FM-2 Indexing Module Reference Manual
FM-2 Indexing Module Reference Manual
FM-2 Indexing Module Reference Manual
Reference Manual
P/N 400507-01
Revision: A7
Date: July 26, 2004
Control Techniques Drives, Inc. 1998, 2001, 2004
P/N 400507-01
Revision: A7
Date: July 26, 2004
Control Techniques Drives, Inc. 1998, 2001, 2004
This document has been prepared to conform to the current released version of the product. Because
of our extensive development efforts and our desire to further improve and enhance the product,
inconsistencies may exist between the product and documentation in some instances. Call your
customer support representative if you encounter an inconsistency.
ii
Customer Support
Control Techniques
12005 Technology Drive
Eden Prairie, Minnesota 55344-3620
U.S.A.
Telephone: (952) 995-8000 or (800) 893-2321
It is Control Techniques goal to ensure your greatest possible satisfaction with the operation
of our products. We are dedicated to providing fast, friendly, and accurate assistance. That is
why we offer you so many ways to get the support you need. Whether its by phone, fax or
modem, you can access Control Techniques support information 24 hours a day, seven days
a week. Our wide range of services include:
FAX
(952) 995-8099
You can FAX questions and comments to Control Techniques. Just send a FAX to the number
listed above.
Website and Email
www.emersonct.com
Website: www.emersonct.com
Email: info@emersonct.com
If you have Internet capabilities, you also have access to technical support using our website.
The website includes technical notes, frequently asked questions, release notes and other
technical documentation. This direct technical support connection lets you request assistance
and exchange software files electronically.
Technical Support
Email: service@emersonct.com
Control Techniques Motion Made Easy products are backed by a team of professionals
who will service your installation. Our technical support center in Eden Prairie, Minnesota is
ready to help you solve those occasional problems over the telephone. Our technical support
center is available 24 hours a day for emergency service to help speed any problem solving.
Also, all hardware replacement parts, if needed, are available through our customer service
organization.
When you call, please be at your computer, with your documentation easily available, and be
prepared to provide the following information:
Product version number, found by choosing About from the Help menu
iii
Need on-site help? Control Techniques provides service, in most cases, the next day. Just call
Control Techniques technical support center when on-site service or maintenance is
required.
Training Services
Email: training@emersonct.com
Control Techniques maintains a highly trained staff of instructors to familiarize customers
with Control Techniques Motion Made Easy products and their applications. A number of
courses are offered, many of which can be taught in your plant upon request.
Application Engineering
Email: applengr@emersonct.com
An experienced staff of factory application engineers provides complete customer support for
tough or complex applications. Our engineers offer you a broad base of experience and
knowledge of electronic motion control applications.
Customer Service (Sales)
Email: customer.service@emersonct.com
Authorized Control Techniques distributors may place orders directly with our Customer
Service department. Contact the Customer Service department at this number for the
distributor nearest you.
Document Conventions
Manual conventions have been established to help you learn to use this manual quickly and
easily. As much as possible, these conventions correspond to those found in other Microsoft
Windows compatible software documentation.
Menu names and options are printed in bold type: the File menu.
Dialog box names begin with uppercase letters: the Axis Limits dialog box.
Dialog box field names are in quotes: Field Name.
Button names are in italic: OK button.
Source code is printed in Courier font: Case ERMS.
iv
In addition, you will find the following typographic conventions throughout this manual.
This
Represents
bold
Characters that you must type exactly as they appear. For example, if you are directed to type
a:setup, you should type all the bold characters exactly as they are printed.
italic
Placeholders for information you must provide. For example, if you are directed to type
filename, you should type the actual name for a file instead of the word shown in italic type.
ALL CAPITALS
SMALL CAPS
KEY1+KEY2
example: (Alt+F)
A plus sign (+) between key names means to press and hold down the first key while you press
the second key.
KEY1,KEY2
example: (Alt,F)
A comma (,) between key names means to press and release the keys one after the other.
Note
For the purpose of this manual and product, Note indicates essential information about
the product or the respective part of the manual.
Epsilon Only
For the purpose of this manual and product, the Epsilon symbol indicates information
about the Epsilon drive specifically.
EN
E Series Only
For the purpose of this manual and product, the EN symbol indicates information about
the EN Series drive specifically.
Throughout this manual, the word drive refers to an Epsilon or EN drive.
Warning indicates a potentially hazardous situation that, if not avoided, could result in
death or serious injury.
Caution indicates a potentially hazardous situation that, if not avoided, may result in
minor or moderate injury.
Caution used without the safety alert symbol indicates a potentially hazardous situation
that, if not avoided, may result in property damage.
Safety Instructions
General Warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages
used in the product can cause severe electric shock and/or burns and could be lethal. Extreme
care is necessary at all times when working with or adjacent to the product. The installation
must comply with all relevant safety legislation in the country of use.
Qualified Person
For the purpose of this manual and product, a qualified person is one who is familiar with
the installation, construction and operation of the equipment and the hazards involved. In
addition, this individual has the following qualifications:
Is trained and authorized to energize, de-energize, clear and ground and tag circuits and
equipment in accordance with established safety practices.
Is trained in the proper care and use of protective equipment in accordance with
established safety practices.
Reference Materials
The following related reference and installation manuals may be useful with your particular
system.
vi
Safety Considerations
Safety Precautions
This product is intended for professional incorporation into a complete system. If you install
the product incorrectly, it may present a safety hazard. The product and system may use high
voltages and currents, carries a high level of stored electrical energy, or is used to control
mechanical equipment which can cause injury.
You should give close attention to the electrical installation and system design to avoid
hazards either in normal operation or in the event of equipment malfunction. System design,
installation, commissioning and maintenance must be carried out by personnel who have the
necessary training and experience. Read and follow this safety information and the instruction
manual carefully.
Enclosure
This product is intended to be mounted in an enclosure which prevents access except by
trained and authorized personnel, and which prevents the ingress of contamination. This
product is designed for use in an environment classified as pollution degree 2 in accordance
with IEC664-1. This means that only dry, non-conducting contamination is acceptable.
Safety of Machinery
Within the European Union all machinery in which this product is used must comply with
Directive 89/392/EEC, Safety of Machinery.
The product has been designed and tested to a high standard, and failures are very unlikely.
However the level of integrity offered by the products control function for example stop/
start, forward/reverse and maximum speed is not sufficient for use in safety-critical
applications without additional independent channels of protection. All applications where
malfunction could cause injury or loss of life must be subject to a risk assessment, and further
protection provided where needed.
