo motors Figure 9 2 Auto phase center For linear torque motor with SW method 1 Figure 9 3 Auto phase center For servo motor LSWIR ...

Page 122: ...Figure 9 3 Pressing the button View opens the Invert area In this Invert area users can correct wiring errors by ticking the motor or encoder to invert their connections The button Details lets users invert the Toggle Direction in the software with out any changes to the wiring Figure 9 4 Auto phase center Advanced View Figure 9 5 Auto phase center Toggle Direction ...

Page 123: ...he axis to control The carriage can be moved with the green arrows Users can then check the count ing direction of the position measuring system and centre the axis prior to Auto tune Clicking Proceed initiates an automatic tuning of the application The drive de termines for example the mass inertia of the application for minimising the posi tion error After successful auto tuning the field Gain i...

Page 124: ...the next step Depending on application in some cases a higher current may have to be selected This may be the case with e g high friction This current is also the current with which the motor is energised during any sub sequent commutation process DCBL WARNING Please ensure that the Auto phase center is open before the controller en able Axis Enable is activated Setting the Axis Enable input when ...

Page 125: ...nable button The motor is now energised Figure 9 8 Controller is enabled Figure 9 9 Starting SM mode The motor is now energised with the specified current Stepper Mode Repeat this process 2 3 times The slider can now be used to move the motor in both directions This movement is important because the program automatically memorises the encoder counting direction during this process and matches the ...

Page 126: ...nge insufficient or incorrect parameters have been selected If the pointer exits the green range when travelling in SM mode it is probable that the motor cannot be controlled in the controlled operation The motor may move violently and unpredictably and cause injury and dam age to the machine If the pointer exits the green range deactivate the axis with the Disable button and adapt the parameters ...

Page 127: ... low a Current SM mode current was selected The motor may need a higher current to move correctly in this mode due to friction or high load Slowly increase the current and see whether there is any improvement in behaviour First ensure that the correct permissible maximum current is set in the motor parameters so that the internal motor protection works and the motor doesn t overheat in the event o...

Page 128: ...is process Suitable control parameters can therefore be automatically established quickly and easily The frequency analyser can be started using the Freq analyzer button in the Au to phase center or in the Performance center Figure 9 13 Starting frequency analyser Note In newer versions of Lightening not only is there the thorough frequency analyser but also the simple version The simple version d...

Page 129: ...Freq analyzer button Please ensure that the motor has enough space to move a little in both directions and that the mechanical brake is open if fitted Start the process by clicking on the Run but ton Figure 9 14 Frequency analyser in Simple Mode Thorough Freq analyzer Select the Step dcbl plant tab to determine general control parameters Please ensure that the motor has enough space to move a litt...

Page 130: ... with different frequencies and starts to oscillate this way and that A loud increasingly high pitched whis tling sound can be heard If necessary you can abort the process at any time by deactivating the HW enable or pressing the F12 button Figure 9 15 Frequency analyser Figure 9 16 Frequency analyser current frequency and progress ...

Page 131: ...9 17 Evaluation of stimulated frequencies Once the process has been completed the amplitude characteristic can be seen depending on the input frequency To determine the control parameters click in the diagram window to display a 20 Db dec line Figure 9 18 Frequency analyser 20 dB dec line ...

Page 132: ...the falling 20 Db line gauge the centre between the individual points by eye and place the line between them The values established are then to the controller by clicking on the Send button The speed controller should now be set well Figure 9 19 Frequency analyser with adapted 20 dB dec line If you accessed the Frequency analyser from the Auto phase center now close the window to return to the Aut...

Page 133: ... controller parameters can be adapted here in advance to make successful commutation possible Launch the SMCL tool with the SMCL tool button Figure 9 22 Launching the SMCL tool In the new window click on the Start SMCL button The aim of this procedure is to reduce the position error during the commutation phase and minimise movement To do this slowly increase the st_cg value and after each change ...

Page 134: ...ause if st_cg is close to the limit value not every click on start will necessarily trigger permanent oscillation Permanent os cillation occurs if too large a control circuit amplification st_cg has been select ed Figure 9 23 SMCL tool Once you have successfully reduced the position error return to the Auto phase center and restart Phase initialization With the SW method 5 commutation can be tuned...

