NSK MEGATHRUST ESA13 User manual

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MEGATHRUST®MOTOR SYSTEM
User’s Manual
(ESA13 Driver Unit)
Document Number: T20011-03
M–E099SA0T2–011
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Limited Warranty
NSK Ltd. warrants its products to be free from defects in material and/or workmanship which NSK
Ltd. is notified of in writing within, which comes first, one (1) year of shipment or 2400 total
operation hours. NSK Ltd., at its option, and with transportation charges prepaid by the claimant,
will repair or replace any product which has been proved to the satisfaction of NSK Ltd. to have a
defect in material and/or workmanship.
This warranty is the sole and exclusive remedy available, and under no circumstances shall NSK
Ltd. be liable for any consequential damages, loss of profits and/or personal injury as a result of
claim arising under this limited warranty. NSK Ltd. makes no other warranty express or implied,
and disclaims any warranties for fitness for a particular purpose or merchantability.
Copyright 1997-2002 by NSK Ltd., Tokyo, Japan
All rights reserved.
No part of this publication may be reproduced in any
form or by any means without permission in writing
from NSK Ltd.
NSK Ltd. reserves the right to make changes to any
products herein to improve reliability, function or design
without prior notice and without any obligation.
NSK Ltd. does not assume any liability arising out of the
application or use of any product described herein;
neither does it convey any licence under its present
patent nor the rights of others.
Patents issued and patents pending.
“MEGATHRUST” is a registered trademark of NSK
Corp. in the United States of America.
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In order to use the Megathrust Motor System properly,
observe the following notes.
1. Matters to be attended to use the Driver Unit of the Megatorque Motor System
1Temperature
lKeep the ambient temperature of the Driver Unit within 0 to 50°C. You cannot put the Driver Unit in an
atmosphere over 50°C. Keep a clearance of 100 mm in upper and lower side of the Driver Unit when it is
installed in the enclosure. If heat is build up on upper side of the Driver Unit, provide the ventilation
openings on the top of the Driver Unit or equip an air cool unit to take the heat out of the Driver Unit.
(Measures against contamination are required for the ventilation openings.)
2Protection against contamination and water
lPut the Driver Unit in an enclosure of which protection code is IP54 or better. Protect the Driver Unit
from oil-mist, cutting oil, metal chips and paint fume etc. Otherwise it may result in failures of electric
circuits of the Driver Unit.
(IP code is in IEC standard. This is to specify the protection level of enclosures from solid contamination
and water.)
3Wiring / Ground
lRefer to User's Manual for proper wiring.
lTake appropriate measures not to contaminate the Driver Unit when wiring or installing it.
4Storing
lStore the Driver Unit in a place at where it is not exposed to rain, water and harmful gas or liquid.
lStore the Driver Unit in a place at where it is not exposed to direct sun light. Keep ambient temperature
and humidity as specified.
2. Matters to be attended to use the Motor of the Megathrust Motor System
1Dustproof and Waterproof of the Motor
lYou cannot use the Megathrust Motor in atmosphere at where paint fumes or chemicals exist.
The Motor is not made for dust-proof or waterproof. You cannot use the Motor in humid or oily
atmosphere.
2Use condition
lKeep the ambient temperature of the Motor between 0 to 40°C. Install thermal sensor circuit to turn off
the main AC power when temperature exceeds the limit.
lThe allowable load mass and the transportable moment load differ depending on the Motor size.
Reconfirm that the using conditions are in the specified limits of the Motor.
lAn excessive offset load or load mass may cause permanent deflection on a part of Motor body, slider,
and Linear Guides. Be careful not to give a shock to the Motor caused by an external interference in
transit or in the process of installation.
lDo not collide the slider to the stroke ends. We recommend providing over travel limit switches with the
stroke ends.
lInstall shock absorber to protect the work that is put on the slider.
lFlatness of the Motor mounting surface shall be 0.05 mm or less
lTake sufficient measures not to dry up the Linear Guides. We recommend to replenish the grease
periodically. (Dried up Linear Guides may cause unstable operation.)
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lThe Linear Guides equip with NSK K1 lubrication unit. Life of K1 lubrication is 5 years or 10 000 km
running, whichever comes first. Be sure to give periodical replenishment with grease thereafter.
lIt is possible to replace the K1 lubrication unit when it comes to its life.
3Periodical check
lPuncture of the Motor, cable shorting or snapping may occur depending on using condition and
environment. If the Motor is left in such conditions, it cannot exhibit its capability 100 % and will lead to
the trouble of the Driver Unit. We recommend the periodical check in order to detect the problem in its
early stage.
3. Before concluding that the system is defective, check the matters again.
1Alarm arises.
lDid you take proper action to the alarm? Refer to the manual for the remedy again.
2Power does not turn on. Indication lamp does not turn on.
lCheck voltage of main and control power by a tester if the voltage is in the range of specification
described in the User’s manual.
3The Motor does not function.
lTurn the power off, disconnect the connector CN4 of the Driver Unit, and then move the slider manually.
Does it operate smoothly? Any unevenness in motion? (Never disassemble the Motor.)
(If the connector CN4 remains connected, the motion of the slider will be heavier due to dynamic brake.)
lAre the control Input/Output signals functioning properly?
®Monitor status of SVON, RUN and IPOS signals by I/O command through the Handy Terminal.
