User Manuals: Copley Controls Xenus XSL Servo Drive

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Copley Controls Xenus XSL User Manual

Copley Controls Xenus XSL User Manual (202 pages)

Brand: Copley Controls | Category: Controller | Size: 2 MB

Table of Contents
4
About this Manual

9
- Overview and Scope
  9
- Related Documentation
  9
- Comments
  9
- Copyrights
  9
- Document Validity
  9
- Product Warnings
  10
- Revision History
  11
1 Introduction

12
- Amplifier
  13
- Cme 2
  14
- Cmo/Cml
  14
2 : Operational Theory

16
- Amplifier Internal Power
  17
  - 1: Logic/Signal Power
    17
  - 2: High Voltage
    17
  - 3: Power and Grounding Diagram
    18
- Synchronizing PWM Switching Frequency
  19
- Commutation Modes
  19
- Feedback
  19
  - 1: Encoder and Resolver Support
    19
  - 2: Secondary Encoder Interface
    19
- Operating Modes
  20
  - 1: Modes and Control Loops
    20
  - 2: Current Mode and Current Loop
    21
  - 3: Velocity Mode and Velocity Loop
    23
  - 4: Position Mode and Position Loop
    25
  - 5: Input Command Types
    26
  - 6: Analog Command Input
    26
  - 7: PWM Input
    28
  - 8: Digital Input
    29
  - 9: CVM Program
    30
- Canopen Operation
  31
- Limit Switches
  33
- Brake Operation
  34
  - 1: Digital Output Controls Brake
    34
  - 2: Brake/Stop Sequences
    34
- Status Indicators
  35
- Protection
  37
  - 1: Faults
    37
- Position and Velocity Errors
  39
- Communication
  42
  - 1: Communication Interfaces
    42
  - 2: CME 2 and CAN Operation
    42
- Inputs
  43
- Outputs
  45
- Regen Resistor Theory
  48
  - 1: Regeneration
    48
  - 2: Regen Resistor
    48
  - 3: Regen Circuit Components
    48
  - 4: Regen Circuit Protections
    48
  - 5: Configurable Custom Resistor
    48
3 Specifications

50
- Agency Approvals
  51
- Power Input
  51
- Power Output
  51
- Control Loops
  52
- Regen Circuit Output
  52
- Digital Command Input
  52
- Analog Command Input
  53
- Digital Inputs
  53
- Digital Outputs
  53
- Brake Output
  54
- Encoder Power Supply Output
  54
- Primary and Secondary Encoder Inputs
  54
- Analog Encoder Inputs
  54
- Hall Switch Inputs
  55
- Resolver Interface
  55
- Encoder Outputs
  55
- Serial Interface
  55
- CAN Interface
  56
- Status Indicators
  56
- Fault Levels
  56
- Power Dissipation
  57
- Thermal Impedance
  57
- Mechanical and Environmental
  57
- Dimensions
  58
4 Wiring

60
- General Wiring Instructions
  61
- AC Mains (J1)
  63
- Motor (J2)
  64
- Regen Resistor (J3) (Optional)
  65
- Logic Supply / Brake (J4)
  66
- RS-232 Serial Communications (J5)
  67
- CAN Bus (J6)
  68
- Control (J7)
  69
- Motor Feedback (J8)
  73
5 : Quick Setup with CME 2

