Control Techniques UD53 User manual

User Guide
UD53UD53
Resolver interface
small option module
for Unidrive
Part Number: 0460-0040
Issue Number: 3

General Information
The manufacturer accepts no liability for any consequences resulting from
inappropriate, negligent or incorrect installation or adjustment of the
operating parameters of the equipment or from mismatching the Drive
with the motor.
The contents of this Guide are believed to be correct at the time of
printing. In the interests of a commitment to a policy of continuous
development and improvement, the manufacturer reserves the right to
change the specification of the product or its performance, or the
contents of this Guide, without notice.
All rights reserved. No part of this Guide may be reproduced or
transmitted in any form or by any means, electrical or mechanical including
photocopying, recording or by any information storage or retrieval system,
without permission in writing from the publisher.
Use within the European Union, etc
The following information applies where the end use of the Drive is within
the European Union, the European Economic Area, or other regions which
have implemented Directives of the European Council or equivalent
measures.
The Drive complies with the Low Voltage Directive 73/23/EEC.
The installer is responsible for ensuring that the equipment into which the
Drive is incorporated complies with all relevant Directives.
The complete equipment must comply with the EMC Directive 89/336/EEC.
If the Drive is incorporated into a machine, the manufacturer is responsible
for ensuring that the machine complies with the Machinery Directive
89/392/EEC. In particular, the electrical equipment should generally
comply with European Harmonised standard EN60204-1.
Copyright © July 1999 Control Techniques Drives Ltd
Author: RFD
Issue Code: 53nu3
Issue Date: July 1999

UD53 User Guide
Issue code: 53nu3
Contents
Chapter
1 Introduction 1
1.1 Main features of the UD53 1
2 Safety Information 2
3 Installing the UD53 5
4 Making Connections 7
4.1 Locations of the terminals 7
4.2 Functions of the terminals 8
5 Setting Up the UD53 10
5.1 Initial setting up 10
5.2 Phase offset 10
5.3 Change in feedback resolution with change
of maximum speed 12
5.4 Simulated-encoder outputs (terminals 40, 41, 43, 44) 12
5.5 Z marker-pulse outputs (terminals 46, 47) 14
6 Related Parameters 16
6.1 Introduction 16
6.2 Programmable software 16
6.3 Parameter descriptions 18
Appendix
A Specifications A-1
B Aligning the Resolver Mechanically B-1
C Diagnostics C-1
D Operation of a Resolver D-1

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1 Introduction
1.1 Main features of the UD53
Applications The UD53 Resolver small option module is an interface module for
installation in a Unidrive. The UD53 operates with resolvers having the
following specifications:
Input impedance: >85Ωat 6kHz
Turns ratio (primary:secondary): 3:1 or 2:1
Excitation voltage: 6VRMS or 4VRMS
The Drive must be operating in the Closed-loop Vector or Closed-loop
Servo mode; the resolver connected to the UD53 is used for speed and
position feedback.
Simulated
encoder
outputs
The simulated-encoder outputs produce quadrature AB signals
corresponding to the line counts from the source encoder. Alternatively,
these outputs can be configured for frequency and direction (F/D) signals.
In both cases, the outputs retain position infomation when direction is
changed.
By default, the resolver is used as the source for the simulated-encoder
outputs; alternatively, the main encoder (Encoder 1) connected to the
15-way D-type on the Drive can be used as the source.
The number of pulses per revolution can be scaled by factors of 2.
Installation The UD53 must be fitted in the small option module bay of the Unidrive.
All connections to the Drive are made by a multi-way connector.
Connections from external equipment are made by a plug-in 16-way
screw-terminal block on the UD53.

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2 Safety Information
2.1 Warnings, Cautions and Notes
A Warning contains information which is essential for avoiding a safety
hazard.
A Caution contains information which is necessary for avoiding a risk of
damage to the product or other equipment.
A Note contains information which helps to ensure correct operation of the
product.
2.2 Electrical safety –
general warning
The voltages used in the Drive can cause severe electric shock and/or burns,
and could be lethal. Extreme care is necessary at all times when working
with or adjacent to the Drive.
Specific warnings are given at the relevant places in this User Guide.
The installation must comply with all relevant safety legislation in the
country of use.
The Drive contains capacitors that remain charged to a potentially lethal
voltage after the AC supply has been disconnected. If the Drive has been
energized, the AC supply must be isolated at least ten minutes before work
may continue.
2.3 System design
The Drive is intended as a component for professional incorporation into
complete equipment or systems. If installed incorrectly the Drive may
present a safety hazard. The Drive uses high voltages and currents, carries
a high level of stored electrical energy, and is used to control mechanical
equipment which can cause injury.
Close attention is required to the electrical installation and the system-
design to avoid hazards either in normal operation or in the event of
equipment malfunction. System-design, installation, commissioning and
maintenance must be carried out by personnel who have the necessary
training and experience. They must read this safety information and this
User Guide carefully.
To ensure mechanical safety, additional safety devices such as
electro-mechanical interlocks may be required. The Drive must not be used
in a safety-critical application without additional high-integrity protection
against hazards arising from a malfunction.

