Copley Controls Xenus XSL User manual

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Xenus XSL™User Guide
P/N 95-00286-000
Revision 7
June 2008
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Xenus XSL User Guide
This page for notes.
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Copley Controls Corp. 3
TABLE OF CONTENTS
About This Manual ................................................................................................................................................................................ 8
Overview and Scope............................................................................................................................................................ 8
Related Documentation ....................................................................................................................................................... 8
Comments........................................................................................................................................................................... 8
Copyrights ........................................................................................................................................................................... 8
Document Validity................................................................................................................................................................ 8
Product Warnings................................................................................................................................................................ 9
Revision History................................................................................................................................................................. 10
1: Introduction ............................................................................................................................................................................... 11
1.1: Amplifier ............................................................................................................................................................................... 12
1.2: CME 2 .................................................................................................................................................................................. 13
1.3: CMO/CML ............................................................................................................................................................................ 13
2: Operational Theory.................................................................................................................................................................... 15
2.1: Amplifier Internal Power........................................................................................................................................................ 16
2.1.1: Logic/Signal Power .................................................................................................................................................. 16
2.1.2: High Voltage ............................................................................................................................................................ 16
2.1.3: Power and Grounding Diagram................................................................................................................................ 17
2.2: Synchronizing PWM Switching Frequency............................................................................................................................ 18
2.3: Commutation Modes ............................................................................................................................................................ 18
2.4: Feedback.............................................................................................................................................................................. 18
2.4.1: Encoder and Resolver Support ................................................................................................................................ 18
2.4.2: Secondary Encoder Interface................................................................................................................................... 18
2.5: Operating Modes .................................................................................................................................................................. 19
2.5.1: Modes and Control Loops ........................................................................................................................................ 19
2.5.2: Current Mode and Current Loop .............................................................................................................................. 20
2.5.3: Velocity Mode and Velocity Loop ............................................................................................................................. 22
2.5.4: Position Mode and Position Loop............................................................................................................................. 24
2.5.5: Input Command Types ............................................................................................................................................ 25
2.5.6: Analog Command Input ........................................................................................................................................... 25
2.5.7: PWM Input............................................................................................................................................................... 27
2.5.8: Digital Input.............................................................................................................................................................. 28
2.5.9: CVM Program.......................................................................................................................................................... 29
2.6: CANopen Operation ............................................................................................................................................................. 30
2.6.1: CAN Network and CANopen Profiles for Motion ...................................................................................................... 30
2.6.2: Supported CANopen Modes .................................................................................................................................... 30
2.6.3: Architecture ............................................................................................................................................................. 31
2.6.4: CAN Addressing ...................................................................................................................................................... 31
2.7: Limit Switches ...................................................................................................................................................................... 32
2.7.1: Use Digital Inputs to Connect Limit Switches........................................................................................................... 32
2.7.2: Diagram: Sample Placement of Limit Switches........................................................................................................ 32
2.7.3: How the Amplifier Responds to Limit Switch Activation............................................................................................ 32
2.7.4: Using Custom Output to Signal Limit Switch Activation ........................................................................................... 32
2.8: Brake Operation ................................................................................................................................................................... 33
2.8.1: Digital Output Controls Brake................................................................................................................................... 33
2.8.2: Brake/Stop Sequences ............................................................................................................................................ 33
2.9: Status Indicators................................................................................................................................................................... 34
2.9.1: Amplifier and CAN Interface Status Indicators ......................................................................................................... 34
2.9.2: Amplifier Status Indicator Operation ........................................................................................................................ 34
2.9.3: CAN Interface Status Indicator Operation ................................................................................................................ 35
2.10: Protection ........................................................................................................................................................................... 36
2.10.1: Faults..................................................................................................................................................................... 36
2.11: Position and Velocity Errors................................................................................................................................................ 38
2.11.1: Error-Handling Methods ......................................................................................................................................... 38
2.11.2: Following Error Faults ............................................................................................................................................ 38
2.11.3: Following Error Warnings....................................................................................................................................... 38
2.11.4: Position and Velocity Tracking Windows................................................................................................................ 38
2.11.5: Following Error Fault Details .................................................................................................................................. 39
2.11.6: Tracking Window Details ....................................................................................................................................... 40
2.12: Communication .................................................................................................................................................................. 41
2.12.1: Communication Interfaces ..................................................................................................................................... 41
2.12.2: CME 2 and CAN Operation.................................................................................................................................... 41
2.13: Inputs ................................................................................................................................................................................. 42
2.13.1: Digital Inputs.......................................................................................................................................................... 42
2.13.2: Input Filters............................................................................................................................................................ 42
2.13.3: Debounce Time ..................................................................................................................................................... 42
2.13.4: Configure for Pull Up/Pull Down Resistors by Groups............................................................................................ 42
2.13.5: Programmable Input Functions.............................................................................................................................. 42
2.14: Outputs............................................................................................................................................................................... 44
2.14.1: Digital Outputs ....................................................................................................................................................... 44
2.14.2: Standard Programmable Output Functions ............................................................................................................ 44
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Table of Contents Xenus XSL User Guide
4Copley Controls Corp.