General warning
Failure to follow safe installation guidelines can cause death or serious injury. The voltages used in
this unit can cause severe electric shock and/or burns, and could be lethal. Extreme care is necessary
vii
viii
The Epsilon drive surrounding air ambient temperature must be 40 C (104 F) or less for
full rated output and up to 50 C (122 F) with output current derated to 3% for every
degree above 40 C (104 F).
Continuous
Peak
Ei-202
1.8
3.6
Ei-203
3.0
6.0
Ei-205
5.0
10.0
Time (seconds)
50
40
30
20
10
0
100
125
150
175
200
ix
CE Declaration of Conformity
The Epsilon Series Digital Servo Drives are marked with the Conformite Europeenne Mark
(CE mark) after passing a rigorous set of design and testing criteria. This label indicates that
this product meets safety and noise immunity and emissions (EMC) standards when installed
according to the installation guidelines and used within the product specifications.
Note
The FM-2 Indexing Module is not required to carry a CE mark because it operates on low
voltages.
Declaration of Conformity
Manufacturers Name:
Manufacturers Address:
Model Number:
System Options:
This declaration covers the above products with the ECI-44 Screw Terminal Interface.
Supplementary information:
The products herewith comply with the requirements of the Low Voltage Directive (LVD) 73/23/EEC and EMC Directive 89/336/EEC
This electronic drive product is intended to be used with an appropriate motor, electrical protection components and other equipment to form a complete end
product or system. It must only be installed by a professional assembler who is familiar with requirements for safety and electromagnetic compatibility
(EMC). The assembler is responsible for ensuring that the end product or system complies with all the relevant laws in the country where it is to be used.
Refer to the product manual for installation guidelines.
European Contact:
Date
Sobetra Automation
Langeveldpark Lot 10
P. Dasterleusstraat 2
1600 St. Pieters Leeuw, Belgium
xi
xii
Table of Contents
Reference Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi
Safety Considerations
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vii
Introduction
Epsilon Ei Indexing Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
FM-2 Indexing Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Operational Overview
User Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How Motion Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
How Jogging Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
How Home Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
How Indexes Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
How Chaining Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Index Input and Output Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
How Alternate Mode Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Drive Modifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Encoder Output Scaling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Current Foldback . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Shunt Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Brake Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Digital Inputs and Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Setting Up Parameters
Setup Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
User Units Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Inputs Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Outputs Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Jog Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Home Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Indexes Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Tuning Tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Position Tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
xiii
109
115
116
134
Quick Start
Off-line Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
On-line Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Tuning Procedures
PID vs. State-Space . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tuning Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Determining Tuning Parameter Values. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
161
162
166
170
xiv
175
176
181
183
184
185
186
186
Specifications
Epsilon Ei Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221
FM-2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 223
Epsilon Ei Dimensions and Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
FM-2 Dimensions and Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Drive and Motor Combination Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Motor Brake Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Motor Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
Axial/Radial Loading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
IP Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Encoder Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
Power Dissipation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
Speed Torque Curves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232
Motor Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
NT Motor Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240
Cable Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
Glossary
Index
xv
xvi
Introduction
Epsilon Ei Indexing Drive
The Epsilon drives are stand-alone, fully digital brushless servo drives designed and built to
reliably provide high performance and flexibility without sacrificing ease of use.
The use of State-Space algorithms make tuning very simple and forgiving. The drives are
designed to operate with up to a 10:1 inertia mismatch right out of the box. Higher (50:1 and
more) inertial mismatches are possible with two simple parameter settings.
The drives can be quickly configured to many applications in less than 5 minutes with
Emerson Control Techniques PowerTools FM1 software on a PC running Windows 95, 98,
NT 4.0, 2000 or XP.
Complete diagnostics are provided for quick troubleshooting. A diagnostic display on the
front of the drive informs the user the operational or fault status. The last 10 faults are stored
in non-volatile memory along with a time stamp for easy recall.
Status Display
Figure 1:
Epsilon drives operate at 96 to 264 Vac or the range can be extended to 42 to 264 Vac with
an APS (Alternate Power Supply) connected and are available in three power ratings. The
drive will fit in a 6 inch deep enclosure with cables connected.
Epsilon Ei-202 650 Watts (1.8 amps cont, 3.6 amps peak)
Epsilon Ei-203 1100 Watts (3.0 amps cont, 6.0 amps peak)
Epsilon Ei-205 1750 Watts (5.0 amps cont, 10.0 amps peak)
1.In this manual, Emerson Motion Control PowerTools FM software will be referred to as PowerTools FM
Figure 2:
Introduction
Locking Latch
Indexing Module
Inputs
100-Pin Connector
1
2
3
4
5
Inputs
6
7
8
Outputs
1
2
3
Aligning Tabs
Outputs
4
10-30 VDC
+
-
10-30 VDC
Front
Figure 3:
MODEL
PART
REV
SER
FM-2
960503-01
EB/09
9820B025
Back
Operational Overview
The FM-2 Module augments the EN drive by providing single axis position control. When an
FM-2 Module is attached to an EN drive, it overrides the operation and user accessible
features of the drive. The drives basic operating mode, Torque Presets is not available when
a FM-2 Module is attached.
The Epsilon Ei drive and FM-2 Module allow you to setup 16 different indexes, Slow and
Fast Jog functions and a single Home routine. They also provide eight digital input lines and
four digital output lines in addition to the four input and three output lines available on the
drive.
User Interface
The Epsilon Ei drive and FM-2 Module are set up using PowerTools FM software.
PowerTools FM is an easy-to-use Windows-based setup and diagnostics tool. It provides you
with the ability to create, edit and maintain your drives setup. You can download or upload
your setup data to or from a device. You can also save it to a file on your PC or print it for
review or permanent storage.
Figure 4:
Figure 5:
Jog Tab
Operational Overview
Jog Acceleration and Deceleration
Jog acceleration and deceleration are in units of ms/(k(user unit)/min) or user unit/sec2,
depending on which Time Scale was selected on the User Units Tab. The default value for
both is 1000 ms/kRPM. For example, at the default values, if you initiated a Jog with a
velocity of 500 RPM, the motor will accelerate to 500 RPM in 0.5 seconds.
Accel Time = 500 RPM x 1000 ms/kRPM x 1 kRPM/1000 RPM
= 500 msec = 0.5 sec
Note
In the table below Jog Velocity = 100 RPM and Jog Fast Velocity = 500 RPM.
