Estun Trio DX4 User Manual
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Estun Trio DX4 User Manual

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  • Page 2 DX4 Product Manual About this Manual Purpose This manual provides the information required for the Selection, Wiring, Connection, Setup, Trial Operation, Tuning and Functions of the DX4 Servo Drive (referred to as DX4). Please read and understand this manual to ensure correct usage of the product. Terms Terms that may be used in this manual are defined as follows.
  • Page 3 DX4 Product Manual Symbols The symbols that may be found in this document are defined as follows. Symbol Description Indicates a hazard with a high level of risk that, if not avoided, may result in death or serious injury. DANGER Indicates a hazard with a medium or low level of risk which, if not avoided, could result in minor or moderate injury.
  • Page 4 DX4 Product Manual Safety Precautions General Precautions Never remove covers, cables, connectors, or optional devices while power is being  supplied to the Drive. Wait for five minutes after turning the power supply OFF and then make sure that  the CHARGE indicator is not lit before starting wiring or inspection work.
  • Page 5 DX4 Product Manual Storage Precautions Follow all instructions on the packages, and never place an excessive load on the  product during storage. Never install or store the product in any of the following locations.  Locations that are subject to direct sunlight ...
  • Page 6 DX4 Product Manual Operation Precautions In order to prevent accidents, please test the Motor with no load (not connected to  the Drive shaft). When starting to operate on the supporting machine, set the user parameters that  match the machine in advance. Note that the signals for the Forward Drive Prohibit (P-OT) and the Reverse Drive ...

  • Page 7: Table Of Contents

    DX4 Product Manual Contents Chapter 1 DX4 Servo Drive ..............1-1 1.1 Product Features ..................1-1 1.2 Interpreting the Nameplate ................1-2 1.3 Model Designations ..................1-2 1.4 Part Names ....................1-3 1.5 Ratings and Specifications ................1-4 1.6 External Dimensions ..................1-6 1.7 System Configuration ...................
  • Page 8 DX4 Product Manual 7.7 Load Identification..................7-25 Chapter 8 Fully Closed Loop Operation ............. 8-31 8.1 Commissioning Procedure ................8-32 8.2 Enable External Encoder ................8-32 8.3 Motor Direction and Machine Movement ............8-1 8.4 Alarm Detection Settings ................8-1 Chapter 9 Appendix ................

  • Page 9: Chapter 1 Dx4 Servo Drive

    DX4 Product Manual DX4 Servo Drive Chapter 1 DX4 Servo Drive 1.1 Product Features The DX4 single axis AC servo drive is designed to work seamlessly with Trio controller and is fully integrated into Trio’s application development tool, Motion Perfect. It comes in power ratings from 50 W to 3 kW.

  • Page 10: Interpreting The Nameplate

    DX4 Product Manual DX4 Servo Drive 1.2 Interpreting the Nameplate Rated Input Rated Output Drive Model Serial Number 1.3 Model Designations Number of axes Output Power Voltage Options Design Sequence Single axis 200VAC EtherCAT + STO 100W 200W 400W 750W 1.5kW ©...

  • Page 11: Part Names

    DX4 Product Manual DX4 Servo Drive 1.4 Part Names Name Description Control Circuit Connector Control power supply (5 pins) Main Circuit Connector Main circuit power supply (6 pins) Status Display Drive status display CHARGE Indicator Lamp Main circuit power supply indicator Motor Connector Motor power Grounding Terminal...

  • Page 12: Ratings And Specifications

    DX4 Product Manual DX4 Servo Drive 1.5 Ratings and Specifications Drive Model: DX4 1A5A 101A 102A 104A 108A 110A 115A 120A 130A Continuous Output Current [Arms] 11.3 16.0 Instantaneous Maximum Output 11.5 19.5 21.0 24.6 33.9 54.0 Current [Arms] Single-phase －...
  • Page 13 DX4 Product Manual DX4 Servo Drive External Encoder Supports A, B, and Z TTL differential type sensor signal. Input Maximum line frequency of 500kHz. Allowable voltage range: 24 V dc ±20% Number of input points: 7 (2 for high-speed optocoupler inputs, fixed as Touch Probe) Touch Probe Signals are TP1 (Touch Probe 1), TP2 (Touch Probe Input Signals...

  • Page 14: External Dimensions

    DX4 Product Manual DX4 Servo Drive Indicator Lamps CHARGE, POWER, RUN, SYS, ERR, L/A IN, L/A OUT DX4-1A5*, DX4-101*, DX4-102* and DX4-104* must connect an Regenerative Processing external regenerative resistor. Other models are built in. Overcurrent, Overvoltage, Undervoltage, Overload, Regeneration Protective Functions Error, Overspeed, etc.

  • Page 15: System Configuration

    DX4 Product Manual DX4 Servo Drive DX4-120 * to DX4-130* 1.7 System Configuration Example Diagram © 2020 Trio Motion Technology Ltd. All right reserved. Document Version: V1.04 (Jan, 2021)
  • Page 16 DX4 Product Manual DX4 Servo Drive Minimum system configuration is:  Power Supply  Breaker  Filter  Contactor  Regen resistor  Drive  Motor  Controller  PC for commissioning  Cables (encoder, motor power, EtherCAT, Ethernet, STO, IO cable) Peripheral Devices Specification Device Name Description...
  • Page 17 DX4 Product Manual DX4 Servo Drive Device Name Description Specification The minimum value of the regenerative resistor depends on the Drive model. Drive Model Regenerative Resistor DX4-1A5* 25 Ω When the busbar capacitance is DX4-101* insufficient, remove the short wiring between B2 and B3, and DX4-102* External connect an external regenerative...