®Check if the voltage of input signal and 24 V power source are stable using an oscilloscope etc.
4Uncontrollable Driver Unit
lCompare the current setting of parameters with the original setting at the installation.
5The Motor vibrates. Positioning is inaccurate. Alarm of software thermal arises frequently.
lAre servo parameters VG, VI, PG, FP and NP adjusted properly
lDo you fasten the fixing bolts of load and the Motor securely? Check and fasten them tightly if necessary.
lConnect FG terminal of the Driver Unit to one point grounding. Ground the Motor and the Driver Unit
respectively. (Refer to the User’s Manual for wiring.)
lIs any external interference to the direction of motion in Servo lock state? (It leads to the Motor overheat
if external force is applied to the Motor in servo lock state.)
lDo you use shielded cable for input signals? Is the shield perfect?
6Fuses are blown. Breaker trip occurs frequently.
lWhen the system recovers by remaking the power, take the following action.
àInstall a delay type breaker.
(Select the breaker that has enough capacity for power consumption of the Driver Unit.)
4. Others
lCombination of the Motor and the Driver Unit shall conform to the specification.
lBe sure to write down the setting of parameters.
lNever modify the cable set.
lLock the connectors securely and check for loose fixing screw(s).
lPlease keep expendable parts and backup parts. (the Motor, the Driver Unit and Cable set for replace)
lUse isoplopyl alcohol for cleaning. Do not apply the thinner.
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MEGAT
MEGATMEGAT
MEGATHRUST
HRUSTHRUST
HRUST®
®®
®
MOTOR
MOTORMOTOR
MOTOR
SYSTEM
SYSTEMSYSTEM
SYSTEM
NSK Ltd.
NSK Ltd.NSK Ltd.
NSK Ltd.
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— i —
About This Manual
lBefore operating the Megathrust Motor System, this manual should be read thoroughly. The
Megathrust Motor System is a unique device, so ‘common sense’ based upon experience with
servo motor may not apply here. Careful consideration of the mechanical design as described in
“Chapter 6” is especially important.
lThis manual describes the interface, function and operation of the Megathrust Motor System
with YS Motor and ESA13 Driver Unit. If your model is not one of these, refer to respective
information.
Technical Information
lFor technical assistance and sales information, please contact your local NSK office. A list of
NSK offices is provided in the back cover.
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— ii —
Terminology
It will be necessary to be familiar with some terms used in
this document.
Connector
Slider
MNS direction PLS direction
Motor
bps bit per second; the unit of communication speed.
closed logic output state; output current will flow.
Driver Unit means Megathrust Motor System’s driver unit when capitalized.
Home Return a built-in sequence program for setting the home position.
kpps kilo pulse per second; the unit of pulse frequency.
MNS direction of Motor motion, minus (negative); see figure above.
Motor means Megathrust Motor System’s motor when capitalized.
OFF (all capital) logic input state; input will see an open circuit.
ON (all capital) logic input state; there will be a current path to the common DC supply.
open logic output state; no output current
P control proportional-only control; the servo algorithm.
PI control proportional and integral control; the servo algorithm.
PLS direction of Motor motion, plus (positive); see figure above.
position gain shorter name for position loop proportional gain
position integrator frequency shorter name for position loop integrator cutoff frequency
position loop control mode a control mode within the position control loop; P control or PI control available.
Programmable Indexer Driver Unit’s built-in indexing ability.
pulse train a series of pulses used as a position command.
quadrature output two pulse train outputs with 90° phase difference.
rated stall force the rated force available at zero speed.
rated force the force not to exceed the maximum Motor winding temperature.
servo-lock one typical state of servo-on; the Motor provides force and remains in position.
servo-of
f
the state where the Driver Unit provides no current to the Motor, and the Motor
provides no force. The Motor slider can be moved easily.
servo-on the state that the Driver Unit is ready to control the Motor, or is controlling the Motor.
shipping set a parameter setting or a Driver Unit function setting at shipping.
stall force the force available at zero speed.
System means Megathrust Motor System when capitalized.
velocity gain shorter name for velocity loop proportional gain
velocity integrator frequency shorter name for velocity loop integrator cutoff frequency
velocity loop control mode a control mode within the velocity control loop; P control or PI control available.