Page 135: ... TM with EnDat 2 2 Selecting an encoder with EnDat 2 2 section 8 4 4 opens Auto phase center in Phase initialization mode STABS The order of steps is the same as for com mutation finding for linear and torque motors in the preceding section Figure 9 24 Auto phase center with EnDat 2 2 encoder ...

Page 136: ...and Commissioning Instructions Servo amplifier D1 N 15 10 2015 The only difference is step 5 STABS test tune Figure 9 25 Auto phase center STABS test tune VORSICHT The motor is energised and moved in the following step ...

Page 137: ...ed manner in manual mode using defined parameters Continuous travel between two points is also possible To launch the performance center go to the main screen in the Lightening software and click on the performance center button or launch it from the Conf Tune menu in Lightening Figure 9 26 Launching the performance center Main interface functions Figure 9 27 Operating interface of the Performance...

Page 138: ...referenced to the reference point SM mode Motor is energised in stepper mode not subject to con trol Motion data Position Units Defines the units in which all values are entered and dis played Speed Traversing speed Acc Acceleration Dec Delay Dec kill Delay for emergency stop Smooth factor Defines the jerk limitation 1 means maximum jerk Higher values result in a gentler start Common Gain Amplific...

Page 139: ... to Jog mode and move the motor with the green arrow buttons Figure 9 28 Jog mode Once the speed and acceleration have been tested in Jog mode you can use the P2P function to keep the motor in permanent motion and test other parameters in the process Figure 9 29 Point to point movement To keep the motor in continuous motion tick Repeat and enter permissible posi tions for P1 and P2 The motor is mo...

Page 140: ...remains in place for as long as the speed is not 0 It switches to Low as soon as the speed reaches a value of 0 The Debounce time is a counter and starts counting down e g 100 ms to 0 as soon as the actual position is within the Target radius The In Position flag is set to 1 as soon as the Debounce time has reached 0 Figure 9 30 Target radius and debounce time ...

Page 141: ...function simply click on the Set scope button in the Perfor mance center start scope function with preset channels Alternatively the scope can be started from the quick start bar Figure 9 31 Starting scope Once the Set scope button has been clicked on the Scope area opens and 4 channels are set automatically Position Error Feedback Velocity Reference Acceleration Feedback Position You can also sel...

Page 142: ...ion tool Select preset input variables Toggle the Always to the fore view Change number of channels The grid intensity can be set using the slider The time for the recording is set in the time field in the bottom right of the screen The Plot View function is provided for more detailed analysis of curve progress This tool does not work continuously like the scope function but is used to analyse the...

Page 143: ... displaying one single curve so that as many details as possible can be seen Do this using the Set show mode button in the toolbar Then select only Graph X where X is the channel that you want to look at in more detail You can also use the left and right mouse buttons to place cursors to define the area to be analysed You can then use the Zoom the area between cursors button to zoom into the selec...

Page 144: ... characteristics of the selected area Figure 9 36 Starting the Statistics table The Plot statistic now automatically shows you the maximum and minimum for the section displayed Figure 9 37 Statistics table The FFT analysis allows you to determine the frequency elements occurring in a recorded curve To perform an FFT analysis click on the FFT button in the toolbar for the Plot view tool Figure 9 38...

Page 145: ...case the position error Select the Direct FFT method and press the Run FFT button to start the process Figure 9 39 Setting up the FFT analysis The Plot view tool now no longer shows the curve progress but the calculated frequency spectrum of the FFT analysis The proportion of all frequency elements can be seen here Figure 9 40 Result of the FFT analysis ...

Page 146: ...s the sampling rate with which the values are recorded At the same time these two values determine the recording period The recording time result ing from Samples and your chosen Rate is displayed in the two fields under samples dt Enter the variables that you want to record in the text boxes un der Variables to be recorded Start the recording with the F5 button or click on Start You can stop the ...

Page 147: ...Assembly and Commissioning Instructions Servo amplifier D1 N 15 10 2015 147 183 Figure 9 42 Curves recorded ...

Page 148: ...t Figure 9 43 shows the scope recording of a motor dis playing a position error of up to 2 during movement The motor was operated here with a Common Gain of 0 5 Figure 9 43 Scope evaluation of point to point movement Figure 9 44 Common Gain Increasing the Common Gain makes control stricter In this example the posi tion error is reduced significantly to approx 0 7 once the Common Gain is in creased...

