Groschopp RBD-325-4/6-S User manual

Product manual
RBD-325-4/6-S
Copyrights
2010 Groschopp BV Drives & More. All rights reserved.
The information and data in this document have been composed to the best of our knowledge.
However, deviations between the document and the product cannot be excluded entirely. For the
devices and the corresponding software in the version handed out to the customer, Groschopp BV
guarantees the contractual use in accordance with the user documentation. In the case of serious
deviations from the user documentation, Groschopp BV has the right and the obligation to repair,
unless it would involve an unreasonable effort. A possible liability does not include deficiencies caused
by deviations from the operating conditions intended for the device and described in the user
documentation.

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Manual “RBD-325-4/6-S“ Version 2.0.0
Groschopp BV does not guarantee that the products meet the buyer’s needs and purposes or that
they work together with other products selected by the buyer. Groschopp BV does not assume any
liability for damages resulting from the combined use of its products with other products or resulting
from improper handling of machines or systems.
Groschopp BV Drives & More reserves the right to modify, amend, or improve the document or the
product without prior notification.
This document may, neither entirely nor in part, be reproduced, translated into any other natural or
machine-readable language nor transferred to electronic, mechanical, optical or any other kind of data
media, without expressive authorization by the author.
Trademarks
Any product names in this document may be registered trademarks. The sole purpose of any
trademarks in this document is the identification of the corresponding products.
RBD-S ServoCommander™ is a registered Trademark.

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Manual“RBD-325-4/6-S“ Version 2.0.0
Revision log
Author: Groschopp BV, Drives & More
Manual name: Manual„ RBD-325-4/6-S“
File name: Manual_RBD-325-4-6-S_2p0_UL
File location: Handleidingen RBD-S
Series No. Description Revisions-Index Date of changing’s
002 Rev. 0.0 Release for distribution 0.0 01.02.2011 SR

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Manual “RBD-325-4/6-S“ Version 2.0.0
TABLE OF CONTENTS:
1 General...............................................................................................................12
1.1 Symbols used ....................................................................................................12
1.2 Area of applications and intended use................................................................12
1.2.1 Type description .................................................................................................12
1.2.2 Area of application and intended use .................................................................13
1.2.3 Features of RBD-S .............................................................................................14
1.3 Specifications of RBD-S ServoCommander
TM
....................................................15
1.3.1 Basic Information................................................................................................15
1.3.2 Specifications of RBD-S ServoCommander
TM
...................................................15
1.3.3 Hard- and Software-conditions ...........................................................................16
1.4 Documentation...................................................................................................16
1.5 Delivery and delivery package............................................................................16
2 Safety notes for electrical drives and controllers ..........................................19
2.1 General notes ....................................................................................................19
2.2 Danger resulting from use ..................................................................................20
2.3 Safety notes .......................................................................................................20
2.3.1 General safety notes ..........................................................................................20
2.3.2 Safety notes for assembly and maintenance .....................................................22
2.3.3 Protection against contact with electrical parts ..................................................23
2.3.4 Protection against electrical shock by means of protective extra-low voltage
(PELV) ................................................................................................................24
2.3.5 Protection against dangerous movement...........................................................24
2.3.6 Protection against contact with hot parts............................................................25
2.3.7 Protection during handling and assembly ..........................................................25
3 First commissioning of drive ...........................................................................27
3.1 System overview ................................................................................................27
3.2 Connection of RBD-S communication interface..................................................28
3.3 Installation and start up of RBD-S ServoCommander
TM
.....................................28
4 First commissioning of drive ...........................................................................29
4.1 First commissioning ...........................................................................................29
4.1.1 Parameter settings at delivery............................................................................29
4.1.2 Manual first commissioning ................................................................................29
4.2 Parameterization across motor data file list ........................................................30
4.3 Basic parameter of new motors..........................................................................31
4.3.1 Angle encoder.....................................................................................................31
4.3.2 Motor data...........................................................................................................34
4.3.3 Power stage........................................................................................................36
4.3.4 Current controller................................................................................................37
4.3.5 DC bus monitoring..............................................................................................38
4.3.6 Motor temperature monitoring ............................................................................39
4.4 Application parameters.......................................................................................40
4.4.1 General configuration .........................................................................................40
4.4.2 Adjustment of the display units...........................................................................41
4.5 Specify input limits ..............................................................................................43
4.6 Safety parameter selection.................................................................................44
4.7 Adjustment controller enable logic......................................................................45
4.8 Setting of the limit switch....................................................................................45
4.9 Set up the rotation direction................................................................................46
4.10 Ready for operation, enable the end stage.........................................................47