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— i —
Contents
1. Introduction------------------------------------ 1-1
1.1. Overview---------------------------------------------------- 1-1
1.2. Functional Principle-------------------------------------- 1-3
1.2.1. Motor ------------------------------------------------- 1-3
1.2.2. Driver Unit------------------------------------------- 1-3
2. Notes to Users-------------------------------- 2-1
2.1. Operational Remarks------------------------------------ 2-1
2.2. Version Number ------------------------------------------ 2-2
3. System Outline ------------------------------- 3-1
3.1. System Configuration ----------------------------------- 3-1
3.2. Reference Number Configuration -------------------- 3-2
3.2.1. System----------------------------------------------- 3-2
3.2.2. Motor ------------------------------------------------- 3-2
3.2.3. Driver Unit------------------------------------------- 3-2
3.2.4. Cable Set-------------------------------------------- 3-3
3.2.5. Handy Terminal------------------------------------ 3-3
4. Specifications --------------------------------- 4-1
4.1. Motor Specifications ------------------------------------- 4-1
4.1.1. Y Series Motor ------------------------------------- 4-1
4.1.1.1. Name of Each Parts----------------------- 4-1
4.1.1.2. Specifications ------------------------------- 4-1
4.1.1.3. Dimensions ---------------------------------- 4-2
4.2. Driver Unit-------------------------------------------------- 4-5
4.2.1. Name of Each Parts ------------------------------ 4-5
4.2.2. Specifications -------------------------------------- 4-6
4.2.2.1. General Specifications-------------------- 4-6
4.2.2.2. Functional Specifications ---------------- 4-7
4.2.2.3. Driver Unit Dimensions------------------- 4-9
4.3. Handy Terminals ----------------------------------------4-10
4.3.1. Name of Each Part and Dimensions --------4-10
4.3.2. Specifications -------------------------------------4-11
5. Connector Specifications ------------------ 5-1
5.1. CN1: RS-232C Serial Communication
Connector--------------------------------------------------- 5-1
5.1.1. CN1 Pin-Out ---------------------------------------- 5-1
5.1.2. CN1 Signal List ------------------------------------ 5-1
5.1.3. RS-232C Communication Specifications---- 5-2
5.1.4. Sample Wiring Diagram ------------------------- 5-2
5.2. CN2: Control I/O Connector --------------------------- 5-4
5.2.1. Setting of I/O type --------------------------------- 5-5
5.2.2. CN2 Pin-Out ---------------------------------------- 5-7
5.2.3. CN2 Signal List ------------------------------------ 5-8
5.2.4. Setting Polarity (A or B contact) of
Input Ports ---------------------------------------- 5-11
5.2.5. Changing I/O Type and Contact Polarity
at Once -------------------------------------------- 5-13
5.2.6. CN2 Electrical Specifications----------------- 5-14
5.2.6.1. General Input Signal -------------------- 5-14
5.2.6.2. Pulse Train Input ------------------------- 5-14
5.2.6.3. General Output Signal ------------------ 5-15
5.2.6.4. Control Output Signal ------------------- 5-15
5.2.6.5. Position Feedback Output Signal ---- 5-16
5.2.7. Wiring Diagram (CN2)-------------------------- 5-18
5.3. CN3: Resolver Cable Connector ------------------- 5-23
5.3.1. CN3 Pin-out--------------------------------------- 5-23
5.3.2. CN3 Signal List ---------------------------------- 5-23
5.4. CN4: Motor Cable Connector------------------------ 5-24
5.4.1. CN4 Pin-out--------------------------------------- 5-24
5.4.2. CN4 Signal List ---------------------------------- 5-24
5.5. TB: Terminal Block for Power Supply ------------- 5-25
5.5.1. Terminal List -------------------------------------- 5-25
5.5.2. Wiring Diagram (TB)---------------------------- 5-25
6. Installation ------------------------------------- 6-1
6.1. Unpacking and Inspection------------------------------ 6-1
6.2. Motor and Driver Unit Combination ------------------ 6-2
6.3. Motor Mounting ------------------------------------------- 6-3
6.3.1. Mounting Location--------------------------------- 6-3
6.3.2. Mounting--------------------------------------------- 6-3
6.4. Driver Unit Mounting ------------------------------------- 6-4
6.4.1. Connecting Power--------------------------------- 6-5
6.4.2. Ground Connection and Wiring ---------------- 6-7
6.5. Connecting Motor and Driver Unit-------------------- 6-8
6.6. Power On and Servo On-------------------------------- 6-9
6.6.1. Precautions ----------------------------------------- 6-9
6.6.2. Turning Power On--------------------------------- 6-9
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— ii —
7. Handy Terminal Communication -------- 7-1
7.1. When Power is Turned ON ---------------------------- 7-1
7.2. Command Entry ------------------------------------------ 7-2
7.3. Password--------------------------------------------------- 7-2
7.4. Cancelling Command ----------------------------------- 7-3
7.5. Error --------------------------------------------------------- 7-3
7.6. Readout Command -------------------------------------- 7-4
8. Trial Running and Adjustment------------ 8-1
8.1. Adjustment Sequence----------------------------------- 8-1
8.2. Automatic Tuning (Adjustment Level 1) ------------ 8-2
8.2.1. Preparations---------------------------------------- 8-2
8.2.2. Initialize Servo Parameters --------------------- 8-4
8.2.3. Execute Automatic Tuning
(Adjustment Level 1) ----------------------------- 8-5
8.2.3.1 When the load weight is known. -------- 8-5
8.2.3.2 When the load weight is not known. --- 8-5
8.2.4. Trial Running (Adjustment Level 1)----------- 8-7
8.2.5. Minor Servo Gain Adjustment
(Adjustment Level 2) ----------------------------- 8-9
8.3. Manual Adjustment -------------------------------------8-11
8.3.1. Precautions ----------------------------------------8-11
8.3.2. Adjustment of the Velocity Gain (VG)-------8-11
8.3.3. Adjustment of Velocity Integrator
Frequency -----------------------------------------8-13
