Lenz PositionServo 940 User Manual
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Lenz PositionServo 940 User Manual

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S929
PositionServo with RS-232
Users Manual

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  • Page 1 S929 PositionServo with RS-232 Users Manual...
  • Page 2 Copyright ©2005 by AC Technology Corporation. All rights reserved. No part of this manual may be reproduced or transmitted in any form without written permission from AC Technology Corporation. The information and technical data in this manual are subject to change without notice. AC Tech makes no warranty of any kind with respect to this material, including, but not limited to, the implied warranties of its merchantability and fitness for a given purpose.

  • Page 3: Table Of Contents

    Contents Introduction..........5 About These Instructions .
  • Page 4 Contents Parameters..........35 Parameter Storage and EPM Operation .
  • Page 5 Contents Compensation ...........43 5.9.1 Velocity P-gain (Proportional) .
  • Page 6 Safety Information All safety information given in these Operating Instruction has a similar layout: Signal Word! (Characteristics the severity of the danger) Note (describes the danger and informs on how to proceed) Pictographs used in these instructions: Signal Words Icon DANGER! Warns of impending danger.

  • Page 7: Introduction

    These drives have the suffix “S1N”. The PositionServo 940 will accept feedback from an incremental encoder (that includes Hall channel information) or from a resolver. It accepts commands from a variety of sources, including analog voltage, RS485 interface (PPP and Modbus RTU), Ethernet interface, CANopen interface, digital pulse train, and master encoder reference.

  • Page 8: Scope Of Supply

    Introduction Scope of Supply Scope of Supply Important • 1 Model 940 Servo type E94P... After reception of the delivery, check immediately • 1 Users Manual (English) whether the scope of supply matches the • 1 MotionView CD ROM including accompanying papers. Lenze does not accept any - configuration software liability for deficiencies claimed subsequently. - documentation (Adobe Acrobat) Claim • visible transport damage immediately to the forwarder...

  • Page 9: Technical Data

    Technical Data Technical Data Electrical Characteristics Single-Phase Models 1~ Mains 1~ Mains Current Current Rated Output Peak Output Mains Voltage (1) Current (4) Current (5) Type (doubler) (Std.) E94P020S1N 120V or 240V E94P040S1N E94P020S2F E94P040S2F 120 / 240V (80 V -0%...264 V +0%) E94P080S2F 15.0 E94P100S2F...

  • Page 10: Operating Modes

    Technical Data Operating Modes Torque Reference ± 10 VDC 16-bit; scalable Torque Range 100:1 Current-Loop Bandwidth Up to 1.5 kHz* Velocity Reference ± 10 VDC or 0…10 VDC; scalable Regulation ± 1 RPM Velocity-Loop Bandwidth Up to 200 Hz* Speed Range 5000:1 with 5000 ppr encoder Position Reference...

  • Page 11: Power Ratings

    Technical Data Power Ratings Output kVA at Rated Leakage Power Loss at Rated Power Loss at Rated Type Output Current (8kHz) Current Output Current (8kHz) Output Current (16 kHz) Units Watts Watts Typical: E94P020S1N >3.5mA* E94P040S1N E94P020S2F E94P040S2F Typical: >3.5mA* E94P080S2F E94P100S2F E94P020Y2N...

  • Page 12: Clearance For Cooling Air Circulation

    Technical Data Clearance for Cooling Air Circulation >25mm >3mm >25mm S94P01B2...

  • Page 13: Installation

    Disconnect incoming power and wait 60 seconds before servicing drive. Capacitors retain charge after power is removed. STOP! • The PositionServo 940 must be mounted vertically for safe operation and enough cooling air circulation. • Printed circuit board components are sensitive to electrostatic fields.

  • Page 14: Wiring

    It may be necessary to earth ground the shielded cable. Ground the shield at both the drive end and at the motor end. If the PositionServo 940 drive continues to pick up noise after grounding the shield, it may be necessary to add an AC line filtering device and/or an output filter (between drive and servo motor).

