Aerotech BA-SineDrive Series User manual

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BA-SINEDRIVE
USER’S MANUAL
P/N: EDU164 (V1.4)
AEROTECH, Inc. •101 Zeta Drive •Pittsburgh, PA. 15238-2897 •USA
Phone [phone] •Fax [phone]
Product Service: [phone]; [phone] (Fax)
www.aerotech.com
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If you should have any questions about the BA-SineDrive or comments regarding the documentation, please refer to
Aerotech online at:
http://www.aerotech.com.
For your convenience, a product registration form is available at our web site.
Our web site is continually updated with new product information, free downloadable software, firmware upgrades,
and special pricing on selected products.
The BA-SineDrive and BAS software are products of Aerotech, Inc.
Windows 95/NT are products of Microsoft Corporation.
The BA-SineDrive User’s Manual Revision History:
Version 1.0 July 17, 1998
Version 1.1 October 22, 1998
Version 1.2 September 19, 2000
Version 1.3 October 6, 2000
Version 1.4 November 20, 2000
© Aerotech, Inc., 2001
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BA SineDrive User’s Manual Table of Contents
Version 1.4 Aerotech, Inc. iii
TABLE OF CONTENTS
CHAPTER 1: INTRODUCTION............................................................................ 1-1
1.1. Product Overview............................................................................... 1-1
1.2. Velocity/Torque Amplifier................................................................. 1-2
1.3. BAS DOS Software............................................................................ 1-3
1.4. BAS Windows Software Interface...................................................... 1-3
1.5. Hardware Overview and Function...................................................... 1-6
1.5.1. Motor and AC Power Connections....................................... 1-7
1.5.1.1. BAS 10/20/30..................................................... 1-7
1.5.1.2. BAS 50/75/100................................................... 1-8
1.5.2. Fusing and Inrush Limiting .................................................. 1-9
1.5.2.1. BAS 10/20/30..................................................... 1-9
1.5.2.2. BAS 50/75/100................................................. 1-10
1.5.3. 20 - 80 Volt Option – BAS 10/20/30 ................................. 1-11
1.5.4. COM Port........................................................................... 1-12
1.5.5. LED Status Indicators ........................................................ 1-12
1.6. Safety Procedures and Warnings...................................................... 1-13
CHAPTER 2: CONFIGURATION AND COMMUNICATION........................... 2-1
2.1. Introduction........................................................................................ 2-1
2.2. BAS Control Board Jumper Selections ..............................................2-1
2.3. BAS Communications Modes ............................................................ 2-2
2.4. Menu Commands................................................................................ 2-3
2.4.1. C-Change Parameter............................................................. 2-3
2.4.2. D-Display Tracking Information.......................................... 2-4
2.5. E - Display Error Message.................................................................. 2-6
2.5.1. BAS Faults........................................................................... 2-6
2.5.1.1. Invalid Hall Sequence ........................................ 2-6
2.5.1.2. RMS Current Error............................................. 2-6
2.5.1.3. Velocity Error..................................................... 2-6
2.5.1.4. Encoder Fault ..................................................... 2-7
2.5.1.5. Thermistor Fault................................................. 2-7
2.5.1.6. RMS Current Error............................................. 2-7
2.5.2. F1- Abort Entry/Up One Menu Level .................................. 2-7
2.5.3. F2/F3 - Previous/Next Menu................................................ 2-7
2.5.4. T - Transfer Parameters........................................................ 2-7
2.5.5. Space Bar ............................................................................. 2-7
2.5.6. CTRL-D............................................................................... 2-7
CHAPTER 3: PARAMETERS................................................................................. 3-1
3.1. Introduction........................................................................................ 3-1