Jog +
Jog -
Jog Fast
Off
Off
Off
Motion
0 RPM
On
Off
Off
+100 RPM
Off
On
Off
-100 RPM
On
Off
On
+500 RPM
Off
On
On
-500 RPM
On
On
Off
0 RPM
On
On
On
0 RPM
On
Off
Jog + Input
Velocity
Time
Figure 6:
Jog Input
Off
Jog + Input
On
Off
Velocity
Time
Figure 7:
When the Jog Fast input function is not active, the target velocity for the jog is the Jog
Velocity. If the Jog Fast input function is active, the target velocity of the jog is the Jog Fast
Velocity. Jog Fast can be toggled On or Off while jogging. Jog acceleration and
deceleration ramps are used to ramp between jog velocities.
If the Jog direction is reversed, the Jog deceleration value will be used to decelerate the motor
to zero speed and then the Jog acceleration will be used to accelerate to the new (opposite
sign) velocity.
Note
The Jog function cannot be initiated when any other motion type (homing, indexing) is in
progress.
If both jog input functions are On there is no motion after a jog deceleration (they
effectively cancel each other). The drives display will show R, for ready.
If the device is jogging with the Jog + Input function On and the Jog - Input function goes
active, the device behaves the same as if it would in Jog + just turned Off.
The Stop input function will override the Jog operation and decelerate the motor to zero
speed.
If the motor reaches a Travel Limit, you can Jog off the Travel Limit in the opposite direction.
(Use Jog + to move off a Travel Limit -).
Operational Overview
Figure 8:
Home Tab
Home Type
Standard Home
The device can home the motor to an external sensor, the motors encoder marker pulse or to
a sensor and then to the encoder marker pulse.
External Home
Sensor
Carriage
Figure 9:
The figure above shows a basic standard home function using a ball screw. This example uses
most of the setup features in the PowerTools FM Home tab.
10
Operational Overview
Figure 10:
Homing to the motors encoder marker will establish the most accurate and repeatable home
position. This method will position the motor relative to the location of the rising edge of the
encoder marker pulse. Most applications will use a sensor and marker to find an accurate
home position in the vicinity of the home sensor.
11
Figure 11:
12
Operational Overview
Several parameters (including input and output functions) affect how the Home function
operates. Each of these parameters are explained in detail on the following pages.
Note
The Home function will NOT be initiated when any other motion command is in progress.
Sensor
Selecting Sensor means the rising edge of the Home Sensor input function is used to establish
the home reference position.
Figure 12:
Figure 13:
13
Figure 14:
Note
The data above assumes the use of a perfectly repeatable home sensor.
Sensor and Marker, and Marker home types will establish a repeatable home position within
one encoder count at any motor velocity.
Note
The one encoder count factor assumes the motor is approaching the marker from the same
direction. If different directions are used, the final home position will be off by four
encoder counts (0.000488 revolutions).
In Sensor and Marker applications, the marker must be at least 800 s after the rising edge of
the sensor input to be considered a valid marker pulse.
Note
At 1000 RPM, the motor will travel 0.0133 revolutions (or 4.8) in 800 s.
14
Operational Overview
>800 sec
Sensor
Marker
Direction of Travel
Figure 15:
The Home Sensor must be On for at least 50 sec to guarantee that it will be recognized.
Sensor Min.
On Time
Sensor
50 sec
Figure 16:
Sensor Position
Home Offset
The Home Offset is the distance from the Reference Position to the final stopping point at the
end of the homing sequence. Regardless of the value you enter for the Offset or which Home
Reference you choose, an offset is always inherent in the homing process.
The user may either specify a desired offset or allow the drive to calculate an offset
automatically. The drive calculates an offset that ensures that the motor will not have to
backup to get to the offset position. This is very convenient for unidirectional applications.
The calculated offset is the distance travelled during deceleration ramp from the home
velocity to a stop plus the distance travelled at the home velocity for 400s. This extra
distance is used to guarantee that the motor will not need to backup after the deceleration
ramp.
15
Figure 17:
Note
If the home reference is detected before the axis has reached its peak velocity, the axis will
still continue to the precise offset position.
16
Operational Overview
Figure 18:
Figure 19:
Calculated Offset
17
18
Figure 20:
Figure 21:
Operational Overview
Example 3: Specified Offset, Back up Required
In the example below the specified offset is located such that the motor must stop and back
up to get to the offset position.
Figure 22:
Figure 23:
19
Gear Reducer
External
Home Sensor
MG Motor with
Encoder
Carriage
Figure 24:
20
Operational Overview
Home
Sensor
Input
Off
On
On
Off
Velocity
Back off
Sensor Move
Time
Start of Normal
Home Routine
Home Reference
Position
Figure 25:
In the figure on the previous page, the motor has restricted travel. In order to find the rising
edge of the Home Sensor input, the motor must back away from the sensor until the Home
Sensor Input Function deactivates, then move forward looking for the rising edge of the
sensor. When backing-off of the sensor, the motor will move in the opposite direction of the
Home Velocity.
Figure 26:
21
Output Functions
End of Home
This output function is used to indicate that a home cycle has been successfully completed.
This output function is deactivated when any Index, Home, or Jog is initiated.
Home Limit Distance Hit
This output function indicates that no home reference was found while traveling to the Home
Limit Distance. The device will decelerate and stop at the Home Limit Distance. This output
function is activated when the motor stops. It is deactivated when any index, home or jog is
initiated.
22
Operational Overview
Absolute Position Valid
This output function is activated when a Home Routine is successfully completed or the
Define Home Input Function is activated. It indicates that the device has been homed. It is
cleared by the Home Initiate, an encoder fault and when the device is powered down.
Home Examples
Example 1: Linear Application
In this example, the device uses an external sensor and the motors encoder marker channel
to establish a Home Reference Position. This is the most accurate and most common way to
home.
Figure 27:
When the device sees the rising edge of the Home Initiate input, it accelerates the motor to
the Home Velocity.
The motor continues at that velocity until it first senses the Home Sensor input. It continues
at the same velocity until the motors encoder marker channel is sensed. The rising edge of
the motors encoder marker channel is used to establish the reference position.
Once the home reference (marker) is detected, the motor decelerates to a stop and moves to
the offset position.
Home Sequence
1.
23
3.
4.
Go to offset
5.
The figure below shows how the PowerTools FM Home tab was setup for this example.