2.14.3: Custom Output Functions ...................................................................................................................................... 45
2.15: Regen Resistor Theory....................................................................................................................................................... 47
2.15.1: Regeneration ......................................................................................................................................................... 47
2.15.2: Regen Resistor ...................................................................................................................................................... 47
2.15.3: Regen Circuit Components .................................................................................................................................... 47
2.15.4: Regen Circuit Protections ...................................................................................................................................... 47
2.15.5: Configurable Custom Resistor ............................................................................................................................... 47
3: Specifications ............................................................................................................................................................................ 49
3.1: Agency Approvals................................................................................................................................................................. 50
3.2: Power Input .......................................................................................................................................................................... 50
3.3: Power Output........................................................................................................................................................................ 50
3.4: Control Loops ....................................................................................................................................................................... 51
3.5: Regen Circuit Output ............................................................................................................................................................ 51
3.6: Digital Command Input ......................................................................................................................................................... 51
3.7: Analog Command Input........................................................................................................................................................ 52
3.8: Digital Inputs......................................................................................................................................................................... 52
3.9: Digital Outputs...................................................................................................................................................................... 52
3.10: Brake Output ...................................................................................................................................................................... 53
3.11: Encoder Power Supply Output............................................................................................................................................ 53
3.12: Primary and Secondary Encoder Inputs.............................................................................................................................. 53
3.13: Analog Encoder Inputs ....................................................................................................................................................... 53
3.14: Hall Switch Inputs ............................................................................................................................................................... 54
3.15: Resolver Interface .............................................................................................................................................................. 54
3.16: Encoder Outputs................................................................................................................................................................. 54
3.17: Serial Interface ................................................................................................................................................................... 54
3.18: CAN Interface..................................................................................................................................................................... 55
3.19: Status Indicators................................................................................................................................................................. 55
3.20: Fault Levels ........................................................................................................................................................................ 55
3.21: Power Dissipation............................................................................................................................................................... 56
3.22: Thermal Impedance............................................................................................................................................................ 56
3.23: Mechanical and Environmental........................................................................................................................................... 56
3.24: Dimensions......................................................................................................................................................................... 57
4: Wiring......................................................................................................................................................................................... 59
4.1: General Wiring Instructions .................................................................................................................................................. 60
4.1.1: Electrical Codes and Warnings................................................................................................................................ 60
4.1.2: Grounding Considerations ....................................................................................................................................... 60
4.1.3: Connector Locations................................................................................................................................................ 61
4.2: AC Mains (J1)....................................................................................................................................................................... 62
4.3: Motor (J2) ............................................................................................................................................................................. 63
4.4: Regen Resistor (J3) (Optional) ............................................................................................................................................. 64
4.5: Logic Supply / Brake (J4)...................................................................................................................................................... 65
4.6: RS-232 Serial Communications (J5)..................................................................................................................................... 66
4.7: CAN Bus (J6) ....................................................................................................................................................................... 67
Control (J7).................................................................................................................................................................................. 68
4.8: Motor Feedback (J8)............................................................................................................................................................. 72
5: Quick Setup with CME 2 ........................................................................................................................................................... 77
5.1: Warnings .............................................................................................................................................................................. 78
5.2: CME 2 Installation and Serial Port Setup.............................................................................................................................. 79
5.2.1: Requirements .......................................................................................................................................................... 79
5.2.2: Downloading Software from Web (Optional) ............................................................................................................ 79
5.2.3: Installing CME 2 Software........................................................................................................................................ 79
5.2.4: Serial Port Setup...................................................................................................................................................... 80
5.3: Prerequisites ........................................................................................................................................................................ 82
5.3.1: Hardware and Equipment ........................................................................................................................................ 82
5.3.2: Starting CME 2 and Choosing an Amplifier .............................................................................................................. 83
5.4: Basic Setup .......................................................................................................................................................................... 84
5.4.1: Basic Setup Screen ................................................................................................................................................. 84
5.5: Motor Setup.......................................................................................................................................................................... 86