8.4. Setting Filters (Adjustment Level 2) ----------------8-15
9. Operational Function ----------------------- 9-1
9.1. General Operation and Function --------------------- 9-1
9.1.1. Servo “ON”------------------------------------------ 9-1
9.1.2. Emergency Stop----------------------------------- 9-2
9.1.3. Position Error Counter Clear Input------------ 9-3
9.1.4. Overtravel Limit------------------------------------ 9-4
9.1.4.1. Hardware Overtravel Limit--------------- 9-4
9.1.4.2. Software Overtravel Limit ---------------- 9-5
9.1.5. Alarm Output --------------------------------------- 9-6
9.1.6. In-Position Output--------------------------------- 9-7
9.1.6.1. Output Signal Format --------------------- 9-8
9.1.6.2. Parameter “IN”------------------------------ 9-9
9.1.6.3. Parameter “IS”------------------------------ 9-9
9.1.6.4. “IPOS” Output for Special
Occasion. ------------------------------------ 9-9
9.1.7. Position Feedback Signal ----------------------9-10
9.1.8. Monitor Functions --------------------------------9-11
9.1.8.1. Velocity Monitor ---------------------------9-12
9.1.8.2. Monitoring the I/O State-----------------9-13
9.1.8.3. Reading the Present Position----------9-14
9.2. To Have More Advanced Operation --------------- 9-15
9.2.1. Position Scale ------------------------------------ 9-15
9.2.1.1. Resolution---------------------------------- 9-15
9.2.1.2. Direction of Position Scale------------- 9-15
9.2.1.3. Position Scale Coordinate ------------- 9-16
9.2.1.4. Position Scale Reset -------------------- 9-16
9.2.1.5. Position Readout ------------------------- 9-16
9.2.1.6. Position Scale Setting Example ------ 9-17
9.2.2. Digital Filter --------------------------------------- 9-18
9.2.3. Feed Forward Compensation ---------------- 9-19
9.2.4. Integrator Limiter : ILV ------------------------- 9-20
9.2.5. Dead Band Setting : DBP --------------------- 9-21
9.3. RS-232C Communication ---------------------------- 9-22
9.3.1. Communication Specification ---------------- 9-22
9.3.2. Communication Procedure-------------------- 9-23
9.3.2.1. When Power is Turned ON ------------ 9-23
9.3.2.2. Command Entry -------------------------- 9-24
9.3.2.3. Password----------------------------------- 9-25
9.3.2.4. Cancelling Command ------------------- 9-26
9.3.2.5. Error ----------------------------------------- 9-27
9.3.2.6. Readout Command---------------------- 9-29
9.3.3. Daisy-Chain Communication ----------------- 9-31
9.3.3.1. Procedure to Set Daisy-chain
Communication --------------------------- 9-31
9.3.3.2. Initial Setting------------------------------- 9-32
9.3.3.3. Interfacing---------------------------------- 9-32
9.3.3.4. Power On ---------------------------------- 9-34
9.3.3.5. Operation----------------------------------- 9-35
10. Positioning ----------------------------------10-1
10.1. Preparation --------------------------------------------- 10-1
10.1.1. Wiring Check------------------------------------ 10-1
10.1.2. Procedure---------------------------------------- 10-1
10.2. Home Return------------------------------------------- 10-2
10.2.1. Home Return Parameter List --------------- 10-4
10.2.2. Adjusting the Home Limit Switch and
Home Offset Value------------------------------ 10-4
10.2.3. Programming the Home Return
Operation (example)---------------------------- 10-7
10.2.4. Position of Origin Limit Switch in TY1
and TY2 I/O Combination --------------------- 10-8
10.3. Programmed Operation ----------------------------- 10-9
10.3.1. Programmable Indexer Channel
Switching -----------------------------------------10-10
10.4. Pulse Train Command------------------------------10-11
10.4.1. Pulse Train Signal Format------------------10-11
10.4.2. Pulse Train Resolution ----------------------10-12
10.4.3. Input Timing------------------------------------10-13
10.5. RS-232C Position Commands--------------------10-15
10.6. Jog Operation-----------------------------------------10-16
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— iii —
11. Programming-------------------------------11-1
11.1. Commands and Parameters------------------------11-1
11.2. Program Editing Command -------------------------11-5
11.3. Inputting a Program -----------------------------------11-6
11.4. Program Example -------------------------------------11-8
12. Command and Parameter --------------12-1
12.1. Command and Parameter List ---------------------12-1
12.2. Command and Parameter---------------------------12-3
AB : I/O polarity-----------------------------------------12-3
AN : Axis Number --------------------------------------12-4
AR : Absolute Positioning, Resolver---------------12-4
AS : Ask Daisy-Chain Status------------------------12-4
AT : Automatic Tuning --------------------------------12-4
AX : Axis Select ----------------------------------------12-5
AZ : Absolute Zero Position Set--------------------12-5
BM : Backspace Mode --------------------------------12-5
CA : Channel Acceleration---------------------------12-6
CC : Clear Channel ------------------------------------12-6
CH : Channel Select-----------------------------------12-6
CL : Clear Alarm ---------------------------------------12-6
CM : Communication Mode --------------------------12-7
CO : Position Error Counter Over Limit -----------12-7
CR : Circular Resolution ------------------------------12-7
CV : Channel Velocity---------------------------------12-8
DBP : Dead Band ----------------------------------------12-8
DI : Direction Inversion ------------------------------12-8
FC : Friction Compensation -------------------------12-9
FD : Feed Back Direction Mode --------------------12-9
FF : Feed Forward Gain -----------------------------12-9
FO : Low-pass Filter OFF Velocity--------------- 12-10
FP : Low-pass Filter, Primary--------------------- 12-10
FR : Feed Back Signal Resolution--------------- 12-11
FS : Low-pass Filter, Secondary----------------- 12-11
FW : FIN Width ---------------------------------------- 12-12
FZ : Feedback Phase Z Configuration --------- 12-12