  • Page 18: Chapter 2 Installation

    Chapter 2 Installation 2.1 Installation Precautions Installation Near Sources of Heat Implement measures to prevent temperature increases caused by external heat sources so that the ambient temperature of the Drive is within the specified limits. Installation Near Sources of Vibration Install a vibration absorber on the installation surface of the Drive so that the Drive will not be subjected to vibration.

  • Page 19: Mounting Hole Dimensions

    2.3 Mounting Hole Dimensions Use all mounting holes to securely mount the Drive to the mounting surface. To mount the Drive, use a screwdriver that is longer than the depth of the Drive. 2.4 Mounting Interval Installing One Drive in a Control Cabinet When installing a single Drive use Figure 2-2 as a reference for free space around the installation.
  • Page 20 Installing multiple Drives in a Control Cabinet When installing a multiple Drives use Figure 2-3 as a reference for free space around the installation. Figure 2-3 Installing multiple Drives in a control cabinet The DX4 can be mounted so that the distance between adjacent Drives is 1mm. NOTE ©...

  • Page 21: Chapter 3 Wiring And Connections

    Chapter 3 Wiring and Connections 3.1 Precautions for Wiring 3.1.1 General Precautions Never change any wiring while power is being supplied in case of risk of electric  shock or injury. DANGER Wiring and inspections must be performed only by qualified engineers. ...
  • Page 22 Whenever possible, use the Cables specified by Trio.  Securely tighten cable connector screws and lock mechanisms to prevent mechanical  failure during operation. Ensure that power lines (e.g. Main Circuit Cable) and low-current lines (e.g. I/O Signal  NOTE Cables or Encoder Cables) are separated by at least 30 cm.
  • Page 23 Figure 3-1 Wiring example for countermeasures against noise Noise Filter Wiring and Connection Precautions Always observe the following precautions when wiring or connecting Noise Filters.  Separate input lines from output lines. Do not place input lines and output lines in the same duct or bundle them together.
  • Page 24 Noise Filter Noise Filter Ground Ground plate plate Separate the circuits.  Separate the Noise Filter ground wire from the output lines. Do not place the Noise Filter ground wire, output lines, and other signal lines in the same duct or bundle them together. Noise Filter Noise Filter The ground wire...
  • Page 25  If a Noise Filter is located inside a control panel, first connect the Noise Filter ground wire and the ground wires from other devices inside the control panel to the grounding plate for the control panel, then ground the plate. Control Cabinet Drive Noise Filter...
  • Page 26 terminal (FG) or ground terminal (FG) of the Motor to the ground terminal on the Drive. Also, be sure to ground the ground terminal Noise on I/O Signal Cables To prevent noise entering the I/O Signal Cable connect the shield of the I/O Signal Cable to the connector shell and ensure the shell is connected to ground.

  • Page 27: Basic Wiring Diagrams

    3.2 Basic Wiring Diagrams © 2020 Trio Motion Technology Ltd. All right reserved. Document Version: V1.04 (Jan, 2021)

  • Page 28: Power Supply (X1, X2)

    3.3 Power Supply (X1, X2) 3.3.1 Terminals Arrangement The power supply to Drive includes main circuit terminals and control circuit terminals. Signal Diagram Pin Layout Symbols Name Specifications and Reference Main circuit power supply Three-phase, 200 V ac to 240 V ac, -15% to +10%, 50 Hz L1, L2, L3 input terminals or 60 Hz...
  • Page 29 3.3.2 Wiring Procedure Prepare the following items before preparing the wiring for the Main Circuit Terminals and Control Circuit Terminals. Required Item Description Flat-blade screwdriver Commercially available screwdriver with tip width of 3.0 mm to 3.5 mm Sleeve type ferrule with cross-section from 1.5 mm to 2.5 mm and a length Cold pressed terminals...
  • Page 30 Figure 3-4 Insert the cable into the ferrule 1 mm or more Crimp the cable that has been inserted into the ferrule and cut off the cable conductor Step 4 portion protruding from the ferrule (The allowable protruding length after cutting should not be more than 0.5 mm).
  • Page 31 The above wiring procedure is also applicable to the Motor Terminals.  NOTE 3.3.3 Wiring Diagrams The wiring diameter of the power input is determined by the Drive model. The following table lists the recommended wire diameters for each Drive model. Drive Model Recommended Wire Cross-sectional area (mm²)
  • Page 32 Wiring Example for Single-phase Power Supply Input NOTE: for single phase wiring L or N can be wired into either L1 or L2 Wiring Example for DC Power Supply Input © 2020 Trio Motion Technology Ltd. All right reserved. 3-12 Document Version: V1.04 (Jan, 2021)

  • Page 33: Motor Power (X3)

    3.4 Motor Power (X3) Connection Diagram Terminals Arrangement Terminals Pin Layout Symbols Color EC3P-B1718 Brown Gray Black Yellow-Green White Green Motor connection side EC3P-N1718 Symbols Color Brown Gray Black Yellow-Green Symbols Color Brown Drive connection side Gray Black © 2020 Trio Motion Technology Ltd. All right reserved. 3-13 Document Version: V1.04 (Jan, 2021)

  • Page 34: Ethercat Communication (X4, X5)

    3.5 EtherCAT Communication (X4, X5) Connection Diagram X4-IN – connects to the OUT of the previous device or controller X5-OUT – connects to the IN of the next device or can be left un-connected Pin Layout EtherCAT communication (X4-IN and X5-OUT) are RJ45 terminals. The communication cable from the network master or controller should be connected to X4-IN and X5-OUT should be connected to the X4-IN terminal of the next Drive (or network device).