5.5.1: Motor Data File ........................................................................................................................................................ 86
5.5.2: Rotary Motor............................................................................................................................................................ 87
5.5.3: Linear Motor............................................................................................................................................................. 88
5.6: Feedback Setup ................................................................................................................................................................... 89
5.6.1: Overview.................................................................................................................................................................. 89
5.6.2: Rotary Motor Feedback Setup Options .................................................................................................................... 90
5.6.3: Linear Motor Feedback Setup Options..................................................................................................................... 90
5.7: Brake/Stop (Optional) ........................................................................................................................................................... 91
5.7.1: Overview.................................................................................................................................................................. 91
5.7.2: Procedure ................................................................................................................................................................ 91
5.7.3: Calculate.................................................................................................................................................................. 92
5.8: Amplifier Configuration ......................................................................................................................................................... 93
5.8.1: Digital Inputs............................................................................................................................................................ 93
5.8.2: Standard Digital Outputs.......................................................................................................................................... 95
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5.8.3: Custom Digital Outputs............................................................................................................................................ 96
5.8.4: Save Input/Output Changes..................................................................................................................................... 96
5.8.5: Fault Latching .......................................................................................................................................................... 97
5.8.6: Regen Resistor ........................................................................................................................................................ 98
5.9: Command Input.................................................................................................................................................................... 98
5.9.1: Analog Input ............................................................................................................................................................ 99
5.9.2: PWM Input............................................................................................................................................................. 101
5.9.3: Digital Position Input .............................................................................................................................................. 102
5.9.4: CAN Interface ........................................................................................................................................................ 104
5.10: Auto Phase....................................................................................................................................................................... 105
5.10.1: Auto Phase Warnings and Notes......................................................................................................................... 105
5.10.2: Auto Phase Procedure......................................................................................................................................... 106
5.10.3: Guidelines for Choosing Auto Phase Current and Increment Rate Values ........................................................... 109
5.10.4: Trouble Shoot Motor Direction Setup ................................................................................................................... 109
5.10.5: Trouble Shoot Motor Wiring Setup....................................................................................................................... 109
5.10.6: Trouble Shoot Halls Wiring Setup........................................................................................................................ 109
5.10.7: Other Problems.................................................................................................................................................... 109
5.11: Current Loop..................................................................................................................................................................... 110
5.11.1: Current Loop Settings.......................................................................................................................................... 110
5.11.2: Manually Tune Current Loop................................................................................................................................ 111
5.12: Velocity Loop.................................................................................................................................................................... 113
5.12.1: Velocity Loop Settings ......................................................................................................................................... 113
5.12.2: Manually Tune the Velocity Loop ......................................................................................................................... 114
5.13: Position Loop.................................................................................................................................................................... 115
5.13.1: Position Loop Settings ......................................................................................................................................... 115
5.13.2: Manually Tune the Position Loop ......................................................................................................................... 116
5.13.3: Test S-Curve Profile............................................................................................................................................. 118
5.14: Completion Steps ............................................................................................................................................................. 119
5.14.1: Objective.............................................................................................................................................................. 119
5.14.2: Steps ................................................................................................................................................................... 119
6: Using CME 2 ............................................................................................................................................................................ 121
6.1: CME 2 Overview................................................................................................................................................................. 122
6.1.1: Main Screen Overview........................................................................................................................................... 122
6.1.2: Tool Bar Overview ................................................................................................................................................. 122
6.1.3: Main Menu Overview ............................................................................................................................................. 123
6.1.4: Functional Diagram................................................................................................................................................ 124
6.1.5: CAN Information and Status Bar............................................................................................................................ 125
6.1.6: Choosing an Amplifier from a List of Amplifiers...................................................................................................... 125
6.1.7: Renaming an Amplifier .......................................................................................................................................... 125
6.2: Manage Amplifier and Motor Data ...................................................................................................................................... 126
6.2.1: Memory.................................................................................................................................................................. 126
6.2.2: Disk Storage .......................................................................................................................................................... 126
6.2.3: Data Management Tools........................................................................................................................................ 127
6.2.4: Quick Copy Setup Procedure................................................................................................................................. 128
6.3: Downloading Firmware ....................................................................................................................................................... 129