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2.4 Environmental limits
Instructions in the Unidrive Installation Guide regarding transport, storage,
installation and use of Drives must be complied with, including the specified
environmental limits. Drives must not be subjected to excessive physical
force.
2.5 Compliance with regulations
The installer is responsible for complying with all relevant regulations, such
as national wiring regulations, accident prevention regulations and
electromagnetic compatibility (EMC) regulations. Particular attention must
be given to the cross-sectional areas of conductors, the selection of fuses or
other protection, and protective earth (ground) connections.
The Unidrive Installation Guide contains instructions for achieving compliance
with specific EMC standards.
Within the European Union, all machinery in which this product is used must
comply with the following directives:
89/392/EEC: Safety of Machinery
89/336/EEC: Electromagnetic Compatibility
2.6 Safety of personnel
The STOP function of the Drive does not remove dangerous voltages from
the output of the Drive or from any external option unit.
The Stop and Start controls or electrical inputs of the Drive must not be
relied upon to ensure safety of personnel. If a safety hazard could exist
from unexpected starting of the Drive, an interlock that electrically isolates
the Drive from the AC supply must be installed to prevent the motor being
inadvertently started.
Careful consideration must be given to the functions of the Drive which
might result in a hazard, either through their intended functions (eg.
Auto-start) or through incorrect operation due to a fault or trip (eg.
stop/start, forward/reverse, maximum speed).
Under certain conditions, the Drive can suddenly discontinue control of the
motor. If the load on the motor could cause the motor speed to be
increased (eg. hoists and cranes), a separate method of braking and
stopping the motor must be used (eg. a mechanical brake).
Before connecting the AC supply to the Drive, it is important that you
understand the operating controls and their operation. If in doubt, do not
adjust the Drive. Damage may occur, or lives put at risk. Carefully follow
the instructions in this User Guide.
Before making adjustments to the Drive, ensure all personnel in the area are
warned. Make notes of all adjustments that are made.

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2.7 Risk analysis
In any application where a malfunction of the Drive could lead to damage,
loss of life or injury, a risk analysis must be carried out, and where necessary,
further measures taken to reduce the risk. This would normally be an
appropriate form of independent safety back-up system using simple
electro-mechanical components.
2.8 Signal connections
The control circuits are isolated from the power circuits in the Drive by basic
insulation only, as specified in IEC664–1. The installer must ensure that the
external control circuits are insulated from human contact by at least one
layer of insulation rated for use at the AC supply voltage.
If the control circuits are to be connected to other circuits classified as
Safety Extra Low Voltage (SELV) (eg. to a personal computer), an additional
isolating barrier must be included in order to maintain the SELV
classification.
2.9 Adjusting parameters
Some parameters have a profound effect on the operation of the Drive.
They must not be altered without careful consideration of the impact on
the controlled system. Measures must be taken to prevent unwanted
changes due to error or tampering.

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3 Installing the UD53
Warning
Before using the following procedure, refer to the
Warnings at the beginning of Chapter 2 Installing the Drive in
the Unidrive Installation Guide.
1 Before installing the UD53 in the Unidrive, ensure the AC supply has
been disconnected from the Drive for at least 10 minutes.
2 Check that the exterior of the UD53 is not damaged, and that the
multi-way connector is free from dirt and debris. Do not install a
damaged or dirty UD53 in the Drive.
3 Remove the terminal cover from the Drive (for removal instructions,
see Installing the Drive and RFI filter in Chapter 2 of the Unidrive
Installation Guide).
4 Position the multi-way connector on the rear of the UD53 over the
connector in the Drive (see Figure 1), and press on the thumb pad to
push the UD53 into place.
5 Re-fit the terminal cover to the Drive.
6 Connect the AC supply to the Drive.
7 Set parameter .00 at 149 to unlock security.
8 Check that parameter 16.01 is set at 3 to indicate that the module is
fitted.
9 If the check in step 8 fails, perform the following:
• Remove the AC supply from the Drive.
• Wait at least 10 minutes.
• Remove the terminal cover.
• Check that the UD53 is fully inserted.
• Replace the terminal cover.
• Re-apply the AC supply.
• Check again that parameter 16.01 is set at 3.

