gefran ADV200 Series User manual

ADV200
English
Electrical Line Shaft Application
User Guide

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 2 of 32
Version Data Author Description
1.3 4-12-2014 CNL Add chapter 1.1
1.2 27-9-2013 SPD - P15 cjhanged section 4.2
- P28 add bit Status Word Mon description
- deleted SIEIDrive
1.1 28-6-2013 CNL Chapt. 1 reviewed
1..0 21-3-2013
------------------------------------------------------------------------------------------------------------------------------
Thank you for selecting this Gefran product.
If you have any information that might help us to improve this manual, please do not hesitate to contact us at
[email protected].
Before using the product, please read the chapter on safety instructions carefully.
Keep the manual in a safe place and available to technical personnel during the product functioning period.
Gefran S.p.A. reserves the right to make changes and variations to products, data and dimensions at any time without
notice.
The data indicated are provided for the sole purpose of describing the product and must not be considered as legally
binding characteristics.
All rights reserved.
------------------------------------------------------------------------------------------------------------------------------

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 3 of 32
TABLE OF CONTENTS
1Introduction............................................................................................................................................... 4
1.1Compatibility Application version / Drive firmware .............................................................................. 4
2General description.................................................................................................................................. 5
2.1Fields of application ............................................................................................................................ 5
3Connection diagrams and system interface.......................................................................................... 6
3.1Control via digital inputs and outputs .................................................................................................. 6
3.2Control via fieldbus interface............................................................................................................... 8
3.3Possible master-slave configurations ............................................................................................... 10
3.3.1Master electrical line shaft from encoder ................................................................................... 10
3.3.2Master electrical line shaft from Fast Link communication interface ......................................... 12
4Commissioning....................................................................................................................................... 14
4.1General information........................................................................................................................... 14
4.2Requirements.................................................................................................................................... 14
4.3Initial operations ................................................................................................................................ 14
4.4Drive parameters managed by the application ................................................................................. 15
55 Control logic and sequences............................................................................................................. 16
5.1Application control modes ................................................................................................................. 16
5.2Jog function ....................................................................................................................................... 16
5.3Zero search ....................................................................................................................................... 16
5.4Positioning......................................................................................................................................... 17
5.4.1Correction of the position of the slave axis in electrical line shaft mode (phase trim)............... 17
5.5Electrical line shaft function............................................................................................................... 18
5.5.1Correction of the electrical line shaft ratio (slip)......................................................................... 18
5.5.2Monitoring of the position of the master with the slave not captured and recovery................... 19
5.6Application block diagram ................................................................................................................. 19
6List of Parameters.................................................................................................................................. 20
6.1SERVO PID menu............................................................................................................................. 20
6.2POSITION menu ............................................................................................................................... 21
6.3LINE SHAFT menu ........................................................................................................................... 23
6.4DIGITAL INPUTS menu .................................................................................................................... 26
6.5DIGITAL OUTPUTS menu ................................................................................................................ 27
6.6HOME REFERENCE menu .............................................................................................................. 28
6.7EXCHANGE menu ............................................................................................................................ 29
6.8ABOUT menu.................................................................................................................................... 29
7Examples................................................................................................................................................. 30
7.1Gear ratio calculation example.......................................................................................................... 30
7.2Startup, tuning and performance check ............................................................................................ 31

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 4 of 32
1 Introduction
This manual contains all the information necessary for the design, wiring and configuration of a system
based on the Electrical Line Shaft application for the ADV200.
Chapter 2 - "General description" provides information about system characteristics and functions.
Chapter 3 - "Connection diagrams and system interface" illustrates typical connection diagrams and the
command interface for controlling the application via digital I/O or fieldbus.
Chapter 4 - "Commissioning" provides information about installing the application on the ADV200 drive.
Chapter 5 - "Control logic and sequences" contains detailed information about application functions and
operating modes.
Chapter 6 - "List of Parameters" contains the complete list of system parameters with a description of their
functions.
Chapter 7 - "Examples" contains a gear ratio calculation example and some guidelines for startup, tuning
and performance check of the application.
1.1 Compatibility Application version / Drive firmware
ELS Drive Firmware
1.0.32 6.X.X ; 7.X.X

