Danaher Motion SERVOSTAR CD-LITE User manual

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Danaher Motion Kollmorgen Speciality Electronics
SERVOSTAR®CD-LITE
User Manual
SERVOSTAR®Product Series
M-SS-008-0302
Firmware version 1.1.0
MOTIONLINK version 4.4.3
Ignite CD-Lite version 1.0.5
Caution – MOTIONLINK version 4.4.3 only works with Firmware version
1.1.0 and vice versa!
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Record of Manual Revisions
ISSUE NO. DATE BRIEF DESCRIPTION OF REVISION FIRMWARE
01 09/01/2001 Initial release 0.1.2
02 02/02/2003 Second edition updates for new firmware. 1.1.0
VGA®and PC-AT®are registered trademarks of International Business Machines Corporation
Windows95®/98®andWindows®NT are registered trademarks of Microsoft Corporation
EnDatTM is a registered trademark of Dr. Johannes Heidenhain GmbH
Kollmorgen GOLDLINE®, Kollmorgen SILVERLINE®, MOTIONEERING®, MOTIONLINK®,
PLATINUMTM, and SERVOSTAR® are registered trademarks of Danaher Motion Kollmorgen.
Copyright Information
Copyright 2001 - 2003 Danaher Motion Kollmorgen Speciality Electronics - All rights reserved.
NOTICE:
Not for use or disclosure outside of Danaher Motion Kollmorgen Speciality Electronics except under written
agreement. All rights are reserved. No part of this book shall be reproduced, stored in retrieval form, or transmitted
by any means, electronic, mechanical, photocopying, recording, or otherwise without the written permission from the
publisher. While every precaution has been taken in the preparation of the book, the publisher assumes no
responsibility for errors or omissions. Neither is any liability assumed for damages resulting from the use of the
information contained herein.
This document is proprietary information of Danaher Motion Kollmorgen Speciality Electronics that is furnished for
customer use ONLY. No other uses are authorized without written permission of Danaher Motion Kollmorgen
Speciality Electronics. Information in this document is subject to change without notice and does not represent a
commitment on the part of Danaher Motion Kollmorgen Speciality Electronics. Therefore, information contained in
this manual may be updated from time-to-time due to product improvements, etc., and may not conform in every
respect to former issues.
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Danaher Motion Kollmorgen Speciality Electronics Table of Contents
SERVOSTAR CD-LITE User Manual i
Table of Contents
PRODUCT DESCRIPTION.........................................................................................................................1
PRODUCT FEATURES ....................................................................................................................................1
Main Features .........................................................................................................................................1
Robust Design..........................................................................................................................................1
FeedBack Devices....................................................................................................................................2
Amplifier Configuration ..........................................................................................................................2
MOTIONLINK Software Environment ....................................................................................................2
Monitoring and Troubleshooting Tools...................................................................................................2
Fault and Safety Detection ......................................................................................................................3
GENERAL......................................................................................................................................................3
CD-Lite versus CD ..................................................................................................................................3
PART NUMBER DESCRIPTION........................................................................................................................4
SYSTEM STARTUP .....................................................................................................................................5
COMPUTER REQUIREMENTS .........................................................................................................................5
RS-232A PROTOCOL SETTINGS....................................................................................................................6
COMMUNICATION.........................................................................................................................................6
INSTALLING MOTIONLINK........................................................................................................................7
USING MOTIONLINK.................................................................................................................................7
Startup Wizard.........................................................................................................................................7
Main MOTIONLINK Screen....................................................................................................................8
TERMINAL MODE .........................................................................................................................................9
INITIAL STARTUP ..........................................................................................................................................9
ENABLING THE SYSTEM..............................................................................................................................10
FEEDBACK..................................................................................................................................................11
Incremental Encoder .............................................................................................................................11
Specifications .....................................................................................................................................................12
Cable Lengths.....................................................................................................................................................12
Resolution and Accuracy....................................................................................................................................12
Resolver.................................................................................................................................................13
Specifications .....................................................................................................................................................14
Cable Lengths.....................................................................................................................................................14
Resolution and Accuracy....................................................................................................................................15
Halls Only...........................................................................................................................................................15
Encoder Equivalent Output...................................................................................................................15
Resolver Systems................................................................................................................................................16
Encoder Systems.................................................................................................................................................16
SYSTEM OPERATION..............................................................................................................................17
OPERATIONAL MODES................................................................................................................................18
