Motrona BY 125 User manual

control – motion – interface
BY12512d_e.doc / Mai-08 Page 1 / 52
BY 125
Low Cost Synchronous-Controller
Operating Instructions for Operator Software OS3.x
•80 kHz counting frequency
•Highly dynamic response (120 μsec)
•Positional synchronization and ratio control
•Marker pulse and print mark registration
•Speed transitions by S-shape profile
•TTL encoder inputs A,A, B,B, Z, Z( )
•Easy PC setting via serial link, data loading on the fly
•Simple to mount (rack or DIN rail)
•Standard version suitable for all 4-quadrant type drives with +/-10 V speed input
•Option UP125 especially suitable for 1-quadrant type inverter drives with positive
speed input only and digital direction select inputs
Operating Instructions
ELEKTRO-TRADING sp. z o.o
Tel. [phone]
Tel/Fax [phone]
E- ail [email protected]
http://www.elektro-trading.com.pl

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Safety Instructions
•This manual is an essential part of the unit and contains important hints about
function, correct handling and commissioning. Non-observance can result in
damage to the unit or the machine or even in injury to persons using the
equipment!
•The unit must only be installed, connected and activated by a qualified electrician
•It is a must to observe all general and also all country-specific and application-
specific safety standards
•When this unit is used with applications where failure or maloperation could cause
damage to a machine or hazard to the operating staff, it is indispensable to meet
effective precautions in order to avoid such consequences
•Regarding installation, wiring, environmental conditions, screening of cables and
earthing, you must follow the general standards of industrial automation industry
•- Errors and omissions excepted –
Version: Description:
BY12512P/ TJ/ Sept. 03/ Encoder input options HTLIN1 and HTLIN2 Page 12
Integrator must be switched off with index registration Page 18, 33
Only one LED on front side Page 23
Serial access codes in fig. 22+23 corrected Page 24
Serial access of control word and status word. Page 34
Encoder supply, input resistance, response time Page 36

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Table of Contents
1. Introduction....................................................................................................................4
2. Principle of operation..................................................................................................... 6
3. Impulse Scaling.............................................................................................................. 9
4. Ratio Change during Operation.....................................................................................12
5. Change of Phase and Relative Position.........................................................................13
5.1. Timer Trimming (Modes 1 - 4 and 8)..........................................................................................13
5.2. Impulse Trimming (Modes 5 and 6)............................................................................................13
5.3. Phase Offset Operation (Mode3)................................................................................................13
6. Index Control (Modes 2, 6 and 8) ..................................................................................14
7. Connections and Hardware Settings.............................................................................16
7.1. Power Supply..............................................................................................................................17
7.2. Encoders......................................................................................................................................17
7.3. Analogue Input and Output ........................................................................................................19
7.4. The Serial Ports ..........................................................................................................................19
7.5. Control Inputs and Outputs ........................................................................................................21
8. Register List and Clarification.......................................................................................24
8.1. General Parameters....................................................................................................................25
8.2. Setup Registers ..........................................................................................................................29
9. The Front LED................................................................................................................33
10. Remarks about Drives, Encoders, Cables etc. ...............................................................34
10.1. Drives ..........................................................................................................................................34
10.2. Encoders......................................................................................................................................34
10.3. Screening....................................................................................................................................35
10.4. Cables .........................................................................................................................................37
10.5. Remote Signal Commutation .....................................................................................................37
11. Steps for Commissioning ..............................................................................................38
12. Hints for Final Operation...............................................................................................45
12.1. Integrator ....................................................................................................................................45
12.2. Correction Divider.......................................................................................................................45
12.3. Offset voltage .............................................................................................................................45
12.4. Other settings .............................................................................................................................46
12.5. Oscilloscope Function.................................................................................................................46
13. Serial Codes..................................................................................................................47
14. Master Reset and EEPROM Erasure..............................................................................48
15. Dimensions and Specifications.....................................................................................49
16. Appendix: Option UP125 ...............................................................................................50