6.3.1: Acquiring Firmware from Web Site (Optional)........................................................................................................ 129
6.3.2: Downloading Firmware to Amplifier........................................................................................................................ 130
6.4: Control Panel...................................................................................................................................................................... 131
6.4.1: Control Panel Overview ......................................................................................................................................... 131
6.4.2: Status Indicators and Messages............................................................................................................................ 131
6.4.3: Monitor Functions .................................................................................................................................................. 132
6.4.4: Control Functions................................................................................................................................................... 133
6.4.5: Jog Mode............................................................................................................................................................... 133
6.5: Scope Tool ......................................................................................................................................................................... 134
6.5.1: Scope Tool Overview............................................................................................................................................. 134
6.5.2: Function Generator and Profile Tabs ..................................................................................................................... 135
6.5.3: Scope Settings ...................................................................................................................................................... 136
6.5.4: Scope Tool Controls .............................................................................................................................................. 139
6.5.5: Control Loop Parameters in the Scope Tool .......................................................................................................... 139
6.5.6: Scope Files............................................................................................................................................................ 141
6.6: Error Log and Communications Log ................................................................................................................................... 142
6.6.1: Error Log................................................................................................................................................................ 142
6.6.2: Communications Log ............................................................................................................................................. 143
6.7: CME 2 Virtual Amplifier ...................................................................................................................................................... 144
6.7.1: Virtual Amplifier Overview...................................................................................................................................... 144
6.7.2: Virtual Amplifier Creation ....................................................................................................................................... 144
6.8: Manual Phasing.................................................................................................................................................................. 145
6.8.1: Manual Phase Objectives ...................................................................................................................................... 145
6.8.2: Manual Phase Instructions, Standard (Non-Resolver) Xenus................................................................................. 145
6.8.3: Manual Phase Instructions, Resolver (-R) Xenus ................................................................................................... 147
6.8.4: Troubleshooting Manual Phase With Halls and Encoder........................................................................................ 148
6.8.5: Verify Motor Pole Count......................................................................................................................................... 148
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Table of Contents Xenus XSL User Guide
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6.9: Auto Tune Current Loop ..................................................................................................................................................... 149
6.9.1: Auto Tune Objective .............................................................................................................................................. 149
6.9.2: Auto Tune Instructions........................................................................................................................................... 149
6.10: Home Function ................................................................................................................................................................. 152
6.10.1: Overview.............................................................................................................................................................. 152
6.10.2: Homing Functions Settings .................................................................................................................................. 152
A: Regen Resistor Sizing and Configuration ............................................................................................................................. 153
A.1: Sizing a Regen Resistor..................................................................................................................................................... 154
A.1.1: Gather Required Information ................................................................................................................................. 154
A.1.2: Observe the Properties of Each Deceleration During a Complete Cycle of Operation ........................................... 154
A.1.3: Calculate Energy Returned for Each Deceleration................................................................................................. 155
A.1.4: Determine the Amount of Energy Dissipated by the Motor .................................................................................... 155
A.1.5: Determine the Amount of Energy Returned to the Amplifier .................................................................................. 155
A.1.6: Determine if Energy Returned Exceeds Amplifier Capacity ................................................................................... 156
A.1.7: Calculate Energy to be Dissipated for Each Deceleration...................................................................................... 156
A.1.8: Calculate Pulse Power of Each Deceleration that Exceeds Amplifier Capacity...................................................... 156
A.1.9: Calculate Resistance Needed to Dissipate the Pulse Power ................................................................................. 156
A.1.10: Calculate Continuous Power to be Dissipated ..................................................................................................... 157
A.1.11: Select Fuses ....................................................................................................................................................... 157
A.2: Configuring a Custom Regen Resistor ............................................................................................................................... 158
A.2.1: Regen Configuration Objective and Warning......................................................................................................... 158
A.2.2: Regen Configuration Instructions .......................................................................................................................... 158
B: I2TTime Limit Algorithm ......................................................................................................................................................... 161
B.1: I2TAlgorithm ...................................................................................................................................................................... 162
B.1.1: I2TOverview.......................................................................................................................................................... 162
B.1.2: I2TFormulas and Algorithm Operation .................................................................................................................. 162
B.1.3: I2TCurrent Limit Algorithm – Application Example ................................................................................................ 163
C: Velocity Loop Filters ............................................................................................................................................................... 167
C.1: Advanced Velocity Loop Filter............................................................................................................................................ 167
C.1.1: Filter Overview ...................................................................................................................................................... 167
C.1.2: Filter Instructions and Details ................................................................................................................................ 167
D: Thermal Considerations.......................................................................................................................................................... 169
D.1: Operating Temperature and Cooling Configurations .......................................................................................................... 170
D.1.2: Heatsink and Fan Configurations .......................................................................................................................... 171