  • Page 35: Connecting Sto Function Signals (X6)

    3.6 Connecting STO Function Signals (X6) A Safety Function Device shall be connected for using the STO function. For the connection and usage, please refers to Chapter 4 STO. 3.7 I/O Connector (X7) Signal Diagram Pin Layout Name Type Function TP1+ Input Touch Probe Input 1...
  • Page 36 Name Type Function DIN1 Input General purpose digital input 1. DIN2 Input General purpose digital input 2. DIN3 Input General purpose digital input 3. DIN4 Input General purpose digital input 4. PIA+ Input External Encoder Input, channel A. PIA- Input PIB+ Input External Encoder Input, channel B.

  • Page 37: Encoder (X8)

    3.8 Encoder (X8) Connection Diagram Terminals Arrangement Terminals Pin Layout Symbols Color Blue Blue-Black ECS-I1724 / ECS-A1724 BAT+ Yellow Green Motor connection side Green-Black PG5V PG0V Black BAT- Yellow-Black Frame ground © 2020 Trio Motion Technology Ltd. All right reserved. 3-17 Document Version: V1.04 (Jan, 2021)
  • Page 38 Terminals Pin Layout Symbols Color Blue Blue-Black BAT+ Yellow EC3S-I1324 / EC3S-A1324 BAT- Green Green-Black PG0V Black PG5V Yellow-Black － － Frame ground Symbols Color PG5V PG0V Black － － － － Green Drive connection side Green-Black Blue Blue-Black BAT+ Yellow BAT- Yellow-Black...

  • Page 39: Chapter 4 Sto

    Chapter 4 STO 4.1 Introduction This product has the integrated safety function Safe Torque Off (STO) according to IEC 61800-5-2, which is equivalent to an uncontrolled stop in accordance with stop category 0 of IEC 60204-1, which can protect people from dangerous movements of the machine and reduce the risk to the operator. The Safe Torque Off (STO) function is a safety function that shuts the Motor current and turns off Motor output torque by turning off the driving signal of the Drive’s internal power transistor when safety input signal is detected.
  • Page 40 The reliability block diagram of safety function is as shown in Figure 4-2. Figure 4-2 Reliability block diagram Input 1 Actuator 1 Power Common Supply Cause Input 2 Actuator 2 4.1.2 Functions and Features The functions or features of STO are as follows: The safe state is a hardware disable of all PWM signals used to generate torque in the Motor.
  • Page 41 Never touch the terminals while the power is on.  Since the STO function only cuts off the torque output of the Motor and does not cut off the physical connection between the Drive and the Motor, there is a risk of electric shock.

  • Page 42: Environmental Conditions

    Item Safety Specification IEC 60068-2-1: 2007  IEC 60068-2-2: 2007  IEC 60068-2-6: 1995  IEC 60068-2-14: 1984  Environmental Requirements IEC 60068-2-27: 1987  IEC 60068-2-78: 2001  IEC 61800-2: 2015  IEC 61800-5-1:2007 + AMD1:2016  4.2 Environmental Conditions Item Specification Single drive: -5 ℃...

  • Page 43: Terminals Arrangement (X6)

    4.3 Terminals Arrangement (X6) Signal Diagram Pin Layout Please use the PELV/SELV switching power supplying to the IO signal of the STO  function. The external signal shall meet the Idle-current principle. WARNING  Signal Name Function － (Do not use these pins because 24 V Power Supply they are connected to internal 24 V...

  • Page 44: Function Description

    Item Characteristics Description Internal Impedance 3.3 kΩ － Operating Voltage 24V ± 20% = 17.6 V; V = 4 V H_min L_max Range The electrical characteristics of the EDM (X6-7, X6-8) output signal are as follows: Item Characteristics Description Maximum Allowable 35 V dc －...
  • Page 45 The EDM signal is not a safety output. Use it only for monitoring for failures.  WARNING If an STO is requested by turning OFF input signals (HWBB1 and HWBB2) when the safety function is operating normally, the EDM output signal will be turned ON within 5 milliseconds. ≤...
  • Page 46 Conditions for STO function reset is that both HWBB1 and HWBB2 are ON.  CAUTION 4.4.3 S-RDY (Servo Ready Output) Signal When the Drive is in Safe State, S-RDY (Servo Ready Output) signal is OFF. When the HWBB1 and the HWBB2 signals are turned ON, and the Servo is OFF, the S-RDY signal will be turned ON, and the Drive will be in Ready State.

  • Page 47: Safety Function Device Connection

    4.4.6 Reset Method for Deviation Counter The Drive will enter the safe state when the STO function takes effect, and the Deviation Counter will reset according to the setting of Pn004.1. Parameter Setting Reset Method When Enabled Reset to zero when Servo is OFF or STO function takes effect.
  • Page 48 4.5.2 Connecting a Safety Function Device Remove the shorting pins on the Safety Connector as shown in Figure 4-3. Step 1 Figure 4-3 Remove the shorting pins Wiring the Safety Function Device Step 2 Connect the Safety Function Device to the X6 port according to the wiring example shown in Figure 4-4.
  • Page 49 Validating Safety Functions Step 3 When the system is commissioned, or maintenance operations are performed, or a Drive is replaced re-validation tests must be run to check the operation of the STO function. It is recommended that the results of any conformation testing are kept as a record for future reference.

  • Page 50: Procedure

    4.6 Procedure Taking the wiring of the Safety Function Device shown in Figure 4-4 as an example, use the STO function as follows. Prepare for maintenance work on the device. Stop the Motor and turn OFF the S-ON signal. The safety light curtain blocked. The HWBB1 and HWBB2 signals are turned OFF and the Servodrive enters the Safe State.