  • Page 15: Emi Protection

    3.2.3 Enclosure The panel in which the PositionServo 940 is mounted must be made of metal, and must be grounded using the SPG method outlined in section 3.2.1. Proper wire routing inside the panel is critical; power and logic leads must be routed in different avenues inside the panel.

  • Page 16: Heat Sinking

    The end user must use the compatible filter to comply with CE specifications. The OEM may choose to provide alternative filtering that encompasses the PositionServo 940 drive and other electronics within the same panel. The OEM has this liberty because CE requirements are for the total system.

  • Page 17: Interface

    Interface Interface The standard PositionServo 940 drive contains seven connectors: four quick-connect terminal blocks, one SCSI connector and two subminiature type “D” connectors. These connectors provide communications from a PLC or host controller, power to the drive, and feedback from the motor. Prefabricated cable assemblies may be purchased from Lenze to facilitate wiring the drive, motor and host computer.

  • Page 18: P2 - Serial Communications Port

    Interface P7 PIN ASSIGNMENTS (OUTPUT POWER) Terminal Function Thermistor (PTC) Input Thermistor (PTC) Input Motor Power Out Motor Power Out Motor Power Out Protective Earth (Chassis Ground) 4.1.2 P2 - Serial Communications Port P2 is a 9-pin D-sub connector that is used to communicate with a host computer via standard RS-232 interface using a proprietary Point-to-Point Protocol (PPP).

  • Page 19: P4 - Motor Feedback / Second Loop Encoder Input

    Interface Name Function Buffered Encoder Output: Channel B- Buffered Encoder Output: Channel Z+ Buffered Encoder Output: Channel Z- 13-19 Empty AIN2+ Positive (+) of Analog signal input AIN2- Negative (-) of Analog signal input ACOM Analog common Analog output AIN1+ Positive (+) of Analog signal input AIN1 - Negative (-) of Analog signal input...
  • Page 20 Interface The PositionServo 940 buffers encoder feedback from P4 to P3. Encoder Feedback channel A on P4, for example, is Buffered Encoder Output channel A on P3. The Hall sensors from the motor must be wired to the 15-pin connector (P4).

  • Page 21: P5 - 24 Vdc Back-Up Power Input

    The speed of the motor is controlled by the frequency of the “step” signal, while the number of pulses that are supplied to the PositionServo 940 determines the position of the servomotor. “DIR” input controls direction of the motion.

  • Page 22: P11 - Resolver Interface Module (Option)

    The ENABLE pin (IN_A3, P3.29) must be wired through a switch or an output on a front-end controller to digital input common (IN_ACOM, P3.26). If a controller is present, it should supervise the PositionServo 940’s enable function. The ENABLE circuit will accept 5-24V control voltage.

  • Page 23: P12 - Second Encoder Interface Module (Option)

    Interface P11 PIN ASSIGNMENTS (Resolver Feedback) Name Function Ref + Resolver reference connection Ref - No Connection Cos+ Resolver Cosine connections Cos- Sin+ Resolver Sine connections Sin- PTC+ Thermal sensor PTC- STOP! Use only 10 V (peak to peak) or less resolvers. Use of higher voltage resolvers may result in feedback failure and damage to the resolver option module.

  • Page 24: Digital I/O Details

    Interface Digital I/O Details 4.2.1 Step & Direction / Master Encoder Inputs (P3, pins 1-4) You can connect a master encoder with quadrature outputs or a step and direction pair of signals to control position in step / direction operating mode (stepper motor emulation). These inputs are optically isolated from the rest of the drive circuits and from each other.

  • Page 25: Digital Outputs

    There are a total of five digital outputs (“OUT1” - “OUT4” and “RDY”) available on the PositionServo 940 drive. These outputs are accessible from the P3 connector. Outputs are open collector type that are fully isolated from the rest of the drive circuits. See the following figure for the electrical diagram.

  • Page 26: Digital Inputs

    Digital Inputs IN_Ax, IN_Bx, IN_Cx (P3.26-30, P3.31-35, P3.36-40) The PositionServo 940 Drive has 12 optically isolated inputs. These inputs are compatible with a 5 -24V voltage source. No additional series resistors are needed for circuit operation. The 12 inputs are segmented into three groups of 4, Inputs A1 - A4, Inputs B1 - B4, and Inputs C1 - C4.