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Manual“RBD-325-4/6-S“ Version 2.0.0
5 Current- and speed controller..........................................................................49
5.1 Functions overview ............................................................................................49
5.2 Speed control command ....................................................................................51
5.2.1 Optimizing speed controller ................................................................................51
5.2.2 Strategy to optimization ......................................................................................52
5.3 Current controller optimization............................................................................54
5.4 Set point over set point selectors .......................................................................54
5.4.1 Speed controller application ...............................................................................55
5.4.2 Torque control command....................................................................................55
5.4.3 Settings via RS232 .............................................................................................56
5.4.4 Set point ramps ..................................................................................................56
5.4.5 Current controller with torque limitation..............................................................57
6 Position application ..........................................................................................58
6.1 Functions overview ............................................................................................58
6.2 Activate commands............................................................................................59
6.3 Positioning adjusting and optimizing...................................................................60
6.3.1 Optimizing the positioning controller ..................................................................61
6.4 General positioning settings ...............................................................................62
6.5 Destination parameters ......................................................................................63
6.6 Move to destination ............................................................................................65
6.7 Settings of digital outputs ...................................................................................66
6.8 Homing mode.....................................................................................................66
6.8.1 Homing movement .............................................................................................66
6.8.2 Setting homing movement..................................................................................70
7 Course program ................................................................................................73
7.1 Composing of course program ..........................................................................75
7.1.1 Options of the course program...........................................................................76
7.1.2 End of program...................................................................................................77
7.1.3 Position branch ...................................................................................................77
7.1.4 Branch (line) .......................................................................................................79
7.1.5 Level test ............................................................................................................80
7.2 Course program debug ......................................................................................81
8 Gear synchronization over X10........................................................................83
8.1 Introduction ........................................................................................................83
8.2 Incremental encoder emulation ..........................................................................83
8.2.1 Description of the function and application.........................................................83
8.2.2 Activating and altitude ........................................................................................84
8.3 Synchronization over [X10].................................................................................85
8.3.1 Description the function and application.............................................................85
8.3.2 Activating and altitude ........................................................................................89
9 Function of in- and outputs..............................................................................92
9.1 Digital inputs DIN0 to DIN9.................................................................................92
9.1.1 Attitude of the digital inputs ................................................................................93
9.2 Extended functions of digital inputs (jogging & Teach) .......................................94
9.2.1 Position Teaching ...............................................................................................95
9.3 Digital outputs DOUT0 to DOUT3.......................................................................97
9.3.1 Settings of digital outputs ...................................................................................97
9.3.2 Settings of messages for the digital outputs.......................................................98
9.4 Holding brake DOUT3 (BRAKE).......................................................................100
9.4.1 Brake functions.................................................................................................100
9.5 Analogue inputs AIN0 and AIN1.......................................................................101

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Manual “RBD-325-4/6-S“ Version 2.0.0
9.6 Analogue output AMON ...................................................................................103
10 Communication interfaces .............................................................................104
10.1 Control of the CAN-Bus....................................................................................104
10.1.1 Function overview.............................................................................................104
10.1.2 Processing of CAN-messages..........................................................................104
10.1.3 Attitudes of the CAN open communications parameters .................................105
10.2 Controlling over the serial interface. .................................................................106
10.2.1 Functions overview...........................................................................................106
10.2.2 Serial communication via RBD-S ServoCommander
TM
...................................107
10.2.3 Settings via RS232 communication parameters ..............................................107
10.2.4 Transfer window ...............................................................................................108
10.2.5 Communication window via RS232 transfer.....................................................108
10.3 Controlling by technologic interface..................................................................109
11 Error message/Error management ................................................................110
11.1 Error control by RBD-S.....................................................................................110
11.1.1 Over current- and short-circuit control ..............................................................110
11.1.2 Monitoring DC-bus voltage ...............................................................................110
11.1.3 Monitoring logic supply .....................................................................................111
11.1.4 Monitoring of the heat sink temperature...........................................................111
11.1.5 Monitoring of the motor.....................................................................................111
11.1.6 Monitoring course of motion .............................................................................111
11.1.7 Additional internal monitoring functions............................................................112
11.1.8 Operating time counter .....................................................................................112
11.2 Error message overview...................................................................................112
11.3 Error signals on RBD-S....................................................................................116
11.4 Error window in RBD-S ServoCommander
TM
....................................................116
11.5 Error management ...........................................................................................117
12 Appendix..........................................................................................................118
12.1 Working description for RBD-S ServoCommander
TM
........................................118
12.1.1 Standard buttons ..............................................................................................118
12.1.2 Numeric input field............................................................................................118
12.1.3 Control units......................................................................................................119
12.1.4 Representation of settings and actual values...................................................119
12.1.5 Actual window...................................................................................................120
12.1.6 Listings..............................................................................................................121
12.1.7 Communication across communications objects .............................................121
12.1.8 Finishing the program.......................................................................................121
12.2 Renew the serial communication......................................................................122
12.3 Info-Window .....................................................................................................124
12.4 Quick access via symbol .................................................................................125
12.5 Use of the oscilloscope functions .....................................................................126
12.5.1 Oscilloscope settings........................................................................................126
12.5.2 Oscilloscope window ........................................................................................128
12.6 Serial communication protocol .........................................................................131
12.7 Use of communication objects..........................................................................133
12.7.1 Basic units ........................................................................................................141
12.7.2 Bit allocation commandword / controlword / errorword ....................................142
12.7.3 RS232-command word / overview important orders ........................................146
12.8 Apendix possibilities diplay units ......................................................................147
12.8.1 Settings of user specified display units ............................................................147
12.8.2 Decimal places .................................................................................................148
12.8.3 Direct input position-, speed- and acceleration units .......................................148
12.9 Course program: Example ...............................................................................150