HA : Home Return Acceleration ------------------ 12-12
HD : Home Return Direction----------------------- 12-13
HO : Home Offset ------------------------------------ 12-13
HS : Home Return Start ---------------------------- 12-13
HV : Home Return Velocity ------------------------ 12-13
HZ : Home Return Near-Zero Velocity---------- 12-14
ILV : Integration Limit -------------------------------- 12-14
IN : In-position --------------------------------------- 12-14
IO : Input/Output Monitor -------------------------- 12-15
IR : Incremental Positioning, Resolver--------- 12-15
IS : In-position Stability Timer-------------------- 12-16
JA : Jog Acceleration ------------------------------- 12-16
JP : Jump ---------------------------------------------- 12-16
JV : Jog Velocity ------------------------------------- 12-16
LG : Lower Gain --------------------------------------12-17
LO : Load Inertia--------------------------------------12-17
LR : Low Torque Ripple ----------------------------12-17
MA : Move Acceleration-----------------------------12-17
MI : Read Motor ID ----------------------------------12-18
MM : Multi-line Mode ---------------------------------12-18
MO : Motor Off -----------------------------------------12-18
MS : Motor Stop---------------------------------------12-19
MT : Factory Use Only ------------------------------12-19
MV : Move Velocity-----------------------------------12-19
NP : Notch Filter, Primary
(primary notch filter frequency)-------------12-19
NS : Notch Filter, Secondary
(secondary notch filter frequency)---------12-20
NW : Neglect Width-----------------------------------12-20
OE : Sequence Option Edit ------------------------12-20
OG : Origin Set ----------------------------------------12-21
OL : Overload Limit ----------------------------------12-21
OS : Origin Setting Mode ---------------------------12-21
OTP : Overtravel Limit Switch Position -----------12-22
OTM : Overtravel Limit Switch Position -----------12-22
PA : Phase Adjust------------------------------------12-22
PC : Pulse Command -------------------------------12-22
PG : Position Gain------------------------------------12-23
PH : Program Home Return -----------------------12-23
RC : Rated Current (Software Thermal) --------12-23
RI : Factory Use Only ------------------------------12-23
RR : Resolver Resolution---------------------------12-24
SE : Serial Error --------------------------------------12-24
SG : Servo Gain --------------------------------------12-24
SI : Set Initial Parameters-------------------------12-25
SM : Servo On Mode---------------------------------12-25
SP : Start Program-----------------------------------12-25
SV : Servo-on -----------------------------------------12-25
TA : Tell Alarm Status-------------------------------12-26
TC : Tell Channel Program ------------------------12-27
TE : Tell Position Error Counter ------------------12-27
TL : Torque Limit Rate------------------------------12-27
TP : Tell Position -------------------------------------12-28
TR : Tell RDC Position Data-----------------------12-28
TS : Tell Settings -------------------------------------12-28
TY : I/O Type ------------------------------------------12-29
VG : Velocity Gain------------------------------------12-29
VI : Velocity Integrator Frequency --------------12-29
VM : Velocity Integrator Mode ---------------------12-30
VO : Velocity Error Over Limit ---------------------12-30
VW : Velocity Error Over Limit Width ------------12-30
WD : Write Data to EEPROM ----------------------12-30
WM : Write Mode to EEPROM ---------------------12-31
ZP : Factory Use Only ------------------------------12-31
ZV : Factory Use Only ------------------------------12-31
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— iv —
13. Maintenance--------------------------------13-1
13.1. Precautions----------------------------------------------13-1
13.2. Maintenance Check -----------------------------------13-2
13.2.1. Motor-----------------------------------------------13-2
13.2.2. Driver Unit and Cable Set --------------------13-2
13.3. Periodical Replacement of Parts-------------------13-3
13.3.1. Motor-----------------------------------------------13-3
13.3.2. Driver Unit ----------------------------------------13-3
13.4. Storing----------------------------------------------------13-3
13.5. Warranty Period and Covering Range -----------13-4
13.5.1. Warranty Period --------------------------------13-4
13.5.2. Range of Warranty -----------------------------13-4
13.5.3. Immunities----------------------------------------13-4
13.5.4. Service Fee --------------------------------------13-4
14. Alarms ---------------------------------------14-1
14.1. Identifying Alarms--------------------------------------14-1
14.1.1. Using LED----------------------------------------14-1
14.1.2. Using TA Command ---------------------------14-2
14.1.3. Alarm List-----------------------------------------14-3
14.2. Description of Alarm ----------------------------------14-4
14.2.1. Normal State-------------------------------------14-4
14.2.2. Alarms Related to Power Amplifier --------14-4
14.2.2.1. Heat Sink Over Temperature---------14-4
14.2.2.2. Abnormal Main AC Line Voltage ----14-5
14.2.2.3. Over Current------------------------------14-5
14.2.2.4. Control AC Line Under-Voltage------14-6
14.2.3. Alarms Related to Motor----------------------14-7
14.2.3.1. Resolver Circuit Error ------------------14-7
14.2.3.2. Software Thermal Sensor-------------14-8
14.2.3.3. Velocity Error Over----------------------14-8
14.2.4. Alarms Related to Control--------------------14-9
14.2.4.1. Memory Error-----------------------------14-9
14.2.4.2. EEPROM Error --------------------------14-9
14.2.4.3. System Error -----------------------------14-9
14.2.4.4. CPU Error ------------------------------- 14-10
14.2.4.5. Excess Position Error ---------------- 14-10
14.2.4.6. Software Over Travel Limit --------- 14-11
14.2.4.7. Hard ware Over Travel Limit ------- 14-11
14.2.4.8. Emergency Stop----------------------- 14-11