SYSTEM I/O................................................................................................................................................18
Analog Input (ANIN1) ...........................................................................................................................18
Remote Enable Input (REMOTE)..........................................................................................................19
Fault Output Relay (RELAY, RELAYMODE)........................................................................................19
Limit switches........................................................................................................................................19
Configurable Analog output (ANOUT)..................................................................................................20
Digital Output........................................................................................................................................15
CONTROL LOOPS ........................................................................................................................................15
Core Processors ....................................................................................................................................15
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Table of Contents Danaher Motion Kollmorgen Speciality Electronics
ii SERVOSTAR CD-LITE User Manual
Servo Loop Description.........................................................................................................................16
Current Loop .........................................................................................................................................16
Commutation Loop................................................................................................................................16
Velocity Loop.........................................................................................................................................16
Torque Loop ..........................................................................................................................................17
Analog Torque....................................................................................................................................................17
Current Sampling ..................................................................................................................................17
FOLDBACK..................................................................................................................................................18
Drive Foldback......................................................................................................................................18
TROUBLESHOOTING..............................................................................................................................19
ERROR CODES............................................................................................................................................19
FATAL FAULTS ERROR CODES.........................................................................................................20
NON-FATAL ERROR CODES...............................................................................................................21
NO MESSAGE FAULTS........................................................................................................................22
FAULT MONITORING SYSTEM.....................................................................................................................22
FIRMWARE UPGRADES ...............................................................................................................................24
Upgrade Procedure...............................................................................................................................24
CUSTOMER SUPPORT..................................................................................................................................26
PERSONALITY MODULE FOR CD-LITE.............................................................................................27
PREPARATION.............................................................................................................................................27
DESCRIPTION AND OPERATION ...................................................................................................................27
Error Display.........................................................................................................................................27
Schematic...............................................................................................................................................28
How To Order........................................................................................................................................28
APPENDIX A...............................................................................................................................................29
MOTOR POWER CONNECTIONS...................................................................................................................29
LR RESOLVER CONNECTION...................................................................................................................29
LE ENCODER CONNECTION........................................................................................................................30
APPENDIX B...............................................................................................................................................31
SETUP EXAMPLE.........................................................................................................................................31
Configure the CD-Lite to a Motor.........................................................................................................31
APPENDIX C...............................................................................................................................................35
LINEAR MOTOR WITH CD-LITE.................................................................................................................35
CALCULATE CD-LITE PARAMETERS ....................................................................................................35
APPENDIX D...............................................................................................................................................37
MOTOR THERMOSTAT WITH CD-LITE.......................................................................................................37
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Danaher Motion Kollmorgen Speciality Electronics Product Description
SERVOSTAR CD-LITE User Manual 1
Product Description
The SERVOSTAR®CD-Lite is a new economic addition to the SERVOSTAR family. Designed
primarily for current loop applications, this amplifier provides high performance with fully digital current
and velocity loop control. Digital control brings with it all the advantages of ease of use, eliminating the
need adjusting potentiometers. Since the control loop parameters are stored digitally, there is no drift in
performance over time. Operating modes enable internal sinusoidal from a ±10 VDC command.
The documentation provided for the SERVOSTAR CD-Lite includes this document, the SERVOSTAR®
CD-Lite Quick Start manual, and the SERVOSTAR®CD-Lite Variable and Command Reference. These
are provided to assist you in installation and use of the SERVOSTAR CD-Lite product.
Product Features
The SERVOSTAR CD-Lite includes a vast array of features. Its various control techniques, interfaces,
and user tools give the customer a fully compatible amplifier to meet most motion control applications.
The user features are:
Main Features
♦ Digital current loop
♦ Velocity loop mode
♦ Available in 3, 6, or 10 amp continuous current
♦ Self protecting power stage
♦ Encoder feedback
♦ PWM switching frequency up to 16 kHz
♦ Supports Danaher Motion Kollmorgen’s wide range of motor solutions
♦ Optional 24 VDC logic input supply, to separate from main supply
♦ Easy tuning and setup using MOTIONLINKfor Windows
♦ Easy initialization utilizing a Personality Module.