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Manual“RBD-325-4/6-S“ Version 2.0.0
12.9.1 Example 1: Linear connected positions............................................................150
12.9.2 Example 2: Linear connected of positions with switching of a digital output....151
12.9.3 Example 3: Settings and checking of digital in- and outputs; continuous loop 152
12.10 Timing overview ...............................................................................................152
12.10.1 Switching sequence..........................................................................................153
12.10.2 Positioning / destination reached .....................................................................154
12.10.3 Speed message................................................................................................154
12.10.4 Error reset.........................................................................................................155
12.10.5 Limit switch .......................................................................................................155
12.11 Parameter set administration............................................................................156
12.11.1 General .............................................................................................................156
12.11.2 Load and save parameters...............................................................................157
12.11.3 Print parameter settings ...................................................................................158
12.12 Offline parameterization ...................................................................................160
12.13 Loading software into the RBD-S / Software Update ......................................161
12.13.1 Loading software ..............................................................................................162
12.14 Technical specifications ...................................................................................164
12.14.1 Site conditions and qualification .......................................................................164
12.14.2 Dimensions and weight ....................................................................................164
12.14.3 Power data [X6], [X2A] .....................................................................................165
12.14.4 Motor temperature control [X2A] ......................................................................165
12.14.5 Motor phases [X6] ............................................................................................165
12.14.6 Resolver [X2A]..................................................................................................166
12.14.7 Analogue Hall sensing [X2A]............................................................................166
12.14.8 Incremental encoder output [X10] ....................................................................166
12.14.9 Incremental encoder input [X10].......................................................................167
12.14.10 RS232 [X5] .......................................................................................................167
12.14.11 CAN-Bus [X4] ...................................................................................................167
12.14.12 Analogue in- and output [X2B]..........................................................................167
12.14.13 Digital in- and output [X2B]...............................................................................168
12.14.14 Warning and status LED RBD-S ......................................................................168
12.15 Mechanical installation .....................................................................................169
12.15.1 Important notes for mounting............................................................................169
12.15.2 Front side – dimensions – position connectors ................................................170
12.15.3 Back side – position of the connector...............................................................171
12.15.4 Side view – dimensions – position of the connectors when using small mounting
plate ..................................................................................................................173
12.15.5 Smallest mounting distance..............................................................................173
12.16 Connectors on the RBD-S................................................................................175
12.16.1 Pin configuration: Analogue and digital I/Os [X2B]...........................................175
12.16.2 Pin configuration: Angle encoder and holding brake [X2A]..............................176
12.16.3 Pin configuration: Motor and power supply [X6]...............................................177
12.16.4 Pin configuration: Internal technologic module connection [X8].......................178
12.16.5 Pin configuration: CAN-Bus [X4] .....................................................................180
12.16.6 Optional: connection: CAN-Bus in- and output |X401, X402]...........................180
12.16.7 Pin configuration: PROFIBUS [X401, X402] ....................................................181
12.16.8 Pin configuration: EtherCAT [X401, X402] .......................................................181
12.16.9 Pin configuration: Serial parameterization interface [X5] .................................182
12.16.10 Pin configuration: Incremental encoder in- and output [X10] ..........................183
12.17 Electrical installation of the RBD-S...................................................................184
12.17.1 Connecting to supply [X6] and motor [X6], [X2B] .............................................184
12.17.2 Detail view – connection of motor with resolver [X6], [X2A].............................187
12.17.3 Detail view – connection of motor with Hallsensing system [X6], [X2A] ..........189
12.17.4 Connection of analogue and digital in- and output [X2B] .................................191
12.17.5 Connection: CAN – Bus [X4] ............................................................................192
12.18 Notes concerning safe and EMC-compliant installation....................................193
12.18.1 Definitions and terminology ..............................................................................193
12.18.2 General information concerning EMC ..............................................................194

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Manual “RBD-325-4/6-S“ Version 2.0.0
12.18.3
EMC ranges: first and second environment .....................................................194
12.18.4 Connection between RBD-S and Motor ...........................................................194
12.18.5 Connection between RBD-S and power- also logic - supply............................194