Figure 28:
Velocity
+ 100
+ 100
Back off
Sensor
Time
- 100
Sensor
Figure 29:
24
Marker
Operational Overview
Marker
Sensor
Home Move
Offset Move
2.0 Revs
Final Position
Offset
Figure 30:
Figure 31:
When the device sees the rising edge of the Home Initiate input function, it accelerates the
motor to the Home Velocity. The motor continues at that velocity until it first senses the
Home Sensor input. The motor continues on at the home velocity until the marker is activated.
The rising edge of the motors encoder marker channel is used to establish the reference
position.
After sensing the rising edge of the motors marker channel, the device will continue moving
and will decelerate to a stop at the specified offset position.
25
26
Figure 32:
Figure 33:
Figure 34:
Operational Overview
Velocity
Run at Velocity
Deceleration
Acceleration
Time
Figure 35:
Figure 36:
Indexes Tab
Dwell
All Indexes use linear acceleration and deceleration ramps which may or may not reach the
specified velocity depending on the total distance and the ramp values. For example, a short
move with long acceleration and deceleration ramps may not reach the peak velocity entered.
27
Index Type
The device supports five types of indexes: Absolute, Incremental, Registration, Rotary plus,
and Rotary minus.
Absolute Indexes
Absolute indexes are used in applications where the motor must travel to a specific position,
regardless of where the motor is when the index is initiated.
The device calculates the distance required to move to the specified position from the current
position.
Absolute Index
Start position = 6
Absolute index position = 4
10
Motor Revolutions
Figure 37:
Absolute Index
In the example above, the index position is 4 revs. If this index is initiated the motor will
travel to a position of 4 revs no matter where it is sitting before the move. From 6 revs, it will
travel -2 revs. If the absolute index to 4 revs is initiated a second time, no motion will occur
because the motor will already be at a position of 4 revs.
The direction of an Absolute Index is determined by the starting position and the absolute
index position. If the starting position for the above index is 9 revs, then the motor will rotate
in the negative direction to end up at 4 revs.
Absolute Indexes with Rotary Rollover enabled will take the shortest path to the position
entered in the index position parameter.
28
Operational Overview
Note
Absolute indexes move to positions relative to where the machine was homed using the
home routine.
Incremental Indexes
An incremental index will move the motor a specified distance in the + or - direction
regardless of the starting position. The direction of the incremental index motion is
determined by the sign (+ or -) of the Index Distance parameter.
Incremental Index
Start position = 6
Index distance = 4
10
11
12
13
14
Motor Revolutions
Figure 38:
Incremental Index
In the example above the motor starts at 6 revs and travels a distance of 4 revs and stops at 10
revs. If the same index is initiated a second time the FM-2 Module would move the system
another 4 revs to a final position of 14 revs.
Registration Indexes
A Registration Index is used in applications where the motor must move until an object is
detected and then move a specific distance from the point of detection, such as finding a
registration mark and moving a distance beyond.
The Registration Index consists of two parts. The first part accelerates the motor to the target
velocity and continues at this velocity until it receives a registration trigger (sensor or torque).
Upon receipt of a registration trigger, the registration offset will be executed at the target
velocity. The Sensor Limit Distance Hit source can be used to turn on an output, if a sensor
input or torque level is not received within the Limit Distance.
29
2.
In the following examples the Rotary Rollover parameter on the Setup - Position view is
set to 360.00. This means that with each revolution of the motor (or rotary table),
feedback will count up to 359.99, then roll over to .
30
Operational Overview
Example 6: As in examples 2 and 4 above, the starting position is at 90 and 80 is the
specified position. A Rotary Minus index would travel 10 in the negative direction. At
the completion of this index the motor position would be 80.
Example 7: If the starting position is 15 and the specified position is 270, a Rotary
Minus index would travel 105 in the negative direction.
Index Parameters
Distance/Position
The Distance/Position parameter specifies the distance the index will travel (incremental
index), the absolute position the index will move to (absolute index), or the limit distance
(registration indexes).
Velocity
The Velocity parameter specifies the peak velocity used for the index. The velocity parameter
is unsigned and must be greater than zero.
Acceleration
The Acceleration parameter specifies the acceleration value to be used during the index.
Deceleration
The Deceleration parameter specifies the deceleration value to be used during the index.
Dwell Time
The Index Dwell Time parameter specifies the amount of time the system will wait after the
index motion before the index is considered complete.
Index Count
The Index Count parameter specifies how many times the index will repeat itself upon being
initiated. There are three different parameters to choose from, Repeat Forever, Repeat Count,
and Repeat while Input Function active.
Registration Tab
Registration indexes are highly accurate indexes that travel until either a sensor or torque limit
is reached, or until a limit distance is achieved. The user may choose to register to one of two
sensors labeled "Registration Sensor 1" and "Registration Sensor 2" or to one of two torque
levels labeled "Torque Level 1" and "Torque Level 2". All items on the registration tab are
unavailable until the Index Type is changed to "Registration".
Registration Sensor 1 option button
If this input function is assigned to an input in the Inputs tab, this sensor will be used for
completing the simple registration move.
31
Note
The torque level parameter will not LIMIT the torque produced by the drive.
(insert screen shot of the torque
Torque Level 2 option button
When chosen the index will use a torque level as defined under the "torque" tab as a
registration sensor.
Note
The torque level parameter will not LIMIT the torque produced by the drive.
Calculated Offset option button
When selected the drive will calculate the offset based on the deceleration and velocity
specified for the index.
Calculated offset
This parameter gives the calculated distance that the motor will travel after the registration
index recognizes a sensor or torque level registration input.
Specified Offset option button
When chosen the drive will use an offset value as specified by the user.
Specified Offset
This parameter is the distance that the motor will travel after the registration index recognizes
a sensor or torque level registration input. This parameter may be changed by the user.
Registration Window enable
This check box when selected enables the Registration Sensor valid Window. When active,
only registration marks that occur inside the registration window are seen as valid.
Registration Window Start
This parameter defines the start of the Registration Sensor Valid Window relative to the start
position of this index. This is an unsigned value and is relative only to starting position of this
index. Index direction does not affect this parameter. The Registration Window Start position
(or distance) should be less than the Registration Window End position. If a registration
32
Operational Overview
sensor is seen outside of this window (not between the WindowStart and WindowEnd
positions) then it will be ignored.
Registration Window End
This parameter defines the end of the Registration Sensor Valid Window relative to start
position of this index. This is an unsigned value and is relative only to starting position of this
index. Index direction does not affect this parameter. The Registration Window End position
(or distance) should be greater than the Registration Window Start position. If a registration
sensor is seen outside of this window (not between the WindowStart and WindowEnd
positions) then it will be ignored.