3.2. Parameters.......................................................................................... 3-1
3.2.1. PRM:1 Proportional Velocity Gain (KP)............................ 3-2
3.2.2. PRM:2 Integral Velocity Gain (KI)..................................... 3-2
3.2.3. PRM:3 Electronic Tach (VSCALE).................................... 3-2
3.2.4. PRM:4 Encoder Resolution (ENCODER) .......................... 3-3
3.2.5. PRM:5 Electrical Cycles/Mechanical Revolution
(POLE PAIRS)..................................................................... 3-4
3.2.6. PRM:6 Hall Effects Available (HALLS) ............................ 3-4
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Table of Contents BA SineDrive User’s Manual
iv Aerotech, Inc. Version 1.4
3.2.7. PRM:7 Initialization Current (INIT CURRENT)................3-5
3.2.8. PRM:8 Velocity Loop Update Rate (UPDATE)................3-6
3.2.9. PRM:9 Low Pass Filter Enable (FILTER) ..........................3-6
3.2.10. PRM:10 Filter Cutoff (CUT. FREQ.)..................................3-7
3.2.11. PRM:11 Commutation Phase Offset (PHASE OFF)...........3-7
3.2.12. PRM:12 Input Command Offset (CMD. OFF)....................3-8
3.2.13. PRM:13,14 Current Offset Adjustment (IA OFFSET,
IB OFFSET).........................................................................3-8
3.2.14. PRM:15 Servo Peak Current Limit (CURR. LIMIT)..........3-9
3.2.15. PRM:16 Servo RMS Limit (RMS LIMIT)..........................3-9
3.2.16. PRM:17 Servo RMS Current Timeout (RMS TIME) .......3-10
3.2.17. PRM:18 Servo Velocity Trap (VEL ERR LMT) ..............3-10
3.2.18. PRM:19 Integral Clamp (INT CLAMP) ...........................3-11
3.2.19. PRM:20 Operating Mode (MODE)...................................3-11
3.2.20. PRM:21 Thermistor Polarity (THERM POL.)..................3-12
3.2.21. PRM:22 Enable Polarity (ENABLE POL.).......................3-13
3.2.22. PRM:23 Fault Output Polarity (FAULT POL.).................3-13
3.2.23. PRM:24 Encoder Polarity (Enc. Mult.).............................3-13
CHAPTER 4: MODE OF OPERATION AND TUNING.......................................4-1
4.1. Introduction ........................................................................................4-1
4.2. Velocity and Current Mode ................................................................4-1
4.2.1. Current Mode ....................................................................... 4-1
4.2.2. Velocity Mode......................................................................4-2
4.3. Tuning.................................................................................................4-2
CHAPTER 5: TECHNICAL DETAILS...................................................................5-1
5.1. Introduction ........................................................................................5-1
5.2. Hardware Overview and Function......................................................5-1
5.2.1. Motor and AC Power Connections.......................................5-2
5.2.1.1. Wiring, Grounding, and Shielding
Techniques..........................................................5-2
5.2.1.2. Minimizing EMI Interference and CE
Compliance.........................................................5-2
5.2.1.3. Minimizing 50/60 HZ Line Interference.............5-3
5.2.2. COM Port.............................................................................5-4
5.2.3. LED Status Indicators ..........................................................5-5
5.3. The I/O Port........................................................................................5-6
5.3.1. SIN, SIN-N, COS, COS-N Signals.......................................5-6
5.3.2. Restore/Reset Signal.............................................................5-7
5.3.3. Input+/Input- Command INPUT .......................................... 5-7
5.3.4. Thermistor Input Signal........................................................5-7
5.3.5. External Enable Input...........................................................5-8
5.3.6. Fault Output..........................................................................5-8
5.4. Encoder/Limits/Hall Effects Port........................................................5-9
5.4.1. Encoder Interface ...............................................................5-10
5.4.2. Hall Effect Interface...........................................................5-10
5.5. Servo Amplifier Specifications.........................................................5-14
5.6. BAS Amplifier Dimensions..............................................................5-15