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1. Introduction
The BY 125 is a cost-effective synchronizer for high performance synchronization and
registration applications between two independent drives, with a convincing value for price
ratio. The units are suitable for any kind of drives (AC, DC, Servo etc.) that are variable in speed
under control of a 0-10 volts speed reference. The 80 kHz counting frequency allows use of
high-resolution encoders even with high operation speeds. Due to the very short response time
of 120 μsec only, the unit also provides a proper synchronization under highly dynamic
conditions with servo drives.
When on the slave site you use a 1-quadrant-type drive (speed reference always with positive
polarity 0...+10 volts), and your drive uses digital forward/reverse select inputs, please see
“Option UP125” and observe the special hints given in section 18 of this manual.
As a matter of course, full ratio control and other functions like index pulse tracking, print mark
registration and remote phase control are included in the wide set of standard functions.
All settings are fully digital and no potentiometer adjustments are necessary. Programming of
parameters is accomplished by PC/Laptop, using our operator software OS3.x (CD included in
delivery). Remote control is possible by serial communication, e.g. with use of one of our
operator terminals TX720 or BT348. PROFIBUS control is possible with use of the PB251
gateway (see “accessories”)
The mechanical construction uses a closed 19" steel cassette with all connections on its front.
Rack mounting of the cassette therefore does not require use of a swivel frame.
Use of our SM 150 back plane (option) also allows easy DIN rail mounting.
The BY 125 operates from an unstabilized 24 VDC supply (18 V... 30V).

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(Up to 32 axis)
SlaveMaster
TX720
Operator
terminal
PROFIBUS
BT348
Miniterminal
PC
RS232/485
Possibilities for remote control
of a BY125 synchronizer
When on the slave site you intend to use a 1-quadrant-type drive
(speed reference always with positive polarity 0...+10 volts and digital
forward/reverse select inputs), please refer to “Option UP125” and observe the
special hints given in section 17 of this manual.

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2. Principle of operation
All operation is based on setting an "analogue synchronization" between the drives first. This
can be achieved by feeding a common speed reference voltage to the drives and tuning the
drive speeds in order to get them into an approximate synchronism. A ratio adaptation may be
necessary for the Slave drive, as shown in figure 1. This analogue pre-synchronization can
match the two speeds within an error range of approx. 1%.
Ratio Adjust
Master
Drive
Speed Reference
Slave
Drive
P1 P2
Fig 1
The digital synchronization now has to compensate for the analogue speed errors in order to
get an absolute, angular and positional synchronization with no drift and no cumulative
displacement of the motor shafts. This needs a digital feedback of the angular shaft position of
the drives. In general, incremental shaft encoders or equivalent signals (e. g. encoder
simulation from a resolver system) are used.
Encoder
Speed Reference
P1
V in
Master Slave Encoder
0-10V 0-10V
V out
AD
E1 E2
Fig 2

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The synchronizer continuously checks the two shaft positions and immediately responds by an
analogue correction signal when an angular error starts to appear. This analogue correction,
added to the slave’s reference with the correct polarity, will keep the shaft positions of Master
and Slave in line. As the synchronizer responds within only microseconds to each individual
encoder pulse, the slave will practically have no chance to drift away.
Fig. 2 shows that a feed forward signal ”Vin” is needed to run the drives, and a correction
voltage is added to receive the total slave speed reference ”Vout”. It is easy to understand that
the feed forward signal must be proportional to the master speed.
There are three ways to generate Vin:
a) Use of the master speed reference voltage, like shown in Fig. 2. This presumes the
master drive does not use any remarkable internal ramps, because otherwise Vin would
not represent the real master speed upon acceleration or deceleration. As a result,
procedure a) must only be used when the master speed reference already includes the
ramp (generated by a PLC output etc.) and the drive’s internal ramp is set to zero or it’s
minimum value. However, a real speed analogue signal from a tacho generator can be
used at any time.
Analogue feed forward should only be used when replacing older existing BY125 units
against a new one.
b) Use of the frequency- to- voltage converter installed in the BY125 units.
This procedure can be used with most of all applications.
Encoder
Speed Reference
P1 V in
Master Slave Encoder
0-10V 0-10V
V out
AD
E1 E2
Vf
Fig 3