14.2.4.9. Program Error -------------------------- 14-12
14.2.4.10. Automatic Tuning Error ------------ 14-12
14.2.4.11. RS-232C Error ----------------------- 14-13
14.2.4.12. CPU Error ----------------------------- 14-13
14.2.5. History of Alarm------------------------------- 14-14
14.2.5.1. Indication of History of Alarm------- 14-14
14.2.5.2. Clear History of Alarm---------------- 14-14
15. Troubleshooting ---------------------------15-1
15.1. Identifying Problem ----------------------------------- 15-1
15.2. Troubleshooting --------------------------------------- 15-2
15.2.1. Power Trouble---------------------------------- 15-3
15.2.2. Motor Trouble----------------------------------- 15-4
15.2.3. Command Trouble----------------------------- 15-6
15.2.4. Terminal Trouble------------------------------15-10
Appendix
Appendix 1: Verify Input/Output Signal -------------------A-1
Appendix 2: How to Check Motor Condition-------------A-3
Appendix 3: Initializing Driver Unit -------------------------A-6
Appendix 4: How to replace ESA13 Driver Unit --------A-8
Parameter • Program Setting List ------------------------ A-15
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— 1-1 —
1. Introduction
lThis section is to introduce the Megathrust Motor System in general. Some part of explanations
are not applicable to all Driver Unit and/or Motors. Refer to respective specifications when
ordering.
1.1. Overview
lThe Megathrust Motor System is a unique actuator with special capabilities. The System consists
of almost all elements that are needed for a complete closed loop servo motor system. With
conventional technology these parts must be purchased and installed separately, but the
Megathrust Motor System incorporates them all into two units; the Motor and the Driver Unit.
Motor
lThe Motor consists of a high thrust force brushless actuator, a high resolution brushless resolver,
and heavy duty precision NSK Linear Guides. The high thrust force actuator has a simple
structure, while the built-in resolver usually makes feedback components, such as encoders
unnecessary. Finally the heavy duty Linear Guides eliminates the need for separate mechanical
support since the Motor case can very often support the load directly in most applications.
Driver Unit
lThe Driver Unit consists of a power amplifier, resolver interface, and digital motor control
circuits. The Driver Unit provides everything that is needed to control the Motor’s force,
velocity, or position; for interface to any standard motor position controller or to act as a stand-
alone digital motion control system with its built-in zero backlash position control capability.
High Speed
lThe Driver Unit features higher speeds than ever before... with less force drop-off at the
intermediate speeds. As a result, smaller Motors may be used for high speed positioning
applications when the thrust requirement is primarily for acceleration.
Ease of Use
lThe digital control makes the System easy to use, for more than one reason:
àThe circuit parameters can be changed by an RS-232C command, rather than by
attempting to adjust a multi-turn pot or changing capacitor values. The parameter
changes are not only a breeze to make, but they are measurable and repeatable, so that
every System behaves the same way, every time.
àThe versatile design means that significant changes in the Driver Unit function can be
made with little or no hardware changes. Numerous options are available at little or no
extra cost.
àStand-alone capability means that the Megathrust Motor System can be operated in
position control mode without the need for a separate CNC or position controller.
Built-in software for flexible motion control means that the complexity of the
electronic system can be cut in half. This reduction of the controls circuitry to one
component saves time and money.
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— 1-2 —
Universal Interface
lBecause of the extreme versatility of the Driver Unit design, a wide variety of interface methods
are possible. The Megathrust Motor System can be interfaced to virtually any control system. It
is very easy to control the Megathrust Motor System with a CNC, a servo motor controller, a
robot controller, or an positioning controller. You can operate the Megathrust Motor System
with a stepper motor controller or with a personal computer or dumb terminal. Versatile position
control can even be implemented with a single switch!
High Repeatability
lWith zero backlash, direct drive and a high resolution resolver, the Megathrust Motor System
offers repeatability as high as 1 micron, or approximately 0.000039 inch. With no mechanical
contact or moving parts other than the Linear Guides, this repeatability will never degrade.
Easy to Maintain
lWith all adjustments, indicators, and test points accessible by the front panel, service or
maintenance is easy. LED (light-emitting diode) and logic diagnostic outputs identify the nature
of any error condition quickly and accurately.
lTogether, the Motor and the Driver Unit provide the ultimate in simplicity for precise and
reliable motion control.
Single Component Servo System
lA conventional brushless servo system requires at least several separate components which must
be selected and packaged together, often at great expense. Furthermore, many of these
components introduce problems of their own to degrade the entire system’s performance. Ball
Screw type actuators, for example, introduce mechanical irregularities such as windup, backlash,
and mechanical inaccuracy. The same functions can be accomplished with just two components
using the Megathrust Motor System; all of the circuits needed to implement a position or
velocity control servo loop (digital motion controller, servo compensation, brushless
commutation logic, power amplifier) are included in the Driver Unit, and all of the mechanical
components that were required (motor, couplings, ball screw, linear guides and encoder) are
either replaced or made unnecessary by the Motor.
