Giddings & Lewis CENTURION DSM100 User manual

GIDDINGS & LEWIS, INC.
HARDWARE AND INSTALLATION MANUAL
CENTURION DSM100
SERVO AMPLIFIERS

NOTE
Progress is an on going commitment at Giddings & Lewis. We continually strive to offer the most
advanced products in the industry; therefore, information in this document is subject to change
without notice. The illustrations and specifications are not binding in detail. Giddings & Lewis
shall not be liable for any technical or editorial omissions occurring in this document, nor for any
consequential or incidental damages resulting from the use of this document.
DO NOT ATTEMPT to use any Giddings & Lewis product until the use of such product is
completely understood. It is the responsibility of the user to make certain proper operation
practices are understood. Giddings & Lewis products should be used only by qualified personnel
and for the express purpose for which said products were designed.
Should information not covered in this document be required, contact the Customer Service
Department, Giddings & Lewis, 660 South Military Road, P.O. Box 1658, Fond du Lac, WI
54936-1658. Giddings & Lewis can be reached by telephone at (920) 921–7100.
108-30083-00
 1996, 1998 Giddings & Lewis, LLC
Microsoft and MS-DOS are registered trademarks and Windows is a trademark of Microsoft Corporation.
UL and cUL are registered trademarks of Underwriters Laboratories.
Centurion, PiC900, PiC90, PiC9 are trademarks of Giddings & Lewis.

Table of Contents Intro-1
DSM Drive Hardware and Installation Manual
Table of Contents
AboutThisManual........................................... 15
AdditionalInstructionsandManuals ................................. 18
HostCommandsandDSMPro ................................... 18
TouchPad.............................................. 18
SymbolsandConventions....................................... 19
TypographicalandWordingConventions ............................. 19
GraphicalSymbolsandWarningClassifications.......................... 20
CHAPTER 1 Safety
Installing and Using the Centurion DSM100 Drive . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SafetyClassifications........................................ 21
Potential Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
VoltagePotentials ......................................... 22
Your Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
SafetyGuidelines ........................................... 23
CHAPTER 2 Selecting Other System Components
CenturionDSM100DriveOverview ................................. 25
DrivePowerRatings ........................................ 25
Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
CenturionDSM100DriveFeatures.................................. 26
Stand-aloneDesign......................................... 26
HighPerformanceMicrocontrollerTechnology .......................... 26
IPMTechnology........................................... 26
Analog and Digital Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
EncoderControl........................................... 26
EncoderOutput........................................... 26
DigitalI/O.............................................. 26
AnalogI/O.............................................. 27
ACInputPower........................................... 27
Personality Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Multiple Protection Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
DSMProSoftware.......................................... 27
Communications...........................................
28
Autotuning..............................................
28
AgencyApprovals.......................................... 28
Options ...............................................
28
Motors.................................................
29
EuropeanUnionRequirements .................................... 30
CHAPTER 3 DSMPro Installation
HardwareandSoftwareRequirements................................. 31
Installing DSMPro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
StartingandQuittingDSMPro..................................... 33
VersionLevel............................................ 33
TheDSMProStart-UpScreen.................................... 33
TheReadmeFile .......................................... 34
FirmwareFiles............................................ 34

Intro-2 Table of Contents
CHAPTER 4 Unpacking,Inspecting and Storing
UnpackingtheDrive..........................................35
InspectionProcedure..........................................35
TestingtheUnit.............................................36
HardwareSetUp...........................................37
DriveCheckoutTest.........................................37
StoringtheUnit.............................................40
CHAPTER 5 Installation
MechanicalInstallationRequirements.................................41
Interface Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Wiring................................................
44
Electromagnetic Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Qualified AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Giddings & Lewis AC Line Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
CHAPTER 6 Interfaces
J1–Controller .............................................
53
DigitalI/OPower ..........................................54
DigitalInputs.............................................55
DigitalOutputs............................................60
AnalogInputs ............................................64
AnalogOutputs ...........................................66
MotorEncoderOutputSignals ...................................67
IOUTSignalGeneration........................................68
Auxiliary Encoder Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Interface Cable Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
J1TerminalStrip/BreakoutBoard..................................75
J2–Encoder ..............................................
77
J2TerminalStrip/BreakoutBoard...................................80
....................................................
80
J3 – Auxiliary Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
J4andJ5–SerialPort .........................................85
SerialCommunicationsOverview..................................86
RS-232Connections.........................................87
FourWireRS-485Connections...................................89
A1,A2andCOM–AnalogOutputs..................................92
CHAPTER 7 Power Connections
TB1–DCBusandACPower.....................................93
MotorPowerCabling ........................................94
MotorOverloadProtection......................................96
EmergencyStopWiring.......................................96
DCBus................................................97
ACPowerCabling..........................................97
Auxiliary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
TB2–ShuntRegulator........................................ 101
ExternalShuntConnection..................................... 103