Calculations Tab
This tab is used to display the specific motion parameters based on the distance, velocity,
acceleration, and deceleration entered into the parameters above. Calculations are displayed
as "Commanded" calculations and do not take into consideration any limitations that the drive
and motor selection may introduce into the system.
Start Position
This parameter is used when the index type is selected to be an Absolute index. Given this
case PowerTools FM uses the position entered as the starting position of the index in order to
display calculations accurately.
Index Distance
This parameter displays the calculated amount of distance that the index will travel
throughout the entire motion.
Acceleration Distance
This parameter displays the calculated amount of distance that the motor will travel while the
index is accelerating. The Acceleration Distance is based completely on calculated motion
and does not include any limitations that might be introduced by the drive, motor, and load
variables.
At Velocity Distance
This parameter displays the calculated amount of distance that the index will travel at the
velocity specified in the velocity parameter. The At Velocity Distance is based completely on
calculated motion and does not include any limitations that might be introduced by the drive,
motor, and load variables.
Deceleration Distance
This parameter displays the calculated amount of distance that the motor will travel while the
index is decelerating. The deceleration distance is based completely on calculated time and
does not include any limitations that might be introduced by the drive, motor, and load
variables.
33
34
Operational Overview
Velocity
Index0
Index1
Index0
Dwell
Figure 39:
Time
Index1
Dwell
Chaining Example
In the above example, Index0 is chained to Index1. When the user activates the Index Initiate,
Index0 starts and, upon completion of Index0 (after Index0 Dwell), Index 1 is automatically
initiated. Index1 could then be chained to a third index, or back to Index0 if desired.
All chaining configuration is done on the Chain tab on the Indexes screen. All index
parameters are setup on the top portion of the screen. The chaining parameters are found on
the Chain tab as shown below.
Figure 40:
35
Chaining Parameters
Several parameters must be setup in order to create an index chain. These parameters are as
follows:
36
Operational Overview
index of the chain is chained to the first index of the chain. If the When this index is complete
then setting is set to Stop, then the chain will not be repeated.
Repeat Forever
If Repeat Forever is selected, then the chain will repeat itself infinitely. The only way to stop
the chain is to activate the Stop input function.
Repeat Count
If Repeat Count is selected, then the user must specify the number of times they wish to repeat
the chain.
Only one Chain Count can be used at a time. The Global Chaining Count applies to all chains
that are setup. If the user wants to run two different chains, then both chains use the same
Chain Count.
Index
Select #1
(value = 2)
Index
Select #2
(value = 4)
Index
Select #3
(value = 8)
Selected
Index
Off
Off
Off
Off
On
Off
Off
Off
Off
On
Off
Off
On
On
Off
Off
Off
Off
On
Off
On
Off
On
Off
Off
On
On
Off
On
On
On
Off
37
Index
Select #1
(value = 2)
Index
Select #2
(value = 4)
Index
Select #3
(value = 8)
Selected
Index
Off
Off
Off
On
On
Off
Off
On
Off
On
Off
On
10
On
On
Off
On
11
Off
Off
On
On
12
On
Off
On
On
13
Off
On
On
On
14
On
On
On
On
15
With all four Index Select input functions inactive, Index number 0 will be initiated when the
Index Initiate input function is activated. If you activate Index Select lines 0 and 1, Index
number 3 (1 + 2 = 3) will be initiated when the Index Initiate function goes active. If you
activate all four Index Select lines simultaneously, the selected Index number is 15 (1 + 2 +
4 + 8 = 15).
It is not necessary to assign all four Index Select input functions to input lines. Unassigned
input functions are considered to be inactive. An application that only required four different
indexes could assign Index Select 0 and 1 to input lines and leave Index 2 and 3 unassigned.
The two input lines could then be used to select indexes 0, 1, 2 and 3.
Registration Sensor 1
This input function is usually used with an external hardware sensor. It is used as the
registration reference in a registration index. If the option button on the registration tab on the
Indexes Tab is set to Registration Sensor 1, then the registration offset portion of the index
will begin when this input function is activated. Two registration sensor input functions have
been provided for applications requiring multiple sensors.
Registration Sensor 2
This input function is usually used with an external hardware sensor. It is used as the
registration reference in a registration index. If the option button on the registration tab on the
Indexes Tab is set to Registration Sensor 2, then the registration offset portion of the index
will begin when this input function is activated. Two registration sensor input functions have
been provided for applications requiring multiple sensors.
Run Next Index
This input function is used when chaining indexes together, and the user wants to wait for an
input to continue the chain, instead of starting the Next Index instantly. If When this index
is complete then is set to Wait for run next index input function, then the current index will
complete itself, and wait until this input function is activated to begin the next index in the
chain.
38
Operational Overview
Repeat Current Index
When the Repeat while Input Function active option button is selected on the Index tab, an
initiated index will continue to function until this input goes low.
End Of Index
This output function is activated when any index is completed. This output function is
deactivated when any Home, Jog or Index is initiated.
End of Chaining Count
This output function is activated when the index chain has repeated the chain the number of
times as specified in the Global Chain Count parameter. When the last index in the chain has
completed the specified Chain Count times (after the Dwell), the End of Chaining Count will
activate and remain on until the next index initiate.
End of Index Motion
This output function activates when the motor ceases motion from a given index and becomes
inactive when the next index is initiated. When indexes are chained together, the "End of
Index Motion" output will turn on in between indexes. If chained indexes are configured such
that there is no stop in motion then this output will still become active for 400usec in between
indexes. When indexes are compounded together the "End of Index Motion" will not become
active between indexes but will at the end of the compounding.
End of Index
This output function Activates when the specified index motion command is completed. If a
stop is activated before the index has completed the function will not be activated. This
function is inactivated when the specified index command is executed. When indexes are
chained together, the "End of Index Motion" output will turn on in between indexes.
Examples
Below is a list of examples that use chaining and show timing diagrams for pertinent input
and output functions based on index motion. The indexes for the examples are setup as
follows:
Index0
Count = 2
Dwell = 100 msec
When this index is complete then Stop
Index1
Count = 2
Dwell = 200 msec
When this index is complete then Start next index
Next Index = 2
Chain Count = 1
39
40
Operational Overview
Index1
Index1
Index2
Index1
Dwell
Index1
Dwell
End of Index
Motion
Index2
Dwell
Less than
10 usec
End of Index
End of Index
Count
End of Chain
Count
Figure 41:
Index4
Index4
Index3
Index3
Index3
Dwell
End of Index
Motion
Index4
Dwell
Index3
Dwell
Index4
Dwell
Less Than
10 usec
End of Index
End of Index
Count
End of Chain
Count
Figure 42:
41
Index6
Index5
Index5
Index6
Dwell
End of Index
Motion
End of Index
End of Index
Count
Run Next
Index
Run Next Index
Input Function
Turned On
Figure 43:
Example 3 Index5 is chained to Index6 using the Wait for Run Next Index
input function.