Long Stroke and Small Cross Section Area
lDifferent from the ball screw system, the cross section area of the Megathrust Motor does not
depend on the stroke. By jointing unit rack bases, up to 30 meters rack base length can be
represented while maintaining the same cross section area. In addition, because the rack base
length does not affect to the repeatability, precise positioning is possible over the full stroke.
Multi Slider System
lOne of the other unique merit of the Megathrust Motor is that several sliders can be mounted on
the same rack base and can be controlled independent of the others. This also will contribute to
design versatile system simple.
lA conventional brushless servo system requires at least several separate components which must
be selected and packaged together, often at great expense.
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— 1-3 —
1.2. Functional Principle
1.2.1. Motor
lBy virtue of its unique design, the Megathrust Motor System is capable of producing extremely
high thrust force at low speeds suitable for direct drive applications. Furthermore, it can produce
these force levels without using an undue amount of power, so it can sustain these torque levels
indefinitely under most conditions without overheating.
Motor Construction
lThis Motor is of a stator and a rack base construction. The stator is constructed of laminated iron
sheets with several poles stamped into the laminations. Each pole has one set of copper windings
around it which provide the magnetic field. The windings are wired in series so that there are
three sets of windings seen by the power amplifier, each winding consisting of some pole pieces.
The face of each pole piece has many teeth, resembling a stepping motor (in appearance, not in
function). The teeth serve to focus the magnetic energy into a series of discrete points along the
pole face. In total there are hundreds of these points along with the stroke of the Motor. (The
number depends upon the rack base length.) The rack base is an iron plate with the same tooth
structure, but without windings or pole pieces. The rotor serves to conduct the magnetic field
from the stator through the rack base, and back again to the adjacent pole piece on the stator. The
rack base teeth also serve to focus the magnetic field into discrete points along with the stroke of
the rack base, and the combined effect of these points of focused magnetic field around both the
stator and the rotor act like electronic gear reduction, multiplying the force hundreds of times
while reducing the speed by the same amount.
Brushless Microprocessor Commutation
lFor each full electrical cycle of commutation, the Motor moves through one magnetic cycle
which is the distance between adjacent teeth. There is one(1) electrical cycle per 4.096 mm
stroke. The commutation of the Motor phases is performed without brushes by direct control of a
high speed microprocessor in the Driver Unit, and it is the phase relationship of the three Motor
phases, not current polarity, that determine the direction of move.
Why No Magnets?
lNo magnets are used in the Motor, since the Motor uses the teeth to focus the magnetic field.
This contributes to the robustness of the Motor and to the high force levels which are produced.
Since demagnetization is not a worry, it is possible to develop high magnetic flux densities
within the Motor which would weaken permanent magnets. Unlike motors which use permanent
magnets, the Megathrust Motors do not weaken with age.
1.2.2. Driver Unit
lAll of the circuits that are needed to operate the Megathrust Motor System in position, velocity
or force control modes are contained in the Driver Unit. These circuit functions are:
àDigital microprocessor
àPower amplifier
àResolver interface
lThe resolver interface and the digital microprocessor are on the control board, a single printed
circuit board which is accessible to you on the right side of the Driver Unit.
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— 1-4 —
Digital Microprocessor Subsystem
lThe digital microprocessor subsystem is a part of the control board. All analog signals are
converted to digital form, and the 16-bit microprocessor on the control board handles all Motor
control functions in the digital domain. Since analog circuits are eliminated, there are no pots to
adjust, no operational amplifier circuits to tweak, and no soldering or component changes are
required. The digital microprocessor receives commands from the outside world in either analog
or digital form, depending upon the selected interface option. The command parameter can be
position, velocity, or force. The digital microprocessor compares the commanded variable with
the actual measured value of the controlled variable, and makes small corrections continuously
so that the Motor always obeys the command. The digital microprocessor receives its feedback
information from the Motor’s built-in resolver via the resolver interface circuit subsystem.
Digital filters may be applied which alter Motor behavior to improve the repeatability, or to
eliminate mechanical resonances:
àA digital integrating function may be selected which improves the repeatability of the
Motor by making it respond to very small command signals. With the integrator, the
Motor can provide zero position error even under full load torque.
àA digital notch filter may be employed to cut out certain frequencies from the Motor
response so that mechanical resonances will not cause the Motor to oscillate. If the
Motor is attached to a load which has a strong natural frequency of oscillation, the
Motor can be made insensitive to it merely by setting the notch frequency to the same
frequency. A 100Hz resonance can be eliminated, for instance, simply by initializing
the Driver Unit with the RS-232C command “NP100.”
àA digital low-pass filter may be employed to modify Motor frequency response and
make the Motor smooth and quiet. Again, the low-pass filter is implemented digitally,
and setting up the filter frequency is as simple as asking for it. There are two
independent low-pass filters available.
Brushless Microprocessor Commutation
lThe digital microprocessor uses the digitized position information obtained from the resolver
interface to determine when to apply current to the Motor phases, and how much. The amount of
current applied to each Motor phase is determined by a mathematical function that takes into
account the force command level, the Motor position, and the Motor velocity. These factors are
taken into account to compensate for the Motor non-linearlities and to produce a smooth output
force.