78
- Warnings
  79
- CME 2 Installation and Serial Port Setup
  80
- Prerequisites
  83
  - 1: Hardware and Equipment
    83
  - 2: Starting CME 2 and Choosing an Amplifier
    84
- Basic Setup
  85
  - 1: Basic Setup Screen
    85
- Motor Setup
  87
  - 1: Motor Data File
    87
  - 2: Rotary Motor
    88
  - 3: Linear Motor
    89
- Feedback Setup
  90
- Brake/Stop (Optional)
  92
  - 1: Overview
    92
  - 2: Procedure
    92
  - 3: Calculate
    93
- Amplifier Configuration
  94
  - 1: Digital Inputs
    94
  - 2: Standard Digital Outputs
    96
  - 3: Custom Digital Outputs
    97
  - 4: Save Input/Output Changes
    97
  - 5: Fault Latching
    98
  - 6: Regen Resistor
    99
- Command Input
  99
  - 1: Analog Input
    100
  - 2: PWM Input
    102
  - 3: Digital Position Input
    103
  - 4: CAN Interface
    105
- Auto Phase
  106
- Current Loop
  111
  - 1: Current Loop Settings
    111
  - 2: Manually Tune Current Loop
    112
- Velocity Loop
  114
  - 1: Velocity Loop Settings
    114
  - 2: Manually Tune the Velocity Loop
    115
- Position Loop
  116
  - 1: Position Loop Settings
    116
  - 2: Manually Tune the Position Loop
    117
  - 3: Test S-Curve Profile
    119
- Completion Steps
  120
  - 1: Objective
    120
  - 2: Steps
    120
6 : Using CME 2

122
- CME 2 Overview
  123
  - 1: Main Screen Overview
    123
  - 2: Tool Bar Overview
    123
  - 3: Main Menu Overview
    124
  - 4: Functional Diagram
    125
  - 5: CAN Information and Status Bar
    126
  - 6: Choosing an Amplifier from a List of Amplifiers
    126
  - 7: Renaming an Amplifier
    126
- Manage Amplifier and Motor Data
  127
  - 1: Memory
    127
  - 2: Disk Storage
    127
  - 3: Data Management Tools
    128
  - 4: Quick Copy Setup Procedure
    129
- Downloading Firmware
  130
  - 1: Acquiring Firmware from Web Site (Optional)
    130
  - 2: Downloading Firmware to Amplifier
    131
- Control Panel
  132
  - 1: Control Panel Overview
    132
  - 2: Status Indicators and Messages
    132
  - 3: Monitor Functions
    133
  - 4: Control Functions
    134
  - 5: Jog Mode
    134
- Scope Tool
  135
  - 1: Scope Tool Overview
    135
  - 2: Function Generator and Profile Tabs
    136
  - 3: Scope Settings
    137
  - 4: Scope Tool Controls
    140
  - 5: Control Loop Parameters in the Scope Tool
    140
  - 6: Scope Files
    142
- Error Log and Communications Log
  143
  - 1: Error Log
    143
  - 2: Communications Log
    144
- CME 2 Virtual Amplifier
  145
  - 1: Virtual Amplifier Overview
    145
  - 2: Virtual Amplifier Creation
    145
- Manual Phasing
  146
- Auto Tune Current Loop
  150
  - 1: Auto Tune Objective
    150
  - 2: Auto Tune Instructions
    150
- Home Function
  153
  - 1: Overview
    153
  - 2: Homing Functions Settings
    153
A: Regen Resistor Sizing and Configuration

154
- A.1: Sizing a Regen Resistor
  155
- A.2: Configuring a Custom Regen Resistor
  159
  - A.2.1: Regen Configuration Objective and Warning
    159
  - A.2.2: Regen Configuration Instructions
    159
B: I 2 T Time Limit Algorithm

162
- B.1: I 2 T Algorithm
  163
Velocity Loop Filters

168
- C.1: Advanced Velocity Loop Filter
  168
  - C.1.1: Filter Overview
    168
  - C.1.2: Filter Instructions and Details
    168
D: Thermal Considerations

170
- D.1: Operating Temperature and Cooling Configurations
  171
  - D.1.2: Heatsink and Fan Configurations
    172
- D.2: Heatsink Mounting Instructions
  173
E: Xenus Filter

174
F: Connecting for Serial Control

184
- F.1: Single-Axis and Multi-Drop
  185
  - F.1.2: Single-Axis Connections
    185
  - F.1.3: Multi-Drop Network Connections
    185
G: Servotube Motor Setup

186
H: Ordering Guide and Accessories

194

Copley Controls Xenus XSL User Manual (202 pages)