Robust Design
♦ Fully isolated electronics
♦ Fault Protection against output phase to phase short circuit, over-voltage, under-voltage, over-
current, over-temperature (motor and drive), feedback loss
♦ Current foldback (I2t) provides protection against over-heating drive
♦ Can be optionally used with Danaher Motion Kollmorgen's Regeneration Resistor
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Product Description Danaher Motion Kollmorgen Speciality Electronics
2 SERVOSTAR CD-LITE User Manual
FeedBack Devices
♦ Incremental Encoder A/B/Z with HED (Hall Effect Device)
♦ Incremental Encoder A/B with HED (Hall Effect Device)
♦ HED (Hall Effect Device) sine wave or six step
♦ Resolver (only w/ Logic power supplied from external 24 VDC)
Amplifier Configuration
♦ Use MOTIONLINKto configure the amplifier
♦ Use the Personality Module to quickly and easily configure additional amplifiers
MOTIONLINK Software Environment
♦ MOTIONLINK version from 4.3
♦ Easy setup, commanding, and monitoring techniques
♦ Setup wizard to assist users in fast, easy setup
♦ Contains an extensive database for many of Kollmorgen’s motor series
♦ A Backup screen that provides automatic loading of system parameters
♦ Realtime measuring of many system parameters
♦ Status screen indicating system operation and fault/error checking
♦ Extensive On-line Help file (F1) designed to assist the user in MOTIONLINK’s intuitive nature
♦ A set of limit folders allowing you to manipulate the, velocity, current, and filtering limits from one
screen
♦ An Input/Output (I/O) screen for easy manipulation of the I/O, thermostat options, encoder output,
and hardware position limits capabilities
♦ A Feedback Device screen that provides realtime pictorial positioning information. It also includes a
Resolver Zeroing routine and an encoder initialization screen
♦ A Control Loop screen that provides direct manipulation of velocity loop gain parameters
Monitoring and Troubleshooting Tools
♦ Control loop monitoring via terminal
o Current/torque (I, IA, IC,ICMD, IMAX, ICONT, DICONT, DIPEAK)
o Speed (V, VCMD, VE)
♦ Dual-state digital output (O1, can be used to communicate occurrences of foldback)
♦ Software status switch indicator provided for Configurable Inputs IN
♦ Analog output to monitor Current/Velocity (V,VE,I,ICMD)
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Danaher Motion Kollmorgen Speciality Electronics Product Description
SERVOSTAR CD-LITE User Manual 3
Fault and Safety Detection
♦ Watchdog faults
♦ Speed and current protection (VOSPD, VLIM, ILIM)
♦ Fatal and non-fatal error coding with text explanation to the host (FLTHIST, FLTCLR). Also
includes a run-time counter (TRUN) that records the time the error occurred
♦ Configurable drive thermal protection through the foldback feature (FOLD, FOLDMODE). It sets
the maximum time limit the drive can provide peak current (3:1) to the motor
♦ Hardware position limit switch detection (INx, where x is 1 or 2)
♦ Configurable fault relay output (RELAY, RELAYMODE)
♦ Active enable indicator through the Status Display decimal (ACTIVE, DRIVEOK, SWEN, READY,
REMOTE)
General
♦ Many enabling and disabling features (K, REMOTE, EN, DIS)
♦ Flash firmware memory for easy field upgrade installation
♦ Danaher Motion Kollmorgen’s patented “Torque Angle Control” for buried magnet motor designs
(MTANGLC, MTANGLP, MVANGLF, MVANGLH - defined as speed and torque optimization
through commutation angle advancing of the drive’s output current waveform with respect to the
motor's back EMF waveform
♦ Firmware and serial number information (VER, MOTOR) via terminal
CD-Lite versus CD
♦ Power board Logic power generated from line (SERVOSTAR CD without Top switch)
♦ Power board Logic power supplied from external 24 VDC. (Same as SERVOSTAR CD.)