D.2: Heatsink Mounting Instructions .......................................................................................................................................... 172
E: Xenus Filter.............................................................................................................................................................................. 173
E.1: Overview ............................................................................................................................................................................ 174
E.1.1: Differential and Common Mode Filtering ............................................................................................................... 174
E.1.2: Description and Functional Diagram...................................................................................................................... 174
E.1.3: PWM Output Plot .................................................................................................................................................. 174
E.2: XSL-FA-01 Edge Filter Specifications ................................................................................................................................ 175
E.3: Thermal Considerations ..................................................................................................................................................... 175
E.4: XSL-FA-01 Edge Filter Dimensions.................................................................................................................................... 176
E.5: XSL-FA-01 Edge Filter Wiring ............................................................................................................................................ 177
E.5.2: Electrical Codes and Warnings ............................................................................................................................. 177
E.5.2: Connector Locations ............................................................................................................................................. 178
E.5.3: Cable Notes .......................................................................................................................................................... 179
E.5.4: Input (J1) From Amplifier....................................................................................................................................... 179
E.5.5: Output (J2) To Motor ............................................................................................................................................. 179
E.5.6: Diagram: Edge Filter Wiring with Brushless Motor................................................................................................. 180
E.5.7: Diagram: Edge Filter Wiring with Brush Motor....................................................................................................... 180
E.6: XSL-FA-01 Edge Filter Ordering......................................................................................................................................... 181
F: Connecting for Serial Control................................................................................................................................................. 183
F.1: Single-Axis and Multi-Drop ................................................................................................................................................. 184
F.1.2: Single-Axis Connections........................................................................................................................................ 184
F.1.3: Multi-Drop Network Connections ........................................................................................................................... 184
G: ServoTube Motor Setup .......................................................................................................................................................... 185
G.1: ServoTube Setup and Configuration .................................................................................................................................. 186
G.1.1: ServoTube Basic Setup Screen Options ............................................................................................................... 186
G.1.2: ServoTube Motor/Feedback Setup........................................................................................................................ 187
G.1.3: Calculating ServoTube Initial Values..................................................................................................................... 188
G.1.4: Setting Up the Motor Over Temperature Input....................................................................................................... 188
G.1.5: Other ServoTube I/O and Fault Latching Setup Steps .......................................................................................... 188
G.2: ServoTube Auto Phase and Manual Phase ....................................................................................................................... 189
G.2.1: ServoTube Auto Phase ......................................................................................................................................... 189
G.2.2: ServoTube Manual Phase..................................................................................................................................... 192
G.3: Special ServoTube Setup Completion ............................................................................................................................... 192
H: Ordering Guide and Accessories ........................................................................................................................................... 193
H.1: Amplifier Model Numbers................................................................................................................................................... 194
H.2: Accessory Model Numbers ................................................................................................................................................ 194
H.3: Order Example................................................................................................................................................................... 195
H.4: Control and Feedback Cable Color Codes ......................................................................................................................... 196
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Xenus XSL User Guide Table Of Contents
Copley Controls Corp. 7
H.4.1: Wire Description Nomenclature............................................................................................................................. 196
H.4.2: Control Cable (XSL-CC-10) ................................................................................................................................... 196
H.4.3: Feedback (XSL-FC-10) ......................................................................................................................................... 197
H.5: Regen Resistor Specifications ........................................................................................................................................... 198
H.5.1: XTL-RA-03, XTL-RA-04 Specifications.................................................................................................................. 198
H.5.2: XTL-RA-03, XTL-RA-04 Dimensions ..................................................................................................................... 198
H.5.3: XSL-RA-01, 02 (Discontinued) Specifications........................................................................................................ 199
H.5.4: XSL-RA-01, 02 (Discontinued) Dimensions........................................................................................................... 199
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Copley Controls Corp. 8
ABOUT THIS MANUAL
Overview and Scope
This manual describes the operation and installation of the Xenus amplifier manufactured by
Copley Controls Corporation.
Related Documentation
Users of the CANopen features should also read these Copley Controls documents:
•CANopen Programmer’s Manual
•CML Reference Manual
•Copley Motion Objects Programmer’s Guide
Also of related interest:
•Copley Indexer Program User’s Guide (describes use of Indexer Program to create motion
control sequences)
•Copley Controls ASCII RS-232 User Guide (describes how to send ASCII format commands
over an amplifier’s serial bus to set up and control one or more amplifiers)
Information on Copley Controls Software can be found at:
http://www.copleycontrols.com/Motion/Products/Software/index.html
Comments
Copley Controls Corporation welcomes your comments on this manual. See
http://www.copleycontrols.com for contact information.
Copyrights
No part of this document may be reproduced in any form or by any means, electronic or
mechanical, including photocopying, without express written permission of Copley Controls
Corporation.
Xenus is a registered trademark of Copley Controls Corporation.
CME 2 is a registered trademark of Copley Controls Corporation.
Windows 95, 98, NT, ME, 2000, and XP, Visual Basic, Excel, and .NET are trademarks or
registered trademarks of the Microsoft Corporation.
LabVIEW is a registered trademark of National Instruments.
Document Validity
We reserve the right to modify our products. The information in this document is subject to change
without notice and does not represent a commitment by Copley Controls Corporation. Copley
Controls Corporation assumes no responsibility for any errors that may appear in this document.
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Xenus XSL User Guide About this Manual
Copley Controls Corp. 9
Product Warnings
Observe all relevant state, regional, and local safety regulations when installing and using this
product. For safety and to assure compliance with documented system data, only Copley Controls
Corporation should perform repairs to amplifiers.
DANGER: Hazardous voltages.
!
DANGER
Exercise caution when installing and adjusting.
Failure to heed this warning can cause equipment damage, injury, or death.
Risk of electric shock.
!
DANGER
High-voltage circuits on J1, J2, and J3 are connected to mains power.
Failure to heed this warning can cause equipment damage, injury, or death.