5.6.1. Mounting Procedures for the BAS 10/20/30/50.................5-17
5.6.2. Mounting Procedures for the BAS 75/100 .........................5-18
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BA SineDrive User’s Manual Table of Contents
Version 1.4 Aerotech, Inc. v
CHAPTER 6: TROUBLESHOOTING.................................................................... 6-1
6.1. Amplifier Related Problems ............................................................... 6-1
APPENDIX A: WARRANTY AND FIELD SERVICE.......................................... A-1
APPENDIX A: WARRANTY AND FIELD SERVICE POLICY.......................... A-1
INDEX
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Table of Contents BA SineDrive User’s Manual
vi Aerotech, Inc. Version 1.4
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BA SineDrive User’s Manual List of Figures
Version 1.4 Aerotech, Inc. vii
LIST OF FIGURES
Figure 1-1. BA-SineDrive Amplifiers (10/20/30/50/75/100)................................ 1-1
Figure 1-2. Illustration of Configuration............................................................... 1-2
Figure 1-3. BAS MMI Main Screen...................................................................... 1-4
Figure 1-4. Parameter Screen................................................................................ 1-4
Figure 1-5. Parameter Information........................................................................ 1-5
Figure 1-6. BA-SineDrive Hardware (10/20/30)................................................... 1-6
Figure 1-7. BA-SineDrive Hardware (50/75/100)................................................. 1-6
Figure 1-8. Motor and AC Power Connections – 10/20/30 Models..................... 1-7
Figure 1-9. Motor and AC Power Connections – 50/75/100 Models................... 1-8
Figure 1-10. Fuse and Inrush Limiting – 10/20/30 Models.................................... 1-9
Figure 1-11. AC Input Fusing – 50/75/100 Models.............................................. 1-10
Figure 1-12. 20 –80V Option................................................................................ 1-11
Figure 2-1. Tracking Screen.................................................................................. 2-2
Figure 2-2. Parameter Screen................................................................................ 2-2
Figure 2-3. The Change Parameter Screen............................................................ 2-3
Figure 2-4. Changing a Parameter in the Change Parameter Screen..................... 2-4
Figure 2-5. Display Tracking Screen .................................................................... 2-4
Figure 2-6. Display Error Message Screen............................................................2-6
Figure 3-1. PI Control Loop.................................................................................. 3-1
Figure 5-1. BA-SineDrive Hardware .................................................................... 5-1
Figure 5-2. Wiring to Minimize EMI and Capacitive Coupling............................ 5-3
Figure 5-3. Back-Propagation Line Filter Connection.......................................... 5-3
Figure 5-4. Isolation Transformer Connection (eliminates torque
disturbance) ........................................................................................ 5-4
Figure 5-5. Over-Temperature Circuitry............................................................... 5-7
Figure 5-6. Electrical Characteristics of Opto-Isolated Input................................ 5-8
Figure 5-7. Electrical Characteristics of Opto-Isolated Output............................. 5-8
Figure 5-8. CW Motor Rotation (Viewed from the Mounting Flange End)........ 5-10
Figure 5-9. Encoder Input Circuit....................................................................... 5-10
Figure 5-10. Hall Effect Input Circuit................................................................... 5-11
Figure 5-11. Hall Effect Motor Phasing................................................................ 5-11
Figure 5-12. Motor Rotation (From Mounting Flange End) ................................. 5-12
Figure 5-13. Motor Phase Voltage Observation Scheme ...................................... 5-13
Figure 5-14. Encoder Phase Voltage Observation Scheme................................... 5-13
Figure 5-15. BAS Amplifier Dimensions (10/20/30)............................................ 5-15
Figure 5-16. BAS Amplifier Dimensions (50/75/100).......................................... 5-16
Figure 5-17. BAS Amp Top View (Preferred Mounting, 10/20/30/50)................ 5-17
Figure 5-18. Preferred Mounting of BAS Amplifiers (10/20/30/50)..................... 5-18