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Manual“RBD-325-4/6-S“ Version 2.0.0
TABLE OF FIGURES:
Figure 1: Overview RBD 325-4/6-S........................................................................................................27
Figure 2: Overshoot current controller....................................................................................................38
Figure 3: Control scheme of the controller cascade...............................................................................50
Figure 4: Speed controller - to light .......................................................................................................53
Figure 5: Speed controller - to hard.......................................................................................................53
Figure 6: Speed controller - right adjustment ........................................................................................53
Figure 7: Positioning control block diagram ...........................................................................................58
Figure 8: Optimised positioncontroller....................................................................................................61
Figure 9: Time optimum and jerkfree positioning ...................................................................................65
Figure 10: Homing with negative limit switch and zero pulse.................................................................67
Figure 11: Homing with positive limit switch and zero pulse ..................................................................67
Figure 12: Homing on negative limit switch............................................................................................68
Figure 13: Homing on positive limit switch .............................................................................................68
Figure 14: Homing only with zero pulse .................................................................................................68
Figure 15: Homing with negative stop and zero pulse ...........................................................................69
Figure 16: Homing with positive stop and zero pulse.............................................................................69
Figure 17: Homing with negative stop ....................................................................................................69
Figure 18: Homing with positive stop .....................................................................................................70
Figure 19: Course program - Position branch ........................................................................................78
Figure 20: Timing diagram Position branch............................................................................................78
Figure 21: Course program - branch (line).............................................................................................79
Figure 22: Timing diagram branch (line) ................................................................................................80
Figure 23: Course program level test .....................................................................................................81
Figure 24: Timing diagram level test ......................................................................................................81
Figure 25: Connection Incremental encoder emulation .........................................................................83
Figure 26: Synchronisation – leveling setpoints speed- and position cotroller ......................................86
Figure 27: Synchronisation – Minimum times for A / B / N Signals........................................................88
Figure 28: Synchronisieren – Minimum times for CLK / DIR Signals.....................................................88
Figure 29: Learning a destination...........................................................................................................96
Figure 30: Time functions Holding brake..............................................................................................101
Figure 31: Safety zero ..........................................................................................................................102
Figure 32: Online-Parametering ...........................................................................................................156
Figure 33: Offline-Parametering ...........................................................................................................160
Figure 34: Front side RBD 325-4/6S ....................................................................................................170
Figure 35: Back side RBD 325-4/6S ....................................................................................................172
Figure 36: Side view RBD 325-4/6S.....................................................................................................173
Figure 37: Smallest mounting distance ...............................................................................................174

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Manual “RBD-325-4/6-S“ Version 2.0.0
Figure 38: Wiring connection cable RBD-S [X5] from COM-interface to the PCs................................182
Figure 39: Connection power- and Logic voltage - principal connection ............................................184
Figure 40: Connection of motor with resolver and holding brake.........................................................187
Figure 41: Motor connection – pin configuration ..................................................................................188
Figure 42: Connection motor with analogue hall sensing system and holding brake ..........................189
Figure 43: Motor connection – pin configuration ..................................................................................190
Figure 44: Connection of analogue and digital in- and outputs............................................................191
Figure 45: CAN-connection for RBD-S.................................................................................................192
Figure 46: Wiring example CAN-Bus ...................................................................................................193
Table of tables:
Table 1: Scope of supply RBD-S 325 4/6S ...........................................................................................16
Table 2: Additional parts.........................................................................................................................17
Table 3: Additional parametering program .............................................................................................17
Table 4: Overview total system RBD 325-4/6-S.....................................................................................28
Table 5: Parameter encoder (grey = not supported) ..............................................................................33
Table 6: Display units .............................................................................................................................42
Table 7: Error reset speed controller......................................................................................................48
Table 8: Course program: Pin configuration digital inputs (Standard) ...................................................73
Table 9: Course program: Pin configuration digital inputs (New I/O lay out) .........................................74
Table 10: Available position sets of activated course program and input WEG = 0 ..............................75
Table 11: RBD-S Digital inputs – possible combinations .......................................................................92
Table 12: Digital input – layout ...............................................................................................................93
Table 13: Jogging & Learning: Layout of digital input ............................................................................95
Table 14: Error overview ......................................................................................................................113
Table 15: Control elements ..................................................................................................................119
Table 16: Listing structure ....................................................................................................................121
Table 17: Problem solving of serial communication.............................................................................123
Table 18: Command syntax OK’s.........................................................................................................131
Table 19: Letter description in the command syntax............................................................................131
Table 20: Command syntax RS232 .....................................................................................................132
Table 21: Letter description in the command syntax............................................................................132
Table 22: List of all OK's.......................................................................................................................133
Table 23: List of display units ...............................................................................................................141
Table 24: List of RS232- Send command (RS232-command word) ....................................................146