42
Operational Overview
Figure 44:
VCA =
Where:
VCA = Velocity Command Analog (RPM)
AI = Analog Input (volts)
AZO = Analog Input Zero Offset (volts)
FSV = Full Scale Velocity (RPM)
AFS = Analog Input Full Scale (volts)
43
Figure 45:
44
Operational Overview
Analog Velocity Command
When the drive is in Analog Velocity mode this parameter shows the current velocity
commanded after the scaling of the Analog input function.
Analog Accel/Decel Limit
Found on the Velocity tab, this feature allows you to limit the accel and decel rate when using
the analog input for velocity control. This makes it very simple to use the drive in high
performance, variable speed, start-stop applications such as Clutch-Brake replacements
without requiring a sophisticated controller to control the acceleration ramps. In applications
which do not require the drive to limit the ramps such as when using an external position
controller, the parameter can be set to 0 (its default value). If the Analog Accel/Decel Limit
parameter value is changed during a ramp, the new ramp limit is imposed within the next
servo loop update.
Note
Velocity related faults and velocity related input and output functions are still enabled
(including Stop and Travel Limits).
In Torque mode the drive receives an Analog Input which is scaled to the Analog Torque
Command by the Full Scale Torque, Analog Input Full Scale, and Analog Input Zero Offset
parameters. The equation is:
TC =
Where:
TC = Torque Command
AI = Analog Input (volts)
AZO = Analog Input Zero Offset (volts)
FST = Full Scale Torque (%)
AFS = Analog Full Scale (volts)
45
Figure 46:
46
Operational Overview
speed down to the Hysteresis point. At this point the drive will switch back into Torque Mode
until the Max Velocity point is reached again.
Pulse Mode
In Pulse mode, the drive will receive pulses which are used to control the position and velocity
of the motor.
There are three pulse interpretations associated with Pulse mode: Pulse/Pulse, Pulse/
Direction and Pulse/Quadrature. These selections determine how the input pulses are
interpreted by the drive.
Figure 47:
47
+/-10 V
+/-10 V
48
Operational Overview
ECI-44 Terminal
Command
Connector Pin #
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
Sync Enc In A
27
Pulse
Pulse +
Sync Enc In A/
41
Pulse/
Pulse +/
A/
Sync Enc In B
26
Direction
Pulse -
Sync Enc In B/
40
Direction/
Pulse -/
B/
Command
Connector Pin #
Pulse-Direction
Signal
Pulse-Pulse
Signal
Pulse Quadrature
Signal
NC2
20
Pulse /
Pulse CW /
NC1
36
Direction
Pulse CCW /
Pulse / :
Direction:
(active).
Positive (+) motion when high (inactive) and Negative (-) motion when low
Pulse CW / :
Commands positive (+) motion on the falling edge (active edge) of a pulse.
Pulse CCW /:
Commands negative (-) motion on the falling edge (active edge) of a pulse.
A and B:
Note
Actual motor rotation direction will depend on pulse ratio polarity and setting of the
Positive Direction bit.
49
Interpretation Group
Pulse/Pulse Interpretation
In Pulse/Pulse interpretation, pulses received on the A channel are interpreted as positive
changes to the Pulse Position Input. Pulses received on the B channel are interpreted as
negative changes to the Pulse Position Input.
Figure 48:
Note
If a travel limit is encountered when in Pulse mode, the user must exit alternate mode and
either jog or index off of the travel limit sensor before continuing.
Pulse/Direction Interpretation
In Pulse/Direction interpretation, pulses are received on the A channel and the direction is
received on the B channel. If the B is high, pulses received on the A are interpreted as positive
changes to the Pulse Position Input. If the B is low, pulses received on the A are interpreted
as negative changes to the Pulse Position Input.
50
Operational Overview
Figure 49:
Pulse/Quadrature Interpretation
In Pulse/Quadrature interpretation, a full quadrature encoder signal is used as the command.
When B leads A encoder counts are received they are interpreted as positive changes to the
Pulse Position Input. When A leads B encoder counts are received they are interpreted as
negative changes to the Pulse Position Input. All edges of A and B are counted, therefore one
revolution of a 2048 line encoder will produce an 8192 count change on the Pulse Position
Input.
Figure 50:
51
Figure 51:
Status Group
Recovery Distance
This parameter is only available on-line and stores the number of counts that have been lost
during the accel portion of pulse mode. These pulses may be used to recover any distance lost
during accel by selecting the Enable Distance Recovery check box.
Master Distance
The Master Distance parameter is only available on-line and displays the master position in
the user units specified on the User Units tab.
Ratio Setup
Ratio
The Ratio parameter includes a numerator that represents motor revolutions, and a
denominator that represents master pulses. The Pulse Ratio Revolutions is allowed to be
negative which reverses all Pulse mode motion.
52
Operational Overview
Acceleration
Max Acceleration
Sometimes when pulse mode is enabled, the Master will already be traveling at a velocity. By
default the drive will attempt to ramp up to this velocity in one processor control loop. In most
applications this very fast accel is not desirable. The maximum acceleration parameter
displays a maximum ramp that the follower will use to ramp up to the specified pulse ratio.
Once the follower is at the Master velocity, this accel parameter is disabled and the follower
will follow pulse for pulse depending on the specified ratio.
If an acceleration greater then 1000 ms/Krpm is entered into this parameter the drive will set
this parameter to 1000 ms.Krpm.
Velocity Group
Enable Distance Recovery Check box
This check box when selected, activates the Distance Recovery feature of the drive. If a
master is traveling at a velocity when pulse mode is initiated the follower will travel up to the
specified ratio using an acceleration as specified by the user. If using the accel causes the
follower to lose any pulses, these pulses will be saved into the Recovery Distance parameter
and will be added onto the followers profile after it obtains the specified ratio.
Max Recovery Vel.
This parameter sets the maximum velocity that the motor may obtain as it corrects for pulses
lost during the accel portion of pulse mode.