Figure 5-19. Preferred Mounting of BAS Amplifiers (75/100)............................. 5-19
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List of Figures BA SineDrive User’s Manual
viii Aerotech, Inc. Version 1.4
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BA SineDrive User’s Manual List of Tables
Version 1.4 Aerotech, Inc. ix
LIST OF TABLES
Table 1-1. COM Port Pinouts............................................................................ 1-12
Table 2-1. Power Board Jumper Selections......................................................... 2-1
Table 2-2. Control Board Jumper Selections....................................................... 2-1
Table 2-3. Bit Patterns......................................................................................... 2-5
Table 3-1. Settings for Proportional Velocity Gain PRM:1................................. 3-2
Table 3-2. Settings for Integral Velocity Gain PRM:2 ........................................ 3-2
Table 3-3. Settings for Electronic Tach PRM:3................................................... 3-2
Table 3-4. Settings for Encoder Resolution PRM:4............................................. 3-3
Table 3-5. Settings for Electrical Cycles/Mechanical Revolution PRM:5........... 3-4
Table 3-6. Settings for Hall Effects Available PRM:6......................................... 3-4
Table 3-7. Settings for Initialization Current PRM:7........................................... 3-5
Table 3-8. Settings for Velocity Update Rate PRM:8.......................................... 3-6
Table 3-9. Settings for Low Pass Filter PRM:9 ................................................... 3-6
Table 3-10. Settings for Filter Cutoff PRM:10...................................................... 3-7
Table 3-11. Settings for Phase Offset PRM:11...................................................... 3-7
Table 3-12. Settings for Input Command Offset PRM:12......................................3-8
Table 3-13. Settings for Position Mode PRM:13, PRM:14 ................................... 3-8
Table 3-14. Settings for Servo Peak Current Limit PRM:15 ................................. 3-9
Table 3-15. Settings for Servo RMS Limit PRM:16.............................................. 3-9
Table 3-16. Settings for Servo RMS Current Timeout PRM:17.......................... 3-10
Table 3-17. Settings for Servo Velocity Trap PRM:18........................................ 3-10
Table 3-18. Settings for Integral Clamp PRM:19................................................ 3-11
Table 3-19. Operating Modes PRM:20................................................................ 3-11
Table 3-20. Settings for Operating Mode PRM:20.............................................. 3-12
Table 3-21. Settings for Thermistor Polarity PRM:21......................................... 3-12
Table 3-22. Settings for Enable Polarity PRM:22 ...............................................3-13
Table 3-23. Settings for Fault Output Polarity PRM:23 ...................................... 3-13
Table 3-24. Settings for Encoder Polarity PRM:24............................................. 3-13
Table 5-1. COM Port Pinouts.............................................................................. 5-4
Table 5-2. I/O Connector Pinouts (P1) ................................................................ 5-6
Table 5-3. Pinouts for the Encoder/Limits/Hall Effects Port ............................... 5-9
Table 5-4. Electrical Specifications................................................................... 5-14
Table 6-1. Amplifier Faults, Causes, and Solutions............................................. 6-1
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List of Tables BA SineDrive User’s Manual
xAerotech, Inc. Version 1.4
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BA SineDrive User’s Manual Regulatory Information
Version 1.4 Aerotech, Inc. xi
DECLARATION OF CONFORMITY
Manufacturer’s Name and Address
Aerotech, Inc.
101 Zeta Drive
Pittsburgh, PA 15238-2897
Declares that the product:
Product Name: BA Intellidrive/BA Sinedrive
Conforms to the following product specifications:
EMC: EN 55011: Class B Emissions
EN 50082-1: Immunity
EN61000-4-2
EN61000-4-3
EN61000-4-4
EN61000-4-11
EN50141
LVD: IEC 204-1
and complies with EMC directive 89/336/EEC.
Pittsburgh, PA David F. Kincel_________________________
October 8, 1998 Quality Assurance Manager
Robert Novotnak__________________________
Engineer Verifying Compliance
General notes concerning the test setup.
This product was tested at Compliance Labs, Middlefield, OH on October 8, 1998.