  • Page 27: Analog I/O Details

    Interface Analog I/O Details 4.3.1 Analog Reference Input AIN+, AIN1- (P3.24 and P3.25) The analog reference input can accept up to a ±10V analog signal across AIN1+ and AIN2-. The maximum limit with respect to analog common (ACOM) on each input is ±18VDC.

  • Page 28: Communication Interfaces

    4.4.2 RS485 Interface (option) PositionServo 940 drives can be equipped with an RS485 communication interface option module (E94ZARS41) which is optically isolated from the rest of the drive’s circuitry. This option module can be used for two functions: drive programming and diagnostics using MotionView from a PC (with RS485 port) or as a Modbus RTU slave.

  • Page 29: Modbus Rtu Support

    Interface 4.4.4 MODBUS RTU Support As a default, the RS232 and RS485 interfaces are configured to support MotionView program operations. In addition, the RS485 interface can be configured to support the MODBUS RTU slave protocol. The interface can be configured through the MotionView program.

  • Page 30: Motor Set-Up

    Interface 4.5.3 Motor Set-up Once you are connected to the PostionServo 940 via MotionView a “Parameter Tree” will appear in the “Parameter Tree Window”. The various parameters of the drive are shown here as folders and files. If the “Motor” folder is selected, all motor parameters can be viewed in the “Parameter View Window”.

  • Page 31: Using A Custom Motor

    Interface Using a Custom Motor You can load a custom motor from a file or you can create a new custom motor. • To create a custom motor click “CREATE CUSTOM” and follow the instructions in the next section “Creating custom motor parameters”. • To load a custom motor click “OPEN CUSTOM” button then select the motor file and click the “OPEN“...

  • Page 32: Autophasing

    Interface 4.6.2 Autophasing The Autophasing feature determines important motor parameters when using a motor that is not in MotionView’s database. For motors equipped with incremental encoders, Autophasing will determine the Hall order sequence, Hall sensor polarity and encoder channel relationship (B leads A or A leads B for CW rotation). For motors equipped with resolvers, Autophasing will determine resolver angle offset and angle increment direction (“CW for positive”).
  • Page 33 Interface 4.6.3.1 Electrical Constants Motor Torque Constant (Kt) Enter the value and select proper units from the drop-down list. NOTE Round the calculated result to 3 significant places. Motor Voltage Constant (Ke) The program expects Ke to be entered as a phase-to-phase Peak voltage. If you have Ke as an RMS value, multiply this value by 1.414 for the correct Ke Peak value.
  • Page 34 Interface Nominal Bus Voltage (Vbus) The Nominal Bus Voltage can be calculated by multiplying the Nominal AC mains voltage supplied by 1.41. When using a model with the suffix “S1N” where the mains are wired to the “Doubler” connection, the Nominal Bus Voltage will be doubled. Example: If the mains voltage is 230VAC, Vbus = 230 x 1.41 = 325V This value is the initial voltage for the drive and the correct voltage will be calculated...
  • Page 35 Interface Halls Order Each hall signal is in phase with one of the three phase-phase voltages from the motor windings. Hall order number defines which hall sensor matches which phase-phase voltage. Motor phases are usually called R-S-T or U-V-W or A-B-C. Phase-Phase voltages are called Vrs, Vst, Vtr.
  • Page 36 Interface The phases that correspond to the Vrs Vst Vtr voltages are Hall B then Hall C then Hall A or Halls number 2 then 3 then 1. Referring to the following table, we find that 2-3-1 sequence is Halls Order number 3. We would enter 3 for the Halls Order field in motor dialog.

  • Page 37: Parameter Storage And Epm Operation

    The white EPM is the only acceptable EPM for the PositionServo 940 drive. If a white EPM is detected, the drive compares data in the EPM to that in its internal memory. In order for the drive to operate, the contents of the drive’s memory and EPM must be the same.