Table of Contents Intro-3
DSM Drive Hardware and Installation Manual
CHAPTER 8 Application and Configuration Examples
AnalogControl.............................................105
HardwareSetUp ..........................................105
ConnectionDiagram ........................................106
Configuration............................................
106
Tuning ...............................................107
Operation..............................................
108
PresetController............................................109
HardwareSetUp ..........................................109
ConnectionDiagram ........................................110
Configuration............................................
111
Tuning ...............................................112
Operation..............................................
113
PositionFollower(MasterEncoder)..................................114
HardwareSetUp ..........................................114
ConnectionDiagram ........................................115
Configuration............................................
115
Tuning ...............................................
117
Operation..............................................
117
PositionFollower(Step/Direction) ..................................119
HardwareSetUp ..........................................119
ConnectionDiagram ........................................120
Configuration............................................
120
Tuning ...............................................
122
Operation..............................................
122
PositionFollower(StepUp/StepDown)................................123
HardwareSetUp ..........................................123
ConnectionDiagram ........................................124
Configuration............................................
124
Tuning ...............................................
126
Operation..............................................
126
IncrementalIndexing .........................................127
HardwareSetUp ..........................................128
ConnectionDiagram ........................................128
Configuration............................................
129
Tuning ...............................................
130
Operation..............................................
131
RegistrationIndexing .........................................132
HardwareSetUp ..........................................132
ConnectionDiagram ........................................133
Configuration............................................
133
Tuning ...............................................135
Operation..............................................
136
AbsoluteIndexing...........................................137
HardwareSetUp ..........................................137
ConnectionDiagram ........................................138
Configuration............................................
138
Tuning ...............................................
140
Operation..............................................
140
ModifyingUserUnits.........................................141
ChangingtheDisplayUnitsSettings................................141

Intro-4 Table of Contents
CHAPTER 9 Tuning
TuningGuidelines .......................................... 143
GeneralTuningRules....................................... 143
HighInertiaLoads......................................... 143
MechanicalResonance....................................... 143
Backlash..............................................
144
AutoTuneMode........................................... 145
AutoTuning............................................ 146
ManualTuneMode.......................................... 147
Gains................................................ 147
Filters................................................
148
ManualTuning........................................... 149
VelocityLoopTuningExamples ................................. 151
CHAPTER 10 Status Display
OperatingMessages.......................................... 153
ErrorMessages............................................ 154
Run-TimeErrorCodes....................................... 154
Power-UpErrorCodes....................................... 155
CHAPTER 11 Maintenance and Troubleshooting
Maintenance .............................................
157
PeriodicMaintenance ....................................... 157
Fuse Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
EEPROMPersonalityModule................................... 157
FirmwareUpgrading......................................... 160
FirmwareUpgradeProcedureusingDSMPro........................... 160
Troubleshooting............................................
161
ErrorCodes............................................. 161
RS-232CommunicationTest ................................... 166
TestingDigitalOutputs ...................................... 167
TestingDigitalInputs ....................................... 168
TestingAnalogOutputs...................................... 169
TestingPositiveandNegativeCurrentLimits........................... 169
TestingEncoderInputs....................................... 171
APPENDIX A Options and Accessories
CenturionDSM100Drives...................................... 173
Fuses .................................................
174
OptionsandAccessories....................................... 174
Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
Serial Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
EncoderFeedbackCables....................................... 177
MotorPowerCables ......................................... 178
ConnectorKits............................................ 179
MatingConnectors.......................................... 179
APPENDIX B Cable Diagrams, Schematics and Examples
Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Serial Interface Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
EncoderFeedbackCables....................................... 192

Table of Contents Intro-5
DSM Drive Hardware and Installation Manual
MotorPowerCables .........................................197
CablingExamples...........................................201
APPENDIX C TouchPad Instructions
InstallationandOperation.......................................205
TouchPadCommands.........................................207
SupplementalInstructions.......................................210
MotorSelection...........................................210
Displays...............................................
210
MotorTable..............................................213
TouchPadOptions...........................................213
TouchPadLists.............................................214
APPENDIX D Electromagnetic Compatibility Guidelines for Machine Design
Filtering ................................................
220
ACLineFilterSelection ......................................220
Grounding...............................................
222
ShieldingandSegregation.......................................223
APPENDIX E Dynamic Braking Resistor Selection
DynamicBrakingEquations......................................225
SampleCalculations.........................................227
APPENDIX F Specifications
Power..................................................
233
PowerDissipation...........................................235
DSM 007 and DSM 007P, DSM120 and DSM120P,
DSM130andDSM130P ..................................243
DSM175andDSM175P........................................244
DSM1150andDSM1150P ......................................245
Interface Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
EU Directives 247