Enable Velocity Filter Check box
The Enable Velocity Filter check box is used to turn on or turn off the Input Pulse Velocity
Filter. When the Enable check box is selected, the filter is active and the user may select the
bandwidth desired to filter above. If clear, the filter is not used.
Filter Bandwidth
This parameter represents the bandwidth in hertz of the input pulses velocity filter. This filter
must be enabled in order for it to function. The valid range of this parameter is 0 to 1200 hertz.
53
Drive Modifiers
This section describes functions that can modify the operation of the drive.
Stop
The Stop input function, when activated, will cause motion to stop regardless of motor
direction or the operating mode. The Stop Deceleration Ramp defines the rate of velocity
change to zero speed.
Activating the Stop input function causes the drive to change to Velocity mode. Therefore, if
you are operating in Torque mode, the drive must be tuned to the load to prevent instability
when activating the Stop input function.
For example, if an application is operating in Torque mode at 1000 RPM, and the Stop input
function is activated with a Stop Deceleration Ramp of 500 ms/kRPM, the motor will
decelerate to a stop in 500 ms.
When the Stop input function is deactivated, the previous operating mode is restored
within 400 s and the drive and motor will respond immediately with no ramping unless
ramping is part of the selected mode.
+/- Travel Limits
The + and - Travel Limit input functions will stop motion in the direction indicated by the
input function using the Travel Limit Deceleration rate. This feature is active in all modes.
When an axis is stopped by a Travel Limit function, it will maintain position until it receives
a command that moves it in the opposite direction of the active Travel Limit.
For example, the + Travel Limit will stop motion only if the motor is moving + but allows motion to move off the limit switch. Conversely, the - Travel Limit will stop motion only if
the motor is moving - but allows + motion to move off the limit switch.
If both input functions are active at the same time, no motion in either direction will be
possible until at least one of the inputs is released.
When either + or - Travel Limit input function is activated, a fault will be logged into the Fault
Log, and the drive will display an L on the LED diagnostics display on the front of the
drive. Once the axis is driven off the limit switch, the fault will be cleared and the L will
disappear.
If both Travel Limit input functions are activated simultaneously, the drive will respond as if
the Stop input function has been activated and will use the Stop Deceleration ramp.
54
Operational Overview
EN
E Series Only
The function of the Travel Limits will be effected by the installation of an Function
Module (FM) to the EN drive. Please refer to the particular FMs reference manual for
complete description.
Current Foldback
Epsilon Only
Current foldback is used to protect the motor and drive from overload. There is one level
of current foldback: RMS Foldback.
RMS Foldback is displayed on the diagnostic display as a "C".
RMS Foldback
RMS foldback protects the motor from overheating. The RMS Foldback parameter models
the thermal heating and cooling of the drive and motor based on the commanded current and
the motor velocity. On power-up, the RMS Foldback level is zero and is continually updated.
When the RMS Foldback level reaches 100 percent, current foldback is activated and the
Foldback Active output function is active.
Each drive is designed to deliver up to 300 percent of the motors continuous torque for no
less the two seconds when running at 100 RPM or more. If only 150 percent of continuous
torque is required, several seconds of operation before RMS foldback is typical.
During current foldback the Torque Command Actual will be limited to 80 percent
continuous motor torque. Current foldback is cancelled when the RMS Foldback level falls
below 70 percent. This could take several seconds or several minutes depending on the load.
The RMS Foldback value is dependent on both torque and velocity. At low speeds (<20
percent of maximum motor speed) the RMS Foldback will closely follow the Torque
Command Actual. At high speeds (>50 percent of maximum motor speed) the RMS Foldback
will read higher than the Torque Command Actual.
55
Figure 52:
Shunt Operation
Shunt Active Output
Epsilon Only
Time indicator of when an external shunt transistor should fire. It can be used to trigger
an external shunt transistor. This output is active on Epsilon drives and indicates when the
bus voltage reaches 390 Vdc. It shuts off when the bus voltage is reduced below 380 Vdc.
Brake Operation
Motor brake operation can be controlled by the Brake Release and Brake Control input
functions. These input functions can be used together to control the state of the Brake output
function. The table below shows the relationship between the Brake input and Brake output
functions (see Diagnostic Display).
56
Operational Overview
Note
No motion should be commanded while the brake is engaged.
Brake Release Input
Brake Control Input
Drive Power
Stage
Off
On
On
Off
On
Off
Enabled
Disabled
Brake Release
The Brake Release input function will release the brake under all conditions. When this input
function is on, the Brake output function will be on (i.e., release brake). This input function
overrides all other brake control, thus allowing the brake to be released while a fault is active
or the power stage is disabled. See also Brake output function.
Brake Control
This input function, when active, will engage the brake unless overridden by the Brake
Release input function. This input lets you externally engage the brake while allowing the
drive to also control the brake during fault and disabled conditions.
Brake
The Brake output function is used to control the motor holding brake. If the Brake output
function is off, the brake is mechanically engaged. When the brake is engaged, the diagnostic
display on the front of the drive will display a b.
The drive outputs are limited to 150 mA capacity, therefore, a suppressed relay is required to
control motor coil. Control Techniques offers a relay, model # BRM-1.
Analog Outputs
The drive has two 10 bit Analog Outputs which may be used for diagnostics, monitoring or
control purposes. These outputs are referred to as Channel 1 and Channel 2. They can be
accessed from the command connector.
Each Channel provides a programmable Analog Output Source.
Analog Output Source options are:
Velocity Command
Velocity Feedback
Torque Command
57
Torque Feedback
Following Error
Source
Offset
Scale
Velocity Feedback
600 RPM/volt
Torque Command
30% /volt
Each channel includes a programmable Analog Output Offset and an Analog Output Scale.
This feature allows you to zoom in to a desired range effectively increasing the resolution.
The units for both of these parameters is dependent upon the Analog Output Source selection.
Analog Output Offset units:
Example:
You could use the Analog Outputs to accurately measure velocity overshoot. For example, to
measure a target velocity of 2000 RPM at a resolution of 10V = 200 RPM do the following.
1.
2.
3.
This will provide an active range from -10 to +10 Volts to represent 1800 to 2200 RPM.
Therefore, the measured resolution has been increased.
58
Operational Overview
EN
E Series Only
EN drives are equipped with five optically isolated input lines (one dedicated to a Drive
Enable function) and three optically isolated output lines. The FM-2 Module has an
additional eight input and four output lines.
The EN drives input and output lines can be accessed through the removable 10-pin I/O
connector (J6), or through the 44-pin command connector (J5).