  • Page 51: Chapter 5 Status Display

    Chapter 5 Status Display The Status indicators on the Drive show the status of the EtherCAT network and the servo control. The POWER LED indicates power is present to the Control board. The CHARGE LED indicates the voltage level on the Main circuit. The seven-segment display shows the status of the motor control.
  • Page 52 This shows the state as Servo Alarm State (FLt) and the alarm code (A01) each separated by the display separator. 5.1.1 Code The table below described the different Code sequences shown on the Drive. Table 5-1 Display meanings of Code Code Meaning Servo initialization failed (check the encoder connection)

  • Page 53: Network Status Indicators

    Network Status Indicators There are 3 indicator lamps on the panel Operator of the Drive to indicate the communication status of EtherCAT: SYS, RUN and ERR. SYS Indicator The SYS indicator shows the system status of EtherCAT communications. Indicator Description Status Pattern No power supplied or EtherCAT is...
  • Page 54 Indicator Description Status Pattern A synchronization error Single occurred and EtherCAT 0.2s flash automatically went to Safe- Operational state An application (Sync Double Manager) watchdog timeout 0.2s 0.2s 0.2s flash error occurred 50 ms Flickering A boot error occurred A PDI watchdog timeout Always lit error occurred 5.2.1 RJ45 LEDs...

  • Page 55: Chapter 6 Commissioning

    Chapter 6 Commissioning All configuration and commissioning of DX4 is performed using Motion Perfect v5.0 (or above). 6.1 Motion Perfect Motion Perfect is a Microsoft Windows™ based application for the PC, designed to be used in conjunction with Trio Motion Technology's range of multi-tasking motion controllers, servo drives, HMI and IO expansion products.
  • Page 56 6.2.1 Initial Connection To make the initial connection to a controller:  Make sure that your controller is powered up and connected to the computer  Start Motion Perfect. Once it has started up the initial screen should be displayed. ...
  • Page 57 EtherCAT State If the EtherCAT state is not operational (green indicator in the controller tree, and green banner in Intelligent Drives), it may be necessary to re-start the EtherCAT network. A re-start of the EtherCAT network can be issued from either the controller tree by right clicking on the EtherCAT root node, or from the Intelligent Drives tool by right clicking on the controller.

  • Page 58: Drive Commissioning Screens

    If there is a conflict during the axis allocation process, and the drive cannot be allocated a node number the EtherCAT network will not achieve an operational state. Typical reasons for this are:  Duplicate axis number allocation in MC_CONFIG. To resolve this, change the NODE_AXIS command in MC_CONFIG to avoid the duplication ...
  • Page 59 The commissioning screens for the Drive are listed below. The menu is split into 2 groups, Drive and Motor. The Drive screens are for status and operations that are not necessarily axis specific. The Motor screens show detail that is axis specific. Drive ...
  • Page 60 Control word, Status word DPOS, MPOS Target Actual Position, Actual Velocity, Actual Torque Status of motor feedback device Basic Setup  Allows easy access to basic drive configuration  Parameters that define the physical operation of the drive Power supply type Motor Direction and Abs.

  • Page 61: Basic Operation

     Filters to identify changes  Import and export of full or partial parameter set  Create STARTUP program based on full or partial parameter set 6.4 Basic Operation To ensure safe and correct operation, check the following items before you start. ...
  • Page 62 If using an absolute encoder, the drive will generate an alarm if it detects a low battery voltage at the encoder. If a battery is fitted and the voltage is correct, this alarm can be cleared from the Motor page in the drive commissioning screens.
  • Page 63 Selecting a digital output in the Basic Setup screen will enable the brake control timing parameters. Brake Operating Sequence The time required to release the brake and the time required to brake should be considered to determine the brake operation timing, as described below. Servo ON command Servo OFF Servo ON...
  • Page 64 If Pn505 is a negative value, when the Servo ON command is received, the power will be supplied to the motor immediately, then the brake signal will change after the delay time. Enabled -> Disabled The brake engage delay time controls the delay between the brake signal and motor power when the drive changes from enabled to disabled when the motor is stationary.
  • Page 65 Parameter Name Range Unit Default Pn507 Brake Enable Speed Threshold 10 to 100 1rpm Pn508 Brake Enable Waiting Time 10 to 100 10ms The brake signal changes when either of the following conditions is satisfied:  When the motor speed falls below the level set in Pn507 after the power to the motor is turned OFF.
  • Page 66 The ‘+’ arrow will cause forward rotation, the ‘-‘ arrow will cause reserve rotation. Forward rotation Reverse rotation Default forward rotation is Default forward rotation is counterclockwise (CCW) as viewed clockwise (CW) as viewed from from the load end of the Motor. the load end of the Motor.
  • Page 67 DPOS will not change during a jog. When the drive is disabled, the update of MPOS and DPOS will resume. © 2020 Trio Motion Technology Ltd. All right reserved. 6-13 Document Version: V1.04 (Jan, 2021)

  • Page 68: Chapter 7 Tuning

    Chapter 7 Tuning Tuning is the process of satisfying the servo performance by adjusting the parameters involved in the control law. The process of tuning is usually an iterative process; the figure below shows the general flow Start Set Parameters Performance Adjust Parameters evaluation...

  • Page 69: Tuning Process

    Indicator Before tuning After tuning Anti-load disturbance 7.1 Tuning Process When tuning a servo drive is if helpful to understand the servo control principle used. The figure below shows the servo control block diagram. The position loop, the speed loop and the torque loop are cascaded structures, corresponding to the position control mode, the speed control mode and the torque control mode respectively.
  • Page 70 Start Perform the Tuning-Less function Response acceptable Perform Load Inertia Identification function Perform the One-Parameter Auto-Tuning function Results acceptable Use the Auto-Tuning/Manual-Tuning Tools Results acceptable Perform the Manual Tuning function It will be necessary to perform the tuning operation again if the motor has been disassembled or the load device had been replaced.