♦ Digital board : Current Card Board (CCB) instead of UCB
♦ C1 – Serial Communication is RS-232 only (support for personality module)
♦ C2 – Feedback: Incremental Encoder A/B/Z/Hall, A/B/Hall, Halls only sine wave or SIX step,
Resolver (only w/ Logic power supplied from external 24 VDC)
♦ C3 – Analog input, fault output, I/O, Analog output.
♦ C4 - Same as SERVOSTAR CD
♦ C7 – Not available
♦ C8 - Not available
♦ Configuration (DIP) switch settings: CD-LITE defines the RS-232 baud rate, hold switch, drive
enable and disable (EN/DIS), and changes to Ember Mode
♦ MOTIONLINK (Same as SERVOSTAR CD except to Record application)
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Product Description Danaher Motion Kollmorgen Speciality Electronics
4 SERVOSTAR CD-LITE User Manual
Part Number Description
The SERVOSTAR CD-Lite serial and model numbers are:
Resolver configuration could be ordered only with Logic power supplied from external 24 VDC.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 5
System Startup
PC
INK
LE
Motor
RS232
Application
Load
MOTIONLINK
For system startup you need a PC with MOTIONLINK for windows, LE- CD-LITE drive brush less
motor, and your application connected to the motor. With MOTIONLINK, you can initialize and
configure you drive to your application. After that, you will connect the drive to your servo controller.
You can communicate with the SERVOSTAR CD-Lite through the serial port.
Since MOTIONLINK is designed to guide you through the operation process of the drive, the
MOTIONLINK discussion in this section covers only general steps of use. A “dumb terminal” can also
be used to communicate to the drive. You may find this method of communication very awkward until a
certain level of familiarity with the drive’s operation is achieved. MOTIONLINK also provides a
terminal emulation feature that contains many useful editing tools for this type of communication.
Computer Requirements
MOTIONLINK requires an IBM-PC or compatible computer with the following features:
♦ IBM-compatible, Pentium or higher computer.
♦ 16 M RAM.
♦ Windows 95, Windows98, WindowsNT 4.0 with Service Pack 3, Windows 2000.
♦ CD-ROM player.
♦ Standard Video Adapter (CGA, MDA, EGA, MCGA, VGA, or SVGA).
♦ Serial Port (for communication link with SERVOSTAR CD-Lite). The serial communications port
may be COM1, COM2, COM3, or COM4. COM1 is the normal configuration:
COM1: Address 3F8h, Interrupt Request #4
COM2: Address 2F8h, Interrupt Request #3
COM3: Address 3E8h, Interrupt Request #4
COM4: Address 2E8h, Interrupt Request #3
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System Startup Danaher Motion Kollmorgen Speciality Electronics
6 SERVOSTAR CD-LITE User Manual
RS-232A Protocol Settings
♦ Baud rate 9600 or 19200*
♦ Data bits 8
♦ No parity
♦ Stop bit 1
*DIP switch 6 determines the serial communication baud rate for either 9600 BPS or 19200 BPS.
Communication
The following chart shows the flow of data between the PC and the SERVOSTAR CD-Lite. When logic
power is applied to the drive, it loads the variable parameters stored in EEPROM into the dynamic RAM
for fast and easy access. You can read (and write) these variable parameters to (and from) the PC by one
of several methods described in the INITIAL STARTUP section below.
RAM
MICRO-
PROCESSOR
EEPRO M
"LOAD" command
or Power-u
p
"SAVE" command
(EEPROM variables)
(operating
parameters)
MOTION LINK PC
OR TERM INAL
USER SETTING
"DUMP" command
VARIABLE FILE
(
*.SSV
)
Memory Flow Chart
The PC transmits serial data to the drive and stores it in dynamic RAM. However, any variable data
changed from the PC is lost when logic power is lost, if it is not saved into non-volatile EEPROM. If you
configure the same system on similar applications, the variables can be saved on disk in an .SSV file for
convenient downloading into other drives.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 7
Installing MOTIONLINK
♦ Insert the CD-ROM to load MOTIONLINK for Windows.
♦ The CD-ROM should AUTORUN. If not, select Start | Run (or browse your CD-ROM drive).
♦ Type “D:AUTORUN.EXE” and press the Enter key (this assumes your CD player has a D: letter
designation).
♦ Select a product and follow the instructions on the screen.