Intro-6 Table of Contents

List of Figures Intro-7
DSM Drive Hardware and Installation Manual
List of Figures
CHAPTER 1 Safety
CHAPTER 2 Selecting Other System Components
CHAPTER 3 DSMPro Installation
CHAPTER 4 Unpacking,Inspecting and Storing
Connection Diagram .............................................38
CHAPTER 5 Installation
DSM Mounting Dimensions .........................................42
MDF AC Line Filter Mounting Diagrams .................................46
MIF Single Phase AC Line Filter Mounting Diagram ...........................48
Power Wiring Diagram for DSM110,110P, 120, 120P, 130 and 130P ..................49
Power Wiring Diagram for DSM175 and DSM175P ...........................50
Power Wiring Diagram for DSM1150 and DSM1150 ...........................51
CHAPTER 6 Interfaces
Digital Input Circuit ..............................................55
Drive Input Connected to a Switch/Relay Contact .............................58
Drive Input Connected to an Opto-Isolator .................................58
Drive Input Connected to an Active High Sourcing Transistor ......................58
Drive Input Connected to Active Low Output using
a Switch/Relay ...............................................58
Drive Input Connected to Active Low Output using
an Opto-Isolator ..............................................59
Drive Input Connected to Sourcing Output .................................59
READY and BRAKE Circuits ........................................60
Digital Output Circuit .............................................61
Drive Output Connected to an Opto-Isolator ................................62
Drive Output Connected to an LED Indicator ...............................62
Drive Output Connected to a Resistive Load ................................63
Drive Output Connected to a Switch/Relay .................................63
Drive Output Connected to Active Low Input using
a Switch/Relay ...............................................63
Drive Output Connected to Active Low Input using
an Opto-Isolator ..............................................63
Drive Output Connected to Active High (Sinking) Input .........................64
Positive and Negative Current Limit Circuits ................................64
Analog COMMAND Input Circuit .....................................65
ANALOG 1 and ANALOG 2 Output Circuits ...............................66
Output Encoder Interface Circuit ......................................67
Unbuffered Encoder Signal Wiring .....................................68
Auxiliary Encoder Input Types .......................................69
Auxiliary Encoder Input Circuit .......................................69
External Encoder Interface via TTL Differential Line Drivers ......................71
Complementary Encoder Interface via 7406 Line Drivers
with Pull-up Resistors ...........................................71
Complementary Encoder Interface via Standard TTL Logic .......................72

Intro-8 List of Figures
Single-Ended Encoder Interface via Open Collector
Transistor without Pull-up (not recommended) ............................ 72
Single-Ended Encoder Interface via Standard TTL Signals
(not recommended) ............................................ 72
Single-Ended Encoder Interface via Open Collector
Transistor with 5 VDC to 12 VDC Pull-up (not recommended) ................... 73
Single-Ended Encoder Interface via Open Collector
Transistor with 24 VDC Pull-up (not recommended) ......................... 73
External Step/Direction Interface via TTL Differential
Line Drivers ................................................ 74
External Step/Direction Interface via Single-Ended TTL
Line Drivers (not recommended) .................................... 74
External CW/CCW (Step Up/Step Down) Interface via TTL
Differential Line Drivers ......................................... 75
External CW/CCW (Step Up/Step Down) Interface via
Single-Ended Line Drivers (not recommended) ............................ 75
Motor Encoder Interface Circuit ...................................... 78
Hall Effect Sensor Circuit .......................................... 78
Centurion DSM Motor Encoder Connections ............................... 79
RS-232/485 Interface Circuit ........................................ 85
Sixteen Position Rotary Addressing Switch ................................ 86
RS-232 Connection Diagrams ........................................ 88
RS-485/RS-422 Communication Comparison ............................... 89
Four Wire RS-485 Daisy Chain Connection Diagram .......................... 91
RS-232 to RS-485 Multi-Drop Connection Diagram ........................... 91
ANALOG 1 and ANALOG 2 Output Circuits ............................... 92
CHAPTER 7 Power Connections
Motor Power EMC Shield Connection ................................... 95
YSMSeriesPigtailGround ......................................... 95
Emergency Stop Contactor Wiring ..................................... 97
External Shunt Wiring Examples ......................................102
External Shunt Mounting Diagram .....................................103
CHAPTER 8 Application and Configuration Examples
Analog Controller Connection Diagram ..................................106
Preset Controller Connection Diagram ...................................110
Master Encoder Connection Diagram ...................................115
Step/Direction Controller Connection Diagram ..............................120
Step Up/Step Down Controller Connection Diagram ...........................124
Incremental Indexing Examples .......................................127
Incremental Indexing Connection Diagram ................................128
Registration Indexing Examples ......................................132
Registration Indexing Connection Diagram ................................133
Absolute Indexing Examples ........................................137
Absolute Indexing Connection Diagram ..................................138
PC Display Units – Default Dialog .....................................141
CHAPTER 9 Tuning
Velocity Loop Structure ...........................................144
Torque Current Conditioning Structure ..................................145