The brushless amplifier was tested with a brushless servo motor. To ensure that the
product passes the conducted emissions tests, a line filter and common mode choke must
be connected to the main inputs. The filter is a Schaffner FN 2070-10-06 and the common
mode choke is a Renco Electronics RL-1329-1200. Ferrite must be added to each line of
the main inputs but not earth ground. In order for the product to conform to the radiated
emission standards, the motor cable must be shielded and the shield must be tied to the
earth ground. Ferrite must also be added (in common mode) to the motor cable but not
around the shield. Finally, a metal 25-pin connector with a metal backshell must be used
when making a connection to the 25-pin receptacle on the amplifier. The shield of the
feedback cable must be tied to the metal backshell. Failure to follow the described
procedures may cause the amplifier/motor to exceed emission limits.
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Regulatory Information BA SineDrive User’s Manual
xii Aerotech, Inc. Version 1.4
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BA SineDrive User’s Manual Preface
Version 1.4 Aerotech, Inc. xiii
PREFACE
This section gives you an overview of topics covered in each of the sections of this
manual as well as conventions used in this manual. This manual contains information on
the following topics:
CHAPTER 1: INTRODUCTION
This chapter contains an introduction to the hardware and software architecture of the
BA-SineDrive.
CHAPTER 2: CONFIGURATION AND COMMUNICATION
This chapter covers the jumper configurations when used with a brush or brushless DC
motor. This chapter also covers the methods used to send commands to the BAS.
CHAPTER 3: PARAMETERS
This chapter describes the various parameters used on the BAS.
CHAPTER 4: MODE OF OPERATION
This chapter contains all information regarding the BAS’s modes of operation.
CHAPTER 5: TECHNICAL DETAILS
This chapter contains all detailed technical information regarding the BA-SineDrive.
CHAPTER 6: TROUBLESHOOTING
This chapter covers symptoms, probable causes, and solutions related to the BA-
SineDrive.
APPENDIX A: WARRANTY AND FIELD SERVICE
Appendix A contains the warranty and field service policy for Aerotech products.
INDEX
The index contains a page number reference of topics discussed in this manual. Locator
page references in the index contain the chapter number (or appendix letter) followed by
the page number of the reference.
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Preface BA SineDrive User’s Manual
xiv Aerotech, Inc. Version 1.4
CUSTOMER SURVEY FORM
A customer survey form is included at the end of this manual for the reader’s comments
and suggestions about this manual. Readers are encouraged to critique the manual and
offer their feedback by completing the form and either mailing or faxing it to Aerotech.
Throughout this manual the following conventions are used:
éThe terms BA-SineDrive and BAS are used interchangeably throughout this
manual
éThe text <ENTER> is used to indicate that the Enter/Return key on the
keyboard is to be pressed.
éHexadecimal numbers are listed using a preceding "0x" (for example, 0x300,
0x12F, 0x01EA, etc.,) to distinguish them from decimal numbers
éGraphic icons or keywords may appear in the outer margins to provide visual
references of key features, components, operations or notes.
éThis manual uses the symbol "∇∇∇" to indicate the end of a chapter.
Although every effort has been made to ensure consistency, subtle differences may exist
between the illustrations in this manual and the component and/or software screens that
they represent.
∇∇∇
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BA SineDrive User’s Manual Introduction
Version 1.4 Aerotech, Inc. 1-1
CHAPTER 1: INTRODUCTION
In This Section:
•Product Overview..................................................... 1-1
•Velocity/Torque Amplifier ...................................... 1-2
•BAS DOS Software.................................................. 1-3
•Hardware Overview and Function............................ 1-6
•Safety Procedures and Warnings............................ 1-13
1.1. Product Overview
The BA-SineDrive (BAS) is a sine wave commutation amplifier (Figure 1-1). The BAS
incorporates a digital control board that allows velocity loop gains and parameters to be
set via PC RS-232. A simple DOS-based (or newer Windows-based) terminal program
supplied with the unit is used to communicate. The BAS10/20/30/50/75/100 are switching
Pulse Width Modulation (PWM) amplifiers. The amplifiers consist of an amplifier,
control board, and internal power supply.