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Figure 1 Installing the UD53 in the Unidrive

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4 Making Connections
Warning
The control circuits are isolated from the power circuits in
the Drive by basic insulation only, as specified in IEC664–1.
The installer must ensure that the external control circuits
are insulated from human contact by at least one layer of
insulation rated for use at the AC supply voltage.
If the control circuits are to be connected to other circuits
classified as Safety Extra Low Voltage (SELV) (eg. to a
personal computer), an additional isolating barrier must be
included in order to maintain the SELV classification.
4.1 Locations of the terminals
Figure 2 Location of the connector on the UD53

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4.2 Functions of the terminals
Terminal Function
40 Simulated-encoder
phase quadrature output A
or frequency output F
(EIA485 serial link)
41 Simulated-encoder
phase quadrature output A\
or frequency output F\
(EIA485 serial link)
42 0V
43 Simulated-encoder
phase quadrature output B
or frequency output D
(EIA485 serial link)
44 Simulated-encoder
phase quadrature output B\
or frequency output D\
(EIA485 serial link)
45 0V
46 Marker pulse Z output
47 Marker pulse Z \ output
48 SIN coil input (low)
49 SIN coil input (high)
50 COS coil input (low)
51 COS coil input (high)
52 Excitation output (high)
53 Excitation output (low)
54 0V
55 0V

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Resolver UD53
(high)
(low)
(high)
(low)
(high)
(low)
SIN
COS
Excitation
Resolver
SIN
COS Excitation
Figure 3 Resolver connections to the UD53

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5 Setting Up the UD53
The instructions in this chapter apply when the Drive is being set up for the
first time with a UD53 fitted.
5.1 Initial setting up
By default, the UD53 is configured for operation with a resolver having a 3:1
turns ratio. If the resolver to be used has a turns ratio of 2:1, set parameter
16.10 Resolver turns ratio select at 1.
5.2 Phase offset
When the Drive is operating in the Servo mode, either the resolver shaft
must be aligned with the motor shaft so that no phase offset exists, or the
phase-offset must be entered in parameter 16.09 Resolver phase offset.
The phase offset can be entered in either of the following ways:
• Performing a resolver phasing test. The UD53 measures the phase
offset automatically and enters the value in 16.09.
• If the phase offset is known, you can enter the value manually in
parameter 16.09.
See also Appendix B Aligning the resolver mechanically.
Resolver phasing test
(Closed-loop Servo mode)
Warning
During the phasing test, the motor shaft rotates slowly.
Before starting, make sure it will be safe for the motor to
be run.
During the phasing test, the motor shaft rotates in two stages, as follows:
• Initial jump in position by up to 1Nrevolution
• Subsequent rotation by 4Nrevolution
Where Nis the number of motor poles.
Examples
No. of poles Initial jump Subsequent rotation
2Up to 12revolution 2 revolutions
6Up to 16revolution 23revolution

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Procedure
1 Ensure the motor is unloaded (any load will create errors in the
phase-offset measurement).
2 Set parameter 16.05 Resolver phasing test at 1.
3 Enable the Drive.
The motor shaft rotates (as described before this procedure) and the
measured value of phase offset is automatically entered in parameter
16.09 Resolver phase offset. The motor shaft should rotate clockwise;
if it rotates anti-clockwise, reverse two of the phase connections from
the Drive to the motor.
If a phasing test is attempted with a motor that has high inertia, no
damping or a small load on the shaft, an incorrect value for the phase
offset will be measured. Refer to parameter 5.27 in the Unidrive
Advanced User Guide.
Note
If the Drive trips and the display indicates trip code
ENC.PH7, this indicates either of the following:
The SIN and COS connections from the resolver are
incorrectly made
The phase sequence of the motor is reversed
Correct the connections and repeat the procedure.
Magnetizing current test (Closed-loop Vector)
Refer to Autotune in Chapter 3 Setting Up the Drive in the Unidrive User Guide,
or to parameter 5.12 in the Unidrive Advanced User Guide. If the Drive trips
while Autotune is being performed, see the Note above.