To run the program, go to your Start/Programs listing and select SERVOSTAR MOTIONLINK from
the menu (or click on the SERVOSTAR MOTIONLINK icon if loaded on the desktop).
Using MOTIONLINK
MOTIONLINK gives you three methods to configure the drive. The first uses a Startup Wizard and is
the easiest and most highly recommended approach. Its main purpose is for initial startups. The second
approach allows you to more indirectly perform the same configuration as the first using the Main
MOTIONLINK screen. This method is most convenient when corrections to an existing configuration
are required. The third method uses the Terminal Mode screen to directly set (or monitor) values for the
same variables and commands that the other two methods configure through a more friendly user
interface. You can gain a more thorough understanding of the SERVOSTAR drive, MOTIONLINK,
and its variable and command set by using the context-sensitive Help (F1) provided in MOTIONLINK.
When you begin, the first screen you see is:
Startup Wizard
This screen appears the first time (and any time after should you choice not to deselect it)
MOTIONLINK is run on a PC. It is designed to guide you through a step-by-step approach to configure
a drive. Click the “START” button on the first user screen and walk through the complete sequence of
buttons provided to set the drive, motor, and application (Opmode, Tune, Backup, Go) variable
parameters.
Should you de-activate this screen, it can be reactivated by going to the Main
MOTIONLINK screen, pulling down the Configuration menu, and selecting the New Drive
(123) option.
Setting Drive Variable Parameters: Click the Drive button. This screen allows you to select a BUS
value that corresponds to the incoming line voltage. This selection actually determines the setting of the
variable VBUS. Also included is a realtime monitoring of the DIP switch on top of the drive so you can
verify the proper setting for the drive address, baud rate, and various other parameters. Click Exit to
return to the Startup Wizard screen.
Setting Motor Variable Parameters: Click the Motor button. This screen allows you to access the
MOTIONLINK motor database. Select a motor family and then a model within that family.
Information will appear in the blank parameter fields on the right. Click on the “To Drive” button
beneath the fields to send the variable parameters to the drive. Click “Exit” to return to the
StartupWizard screen.
For you that has a configured drive, a “From Drive” button is provided to retrieve the
motor data already in the drive. Retrieving this data will not erase it from the drive.
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System Startup Danaher Motion Kollmorgen Speciality Electronics
8 SERVOSTAR CD-LITE User Manual
If the motor cannot be found in the database, click on you Define tab. Contact Danaher
Motion Customer Support for detailed instructions.
Customizing to Application: Click the “Opmode” button in the Startup Wizard screen to select the
mode of loop control desired; velocity, or torque. Click Exit to return to the Startup Wizard screen.
Click on the Tune button in the Startup Wizard screen to set the system bandwidth, the type of loop
control, and the filtering necessary for the application.
Caution should be used when executing the AutoTune feature. Some applications are not
capable of handling the vibration caused as the shaft senses its load. If this is in question,
manually tune the drive. Also, when the load inertia is very large and the selected
bandwidth is high, this feature may fail to perform.
Setup Complete: Click EXIT to go to the Main MOTIONLINK screen.
For explanation on these functions, refer to the Main MOTIONLINK screen.
Saving Variables Parameters to EEPROM
Saving Variables Parameters to .SSV file
Restoring Factory Variable Parameters
Restoring Custom Variable Parameters
Main MOTIONLINK Screen
This screen appears the when you exit out of the MOTIONLINK Startup Wizard screen. All the screens
mentioned in the method above can be accessed from this screen and should be used to make corrections
in the current system configuration.
Setting Drive Variable Parameters: From the Configure menu, click the Drive option. The same
screen appears as described in the Startup Wizard screen section. Click Exit to return to Main
MOTIONLINK screen.
Setting Motor Variable Parameters: Selecting the Motor option under the Configure menu, you can
obtain the same parameter screen found in the Startup Wizard screen. Click Exit to return to Main
MOTIONLINK screen.
Customizing to Application: By dropping down the Operational Mode listing, you can select the mode
of loop control desired (velocity, torque). Clicking the “Tune” button, you can select the system
bandwidth, the type of loop control, and the filtering necessary for the application. These are the same
parameter screens found in the Startup Wizard screen. Click Exit to return to Main MOTIONLINK
Screen.