Power Amplifier Subsystem
lThe Motor windings are driven by a current regulated unipolar switching power amplifier that
delivers the current designated by the commutation logic circuits to each of the Motor phases.
The power amplifier monitors its internal voltages to protect itself from damage. If the AC line
is too high or too low, the power amplifier will disable itself and activate alarm indicators. If the
amplifier’s internal DC bus voltage is too high as a result of Motor regeneration, the monitor
circuits will switch on a power resistor to dissipate some of that excess energy. If the power
amplifier temperature is too high, it will activate an alarm signal. For any of the alarm conditions,
the type of the alarm is communicated back to the digital microprocessor, which activates the
alarm condition indicators to identify the specific nature of the alarm condition.
Resolver Interface Subsystem
lPosition and velocity feedback signals are provided by the resolver interface circuit. This circuit
provides the excitation signal to the resolver, and receives the three phase resolver analog signals.
These signals are decoded by the resolver-to- digital converter (RDC) to produce digital cyclic
absolute position and velocity feedback signals. The cyclic absolute position data is used by the
commutation circuits and is used internally to maintain absolute position data.
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— 2-1 —
2. Notes to Users
lThis manual describes the interface, function and operation of ESA13 Driver Unit .
lEspecially when you use Megathrust Motor System for the first time, please thoroughly read this
manual.
lFor the explanations of Motor, only standard Y Motor series is described in this manual. If your
Motor is not Y series, please refer to respective specifications or applicable document.
lSpecial-order ESA13 Driver Units are made in compliance with this manual. When the Unit
design is prescribed separately in another specification document, priority is given to the
specification.
lFollowing notice is added to the clause of safety precautions to get your attention.
！Danger : Might cause serious injuries.
！Warning : Might result in injuries.
！Caution : Might damage the equipment (machine) and/or the load (work).
2.1. Operational Remarks
lPay special attention to the following precautions when installing, adjusting, checking and
trouble-shooting Megathrust Motor System.
！Caution : Make sure that Motor size and maximum force number of Motor and
Driver Unit are the same. Refer to “3.2. Reference Number
Configuration” for the details.
àIf the numbers are different, the system does not operate properly.
！Caution : Do not make Cable Set shorter or longer. Changing the length may
worsen Motor and Driver Unit performance.
！Caution : Do not disassemble the Motor since it is precisely adjusted and
assembled. If disassembled, it may cause abnormalities such as
deterioration in accuracy and rigidity as well as noise.
！Caution : Do not touch Driver Unit. Touching the Driver Unit just after the power is
turned off may cause electric shock.
àDriver Unit has high capacity conductors in its internal circuits and there
is high residual voltage for few minutes after the power is turned off.
àDo not detach Driver Unit cover unless it is necessary. When the cover
has to be removed, follow procedures described below.
(1) Turn off the control and main power. If only main power has been
turned on, turn the control power on for more than 5 seconds, then
turn off both powers.
Neglecting this procedure is very dangerous. The procedure is to
reduce residual voltage of capacitors.
(2) Wait for 5 minutes or more, then remove the cover.
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— 2-2 —
Figure 2-1
5 seconds
or more
5 minutes or more
ON
OFF
ON
OFF
Control power
Main power
Remove cover
！Caution : Using an optional regenerative dump resistor shall be considered for
heavy duty operation .
àWhen Motor is decelerating, rotational energy is dissipated by internal
dump resistor. Excessive rotational energy causes very high
regeneration of Motor, the dump resistor is overheated, then the alarms
goes off and Motor stops.
àGentler deceleration rate or decreasing duty cycle prevents
overheating of the dump resistor.
àIf heavy duty operation is still needed, installation of optional
“Regenerative Dump Resistor” is recommended. Refer to “Appendix 5”
for the details.
！Danger : Never apply any water or oil to Driver Unit. Take appropriate measures
to protect Driver Unit from water, oil, slag , dust and corrosive gas.
！Warning : Do not conduct an “Isolation test” or “Megger test” on Driver Unit. It may
damage the internal circuit.
！Caution : Be sure to adjust the servo parameters according to conditions of actual
use. In most cases, the Direct Drive Motor System cannot exhibit its full
performance unless the shipping set of these parameters are altered.
Refer to “8. Trial Running and Adjustment” for the details about
parameter setting.
2.2. Version Number
lVersion number applicable to this manual is upgraded to 21 from 11.
lThe number noted on the seal affixed to the Driver Unit is shown below.
<Example of version number>
ESA-LYA2A13-21
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— 3-1 —
3. System Outline
3.1. System Configuration
Figure 3-1
Motor
Cable
Cable Set
Resolver Cable
RS-232C
3-phase 200VAC
Single phase
200VAC or 100VAC
Power
Megathrust Motor
・Controller (Pulse Output)
・Sequencer
24VDC Power Supply
ESA13 Driver Unit
Handy Terminal FHT11
3 < 2 $ 1 #- + 5 % 4 >
8 ( 7 ‘ 6 &. = 0 ? 9 )
CBA FED
IHG LKJ
ONM RQP
UTS XWV
?ZY */,
CTRLESCSHIFT ENTSPBS
NS
K
HANDY TER MINAL
Components Supplied by NSK
lNSK can supply the ESA13 Driver Unit, Megathrust Motor, Cable Set (resolver cable and Motor
cable) and Handy Terminal. Users are requested to acquire other equipment and wiring from
other sources.
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