Figure 1-1. BA-SineDrive Amplifiers (10/20/30/50/75/100)
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Introduction BA SineDrive User’s Manual
1-2 Aerotech, Inc. Version 1.4
1.2. Velocity/Torque Amplifier
The BAS reads in a +/-10 volt signal and commutates a brushless motor with a sine wave
current command. Sine wave commutation is done via an encoder (quadrature input) and
provides the smoothest possible motion for a brushless motor. The input signal can be
either a velocity command or a torque (current) command. If the input signal is a current
command, a two-phase current command is sent directly to the amplifier. If the input
signal is a velocity command, the BAS closes the velocity loop digitally (using the
encoder, two controller gains and the velocity command). The output from the internal
control board is a two-phase current command to the amplifier.
The operating parameters are changed through the RS-232 interface. This interface is
menu driven and interfaces with either a hand held terminal or DOS emulation software.
All parameters are stored in flash memory. After the initial setup, the unit will boot in the
user-defined configuration. Figure 1-2 shows a typical configuration using the BAS.
Figure 1-2. Illustration of Configuration
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BA SineDrive User’s Manual Introduction
Version 1.4 Aerotech, Inc. 1-3
1.3. BAS DOS Software
The BAS DOS software package is stored on a 1.44MB floppy disk, labeled “ BAS
Software Package.” The software includes a HT terminal emulator (com_bai.exe) and the
source files. The purpose of the com_bai.exe is to setup the BAS.
In order for the com_bai.exe to function correctly in DOS, the ansi.sys driver must be
added to the config.sys file.
DEVICE=c:\dos\ansi.sys
These programs can also run in a DOS shell under Windows 95/NT. Again, in order for
the com_bai.exe file to run correctly, the ansi.sys driver must be loaded. The following
examples illustrate how to load ansi.sys in Windows 95/NT.
For Windows 95, add the following line to the config.sys file.
device=c:\win95\command\ansi.sys
For Windows NT, add the following line to the config.nt file in the winnt\system32
directory.
device=%SystemRoot%\system32\ansi.sys
Restart the PC after making these changes.
The BAS must be in local mode to operate with the com_bai software. Pressing
CTRL-A will toggle between remote and local mode.
1.4. BAS Windows Software Interface
Included in the standard software package is the BAS Windows Software Interface. This
windows program is intended to take the place of the COM_BAI.EXE program for users
of Windows 95/98/NT.
To install the BAS Windows Software Interface:
1. Insert the BAS software CD into the CD-ROM drive of the PC.
2. From Windows 95/98/NT select the start button, then click Run, and type
“X:\Setup.exe” (where X is the drive letter corresponding to the CD-ROM
drive).
After the software has been installed, the program can be executed by double-clicking the
BASMMI icon.
In order for the MMI to communicate, the BAS be in remote mode. To enter remote
mode, run the com_bai.exe software in a DOS shell, and press CTRL-A.
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Introduction BA SineDrive User’s Manual
1-4 Aerotech, Inc. Version 1.4
Figure 1-3. BAS MMI Main Screen
The BAS MMI interface is a graphical interface that allows the user to quickly view all
the parameters available on the SineDrive and make any adjustments that are required.
The parameters on the system are divided up by type. Select the button on the left for the
type of parameters that you wish to view/edit. Also available on this sub-menu is a
diagnostic utility and a setup utility for airing in configuring the unit. The Online Help
file (selectable from the Help menu) contains more information on these utilities.
To view the maximum and minimum value for any parameter, place , the mouse pointer
over the name of the parameter and the name will become highlighted. Click and hold the
left mouse button to see the parameter , range. Releasing the mouse button will hide the
range.
Figure 1-4. Parameter Screen
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BA SineDrive User’s Manual Introduction
Version 1.4 Aerotech, Inc. 1-5
To view more information about a parameter (such as the purpose of a parameter or the
units associated with a parameter,), click on the right mouse button while the parameter
name is highlighted.
Figure 1-5. Parameter Information
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