Saving Variable Parameters to EEPROM: At the top of this screen, you can click the button labeled
“RAM/E2” to save the modified variables from RAM to EEPROM.
Saving Variable Parameters to .SSV file: Occasionally, you may desire to backup the variable
parameters from one drive for use in another. To do this, you must pull down the Edit menu and select
Backup Variables, request the information from the drive (“Receive” button) into the editor, and save
(“Save” button) the contents in a .SSV format to a specified disk location.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 9
Restoring Factory Variable Parameters: To restore the original factory variable parameters, pull
down the Configure menu, select Motor, and select the motor family and motor model. Click the “To
Drive” button to send the variable parameters to RAM and the “RAM/E2SAVE” button to save to
EEPROM.
Restoring Custom Variable Parameters: This process assumes that you saved the custom variable
parameters to a .SSV file, as described above. To restore the custom parameters, pull down the Edit
menu, select Backup Variables, and click on “Open”. Highlight the custom .SSV file to import variable
parameters into editor. Click “Xmit” to send variable parameters to drive.
Terminal Mode
Use the MOTIONLINK Terminal Mode (or any other “dumb” host) to directly monitor or modify the
variable set and command the drive. This approach should only be taken when a PC with a Windows
operating system is not available and/or you are well-versed with the variable and command set.
Each variable and command are referenced for its syntax and parameter definition. The variables and
commands are grouped alphabetically for easy look-up and are found at the end of this manual. Be sure
you review this information before you begin.
Initial Startup
Most drives are shipped from the factory already configured for a particular motor. You can verify this
by applying logic power and monitoring the Status Display. A factory-configured drive goes through a
power-up sequence flashing all segments of the display before settling out to a number indicating the
mode of operation. If the drive is not configured with a particular motor, the display will flash a minus
sign "-", indicating that you must enter drive, motor, and application variable parameters. The remainder
of this section describes the process of setting up a non-configured drive.
Caution must be taken when applying power to the drive. It is factory-configured to
enable upon application of power. Verify that the hardware Remote Enable
(REMOTE) enable switch is disabled.
Upon powering up, the SERVOSTAR performs a series of self-tests. If the Status Display illuminates a
solid number, then no errors were found and the EEPROM has loaded its variable parameters (or loaded
with default values in case of invalid EEPROM data) into RAM. The Remote Enable switch on the I/O
connector (C3) may now be energized, thus enabling the servo loops.
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System Startup Danaher Motion Kollmorgen Speciality Electronics
10 SERVOSTAR CD-LITE User Manual
Enabling the System
24 volts must be present at the C3 enable input to get power to the motor.
The drive enable logic is based on the following variable switches and flags:
ACTIVE: This is the overall readiness flag indicating the enable/disable state of the drive. If high
(1), the drive is enabled and power is being applied to motor. The following equation
must hold true for ACTIVE to go high: ACTIVE = (READY) AND (REMOTE)
where READY = (DRIVEOK) AND (SWEN)
READY: Flag that indicates the drive is free of faults and ready to hardware enable.
DRIVEOK: Switch indicates the status of the drive faults.
SWEN: Switch indicates the status of the software enable (EN or DIS).
REMOTE: Switch indicates the status of the hardware Remote Enable line on the C3 connector.
Ready Flag
DRIVEOK
(fault status) SWEN (software enable) READY (drive ready)
0 (fault exists) 0 (disable) 0
0 (fault exists) 1 (enable) 0
1 (no faults) 0 (disable) 0
1 (no faults) 1 (enable) 1
Active Flag
READY
(drive ready) REMOTE (hardware enable) ACTIVE (power to the motor)
0 X 0 (no)
X 0 0 (no)
1 1 1 (yes)
If the drive will not enable, check the state of the switches and flags by clicking the “Status” button in the
upper right-hand corner of the Main MOTIONLINK screen. If using a terminal, you can query the drive
for the value stored in the STATUS variable. The Status Display indicates an enabled drive when the
decimal point is illuminated solid.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 11
Feedback
The SERVOSTAR provides a motor position output to you in the form of quadrature encoder
signals eliminating the need for an additional position feedback device. The outputs are
differential line drivers. There is an associated DC common output (C4: pin 3) which can connect
to your port to keep common mode noise and voltage spikes minimized for device protection.