Brand: Copley Controls | Category: Controller | Size: 5 MB

Table of Contents
4
About this Manual
9
Overview and Scope
9
Related Documentation
9
Comments
9
Copyrights
9
Document Validity
9
Product Warnings
10
Revision History
11
Introduction
12
Amplifier
13
Cme 2
14
Cmo/Cml
14
2: Operational Theory
16
Amplifier Internal Power
17
1: Logic/Signal Power
17
2: High Voltage
17
3: Power and Grounding Diagram
18
Synchronizing PWM Switching Frequency
19
Commutation Modes
19
Feedback
19
1: Encoder and Resolver Support
19
2: Secondary Encoder Interface
19
Operating Modes
20
1: Modes and Control Loops
20
2: Current Mode and Current Loop
21
3: Velocity Mode and Velocity Loop
23
4: Position Mode and Position Loop
25
5: Input Command Types
26
6: Analog Command Input
26
7: PWM Input
28
8: Digital Input
29
9: CVM Program
30
Canopen Operation
31
1: CAN Network and Canopen Profiles for Motion
31
2: Supported Canopen Modes
31
3: Architecture
32
4: CAN Addressing
32
Limit Switches
33
1: Use Digital Inputs to Connect Limit Switches
33
2: Diagram: Sample Placement of Limit Switches
33
3: How the Amplifier Responds to Limit Switch Activation
33
4: Using Custom Output to Signal Limit Switch Activation
33
Brake Operation
34
1: Digital Output Controls Brake
34
2: Brake/Stop Sequences
34
Status Indicators
35
1: Amplifier and CAN Interface Status Indicators
35
2: Amplifier Status Indicator Operation
35
3: CAN Interface Status Indicator Operation
36
Protection
37
1: Faults
37
Position and Velocity Errors
39
1: Error-Handling Methods
39
2: Following Error Faults
39
3: Following Error Warnings
39
4: Position and Velocity Tracking Windows
39
5: Following Error Fault Details
40
6: Tracking Window Details
41
Communication
42
1: Communication Interfaces
42
2: CME 2 and CAN Operation
42
Inputs
43
1: Digital Inputs
43
2: Input Filters
43
3: Debounce Time
43
4: Configure for Pull Up/Pull down Resistors by Groups
43
5: Programmable Input Functions
43
Outputs
45
1: Digital Outputs
45
2: Standard Programmable Output Functions
45
3: Custom Output Functions
46
Regen Resistor Theory
48
1: Regeneration
48
2: Regen Resistor
48
3: Regen Circuit Components
48
4: Regen Circuit Protections
48
5: Configurable Custom Resistor
48
Specifications
50
Agency Approvals
51
Power Input
51
Power Output
51
Control Loops
52
Regen Circuit Output
52
Digital Command Input
52
Analog Command Input
53
Digital Inputs
53
Digital Outputs
53
Brake Output
54
Encoder Power Supply Output
54
Primary and Secondary Encoder Inputs
54
Analog Encoder Inputs
54
Hall Switch Inputs
55
Resolver Interface
55
Encoder Outputs
55
Serial Interface
55
CAN Interface
56
Status Indicators
56
Fault Levels
56
Power Dissipation
57
Thermal Impedance
57
Mechanical and Environmental
57
Dimensions
58
Wiring
60
General Wiring Instructions
61
1: Electrical Codes and Warnings
61
2: Grounding Considerations
61
3: Connector Locations
62
AC Mains (J1)
63
Motor (J2)
64
Regen Resistor (J3) (Optional)
65
Logic Supply / Brake (J4)
66
RS-232 Serial Communications (J5)
67
CAN Bus (J6)
68
Control (J7)
69
Motor Feedback (J8)
73
5: Quick Setup with CME 2
78
Warnings
79
CME 2 Installation and Serial Port Setup
80
1: Requirements
80
2: Downloading Software from Web (Optional)
80
3: Installing CME 2 Software
80
4: Serial Port Setup
81
Prerequisites
83
1: Hardware and Equipment