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 5 of 32
2 General description
The Electrical Line Shaft application allows a group of drives to operate in a previously defined position with
respect to a "master" reference; this position reference may be provided by the feedback from a motor, a line
encoder or a specific communication interface. The drives that follow the master position reference are called
"slaves"; the position ratio between the master and slaves can be changed proportionally by means of a
parameter called "electronic gear ratio".
The Electrical Line Shaft application requires at least firmware version 5.00 of the ADV200 drive with the
relative optional encoder signal acquisition cards and for the Fast Link system bus; some typical
configurations are illustrated in section 3.3 "Possible master-slave configurations".
Characteristics of the Electrical Line Shaft application for the ADV200:
Slave axis homing function that enables the use of an external sensor, encoder marker and freeze
encoder signal for axis phasing; user-definable zero offset.
Slave axis incremental positioning function with user-definable trapezoidal speed profile.
Slave axis jog function with different ramps and speeds for service movements.
Electrical line shaft function with master position reference selectable between encoder repetition or
Fast Link system bus interface. Possibility of "chain"-type configurations (each slave acts as master
for the next slave) or “equal ranking” (one master for all slaves).
Electronic gear ratios selectable from previously defined settings; possibility of continuously
changing the ratio (Slip function).
Phase trim function to change the position of the slave with respect to the master while the slave
follows the master.
Slave position error signal with dual threshold setting (warning, alarm).
2.1 Fields of application
The Electrical Line Shaft application is particularly recommended for use in the following sectors:
Material Handling
- 2 or 3-axis gantries
- Stackers / De-stackers
- Pick & Place
Transport
- Trolleys
- Hoisting equipment
- Vehicles on rails
Logistics
- Rack feeders for automated warehouses
- Shuttles

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 6 of 32
3 Connection diagrams and system interface
The input and output signals of the Electrical Line Shaft application for ADV200 drives and the relative
sequences are managed by a superordinate control device such as a PLC or IPC.
The application can thus be controlled via discrete digital I/O (digital input and output terminals on the
ADV200 regulation card and any expansion cards, such as EXP-IO-D6A4R1-ADV); the use of a fieldbus
interface (Profibus, Devicenet, Canopen, EtherCAT) allows more flexible management (virtual I/O,
positioning and phase variation). Moreover, the fieldbus configuration channel enables access to all drive
and application parameters in read and write mode.
3.1 Control via digital inputs and outputs
The example below shows a typical configuration of the digital inputs and outputs of the drive with the EXP-
IO-D6A4R1-ADV expansion card.
This configuration enables zero searches using a sensor and positioning operations by selecting one of the
first 16 available position presets.
The digital input signals must be set as shown in the figure in the ELS / DIGITAL INPUTs menu.
The digital outputs relating to the application must be set in the ELS / DIGITAL OUTPUTs menu.
Figure 3.1: Layout of I/Os ADV200 slave with EXP-IO-D6A4R1-ADV

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 7 of 32
Recommended programming of I/O terminals (regulation + expansion)
Dig Input E Enable (not programmable) Digital output 1 Drive healthy
Dig Input 1 ELS Engage Digital output 2 Drive Enable
Dig Input 2 Home Request Digital output 3 Pos Zero Found
Dig Input 3 Home Sensor Digital output 4 In Sync
Dig Input 4 Move Trigger Digital output 1X In Position
Dig Input 5 Jog Input Digital output 2X Pos Error Alarm (*)
Dig Inp 1X Jog Direction
Dig Inp 2X Ratio Select B0
Dig Inp 3X Ratio Select B1
(*) Connect to the digital input of the master drive programmed as "External Fault"
NB! The ADV200 drive requires the installation of the EXP-IO-D6A4R1-ADV optional card in slot 1, and of the EXP-FL-
XCAN-ADV optional card for the Fast Link system bus, which can be used to send the position reference between
the master and slaves.
The two optional cards cannot therefore be installed simultaneously on the same drive.