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The feed forward signal now is generated internally from the frequency of the master
encoder and no external voltage must be applied to the analogue input. This allows the
master drive to use internal ramps, because the encoder frequency always represents
the real actual speed of the master.
Also, procedure b) allows the ”Master” to be just a measuring wheel with encoder, and
not really a drive.
Digital feed forward like shown here requires encoder frequencies of at least 1 kHz at
maximum speed of the master drive. Where we cannot reach this frequency at
maximum speed, slight instability of the synchronization may be the result.
c) Use of an external voltage- to- frequency converter
This procedure is used only exceptionally.
Encoder
Vin
Maesuring
Wheel
Slave Encoder
0-10V 0-10V
Vout
AD
E2E1
Fig 4
With use of our ultra fast precision converter type FU252, also extremely low master
frequencies will be acceptable with no problem.
The mode of generating the feed forward signal can be selected by
register ”LV- Calculation”.

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3. Impulse Scaling
Both, Master and Slave impulses can be scaled separately, for easy adaptation of the
synchronizer to existing conditions (gear ratios, encoder resolution, roll diameters etc.). The
scaling factor "Factor 1" provides impulse scaling for the Master channel and the scaling factor
"Factor 2" does the same for the slave. Both factors are 5 decade and operate in a range from
0.0001 to 9.9999. Setting them both to 1.0000 will result in a 1:1 speed and phase
synchronizations.
The factors can be set via serial link, using the RS232 or the optional RS485 interface
(ordering number SS124).
Independent of the way of factor setting, the slave always changes its shaft position with
respect to the master according to the following formula:
Slave
=
Factor 1
Factor 2 Master (Proportional - operation)
Slave
=
1
Factor 2 Master
1
Factor 2 (Reciprocal operation)
Proportional or reciprocal operation can be selected by the parameter "LV-Calc "
Remarks to previous formulae:
When positional and angular synchronization is required, we recommend to set SMaster and
SSlave to a number of encoder pulses as received from the encoders when both drives move a
defined synchronous distance or one machine cycle forward.
When only speed synchronization is needed (i.e. speed errors in a range of 0.01% can be
accepted), SMaster and SSlave can also be set to the encoder frequencies at synchronous speed.
For a normal, proportional operation, under consideration of all geometrical machine data, one
would try to fix up the value of Factor 2 in a way to receive a Fact1 scaling directly in
"User units". (Factor 1 is the parameter that would be changed during production, and Factor 2
is a "machine constant" containing all mechanical gearings, which normally would never
change).

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The following example should explain the calculations for Factor 1 and Factor 2 with a feed roll
system, where the tension of the material should be varied remotely by adapting the slave
speed:
d=300
Master
1024 Imp./rev.
d=100
Slave
500 Imp./rev.
tension
control
Fig 5
With one full revolution of the master must roll, we receive 5 x 1024 = 5120 impulses from the
master encoder. If the material must pass the roll without any tension, the slave roll would
exactly need three revolutions at the same time. So we will get 3 x 2 x 500 = 3000 impulses
from the slave encoder. This means, we need 3000 slave pulses for every 5120 master pulses
to operate synchronously.
We subsequently have to set up Factor 1 and Factor 2 so, that the relation
becomes true. The simplest way to do this is by setting the factors exactly to the digital value
of the impulse numbers from the opposite side, i.e. Factor 1 = 0.3000 and Factor 2 = 0.5120.
Then, the synchronous condition will absolutely match the formula, but there could be little
comprehension from the operator, that he needs to set a value of 0.3000 on his terminal to
have tension-free synchronism. He would understand more clearly, if the setting was 1.0000.
So, we need to use the formula with different figures:
As a result we find that Factor 2 must be 5120 : 3000 = 1.7067. This setting calibrates the
Factor 1 to comprehensible "user units" (1.0000 = no tension, 1.0375 = 3,75% tension).
The same result can be achieved when using the parameter "F1-Scaling Factor" to scale the
values transmitted from the operator terminal (see chapter 8.1).