Page 149: ...Common Gain is highly dependent on the motor used and its application Proceed as shown above to establish the Common Gain Use the scope function to display the values of importance to your application e g the position error Keep the motor moving and watch the values while gradually and slowly changing the Common Gain until you find the best possible motor behav iour ...

Page 150: ... To under take further fine tuning of the control circuit and to set filters open the Advanced gains menu Here you can filter frequency elements out of the control circuit and activate special controller functions Open the Advanced gains window from the Conf Tune menu in the main Lightening interface Figure 9 46 Opening the Advanced gains window Figure 9 47 Advanced gains ...

Page 151: ...on Friction compensation is used to set the friction compensation 9 7 1 Setting filters Clicking on the Bode button opens a window for depicting the frequency re sponse The following settings apply for a typical low pass filter Fr Limit frequency in Hz the default of 500 Hz is normally sufficient Too low a value decreases the cut off frequency and therefore the drive ampli fier s bandwidth xi Damp...

Page 152: ...eedforward First set the value for Acc feedforeward gain to 0 Then start the scope using the button in the window Ensure that the motor performs the desired acceleration profile during the record ing The feedforward is calculated as follows Acc feedforward gain max command max ref acceleration In the following example the max command is 17 and max ref acceleration 95 000 This produces a gain of 1 ...

Page 153: ...structions Servo amplifier D1 N 15 10 2015 153 183 Figure 9 49 Scope for determining the acceleration feedforward The position error in the acceleration was reduced from 90 to 60 counts Figure 9 50 Result obtained with feedforward ...

Page 154: ...n the drive is in motion moving sg_stop Mainly when the drive is in its settling time settling sg_idle Mainly when the drive is stationary in a position in position The value entered is multiplied internally by the CG The vpg Velocity proportional gain was set automatically after the mass inertia measurement This value is ideal when the load and friction don t change Howev er if these parameters c...

Page 155: ...nput Figure 9 52 Advanced gains Analog input If a nominal analogue value is used for speed or torque force control an offset correction can be undertaken If the voltage value at zero volts is not zero or is slightly unstable the negative effect of this offset can be corrected by pressing the Set Offset button ...

Page 156: ...culates the amplification factors for the current loop using motor inductance and motor resistance For most applications these values do not have to be adapted The Freq analyzer can be used to determine whether these values are ideal or require tuning A low pass filter is used as the current filter to minimise motor noise The standard filter has a cut off frequency of 1000 Hz ...

Page 157: ...lifier D1 N 15 10 2015 157 183 9 7 6 Advanced gains VSF velocity suppression function Figure 9 54 Advanced gains VSF This function is used to filter low frequency oscillation The frequency in question can be determined with the scope and or plot view ...

Page 158: ...ns Figure 9 55 Advanced gains friction compensation Before determining the appropriate value set the start value to 0 Start the desired movement via the performance center or specify the corresponding nominal values Start the scope by clicking on the Set scope button Figure 9 56 Recording current and position error ...

Page 159: ...unction to assess the position error and current Figure 9 57 Assessing with plot view Figure 9 58 Assessing current and position error Enter the command s Avr value in the field for friction compensation You will see a reduction in the position error Figure 9 59 Entering the command Avr for friction compensation ...

Page 160: ...r to section 11 for the meaning of the individual errors and how to rem edy them You can start the Errors and Warnings Log from the main Lightening operating interface by going to the Conf Tune menu item Figure 9 60 Starting Errors and Warnings Log The Errors and Warnings Log operating interface shows a list of all the errors which have occurred since the drive amplifier was last restarted They ar...

Page 161: ...al Basic and LabView applications and can be installed with the following operating systems Windows 95 98 2000 XP Win7 The MPI library consists of 4 files mpi lib mpi dll canlib32 dll mpint h Additional software called WinPcap must be installed for devices which are to be controlled via EtherCAT This is open source software that can be downloaded from http www winpcap org 10 1 Features of the MPI ...