Risk of unexpected motion with non-latched faults.
!
DANGER
After the cause of a non-latched fault is corrected, the amplifier re-enables the PWM
output stage without operator intervention. In this case, motion may re-start
unexpectedly. Configure faults as latched unless a specific situation calls for non-
latched behavior. When using non-latched faults, be sure to safeguard against
unexpected motion.
Failure to heed this warning can cause equipment damage, injury, or death.
Using CME 2 or serial commands may affect or suspend CAN operations.
!
DANGER
When operating the amplifier as a CAN node, the use of CME 2 or ASCII serial
commands may affect CAN operations in progress. Using such commands to initiate
motion may cause CAN operations to suspend.
CAN operations may restart unexpectedly when the commanded motion is stopped.
Failure to heed this warning can cause equipment damage, injury, or death.
Latching an output does not eliminate the risk of unexpected motion with non-
latched faults.
!
DANGER
Associating a fault with a latched, custom-configured output does not latch the fault
itself. After the cause of a non-latched fault is corrected, the amplifier re-enables
without operator intervention. In this case, motion may re-start unexpectedly.
For more information, see Clearing Non-Latched Faults (p. 36).
Failure to heed this warning can cause equipment damage, injury, or death.
Use equipment as described.
!
DANGER
Operate amplifiers within the specifications provided in this manual.
Failure to heed this warning can cause equipment damage, injury, or death.
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About this Manual Xenus XSL User Guide
10 Copley Controls Corp.
Revision History
Revision Date DECO # Comments
1.0 June 2003 Initial publication.
1.1 July 2003 New CAN termination plug requires documentation changes in
CAN Interface (p. 55) and CAN Bus (J6) (p. 67).
2.0 April 2005 Support for resolvers and dual feedback configurations, and emulated
digital encoder output source. See Feedback (p. 18).
Copley Virtual Machine (CVM) and Indexer Program for writing motion
control sequences to run on the Xenus. See CVM Program (p. 29).
Xenus filter. See Xenus Filter (p.173).
High res input. See
General Programmable Input Functions (p. 43).
Velocity loop input filter.
See Velocity Loop Filters (p. 167).
Position loop Gain Multiplier.
See Position Mode and Position Loop (p. 24).
Over Current fault.
See Fault Descriptions (p. 37.)
RS-232 multi-drop serial control.
See Connecting for Serial Control (p. 183).
New CAN addressing interface.
See CAN Interface (p. 104 ).
New CME 2 homing function for setting up and testing homing moves.
See Home Function (p. 152).
3April 2006 12526 Changed drawing in Heatsink Mounting Instructions (p. 172) to clarify that
two sheets of clear plastic carrier should be removed from phase change
material and discarded.
4April 2006 14711 Internal version control adjustment.
5January 2008 16585 Add XSL to title to avoid confusion with Xenus XTL document.
6June 2008 17112 Changes to Control and Feedback Cable Color Codes (p. 196) and
Regen Resistor Specifications (p. 198).
7June 2008 17137 Updated Web page references.
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Copley Controls Corp. 11
CHAPTER
1: INTRODUCTION
This chapter provides an overview of Copley Controls’ Xenus amplifier.
Contents include:
Title Page
1.1: Amplifier ............................................................................................................................................................................... 12
1.2: CME 2 .................................................................................................................................................................................. 13
1.3: CMO/CML ............................................................................................................................................................................ 13
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Introduction Xenus XSL User Guide
12 Copley Controls Corp.
1.1: Amplifier
Xenus provides 100% digital control of brushless or brush motors in an off-line powered package.
It can also control a Copley Controls ServoTube motor (see ServoTube Setup, p. 84). Xenus can
operate from single or three-phase mains with a continuous power output of up to 4 kW.
Xenus is offered in two versions to support three types of feedback devices. The standard version
supports digital quadrature or analog sin/cos encoders. The -R version supports brushless
resolvers. Both versions can emulate a digital quadrature encoder output from the analog encoder
or resolver respectively
Xenus can operate in several basic ways:
•As a traditional motor amplifier accepting current, velocity or position commands from an
external controller. In current and velocity modes it can accept ±10 Vdc analog, digital 50%
PWM or PWM/polarity inputs. In position mode, inputs can be incremental position commands
from step-motor controllers in Pulse and Direction or Count Up/Count Down format, as well as
A/B quadrature commands from a master-encoder. Pulse-to-position ratio is programmable for
electronic gearing.
•As a node on a CANopen network. CANopen compliance allows the amplifier to take
instruction from a master application over a CAN network to perform torque, velocity, and
position profiling, interpolated motion, and homing operations. Multiple drives can be tightly
synchronized for high performance coordinated motion.
•As a stand-alone controller running Copley Virtual Machine (CVM) control programs such as
the Indexer Program. It can also be controlled directly over an RS232 serial link with simple
ASCII format commands.