83
2: Starting CME 2 and Choosing an Amplifier
84
Basic Setup
85
1: Basic Setup Screen
85
Motor Setup
87
1: Motor Data File
87
2: Rotary Motor
88
3: Linear Motor
89
Feedback Setup
90
1: Overview
90
2: Rotary Motor Feedback Setup Options
91
3: Linear Motor Feedback Setup Options
91
Brake/Stop (Optional)
92
1: Overview
92
2: Procedure
92
3: Calculate
93
Amplifier Configuration
94
1: Digital Inputs
94
2: Standard Digital Outputs
96
3: Custom Digital Outputs
97
4: Save Input/Output Changes
97
5: Fault Latching
98
6: Regen Resistor
99
Command Input
99
1: Analog Input
100
2: PWM Input
102
3: Digital Position Input
103
4: CAN Interface
105
Auto Phase
106
1: Auto Phase Warnings and Notes
106
2: Auto Phase Procedure
107
3: Guidelines for Choosing Auto Phase Current and Increment Rate Values
110
4: Trouble Shoot Motor Direction Setup
110
5: Trouble Shoot Motor Wiring Setup
110
6: Trouble Shoot Halls Wiring Setup
110
7: Other Problems
110
Current Loop
111
1: Current Loop Settings
111
2: Manually Tune Current Loop
112
Velocity Loop
114
1: Velocity Loop Settings
114
2: Manually Tune the Velocity Loop
115
Position Loop
116
1: Position Loop Settings
116
2: Manually Tune the Position Loop
117
3: Test S-Curve Profile
119
Completion Steps
120
1: Objective
120
2: Steps
120
6: Using CME 2
122
CME 2 Overview
123
1: Main Screen Overview
123
2: Tool Bar Overview
123
3: Main Menu Overview
124
4: Functional Diagram
125
5: CAN Information and Status Bar
126
6: Choosing an Amplifier from a List of Amplifiers
126
7: Renaming an Amplifier
126
Manage Amplifier and Motor Data
127
1: Memory
127
2: Disk Storage
127
3: Data Management Tools
128
4: Quick Copy Setup Procedure
129
Downloading Firmware
130
1: Acquiring Firmware from Web Site (Optional)
130
2: Downloading Firmware to Amplifier
131
Control Panel
132
1: Control Panel Overview
132
2: Status Indicators and Messages
132
3: Monitor Functions
133
4: Control Functions
134
5: Jog Mode
134
Scope Tool
135
1: Scope Tool Overview
135
2: Function Generator and Profile Tabs
136
3: Scope Settings
137
4: Scope Tool Controls
140
5: Control Loop Parameters in the Scope Tool
140
6: Scope Files
142
Error Log and Communications Log
143
1: Error Log
143
2: Communications Log
144
CME 2 Virtual Amplifier
145
1: Virtual Amplifier Overview
145
2: Virtual Amplifier Creation
145
Manual Phasing
146
1: Manual Phase Objectives
146
2: Manual Phase Instructions, Standard (Non-Resolver) Xenus
146
3: Manual Phase Instructions, Resolver (-R) Xenus
148
4: Troubleshooting Manual Phase with Halls and Encoder
149
5: Verify Motor Pole Count
149
Auto Tune Current Loop
150
1: Auto Tune Objective
150
2: Auto Tune Instructions
150
Home Function
153
1: Overview
153
2: Homing Functions Settings
153
A: Regen Resistor Sizing and Configuration
154
A.1: Sizing a Regen Resistor
155
A.1.1: Gather Required Information
155
A.1.2: Observe the Properties of each Deceleration During a Complete Cycle of Operation
155
A.1.3: Calculate Energy Returned for each Deceleration
156
A.1.4: Determine the Amount of Energy Dissipated by the Motor
156
A.1.5: Determine the Amount of Energy Returned to the Amplifier
156
A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity
157
A.1.7: Calculate Energy to be Dissipated for each Deceleration
157
A.1.8: Calculate Pulse Power of each Deceleration that Exceeds Amplifier Capacity