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 8 of 32
3.2 Control via fieldbus interface
The example below shows a typical configuration of the digital inputs and outputs provided with the drive
regulation card and an assignment of process data on a fieldbus interface card; the latter must be installed in
slot 3 dedicated to expansion cards.
Since process data are assigned in the parameters in the drive COMMUNICATION menu, the settings
described below are applicable regardless of the type of fieldbus used.
The digital input signals must be set as shown in the figure in the DIGITAL INPUTs menu, where they are
assigned to the regulation card terminals or to the control word bits (Word decomp).
The digital output signals must be set as shown in the figure in the DIGITAL OUTPUTs menu, where they
are assigned to the regulation card terminals or to the status word bits (Word comp); an application status
word can also be mapped in the process channel (see IPA 12036 Status Word Mon), bringing together all
the digital output signals defined in the DIGITAL OUTPUTs menu so that the Word comp can be used for
other signals.
Figure 3.2: Layout of I/Os ADV200 with EXP-...Fieldbus

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 9 of 32
Recommended programming of I/O terminals (regulation only)
Dig Input E Enable (not programmable) Digital output 1 Drive healthy
Dig Input 1 Null Digital output 2 Drive Enable
Dig Input 2 Null Digital output 3 Pos Zero Found
Dig Input 3 Home Sensor Digital output 4 Pos Reached
Dig Input 4 Null Digital output 1X In Position
Dig Input 5 Null Digital output 2X Pos Error Alarm
(*) Connect to the digital input of the master drive programmed as "External Fault"
Assignment of process data
Fieldbus M->S1 Word Decomp Fieldbus S->M1 Status Word Mon
Fieldbus M->S2 Ramp ref 1 Fieldbus S->M2 Word Comp
Fieldbus M->S3 Target Pos (**) Fieldbus S->M3 Actual Pos
Fieldbus M->S4 … Fieldbus S->M4 Error Pos
Fieldbus M->S5 … Fieldbus S->M5 Motor Speed
Fieldbus M->S6 … Fieldbus S->M6 Output Current
(**) automatically assigned with parameter “Target Source = From FB W3”
NB! (*) There should preferably be a direct connection between the "Pos Error Alarm" or "Drive Healthy" digital output on
the slave axis and the "External fault" digital input on the master drive; if that is not possible, an emergency stop
mechanism must be provided at the superordinate control level (PLC) to stop the master drive in case of a fault on
the slave drive(s).

____________________ _
User Guide Electrical Line Shaft for ADV200 Page 10 of 32
3.3 Possible master-slave configurations
The IPA 11394 Master Pos Source application parameter is used to select the source for the position
reference to which the slave axis is connected during operation in electrical line shaft mode.
The master position reference may come from an encoder or from the Fast Link communication interface.
3.3.1 Master electrical line shaft from encoder
In this case the master position reference comes from an encoder, which may be installed on a motor or
connected directly to the machine.
For the slave axis, the IPA 11394 Master Pos Source parameter must be set to “Encoder 2”.
In configurations with at least 2 slave axes, it is possible for each slave axis to be the master position
reference for the next slave or to use the same master encoder for all the slaves.
An example of a configuration in which each slave axis acts as the master position reference for the next
slave is shown in the figure below.
Figure 3.3: Cascade repetition of encoders between slave axes
In this case, each slave axis needs an optional card with a double digital encoder input (type EXP-DE-
I2R1F2-ADV); the encoder emulation output of this card repeats the Encoder 1 input, i.e. the motor encoder
of the slave axis.
The figure below shows an example of configuration in which the master axis motor encoder is repeated to
all the slave axes.
.