  • Page 38: Epm Fault

    Parameters 5.1.3 EPM Fault If the EPM fails during operation or the EPM is removed from the EPM Port the drive will generate a fault and will be disabled (if enabled). The fault is logged to the drives memory. Further operation is not possible until the EPM is replaced (inserted) and the F_EP drive’s power is cycled.

  • Page 39: Drive Pwm Frequency

    Parameters 5.3.1.3 Position Mode In this mode the drive reference is a pulse-train applied to P3.1-4 terminals, if the parameter “Reference” is set to “External”. Otherwise the reference is taken from the drive’s internal variables. (Refer to Programmer’s manual for details). P3.1-4 inputs can be configured for two types of signals: step and direction and Master encoder quadrature signal.

  • Page 40: Accel/Decel Limits (Velocity Mode Only)

    Parameters 5.3.7 ACCEL/DECEL Limits (Velocity Mode Only) The ACCEL setting determines the time the motor takes to ramp to a higher speed. The DECEL setting determines the time the motor takes to ramp to a lower speed. If the ENABLE ACCEL\DECEL LIMITS is set to DISABLE, the drive will automatically accelerate and decelerate at maximum acceleration limited only by the current limit established by the PEAK CURRENT LIMIT and CURRENT LIMIT settings.

  • Page 41: Regen Duty Cycle

    Parameters 5.3.14 Regen Duty Cycle This parameter sets the maximum duty cycle for the brake (regen) resistor. This parameter can be used to prevent brake resistor overload. Use the following formula to set the correct value for this parameter. D = P * R / (Umax) * 100% where: D (%)

  • Page 42: Group Id

    This delay is needed for some types of Modbus masters to function correctly. Analog I/O 5.5.1 Analog Output The PositionServo 940 has one analog output with 10-bit resolution on P3.23. The signal is scaled to ± 10V. The analog output can be assigned to following functions: • Not Assigned •...

  • Page 43: Analog Output Current Scale (Volt / Amps)

    Parameters 5.5.2 Analog Output Current Scale (Volt / amps) Applies scaling to all functions representing CURRENT values. 5.5.3 Analog Output Velocity Scale (mV/RPM) Applies scaling to all functions representing VELOCITY values. (Note: that mV/RPM scaling units are numerically equivalent to volts/kRPM). 5.5.4 Analog Input Dead Band Allows the setting of a voltage window (in mV) at the reference input AIN1+ and...

  • Page 44: Hard Limit Switch Action

    Parameters 5.6.2 Hard Limit Switch Action Digital inputs IN_A1-IN_A2 can be used as limit switches if their function is set to “Fault” or “Stop and Fault”. Activation of this input while the drive is enabled will cause the drive to Disable and go to a Fault state. The “Stop and Fault” action is available only in Position mode when the “Reference”...

  • Page 45: Compensation

    Parameters Compensation 5.9.1 Velocity P-gain (Proportional) Proportional gain adjusts the system’s overall response to a velocity error. The velocity error is the difference between the commanded velocity of a motor shaft and the actual shaft velocity as measured by the primary feedback device. By adjusting the proportional gain, the bandwidth of the drive is more closely matched to the bandwidth of the control signal, ensuring more precise response of the servo loop to the input signal.

  • Page 46: Gain Scaling Window

    5.10.1 Oscilloscope Tool The oscilloscope tool gives real time representation of different signals inside the PositionServo 940 drive and is helpful when debugging and tuning drives. Operation of the oscilloscope tool is described in more detail in the MotionView Software User’s Manual.

  • Page 47: Operation

    Proceed to Section 6.2. Configuration of the PositionServo Regardless of the mode in which you wish to operate, you must first configure the PositionServo 940 for your particular motor, mode of operation, and additional features if used. Drive configuration consists of following steps: •...
  • Page 48 Operation To configure drive: Ensure that the control is properly installed and mounted. Refer to Section 3 for installation instructions. Perform wiring to the motor and external equipment suitable for desired operating mode and your system requirements. Connect the serial port P2 on the drive to your PC serial port. Make sure that the drive is disabled.