Page 162: ... be downloaded from www hiwin de Alter natively contact the technical support team at HIWIN see section 2 9 Position orders can be undertaken operating changeovers e g position control speed control or current control can be performed and outputs can be controlled via the digital inputs 10 3 Features of PDL programming Capable of multitasking up to 4 tasks can be processed in parallel Quick execut...

Page 163: ...run Wait until motor has reached the position till I5 Wait until input I5 is activated X_trg 1441792 Absolute positioning in increments till X_run Wait until motor has reached the position goto _Loop Program jump ret Example 2 Using a procedure for positioning with the variable factors speed acceleration deceleration jerk limitation and input coded position orders proc move_p_v_a_d long p long v l...

Page 164: ... Pos1 if I1 I2 I3 I4 do If input I1 1 and I2 1 and I3 0 and I4 0 then move_p_v_a_d 8850 20000 20000 20000 Position order in count absolute values 1 count 1µm standardised till X_run seton O1 setoff O2 setoff O3 sleep 500 end Pos2 if I1 I2 I3 I4 do If input I1 1 and I2 0 and I3 1 and I4 0 then move_p_v_a_d 113850 20000 200000 200000 in count till X_run setoff O1 seton O2 setoff O3 sleep 500 end Pos...

Page 165: ... I5 X_trg 1441792 Relative position in negative direction in increments till X_run goto _Loop Program jump ret Example 4 Use of customer specific variables motion profile parameters IF ELSE DO conditions and stop command Custom variable Cycle counter and automatic stop once the Stop conditions are reached long ciclo Cycle variable long numero Number variable task 1 X_vel_max 1000000 Max speed in i...

Page 166: ...Lightening software is used to write PDL programs compile them and save them to D1 N For a description of the Lightening software and how to install it see section 8 Once motor commissioning is complete see section 9 select the PDL symbol in the main toolbar in the main window Figure 10 2 Selecting PDL programming In the following window press the button Edit Figure 10 3 Opening the compiler Progr...

Page 167: ...ritten as txt files and copied pasted to User PDL Alternatively the program can be written directly in the compiler The syntax check looks for spelling mistakes or whether variables and parameters not available have been used It is important that there are no errors Errors 0 Figure 10 5 PDL compiler result of syntax check ...

Page 168: ...RSICHT If you press the Download to amplifier button while the motor is ener gised moving the drive amplifier immediately de energises the motor The motor is NOT decelerated by the drive amplifier and coasts to a stop To check whether the written program is active in the D1 N press the Ctrl and X keys on your keyboard A new item called Advanced appears in the Lightening main toolbar Figure 10 6 Ad...

Page 169: ...If Run is displayed in the State column of the individual tasks the saved pro gram is running in the D1 N Figure 10 8 Task List in Lightening selection 10 6 Stopping PDL program allowing it to run on and deleting it The Lightening software has an input window called Message window under Performance center for stopping a PDL program Figure 10 9 Calling up the Message window ...

Page 170: ...ages command prompts Task 1 see Figure 10 8 can be stopped using the following command stop 1 Enter commands in message window and press the Enter button Figure 10 11 Message window stopping task 1 The drive amplifier confirms the command with OK To check you can open PDL Task List see Figure 10 7 and Figure 10 8 ...

Page 171: ...ure 10 13 Message window task 1 started again Task 1 see Figure 10 12 can be cancelled using the following command kill 1 Enter commands in message window and press the Enter button Figure 10 14 Message window cancelling task 1 While the drive amplifier is energised task 1 remains cancelled This task is auto matically restarted either with the Reset button see section 8 3 4 or if the drive control...

Page 172: ...the Common Gain amplification is set correctly or whether too low a maximum pos error value is perhaps selected under the Protection tab in the Application center E04 E04ENCOD Encoder error Error in encoder signal Rectification of problem Check whether the encoder is connected correctly and whether the cor rect encoder type has been selected in the Configuration center E05 E05SWHOT Soft thermal th...

Page 173: ...ectly connected to the drive amplifier and whether the energy supply voltage is within the drive amplifier specification E10 E10V5ERR 5 V for encoder card fail Error in encoder power supply Rectification of problem Switch off the drive amplifier and connect the encoder plug again Check the encoder cable for damage E11 E11PHINI Phase initialisation error Error during commuta tion Rectification of p...