  • Page 71: Tuning Modes

    7.2 Tuning Modes The drive supports 3 different tuning modes and different features are available in each mode. Tuning-less: the drive performs auto-tuning to obtain a stable response regardless of the type of machine or changes in the load. One-Parameter Auto-Tuning: similar to the tuning-less function but requires an inertia measurement of the load and uses a rigidity parameter to control the system bandwidth.
  • Page 72 7.2.1 Tuningless In Tuning-less mode the drive performs auto-tuning to obtain a stable response regardless of the type of machine or changes in the load. Autotuning is started when the servo is turned on. The tuning-less function uses an Autotune parameters adjustment module that updates the position loop and speed loop parameters in real time based on the servo operating state (position, speed, current).
  • Page 73 Function Tuning-less Friction Compensation Automatic Vibration Suppression Intermediate Frequency Vibration Suppression Notch Filter 7.2.2 One-Parameter Auto Tuning This tuning function is similar to the tuning-less function, using an Autotune parameters adjustment module that updates the position loop and speed loop parameters in real time based on the servo operating state (position, speed, current).
  • Page 74 The stiffness of the control is selected by a rigidity parameter. This can be adjusted by a slider on the Tuning page in the drive commissioning screens. Alternatively, the rigidity can be entered by directly writing to parameter Pn101. Parameter Name Description Determines the response characteristic of the position...
  • Page 75 Applicable for applications of any motor speed. Parameters Parameter Setting Meaning Pn100.0 Set the Tuning Mode as One-Parameter Auto-Tuning. 0 [Default] Set the damping method in One-Parameter Auto-Tuning as Standard. Pn100.3 Set the damping method in One-Parameter Auto-Tuning as Stable. Pn101 Servo Rigidity (setting depends on application) －...
  • Page 76 Adjust parameter manually Servo gain parameters Motor Position reference Host Position loop Speed loop Torque loop Controller Position Speed Current Drive Encoder It is necessary to adjust the three-loop control parameters of the Servo from the inside out, that is, the adjustment sequence is Torque loop →...
  • Page 77 Response Curve Description Adjustment method Properly decrease the Speed Speed loop bandwidth is high Loop Gain or increase the Speed Loop Integral Time. Properly increase the Speed Speed loop damping ratio is low Loop Integral Time. Properly decrease the Speed Steady-state error is existed Loop Integral Time.
  • Page 78 Block Parameter Name Position Control Pn104 Position Loop Gain Position Control Pn109 Second Position Loop Gain Speed Feedforward Pn112 Speed Feedforward Speed Feedforward Pn113 Speed Feedforward Filter Time Speed Control Pn102 Speed Loop Gain Speed Control Pn107 Second Speed Loop Gain Speed Control Pn103 Speed Loop Integral Time...

  • Page 79: Compensation

    Function Manual Intermediate Frequency Vibration Suppression Notch Filter Load Oscillation Suppression P / PI Switching Gain Switching Model Following Control 7.3 Compensation The Drive offers several compensation techniques which can be used in various tuning modes to improve performance. 7.3.1 Feedforward The table below shows the tuning modes where the feed forward function can be used.
  • Page 80  Internal Torque Feedforward ＝ Differential of speed reference × Load Inertia Percentage × Torque Feedforward Increasing the feedforward term will tend to reduce error during periods where the reference is constant. i.e. during periods of constant speed, the speed feed forward will allow to the control scheme to reduce following error, however the feedforward can introduce overshoot.
  • Page 81 Friction Compensation function Available Tuning-less One-Parameter Auto Tuning Manual Tuning Load friction will exist in the transmission system. However, severe load friction may cause low-speed crawling, waveform distortion at speed zero-crossing, positioning lag, etc. This can affect the dynamic and static performance of the system. The friction compensation function allows the drive to compensate for this and may be a requirement in applications with frequent forward and reverse motion, and high speed-stability requirements.
  • Page 82 As the speed increase, so the viscous friction compensation increases with a rate defined by the Viscous Friction Compensation parameter. 7.3.3 Speed Feedback Selection The table below shows the tuning modes where the speed feedback function can be used. Speed Feedback function Available Tuning-less One-Parameter Auto Tuning...
  • Page 83 The figure below shows the speed drop caused by a sudden load torque. The load torque compensation function can be used to reduce the effect of the load torque change. Before tuning After tuning Speed Speed Tuning the load torque compensation function can be used to improve the anti-load disturbance performance, considering that the reference response performance and the load disturbance resistance cannot be balanced.

  • Page 84: Vibration Suppression

    Stabl e St andard Positioning point The damping selection can be made from the Tuning page in the drive commissioning screens. Alternatively, the damping selection can be changed by directly writing to parameter Pn100.3. Parameter Setting Meaning 0 [Default] Shorter positioning time, but prone to overshoot Pn100.3 Longer positioning time, but stable 7.4 Vibration Suppression...
  • Page 85 Parameter Setting Meaning Pn179 Amplitude Threshold for Vibration Detection － 7.4.2 IF (Intermediate Frequency) Vibration Suppression The table below shows the tuning modes where the IF vibration suppression function can be used. IF Vibration Suppression Available Tuning-less One-Parameter Auto Tuning Manual Tuning The IF vibration suppression filter is used to process the speed deviation and provide compensation to the torque reference.
  • Page 86 Notch Filter Available Tuning-less One-Parameter Auto Tuning Manual Tuning The notch filter is used to eliminate vibration caused by mechanical resonance. There are three notch filters in the Drive, those who can used independently or in combination. Motor Position Reference Notch Filter Position loop Speed loop...
  • Page 87 Alternatively, the filters can be configured by directly writing to the parameters. Parameter Setting Meaning Pn181 Frequency of Notch Filter 1 － Pn182 Depth of Notch Filter 1 － Pn183 Width of Notch Filter 1 － Pn184 Frequency of Notch Filter 2 －...