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5.3 Change in feedback resolution
with change of maximum speed
The resolver feedback signals are sampled by the UD53 at a resolution that
depends on the maximum speed of the Drive. (This is determined by the
value of 1.06 Maximum speed,and when 1.08 Negative minimum speed select
is set at 1, it can also be determined by 1.07 Maximum reverse speed.)
The resolution of the SIN and COS inputs is affected as follows:
Maximum speed [1.06] Resolution of the SIN and COS inputs
RPM
0 ~ 3000 14-bit
3001 ~ 12000 12-bit
>12000 10-bit
Note that the simulated-encoder outputs are affected by the value of 1.06
(and/or 1.07). See Simulated-encoder outputs.
5.4 Simulated-encoder outputs
(terminals 40, 41, 43, 44)
The simulated-encoder outputs can be connected to external equipment for
monitoring the output of either a resolver connected to the UD53 or the
main encoder (Encoder 1) that is connected to the 15-way D-type on the
Drive. By default, the resolver is used as the source. To select Encoder 1,
set parameter 16.06 Simulated encoder output select at 1.
Quadrature AB, or frequency and direction
By default, the simulated-encoder outputs are phase-quadrature Aand B
signals. For frequency (F) and direction (D) signals, set parameter 16.08
Simulated-encoder F/D output enable at 1.

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Pulses per revolution
The maximum number of pulses per revolution (PPR) of the simulated-
encoder outputs depends on the resolution of the SIN and COS inputs; the
resolution is affected by the maximum speed which is set in 1.06 and/or
1.07), as follows:
Maximum speed
[1.06]
Resolution of
the SIN and COS
inputs
Maximum pulses per revolution of
the simulated-encoder outputs
RPM Quadrature
Frequency and
direction
0 ~ 3000 14-bit 4096
8192
3001 ~ 12000 12-bit 1024
4096
12000 10-bit 256
1024
The actual PPR is dependent on the resolution of the SIN and COS inputs as
well as on the value of 16.07 Simulated-encoder output scaling.
If a different PPR is required, enter the required scaling value in parameter
16.07 Simulated-encoder output scaling. The scaling factor is given by the
following:
1
216 07[.]

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5.5 Z marker-pulse outputs
(terminals 46, 47)
The Z marker pulse is created each time the resolver passes through its zero
position. If the marker pulse is required to occur at a different position, it is
necessary to re-position the resolver on the motor shaft. It will then be
necessary to change the value of parameter 16.09 Resolver phase offset by
an appropriate means (see Phase offset earlier in this chapter).
The Z marker pulse outputs are by default synchronized to the quadrant
where the quadrature A and B signals are both low. When synchronization
is disabled, the Z marker pulse can be present in any of the four quadrants, as
follows:
A and B both low
A and B both high
A low and B high
A high and B low
Drive software version V03.xx.07 onward
UD53 version 2 onward
(both present)
Synchronization of the Z marker-pulse output can be disabled by setting
parameter 16.12 Simulated-encoder output marker-pulse synchronization
disable at 1. Synchronization is automatically disabled when parameter
16.07 Simulated-encoder output scaling is set at either of the following:
• At a value that would cause the resolution of the encoder-simulation
outputs not to be an integral number of lines per revolution
(LPR)
• At such a high value that the number of lines per revolution (LPR) of
the simulated-encoder outputs is less than 1
Parameter 16.13 Simulated-encoder Z marker-pulse outputs synchronization
inactive indicator indicates the state of synchronization.
See the following logic table.
16.07 16.12
Synchronization
16.13
Set for integral number of lpr 0
Enabled
0
1
Disabled
1
Set for no integral number of LPR
Set for less than 1 LPR
0
Disabled
1
1
Disabled
1

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Drive software V03.xx.05 or earlier
UD51 version 3 or earlier
(either or both present)
The Z marker-pulse outputs are sychronized to the simulated-encoder
quadrature AB outputs only when the resolution of the AB outputs is
equal to or greater than 1 LPR.
Drive software V03.xx.04 or earlier
No simulated-encoder outputs are available.

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6 Related Parameters
6.1 Introduction
The parameters listed in this chapter are used for programming and
monitoring the UD53. Refer to the Unidrive User Guide for programming
instructions.
Warning
Before attempting to adjust any parameters, refer to the
Warnings and Notes at the beginning of Chapter 3 Setting up
the Drive in the Unidrive User Guide.
6.2 Programmable software
Key
Type of parameter
RO Read-only
RW Read–write
...select Select from two settings
...enable Make or allow a function to operate
...disable Stop or disallow a function from operating
...indicator The value can only be read
Limitations of use
S The new parameter-value is saved when the AC supply is
disconnected from the Drive.
P Protected parameter; the parameter cannot be used as the
destination parameter for a programmable input.
Range
Bi Variable parameter having bipolar value range.
Uni Variable parameter having unipolar value range.
Bit Bit parameter
Symbols
ð Default value
ô Range of values
~Indicates a range of values
(in the case of bit parameters, ~indicates or).