  • Page 49: Position Mode Operation (Gearing)

    Operation Position Mode Operation (gearing) In position mode the drive will follow the master reference signals at the P3. 1-4 inputs. The distance the motor shaft rotates per each master pulse is established by the ratio of the master signal pulses to motor encoder pulses (in single loop configuration). The ratio is set by “System to Master ratio”...

  • Page 50: Enabling The Positionservo

    Operation Enabling the PositionServo Regardless of the selected operating mode, the PositionServo must be enabled before it can operate. A voltage in the range of 5-24 VDC connected between P3.26 and 3.29 (input IN_A3) is used to enable the drive. There is a difference in the behavior of input IN_A3 depending on how the “Enable switch function”...

  • Page 51: Tuning The Drive In Velocity Mode

    Operation WARNING! During both the Velocity and Position tuning procedures the PositionServo drive will perform rotation (motion) of the motor shaft in the forward and reverse directions at velocities based on the settings made by the user. Ensure that the motor and associated mechanics of the system are safe to operate in the way specified during these procedures.
  • Page 52 Operation Compile and Download Indexer Program to Drive In the [Indexer program] folder in MotionView, select [Compile and Load with Source] from the pull down menu. The TuneV program will be compiled and sent to the drive. Select [Run] from the pull down menu to run the TuneV program. Do NOT enable the drive (via input A3) at this stage.
  • Page 53 Operation Gain Scaling set OK Motor Velocity resembles Commanded Velocity. Motor Velocity is reasonably close with a slight overshoot. Gain Scaling set too HIGH Motor Velocity shows significant overshoot following the acceleration periods. Gain Scaling set significantly too HIGH Motor Velocity exhibits instability throughout the steady state Commanded Velocity.
  • Page 54 Operation Step 2: Fine Tuning the Velocity P-Gain Slowly alter the Velocity P-Gain (increase and decrease) and observe the motor velocity waveform on the oscilloscope. As the P-Gain increases the gradient of the velocity during acceleration and deceleration will also increase as will the final steady state velocity that is achieved.
  • Page 55 Operation I-Gain set OK No error between Commanded steady state velocity and Actual steady state velocity with excellent stability. I-Gain set too HIGH Additional overshoot and oscillations are starting to occur. Steady state velocity regulation Step 4: Check Motor Currents Finally check the motor currents on the Oscilloscope.

  • Page 56: Tuning The Drive In Position Mode

    Operation Good Current Trace Uniform current pulses during accel/ deceleration and stable current during steady state velocity. Instability in Drive Output Current (Note: Channel 2 trace has been removed for clarity). End Velocity Tuning Remove the Enable Input from input A3 (disable the drive). In MotionView, click on the [Indexer] folder for the drive.
  • Page 57 Operation Importing the Position Tuning Program Before importing the Position Tuning Program, the example programs must be installed from the Documentation CD that shipped with the drive. If this has not been done then please do so now. To load the TuneP program file to the drive, select [Indexer Program] in MotionView. Select [Import program from file] on the main toolbar.
  • Page 58 Operation Oscilloscope Settings Open the [Tools] folder]in MotionView and select the [Oscilloscope] tool. Click the [Set on Top] box to place a checkmark in it and keep the scope on top. In the Scope Tool Window, make the following settings: Channel 1: Signal = “Position Error”...
  • Page 59 Operation Increased Position P-Gain Shows improvement to the maximum error and the final positioning accuracy At some point while increasing the P-Gain, additional oscillations (Average Error) will start to appear on the position error waveform. Further Increased Position P-Gain Shows very good reduction to the maximum error but with additional oscillations starting to occur.
  • Page 60 Operation Step 3: Setting the Position I-Gain and Position I-Gain Limit The objective here is to minimize the position error during steady state operation and improve positioning accuracy. Start to increase the Position I-gain. Increasing the I-gain will increase the drive’s reaction time while the I-Limit will set the maximum influence that the I-Gain can have on the Integral loop.
  • Page 61 Operation Setting the Position Error Limits Look at the position error waveform on the oscilloscope. Note the maximum time that position errors exist (from the time axis of the scope) and the maximum peak errors being seen (from the value at the top of the screen). Use this values to set the position error limits to provide suitable position error protection for the application.