  • Page 88: Gain Scheduling

    Load Oscillation Suppression Motor Model following Position loop Speed loop Torque loop control Position Speed Current Speed feedforward Torque feedforward Encoder This function is based on the Model Following Control (7.6 ) and enabled via Pn150. Parameter Setting Meaning Pn150.0 Use the model following control and load oscillation suppression.
  • Page 89 Parameter Setting Meaning Use position deviation counter as the condition (threshold setting: Pn118). Use acceleration reference as the condition (threshold setting: Pn119) Use the speed reference as the condition (threshold setting: Pn120). Fixed to PI Control. NOTE: Changing the P/PI switching condition will require the drive to be restarted. The relevant threshold parameters are shown in the table below.
  • Page 90 Gain switching can be enabled from the Tuning page in the drive commissioning screens. The conditions for gain switching are selected from a drop down. Options are:  Fixed to first group gains.  Use digital input (G-SEL) as the condition. ...

  • Page 91: Model Control Following

    Parameter Setting Meaning Use position reference as the condition (threshold setting: Pn123). Use actual speed as the condition (threshold setting: Pn123). Use position reference (Pn123) and actual speed (Pn124) as the condition. Fixed to second group gains. Use positioning completed flag as the condition. NOTE: Changing the gain switching condition will require the drive to be restarted.

  • Page 92: Load Identification

    The Model Following Control function is enabled via Pn150. Parameter Setting Meaning 0 [Default] Do not use Model Following Control. Pn150.0 Use the model following control. Use the model following control and load oscillation suppression. NOTE: Changing the model following control mode will require the drive to be restarted. To use the Model Following Control properly, the system should be setup in the following order: Torque Loop →...
  • Page 93 This will launch a wizard to guide the inertia detection sequence. The identification routine will rotate the Motor back and forth either 4 or 8 times, during this movement the inertia is calculated. At the end of the identification routine, the result is displayed with the option to update the inertia value in Pn106.
  • Page 94 Start Load Inertia Percentage Set parameters for reference generator Check and confirm the safety of the motion Use the Auto-Tuning Tool Result of execution Success Faulure Save Execute again Write parameters The steps in the wizard are:  Detect Inertia ...
  • Page 95 Round trip in Round trip in positive direction negative direction Speed Speed Movement in Movement in Positive direction negative direction Speed Speed The Setup screen allows entry of the parameters which describe the motion. Motion Trajectory: This is an opportunity to review the defined motion sequence before starting the tuning sequence.
  • Page 96 Tuning: During the internal tuning process, the progress is displayed on screen. Results: Once the tuning process has completed, the calculated gain terms will be displayed with an option to save them to the drive. © 2020 Trio Motion Technology Ltd. All right reserved. 7-29 Document Version: V1.04 (Jan, 2021)
  • Page 97 © 2020 Trio Motion Technology Ltd. All right reserved. 7-30 Document Version: V1.04 (Jan, 2021)

  • Page 98: Chapter 8 Fully Closed Loop Operation

    Chapter 8 Fully Closed Loop Operation With a fully-closed system, the encoder on the motor is used in conjunction with an external encoder (external to the motor) is used to detect the position of the load. This is also known as dual encoder feedback.

  • Page 99: Commissioning Procedure

    8.1 Commissioning Procedure The commissioning procedure for the Drive for fully-closed loop control is given below. Complete the wiring and connection of the Drive and Motor and connect to the machine. Step 1 Ensure Pn210.0 is set to 0 to use the encoder on the motor (semi-closed loop control). Step 2 Using the Jog operation, move the movable part on the machine side to an appropriate Step 3...

  • Page 100: Motor Direction And Machine Movement

    8.3 Motor Direction and Machine Movement For fully-closed loop operation the Motor direction and the machine movement direction must configured. The table below shows the relationship between Pn001.0, Pn210.3 and direction. Pn210.3 (Direction of External Encoder) Pn001.0 (CCW, CW) 0 (Not invert) 1 (Invert) Forward Reverse...
  • Page 101 Pn214 = 0 Large Deviation between motor and external encoder Pn214 = 20 Small Pn214 = 100 Motor rotations 1st rotation 2nd rotation 3rd rotation 4th rotation © 2020 Trio Motion Technology Ltd. All right reserved. Document Version: V1.04 (Jan, 2021)

  • Page 102: Chapter 9 Appendix

    Chapter 9 Appendix 9.1 EtherCAT Communications 9.1.1 Introduction EtherCAT is a real-time Industrial Ethernet technology originally developed by Beckhoff Automation. The EtherCAT protocol which is disclosed in the IEC standard IEC61158 is suitable for hard and soft real-time requirements in automation technology, in test and measurement and many other applications. The EtherCAT master sends a telegram that passes through each node.
  • Page 103 The ESI file for the DX4 is available on the Trio website and has the name: TRIO_DX4_V***.xml NOTE: The asterisks (***) indicate the version number. 9.1.4 EtherCAT State Machine A state machine is used to manage the communications states between the master and slave applications, shown in Figure 9-1.
  • Page 104 State or Transition Operation The master sends available output data. Safe-Operational to  Operational (SO) The master requests the Operational state.  Operational (O) Process data communications are available. Table 9-1 Description of state or transition The state of the drive can be seen in the EtherCAT Info frame in the device configuration screen within Motion Perfect.
  • Page 105 NOTE: Only the object 1C33-03h can be set. 9.1.6 Relevant Settings For correct operation using EtherCAT ensure the parameters below are set correctly. Parameter Name Setting Meaning Pn006.0 Bus Selection Use EtherCAT. [Default] The Device Node Number can be used to force the axis number used by the controller. If the Drive has a non-zero device node number (Pn704) and this node number is unique on the network, then the axis number will be the node number -1.