Page 174: ... set the linear and rotary encoder directions agree and the linear encoder is not experiencing EMC problems Please check that the motor coupling and gears are connected correctly and that the pitch tolerance and spin dle backlash are small enough E18 E18STO STO active Safe stop active Rectification of problem Make sure that there is no longer any danger Afterwards switch back ON the 24 V mains for...

Page 175: ...er head Table 11 1 Error codes and troubleshooting 11 2 Warnings and troubleshooting W01 W01SWLL Left SW limit Motor has reached maximum left position and must not exceed this Rectification of problem Adapt the Lower SW limit value under the Protection tab in the Ap plication center W02 W02SWRL Right SW limit Motor has reached maximum right position and must not exceed this Rectification of proble...

Page 176: ...eck whether the Common Gain amplification is set correctly and whether too low a Position error value is perhaps selected under the Protection tab in the Application center W07 W07VE Velocity error warning Motor speed exceeds set warning limit Rectification of problem Check whether the Common Gain amplification is set correctly and whether too low a Position error value is perhaps selected under t...

Page 177: ...fication of problem Check that the imposed load or movement cycle is too large Reduce the mass or increase the number of pauses Check the friction in the system and that the motor can move without obstruction Check motor type W13 W13HOM E Homing fail Reference travel failed Rectification of problem Please check the limit sensor switch positive and negative the refer ence switch and the reference m...

Page 178: ...t the positive direction of motion 3 The motor is subject to control but is not moving none Rectification of problem 1 Use the scope function to check whether the drive amplifier is receiving pulses from the controller 2 Check the control cable 3 Check whether the 0V potential and earth and or shielding are short circuited 4 Check whether the drive amplifier and motor are earthed cor rectly 4 The ...

Page 179: ...4 23 0001 D1 N 09 F0 2 0 00 1 D1 N 1 Connector kit CK4 23 0005 D1 N 18 E0 2 0 00 1 D1 N 1 Connector kit CK4 23 0002 D1 N 18 F0 2 0 00 1 D1 N 1 Connector kit CK4 23 0006 D1 N 36 E0 2 1 00 1 D1 N 1 Connector kit CK4 23 0003 D1 N 36 F0 2 1 00 1 D1 N 1 Connector kit CK4 23 0007 D1 N 90 E0 2 1 00 1 D1 N 1 Connector kit CK4 23 0004 D1 N 90 F0 2 1 00 1 D1 N 1 Connector kit CK4 23 0008 Table 13 1 Item num...

Page 180: ...onnection at X10 X11 1 Sub D connector 15pol HD female for connection at X12 1 hose clamp for shield connection at motor connector 10 mm 16 mm 8 10 0800 Connector kit CK4 D1N 90 1 connector for main voltage X1 1 connector for brake resistor X2 1 connector for motor connection X3 1 connector for control voltage X4 1 connector for I O connection X6 2 connector for safety function X7 X8 1 connector f...

Page 181: ...0 0069 5 m 8 10 0070 8 m 8 10 0071 10 m 8 10 0072 HIWIN motor cable for linear motors suitable for drag chains 2 5 mm on motor side with M23 connect or on D1 N side with open ends 3 m 8 10 0593 5 m 8 10 0594 8 m 8 10 0595 10 m 8 10 0596 HIWIN motor cable for torque motors suitable for drag chains 1 5 mm on motor side with M17 connect or on D1 N side with open ends 3 m 8 10 0109 5 m 8 10 0110 8 m 8...

Page 182: ... 10 0687 10 m 8 10 0688 HIWIN encoder cable for digital encoder systems drag chains on motor side with M17 connector on D1 N side with Sub D connector for X10 3 m 8 10 0690 5 m 8 10 0691 7 m 8 10 0692 10 m 8 10 0693 HIWIN encoder cable for analogue encoder systems and digital Hall sensor suitable for drag chains on motor side with M17 connector on D1 N side with sub D connector for X10 and X11 3 m...

Page 183: ...r The declaration is no more valid if the product is modi fied without agreement Product denomination Servo drive Model type D1 N 09 D1 N 18 D1 N 36 D1 N 90 Year of manufacture from 2013 The manufacturer herewith declares that the product is complying with all essential re quirements of the Machinery Directive 2006 42 EC In addition the partly completed machinery is in conformity with EC Low Volta...

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