157
A.1.9: Calculate Resistance Needed to Dissipate the Pulse Power
157
A.1.10: Calculate Continuous Power to be Dissipated
158
A.1.11: Select Fuses
158
A.2: Configuring a Custom Regen Resistor
159
A.2.1: Regen Configuration Objective and Warning
159
A.2.2: Regen Configuration Instructions
159
B: I 2 T Time Limit Algorithm
162
B.1: I 2 T Algorithm
163
B.1.1: I 2 T Overview
163
B.1.2: I 2 T Formulas and Algorithm Operation
163
B.1.3: I 2 T Current Limit Algorithm - Application Example
164
Velocity Loop Filters
168
C.1: Advanced Velocity Loop Filter
168
C.1.1: Filter Overview
168
C.1.2: Filter Instructions and Details
168
D: Thermal Considerations
170
D.1: Operating Temperature and Cooling Configurations
171
D.1.2: Heatsink and Fan Configurations
172
D.2: Heatsink Mounting Instructions
173
E: Xenus Filter
174
E.1: Overview
175
E.1.1: Differential and Common Mode Filtering
175
E.1.2: Description and Functional Diagram
175
E.1.3: PWM Output Plot
175
E.2: XSL-FA-01 Edge Filter Specifications
176
E.3: Thermal Considerations
176
E.4: XSL-FA-01 Edge Filter Dimensions
177
E.5: XSL-FA-01 Edge Filter Wiring
178
E.5.2: Electrical Codes and Warnings
178
E.5.2: Connector Locations
179
E.5.3: Cable Notes
180
E.5.4: Input (J1) from Amplifier
180
E.5.5: Output (J2) to Motor
180
E.5.6: Diagram: Edge Filter Wiring with Brushless Motor
181
E.5.7: Diagram: Edge Filter Wiring with Brush Motor
181
E.6: XSL-FA-01 Edge Filter Ordering
182
F: Connecting for Serial Control
184
F.1: Single-Axis and Multi-Drop
185
F.1.2: Single-Axis Connections
185
F.1.3: Multi-Drop Network Connections
185
G: Servotube Motor Setup
186
G.1: Servotube Setup and Configuration
187
G.1.1: Servotube Basic Setup Screen Options
187
G.1.2: Servotube Motor/Feedback Setup
188
G.1.3: Calculating Servotube Initial Values
189
G.1.4: Setting up the Motor over Temperature Input
189
G.1.5: Other Servotube I/O and Fault Latching Setup Steps
189
G.2: Servotube Auto Phase and Manual Phase
190
G.2.1: Servotube Auto Phase
190
G.2.2: Servotube Manual Phase
193
G.3: Special Servotube Setup Completion
193
H: Ordering Guide and Accessories
194
H.1: Amplifier Model Numbers
195
H.2: Accessory Model Numbers
195
H.3: Order Example
196
H.4: Control and Feedback Cable Color Codes
197
Copley Controls Corp
197
H.4.1: Wire Description Nomenclature
197
H.4.2: Control Cable (XSL-CC-10)
197
H.4.3: Feedback (XSL-FC-10)
198
H.5: Regen Resistor Specifications
199
H.5.1: XTL-RA-03, XTL-RA-04 Specifications
199
H.5.2: XTL-RA-03, XTL-RA-04 Dimensions
199
H.5.3: XSL-RA-01, 02 (Discontinued) Specifications
200
H.5.4: XSL-RA-01, 02 (Discontinued) Dimensions
200

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User Manuals: Copley Controls Xenus XSL Servo Drive

Copley Controls Xenus XSL User Manual (202 pages)

Table of Contents

About this Manual

1 Introduction

2 : Operational Theory

3 Specifications

4 Wiring

5 : Quick Setup with CME 2

6 : Using CME 2

A: Regen Resistor Sizing and Configuration

B: I 2 T Time Limit Algorithm

Velocity Loop Filters

D: Thermal Considerations

E: Xenus Filter

F: Connecting for Serial Control

G: Servotube Motor Setup

H: Ordering Guide and Accessories

Copley Controls Xenus XSL User Manual (202 pages)

Table of Contents

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