  • Page 106: Object Dictionary

    9.2 Object Dictionary Group 1000h Data Index Subindex Name Access Unit Range Default Type Mapping Pre-defined error field Number of entries UINT8 － － － Standard error field 1 UINT32 － － － Standard error field 2 UINT32 － － －...
  • Page 107 Data Index Subindex Name Access Unit Range Default Type Mapping Mapping entry 5 UINT32 － － － Mapping entry 6 UwINT32 － － － Mapping entry 7 UINT32 － － － Mapping entry 8 UINT32 － － － 2nd Receive PDO Mapping Number of entries UINT8 －...
  • Page 108 Data Index Subindex Name Access Unit Range Default Type Mapping Mapping entry 7 UINT32 － － － Mapping entry 8 UINT32 － － － 1st Receive PDO Mapping Number of entries UINT8 － － － Mapping entry 1 UINT32 － －...
  • Page 109 Data Index Subindex Name Access Unit Range Default Type Mapping 4thTransmit PDO Mapping Number of entries UINT8 － － － Mapping entry 1 UINT32 － － － Mapping entry 2 UINT32 － － － Mapping entry 3 UINT32 － － －...
  • Page 110 Group 3000h Data Index Parameter Name Access Unit Range Default Type Mapping 30A5 SinglePos DINT － － － － 30A6 MultiPos UDINT － － － － External Encoder -231～ 30A8 INT32 1 pulse － － Position (231-1) Basic Function 0000 to 3164 Pn000 INT32...
  • Page 111 Data Index Parameter Name Access Unit Range Default Type Mapping Second Speed Loop 31D0 Pn108 INT32 rad/s 1 to 5000 Integral Time Second Position 31D1 Pn109 INT32 0 to 1000 Loop Gain Second Torque Reference Filter 31D2 Pn110 INT32 0.01ms 0 to 2500 Time 31D4...
  • Page 112 Data Index Parameter Name Access Unit Range Default Type Mapping Viscous Friction 31E8 Pn132 INT32 0.1%Tn/1000rpm 0 to 1000 Compensation Encoder Speed 31EB Pn135 INT32 0.01ms 0 to 30000 Filter Time Model Following 0000 to 31FA Pn150 INT32 0000 － Control Function 0002 Model Following...
  • Page 113 Data Index Parameter Name Access Unit Range Default Type Mapping Frequency of Vibration 3211 Pn173 INT32 100 to 2000 2000 Suppression Filter Adjust Bandwidth of Vibration 3212 Pn174 INT32 1 to 100 － Suppression Filter Vibration 3213 Pn175 INT32 0 to 500 －...
  • Page 114 Data Index Parameter Name Access Unit Range Default Type Mapping Resolution of 3238 Pn212 INT32 1 pulse 1 to 2 10000 External Encoder Position Deviation Threshold between 3239 Pn213 INT32 1 pulse 0 to 2 1000 Encoder and External Encoder Position Deviation Clear between 323A...
  • Page 115 Data Index Parameter Name Access Unit Range Default Type Mapping Release Time for Torque Limit at 32FB Pn407 INT32 0 to 1000 Main Circuit Voltage Drop Speed Limit during 32FC Pn408 INT32 0 to 6000 1500 Torque Control Position Arrival 3358 Pn500 INT32...
  • Page 116 Data Index Parameter Name Access Unit Range Default Type Mapping Position Arrival Status Detection 336C Pn520 INT32 0.1 ms 0 to 60000 Time Threshold 0000 to 336D Pn521 Alarm Masks INT32 0000 － 0011 Motor Overload Detection Start 3371 Pn525 INT32 100 to 150 Threshold...
  • Page 117 Data Index Subindex Name Access Unit Range Default Type Mapping 6040 Control word UINT16 0 to 65535 － 6041 Status word UINT16 0 to 65535 － － Quick stop 605A INT16 0, 1, 2, 5, 6 － option code Shutdown 605B INT16 0, 1...
  • Page 118 Data Index Subindex Name Access Unit Range Default Type Mapping -2147483648 Velocity 606C INT32 Speed units － actual value 2147483647 Velocity 606D UINT16 Speed units 0 to 65535 window Velocity 606E UINT16 0 to 65535 window time Velocity 606F UINT16 Speed units 0 to 65535 threshold...
  • Page 119 Data Index Subindex Name Access Unit Range Default Type Mapping Profile 6081 UINT32 Speed units 0 to 200000 10000 velocity 0 to 6082 End velocity UINT32 Speed units 4294967295 Profile Acceleration 0 to 6083 UINT32 200000 acceleration units 4294967295 Profile Acceleration 0 to 6084...
  • Page 120 Data Index Subindex Name Access Unit Range Default Type Mapping Positive 60E0 Torque Limit UINT16 0.1% 0 to 65535 3500 Value Negative 60E1 Torque Limit UINT16 0.1% 0 to 65535 3500 Value -2147483648 Following Position 60F4 INT32 － Error units 2147483647 Position -2147483648...