  • Page 62: Quick Start Reference

    Reference Quick Start Reference This section provides instructions for External Control, Minimum Connections and Parameter Settings to quickly setup a PositionServo drive for External Torque, Velocity or Positioning Modes. The sections are NOT a substitute for reading the entire PositionServo User Manual. Observe all safety notices in this manual. Quick Start - External Torque Mode Mandatory Signals: These signals are required in order to achieve motion from the motor.

  • Page 63: Quick Start - External Velocity Mode

    Reference Optional Parameter Settings: These parameters may require setting depending on the control system implemented. Folder / Sub-Folder Parameter Name Description Parameters Resolver Track PPR for simulated encoder on 941 Resolver drive IO / Digital IO Output 1 Function Set to any pre-defined function required Output 2 Function Set to any pre-defined function required Output 3 Function...
  • Page 64 Reference Mandatory Parameter Settings: These parameters are required to be set prior to running the drive. Folder/Sub-Folder Parameter Name Description Parameters Drive Mode Set to [Velocity] Reference Set to [External] Enable Velocity Accel / Decel Limits Enable Ramp rates for Velocity Mode Velocity Accel Limit Set required Acceleration Limit for Velocity command Velocity Decel Limit...

  • Page 65: Quick Start - External Positioning Mode

    Reference Quick Start - External Positioning Mode Mandatory Signals: These signals are required in order to achieve motion from the motor. Connector-Pin Input Name Description P3-1 Position Reference Input for Master Encoder / Step-Direction Input P3-2 Position Reference Input for Master Encoder / Step-Direction Input P3-3 Position Reference Input for Master Encoder / Step-Direction Input P3-4...
  • Page 66 Reference Mandatory Parameter Settings: These parameters are required to be set prior to running the drive. Folder / Sub-Folder Parameter Name Description Parameters Drive Mode Set to [Position] Reference Set to [External] Step Input Type Set to [S/D] or [Master Encoder]. (S/D = Step + Direction) Set ‘Master’...

  • Page 67: Diagnostics

    Diagnostics Display The PositionServo 940 drives are equipped with a diagnostic LED display and 3 push buttons to select displayed information and to edit a limited set of parameter values. Parameters can be scrolled by using the “UP” and “DOWN” ( ) buttons.

  • Page 68: Leds

    Diagnostics LEDs The PositionServo has five diagnostic LEDs mounted on the periphery of the front panel display as shown in the drawing below. These LEDs are designed to help monitor system status and activity as well as troubleshoot any faults. S913 Function Description...
  • Page 69 Diagnostics Fault Code Fault Description (Display) Statement executed within the Indexer Program results in a value being Arithmetic Error F_19 generated that is too big to be stored in the requested register. Drive Register overflow programming error (error in drive source code). Exceeded 32 levels subroutines stack depth.

  • Page 70: Fault Event

    Diagnostics 8.3.2 Fault Event When drive encounters any fault, the following events occur: • Drive is disabled • Internal status is set to “Fault” • Fault number is logged in the drive’s internal memory for later interrogation • Digital output(s), if configured for “Run Time Fault”, are asserted •...
  • Page 71 Diagnostics Problem Ready LED is on but motor does not run Suggested Solution If in Torque or Velocity mode: Reference voltage input signal is not applied. Reference signal is not connected to the PositionServo input properly; connections are open. In MotionView program check <Parameters> <Reference> set to <External> For Velocity mode only: In MotionView check <Parameters>...
  • Page 72 Notes S94P01B2...
  • Page 73 Notes S94P01B2...
  • Page 74 Notes S94P01B2...
  • Page 76 Lenze AC Tech Corporation 630 Douglas Street • Uxbridge, MA 01569 • USA Sales: (800) 217-9100 • Service: (508) 278-9100 www.lenze-actech.com (S94P01B2) S94P01B2-e2...

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