Mains input voltage to the amplifier can range from 100 to 240 Vac, single or three-phase, and 47
to 63 Hz. This allows Xenus the ability to work in the widest possible range of industrial settings.
Several models are available, with peak current ratings of 18 to 40 amps:
Model
Encoder Resolver
Continuous
Current
Peak
Current
Vac
XSL-230-18 XSL-230-18-R 6 A 18 A
XSL-230-36 XSL-230-36-R 12 A 36 A
XSL-230-40 XSL-230-40-R 20 A 40 A
100 to
240
Aseparate +24 Vdc logic supply powers the internal logic and control circuits. These are isolated
from the high-voltage power supply and inverter stage that connect to the mains. This simplifies
system design by allowing the mains to be completely disconnected from the amplifier for safety
reasons, but allows the logic side of the amplifier to stay powered. This allows the amplifier to
retain position information and maintain communication through the digital I/O or over the serial or
CAN ports when disconnected from the mains.
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Xenus XSL User Guide Introduction
Copley Controls Corp. 13
1.2: CME 2
Amplifier commissioning is fast and simple using Copley Controls CME 2 software. CME 2
communicates with Xenus via an RS-232 link, and all of the operations needed to configure the
amplifier are accessible through CME 2.
The multi-drop feature allows CME 2 to a single RS-232 serial connection to one amplifier as a
gateway to other amplifiers linked together by CAN bus connections.
Auto phasing of brushless motor Hall sensors and phase wires eliminates “wire and try.”
Connections are made once and CME 2 does the rest. Encoder or resolver wire swapping to
establish the direction of positive motion is also eliminated.
Motor data can be saved as .ccm files. Amplifier data is saved as .ccx files that contain all
amplifier settings plus motor data. This makes it possible to quickly set up amplifiers by copying
configurations from one amplifier to another.
1.3: CMO/CML
Copley Motion Libraries (CML) and Copley Motion Objects (CMO) make CANopen system
commissioning fast and simple. All network housekeeping is taken care of automatically by a few
simple commands linked into your application program. CML provides a suite of C++ libraries,
allowing a C++ application program to communicate with and control an amplifier over the
CANopen network. CMO provides a similar suite of COM objects that can be used by Visual
Basic, .NET, LabVIEW, or any other program supporting the Microsoft COM object interface.
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Introduction Xenus XSL User Guide
14 Copley Controls Corp.
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Copley Controls Corp. 15
CHAPTER
2: OPERATIONAL THEORY
This chapter describes the basics of Xenus operation. Contents include:
Title Page
2.1: Amplifier Internal Power........................................................................................................................................................ 16
2.2: Synchronizing PWM Switching Frequency............................................................................................................................ 18
2.3: Commutation Modes ............................................................................................................................................................ 18
2.4: Feedback.............................................................................................................................................................................. 18
2.5: Operating Modes .................................................................................................................................................................. 19
2.6: CANopen Operation ............................................................................................................................................................. 30
2.7: Limit Switches ...................................................................................................................................................................... 32
2.8: Brake Operation ................................................................................................................................................................... 33
2.9: Status Indicators................................................................................................................................................................... 34
2.10: Protection ........................................................................................................................................................................... 36
2.11: Position and Velocity Errors................................................................................................................................................ 38
2.12: Communication .................................................................................................................................................................. 41
2.13: Inputs ................................................................................................................................................................................. 42
2.14: Outputs............................................................................................................................................................................... 44
2.15: Regen Resistor Theory....................................................................................................................................................... 47
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Operational Theory Xenus XSL User Guide
16 Copley Controls Corp.
2.1: Amplifier Internal Power
Power distribution within Xenus is divided into three sections: +24 Vdc, logic/signal, and high
voltage. Each is isolated from the other.
2.1.1: Logic/Signal Power
An internal DC/DC converter operates from the +24 Vdc Logic Supply input and creates the
required logic/signal operating voltages, the isolated voltages required for the high-voltage control
circuits, and a +5 Vdc supply for powering the motor encoder and Hall circuits. All the digital and
analog inputs, digital outputs (with the exception of OUT4), Hall and encoder inputs are referenced
to the same signal common. OUT4 is controlled through an opto-isolator, and is referenced to the
+24 Vdc return. The CAN interface is also optically isolated.
Deriving internal operating voltages from a separate source enables the amplifier to stay on-line
when the mains have been disconnected for emergency-stop or operator-intervention conditions.
This allows CAN bus and serial communications to remain active so that the amplifier can be
monitored by the control system while the mains power is removed.
2.1.2: High Voltage
Mains power drives the high-voltage section. It is rectified and capacitor-filtered to produce the DC
bus: the DC ‘link’ power that drives the PWM inverter, where it is converted into the voltages that
drive a three-phase brushless or DC brush motor. An internal solid-state switch, together with an
external power resistor, provides dissipation during regeneration when the mechanical energy of
the motor is converted back into electrical energy. This prevents charging the internal capacitors
to an overvoltage condition.