  • Page 121: Parameter List

    9.3 Parameter List 9.3.1 Parameter Table Name Range Default Unit Function Description Restart Basic Function b0000 ~ Pn000 0000 — Selection 0 b0111 Pn000.0 Reserved 0 ~ 0 — [0] Enabled. The motor is stopped according to Forward Drive Pn003.1 when an overtravel Pn000.1 0 ~ 1 —...
  • Page 122 Name Range Default Unit Function Description Restart [0] Dynamic brake then coast [1] Dynamic brake then DB state Motor Stopping [2] Coast Pn004.0 Methods for Gr.2 0 ~ 5 — [3] Reverse brake then DB Alarms state [4] Reverse brake then coast [5] Treat as warning, no action [0] Reset to zero when Servo...
  • Page 123 Name Range Default Unit Function Description Restart AC Supply [0] 50Hz Pn007.3 0 ~ 1 — Frequency [1] 60Hz Pn008 Reserved 0 ~ 9999 9999 — Application Function h0000 ~ Pn009 0000 — Selection 9 h0001 Common DC Bus [0] Disabled Pn009.0 Function [1] Enabled...
  • Page 124 Name Range Default Unit Function Description Restart Second Speed Loop Pn107 1 ~ 10000 rad/s Gain Second Speed Loop Pn108 1 ~ 5000 0.1ms Integral Time Second Position Pn109 0 ~ 1000 Loop Gain Second Torque Pn110 Reference Filter 0 ~ 2500 0.01ms Time This value is a percentage of...
  • Page 125 Name Range Default Unit Function Description Restart [0] Fixed to first gain set [1] Use digital input (G-SEL) [2] Use torque reference (see Pn117) [3] Use position deviation counter (see Pn118) [4] Use acceleration (see Pn119) [5] Use speed reference (see Pn120) Pn121 Gain Switch Mode...
  • Page 126 Name Range Default Unit Function Description Restart Determines the response characteristic of the servo Model Following system. Increasing this will Pn151 10 ~ 1000 Control Gain improve the response characteristic and reduce the positioning time. Model Following Used for correcting the Pn152 Control Gain 20 ~ 500...
  • Page 127 Name Range Default Unit Function Description Restart Frequency of Pn173 Vibration 100 ~ 2000 2000 Suppression Filter Adjust Bandwidth of Pn174 Vibration 1 ~ 100 — Suppression Filter Vibration Pn175 0 ~ 500 — Suppression Low pass Filter Time Pn176 for Vibration 0 ~ 50 0.1ms...
  • Page 128 Name Range Default Unit Function Description Restart Position Deviation Clear between Pn214 0 ~ 100 Encoder and External Encoder Delay Compensation [0] Automatic compensation Pn225 Method for Biss 0 ~ 1 — [1] Manual compensation Encoder Manual Delay Pn226 Compensation Value 0~0xFF 10ns for Biss Encoder...
  • Page 129 Name Range Default Unit Function Description Restart Reverse External Pn404 0 ~ 400 Torque Limit Reverse Brake Pn405 0 ~ 400 Torque Limit Torque Limit at Pn406 Main Circuit Voltage 0 ~ 100 Drop Release Time for Torque Limit at Pn407 0 ~ 1000 Main Circuit Voltage...
  • Page 130 Name Range Default Unit Function Description Restart delay exceeds the specified value after receiving the command. Note: the brake signal will remain ON as long as one of the conditions (Pn507, Pn508) is satisfied. Select the function assigned to each digital input [0] S-ON [1] P-OT [2] N-OT...
  • Page 131 Name Range Default Unit Function Description Restart Select function assigned to digital output: [0] COIN/VCMP [1] TGON [2] S-RDY [3] CLT X7-6,7 Signal [4] BK Pn511.0 h0 ~ hb — Allocation [5] PGC [6] OT [7] RD [8] TCR [9] Remote0 [a] Remote1 [b] Remote2 Select function assigned to...
  • Page 132 Name Range Default Unit Function Description Restart Digital Input Signal b0000 ~ Pn516 0000 — Inversion 1 b1111 X7-14 inverse [0] Normal Pn516.0 0 ~ 1 — selection [1] Inverted X7-15 inverse [0] Normal Pn516.1 0 ~ 1 — selection [1] Inverted X7-16 inverse [0] Normal...
  • Page 133 Name Range Default Unit Function Description Restart /TCR (Torque Limit Detection Output) signal turns ON. When the torque output exceeds the setting of Pn529 Torque Reaches and the time is greater than Pn530 Status Detection 1 ~ 1000 the setting of Pn530, the Time Threshold /TCR (Torque Limit Detection Output) signal...

  • Page 134: Alarms Displays

    9.4 Alarms Displays 9.4.1 Alarm Classifications There are three classifications of alarms for the Drive: Gr.1, Gr.2, and Warning. They will affect the display and operation for the Servo System. Classification Stopping Method Panel Display The Panel Operator displays between Alarm No and Servo state FLT by Stops the Motor according to the turns.
  • Page 135 9.4.2 Alarm Table Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Reset the parameters to the factory settings using 'Restore Parameter Error in the stored Factory Settings' from the Gr.1 Checksum Error parameter data Parameter page. If the problem persists, contact TRIO or the Authorized Distributor Gr.1...
  • Page 136 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information The junction temperature IPM Junction Gr.1 of the IPM has exceeded Reduce the load Overtemperature the limit The current limit of the...
  • Page 137 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Reserved Reserved No information Reserved Reserved No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused...
  • Page 138 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) The battery power of the Encoder Battery V. Encoder operate Gr.1 absolute encoder is lower correctly. Replace the battery than 2.45V The battery power of the Encoder Battery Gr.1 absolute encoder is lower Replace the battery than 3.1V.
  • Page 139 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information The difference between Delta Target two sequential target Check position trajectory Gr.1 Position Overflow position exceeds the...
  • Page 140 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Reserved Reserved No information The wiring of the motor Check if the motor power lines Motor Power (U, V, Gr.1 power phases (U, V, W) is (U, V, and W phases) are...
  • Page 141 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused...
  • Page 142 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused...
  • Page 143 Alarm Alarm Alarm Name Description Trouble shooting tips Category Classifications (hex) Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Unused Unused No information Reserved Reserved No information Reserved Reserved No information Reserved...

  • Page 144: Chapter 10 Revision History

    Chapter 10 Revision History Date Version Revised Contents Mar, 2020 V0.01 First Draft. Jun, 2020 V1.00 Added Motion Perfect and commissioning details Jul, 2020 V1.01 Updated with comments from ETG Jul, 2020 V1.02 Updated Object Dictionary table Sep, 2020 V1.03 Update with single phase filter recommendation Added Pn details for re-gen resistor Added current for second encoder supply...
  • Page 145 Trio Motion Technology Limited www.triomotion.uk...

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