Because there are normally differences of potential between your controller and the drive,
connection is recommended (if ground loops occur, disconnect and retest).
The source of the Encoder Equivalent Output (EEO) signals depends on the type of motor
feedback device:
This section describes the various feedback types and how they function beginning with firmware version
0.1.8.
Type MENCTYPE Comments
Incremental A/B/Z/Halls 0
Incremental A/B/H 6
Resolver NA
Halls only w/ sinus commutation 5 Defined in MOTIONLINK
Hall only w/ six step commutation 10 Defined by setting DIP switch 2 to ON
Incremental Encoder
The output signal is the actual encoder feedback signal that is pre-configured (MENCRES) in the
drive’s motor parameters. It can be scaled down by multiples of two (ENCOUTO: 1, 2, 4, 8, 16)
and has a maximum frequency limit of 3 MHz.
The SERVOSTAR can use encoder feedback to monitor the motor shaft position. As opposed to
a resolver, which is an absolute position feedback device, the encoder is an incremental device
that indicates changes in position. The encoder resolution of the SERVOSTAR (and therefore
the drive’s encoder equivalent output) is fixed because it is a hardware characteristic of the
encoder device. The encoder interface includes three groups of wires:
1. A/B (and complements) lines make up the encoder quadrature signals. The signals are
received differentially through line receivers before being passed through a wire-break
detection circuit.
2. The narrow Index pulse normally appears once per revolution and indicates a known
physical position of the shaft. This pulse is received differentially through a line receiver
before being passed through a wire-break detection circuit. This signal is hardware-
capturable.
3. Hall signals provide information representing the approximate absolute location of the
motor shaft. From this information, the motor can sinusoidally commutate forward until
the index signal is detected - at which time, true position is known. These signals are
isolated by an opto-coupler and can be differential or open-collector type signals.
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System Startup Danaher Motion Kollmorgen Speciality Electronics
12 SERVOSTAR CD-LITE User Manual
Specifications
Encoder Requirements
Required Signals Types: A, B with or without Index pulse
A, B, Index with or without Hall Channels
* Halls may be integral or discrete
Signal Type: A-quad-B and Marker
Halls Differential: do not connect single-ended Differential or Open Collector
System Voltage 5 VDC
Maximum Input Frequency From encoder: 3 MHz (before quad), 12 MHz (after quad)
Maximum Cable Length System Dependent: 50 ft. (15 m) Recommended
Maximum Line Count Per Motor Electrical Cycle 10,000,000
Maximum Supply Current from SERVOSTAR 250 mA
Protection Separate Voltage Regulator, Broken wire detector for A,
B, Index, and Hall channels, Illegal Hall Code Detection
Cable Lengths
The recommended cable length when using the SERVOSTAR to source the encoder is no longer
than 50 ft. (15 m). Long encoder cables tend to have high DC resistance that may create
significant loading effects in the supply lines to the encoder. Please consider this carefully when
designing the system. An option that would allow the use of longer lengths, implements a
separate supply located at the motor to source the encoder. Quadrature signals returned to the
drive are differentially connected which normally do not constitute a problem with longer cable
lengths.
Resolution and Accuracy
A SERVOSTAR encoder-based system typically exhibits minimal inaccuracies outside of the
encoder itself. To get an approximate total value the customer need only look to the
specifications listed for the encoder being used.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 13
One mechanical Rev
PFB = 4 X MENCRES
PRD
0 65536
Electrical degree
360 360360 360
Halls
100 001
101 011
010
110
60 120180240
300
MPHASE
MENCOFF
Z index pulse
Number of electrical degree = MPOLES / 2
MENCRES - resolution of the motor encoder (PPR)
Incremental Encoder
A/B/Z/Halls
• The Drive according to the hall section start commutates.
• The Drive set the electrical angle after first hall switch.
• The Drive re-set the electrical angle after first Index pulse switch.
• From now on the Drive calculates the electrical angle according to A/B counter.
A/B/Halls
• The Drive according to the hall section start commutates.