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Xenus XSL User Guide Operational Theory
Copley Controls Corp. 17
2.1.3: Power and Grounding Diagram
+24
VDC LOGIC
&
SIGNAL
POWER
RTN
PWM
INVERTER
L1
CONTROL
LOGIC
MAINS
L3
+5 Vdc
U
V
W
MOTOR
HALLS
ENCODER
CASE
ISOLATION BARRIER
+5 Vdc
DC BUSS(+)
DC BUSS(-)
L2
AMPLIFIER
CHASSIS
CONTROL
SYSTEM
ENABLE [IN1]
SIGNAL GND
SIGNAL GND
SHIELD
J8
J7
J1
J2
FRAME
(SAFETY)
GROUND
CONTROL
SIGNAL
GROUND
~
~-
+
~+
REGEN(-) REGEN(+)
SHIELD
BRAKE
+24 Vdc
+24 Vdc
GROUND
J3
J4
1760 RF
DC/DC
Cntrl
DC/DC
Converter
+5 Vdc @
400mA
PWM
STAGE
CONTROL
POWER
+5 Vdc
BRAKE
CAN
Bus
Ckt
CAN
Network
SIGNAL GND
J6
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Operational Theory Xenus XSL User Guide
18 Copley Controls Corp.
2.2: Synchronizing PWM Switching Frequency
In some situations, such as when sampling small analog signals, it is desirable to synchronize the
PWM switching frequency among multiple amplifiers. In these cases, one amplifier serves as a
master for one or more slave amplifiers. The PWM sync output of the master sends a signal that
is received as a PWM sync input by each slave.
2.3: Commutation Modes
The amplifier supports three commutation modes to drive brush and brushless motors: AC
brushless sinusoidal, AC brushless trapezoidal, and DC brush.
In most applications, sinusoidal commutation is preferred over trapezoidal, because it reduces
torque ripple and offers the smoothest motion at any velocity or torque. In the sinusoidal
commutation mode, an encoder or a resolver are required for all modes of operation.
In AC brushless trapezoidal commutation mode, the amplifier provides traditional six-step
commutation.
When driving a DC brush motor, the amplifier operates as a traditional H-Bridge amplifier.
2.4: Feedback
2.4.1: Encoder and Resolver Support
The Xenus amplifier is offered in two versions to support encoder or resolver feedback. The
encoder version supports digital quadrature or analog sin/cos encoders. This version normally
requires the use of Hall switches for the commutation of brushless motors. The resolver version
supports standard, single speed, transmit-type resolvers.
2.4.2: Secondary Encoder Interface
Both versions support a secondary encoder interface. This interface can be configured to:
•Provide a buffered digital encoder output based on the digital encoder input.
•Provide an emulated digital encoder output based on the analog encoder or resolver input.
•Provide a second digital encoder input to be used in the dual encoder position mode. In this
mode, an encoder attached to the load provides position loop feedback, and the motor
encoder or resolver provides velocity loop feedback.
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Xenus XSL User Guide Operational Theory
Copley Controls Corp. 19
2.5: Operating Modes
2.5.1: Modes and Control Loops
Nesting of Control Loops and Modes
Copley Controls amplifiers use up to three nested control loops - current, velocity, and position - to
control a motor in three associated operating modes.
Control Loops Illustration
In position mode, the amplifier uses all three loops. As shown below, the position loop drives the
nested velocity loop, which drives the nested current loop.
Target
Position
Position
Command
Actual CurrentDerived VelocityActual Position
Velocity
Command
Cur r ent
Command
Limited
Velocity
Limited
Current
PWM
Command
Trajectory
Generator
Position
Loop
Velocity
Limiter
Cur rent
Limiter
Current
Loop
Motor/
Sensors
Limits
Velocity
Loop
FILTER
FILTER
In velocity mode, the velocity loop drives the current loop. In current mode, the current loop is
driven directly by external or internal current commands.
Basic Attributes of All Control Loops
These loops (and servo control loops in general) share several common attributes:
Loop Attribute Description
Command input Every loop is given a value to which it will attempt to control. For example, the velocity loop
receives a velocity command that is the desired motor speed.
Limits Limits are set on each loop to protect the motor and/or mechanical system.
Feedback The nature of servo control loops is that they receive feedback from the device they are
controlling. For example, the position loop uses the actual motor position as feedback.
Gains These are constant values that are used in the mathematical equation of the servo loop. The
values of these gains can be adjusted during amplifier setup to improve the loop
performance. Adjusting these values is often referred to as tuning the loop.
Output The loop generates a control signal. This signal can be used as the command signal to another
control loop or the input to a power amplifier.
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