• The Drive set the electrical angle after first hall switch.
• From now on the Drive calculates the electrical angle according to A/B counter.
Resolver
The SERVOSTAR uses either single (two poles) or multi-speed (multiple poles) resolver
feedback to monitor the motor shaft position. A resolver can be thought of as a transformer
whose output is unique for any given shaft position (an absolute position feedback). The
transformer is driven with a sinewave reference signal. Two AC signals are returned from the
resolver into the Sine and Cosine inputs. All three of these sinewave signals are low-level and
susceptible to noise.
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System Startup Danaher Motion Kollmorgen Speciality Electronics
14 SERVOSTAR CD-LITE User Manual
One mechanical Rev
PFB = 4 X 4096 = 16384
PRD
0 65536
Electrical degree
360 360360 360
Resolver feed back
Number of electrical degree = MPOLES / 2
MENCRES - is fix to 4096
The Drive obtains its absolute position from the ATAN of the sin and cos of the Resolver.
Specifications
Resolver Requirements
Type Control Transmitter
Transformation Ratio 0.47
Modulation Frequency 7-8 kHz
Input Voltage (From Drive) 4.25 VAC
Max DC Resistance 120 Ohms (stator)
Max Drive Current 55mA AC-RMS
Output Voltage (To Drive) 2 VAC
Cable Lengths
It is important to use properly- shielded cable and to keep it away from other noise-radiating
devices and cables. It is not recommended to run the feedback and motor cables in the same
conduit. Danaher Motion Kollmorgen has tested cable lengths up to 75 ft. (22.9 m). without
degradation of performance. However, performance may vary, depending on motor and resolver
type. Tests were performed with standard Danaher Motion Kollmorgen cable and its low-
impedance and Danaher Motion Kollmorgen GOLDLINE motor resolver. Please consult the
factory for cable and resolver impedance specifications when long cable runs above 250 ft. (76
m) are desired. Danaher Motion Kollmorgen recommends twisted-shielded pair for feedback
cables.
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Danaher Motion Kollmorgen Speciality Electronics System Startup
SERVOSTAR CD-LITE User Manual 15
Resolution and Accuracy
The SERVOSTAR calculates motor velocity as the derivative of position (change in position
over time). With its patented technique, all readings are extended to a resolution of 16-bit. For
velocity feedback calculations, the drive converts the resolver input to 18-bits of resolution,
giving smooth motor velocity control. The digital resolution (RDRES) of the Resolver-to-Digital
Converter system is determined automatically according to the application velocity limit (VLIM).
The following is a summary of the SERVOSTAR’s resolution capabilities:
VLIM (RPM) RDRES Counts/Rev Encoder Eqv. Output (C4)
> 6100 12 4096 4096 quad counts
1500 to 6100 14 16384 16384 quad counts
< 1500 16 65536 65536 quad counts
R/D Converter Specifications
System accuracy using resolver feedback is effected by several components. The following table
gives information on the inaccuracy that each of these components contribute to the total
accuracy of a standard SERVOSTAR system:
Components ArcMinutes
R/D Converter 4
Resolver mechanics (rotational) 8
Resolver mounting on motor shaft 2
Inter-LSB (digital dither over the least significant bit) 5
Total (Worse-case) 19
Resolver Accuracy Specifications
Halls Only
Halls only with sinus commutation
According to halls, the drive creates the sine wave for the commutation, which is updated
every halls switch.
Hall only with six step commutation.
Electrical Degree HA HB HC Current from phase to phase for clockwise direction Disconnect Phase
0-60 100 A to B C
60-120 101 C to B A
120-180 001 C to A B
180-240 011 B to A C
240-300 010 B to C A
300-360 110 A to C B
Encoder Equivalent Output
The SERVOSTAR provides a motor position output to you in the form of quadrature encoder
signals eliminating the need for an additional position feedback device. The outputs are
differential line drivers. There is an associated DC common output (C4: pin 3) which can connect
to your port to keep common mode noise and voltage spikes minimized for device protection.
Because there are normally differences of potential between your controller and the drive,
connection is recommended (if ground loops occur, disconnect and retest).
The source of the Encoder Equivalent Output (EEO) signals depends on the type of motor
feedback device:
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