All inputs and outputs are configured as sourcing and are designed to operate from a +10 to
30 Vdc power source. You are responsible for limiting the output current to less than 150 mA
for each digital output.
Note
Input functions which initiate motion (Jog +, Jog -, Index Init and Home Init) cannot be
set Active Off.
You can also make an input function "Always Active", which means that it is active
regardless of whether or not it is assigned to an input line, and, if you assign it to an input line,
it will be active whether or not voltage is applied to that line. This is useful for testing the
drive operation before I/O wiring is complete.
Input Lines Forced On and Forced Off
You can force an input line to a level by using the "Forced On" and "Forced Off" check boxes.
When you force an input line On or Off, all the functions assigned to that line will be
affected.
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
59
Figure 53:
If the Input Line attached to the home sensor is debounced, the actual rising edge of the Home
Sensor is used to determine the Home Reference Position (the debounce time ensures a
minimum pulse width).
Output Lines Forced On and Forced Off
You can force an output line to a level by using the Forced On and Forced Off check boxes.
When you force an output line On or Off, the output functions are not affected.
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
Input Functions
Alternate Mode Enable
This input function will enable the Alternate Mode features.
60
Operational Overview
Brake Release
This input function will release the brake under all conditions. If this input function is active,
the brake output function is switched to active (i.e. release brake). This overrides all other
brake control, thus allowing the brake to be released while a fault is active or the power stage
is disabled.
Brake Control
This input function, when active, will engage the brake unless overridden by the Brake
Release input function. This input function lets you externally engage the brake, while
allowing the drive to also control the brake during fault and disabled conditions.
Define Home
This input function is used to set the absolute position to zero. On the rising edge of this input
function the absolute position is set to zero and the Absolute Position Valid output function
is activated.
Home Initiate
This input function is used to initiate a home routine. The home is initiated on the rising edge
of this input function. The drive will not initiate a home routine if there is an Index or Jog in
progress or the stop input function is active. The Home Initiate Input function cannot be set
Active Off.
Home Sensor
This input function defines the sensor used for homing. It is required if you are homing to a
sensor or a sensor and marker. This function is edge sensitive. The sensor position is defined
when the device senses the rising edge of the sensor.
Index Initiate
This input function initiates the selected index. The index to be initiated is specified using the
index select input functions 0 through 3. If none of the index select functions are assigned then
index #0 will be initiated. This input function cannot be set Active Off.
Index Select 0 through 3
The Index Select Input functions are used to specify the index to be initiated with the Index
Initiate input function. The format of the Index Select functions (0 through 3) is binary. That
is, the first line, Index Select 0, has the value of 1, the second, Index Select 1, a value of 2,
the third, Index Select 2, a value of 4, the fourth, Index Select 3, a value of 8. The index
number selected is the sum of the values of the active index select functions. The table below
shows this concept.
61
Index
Select #0
(value = 1)
Index
Select #1
(value = 2)
Index
Select #2
(value = 4)
Index
Select #3
(value = 8)
Selected
Index
Off
Off
Off
Off
On
Off
Off
Off
Off
On
Off
Off
2
3
On
On
Off
Off
Off
Off
On
Off
On
Off
On
Off
Off
On
On
Off
6
7
On
On
On
Off
Off
Off
Off
On
On
Off
Off
On
Off
On
Off
On
10
On
On
Off
On
11
Off
Off
On
On
12
On
Off
On
On
13
Off
On
On
On
14
On
On
On
On
15
With all four Index Select lines assigned, but none of them active, Index number 0 will be
initiated when the Index Initiate input function goes activated. If you activate Index Select
lines 0 and 1, Index number 3 (1 + 2 = 3) will be initiated when the Index Initiate function
goes active. If you activate all four Index Select lines simultaneously, the selected Index
number is 15 (1 + 2 + 4 + 8 = 15).
Jog +
This input function causes the drive to jog in the positive direction. It cannot be set Active
Off. This input function will have no affect if the device is already performing a home or an
index, or if the stop input function is active or if the Travel Limit + Input function is active.
Jog This input function causes the drive to jog in the negative direction. It cannot be set Active
Off. This input function will have no affect if the device is already performing a home or an
index, or if the stop input function is active.
Jog Fast
This input function is used in conjunction with the Jog+ and Jog- functions to specify the
desired jog speed. When it is not active and Jog + or Jog - is activated, the drive will jog at
the velocity specified by the Jog Velocity parameter. When it is active and Jog + or Jog - is
activated, the drive will jog at the velocity specified by the Jog Fast Velocity parameter.
62
Operational Overview
Registration Sensor 1
This input function is usually used with an external hardware sensor. It is used as the
registration reference in a registration index. If the option button on the registration tab on the
Indexes Tab is set to Registration Sensor 1, then the registration offset portion of the index
will begin when this input function is activated. Two registration sensor input functions have
been provided for applications requiring multiple sensors.
Registration Sensor 2
This input function is usually used with an external hardware sensor. It is used as the
registration reference in a registration index. If the option button on the registration tab on the
Indexes Tab is set to Registration Sensor 2, then the registration offset portion of the index
will begin when this input function is activated. Two registration sensor input functions have
been provided for applications requiring multiple sensors.
Repeat Current Index
When the Repeat while Input Function active option button is selected on the Index tab, an
initiated index will continue to function until this input goes low.
Reset
This input function is used to reset fault conditions and is logically ORed with the Reset/
Setup button on the front of the drives. A rising edge is required to reset faults.
Run Next Index
This input function is used with index chaining. If the "When this index is complete then..."
setting is set to "Wait for Run Next Index input function", then the current index will stop and
wait until this input function is activated before starting the next index in the chain.
Stop
The Stop input function uses the Stop Deceleration Ramp to decelerate the motor to zero
velocity and hold position. If the Stop input function is activated when a Jog, Index or Home
is in progress, it will be terminated. When this function is active, all Jog, Index and Home
input functions will be ignored.
When it is deactivated, all level sensitive and active input functions (Jog +, Jog -, Jog Fast)
will become operational. For example, if the Jog + input function is active when the Stop
input function is deactivated, the Jog + motion will initiate using the Jog Acceleration
parameter.
The decimal point on the EN drive LED goes Off when the stop function is activated (or
the drive is disabled).
Torque Limit Enable
This input function, when active, causes the Torque Command to be limited to the value of
the Torque Limit parameter.
63
Output Functions
Absolute Position Valid
This output is activated when either the Define Home input function is activated or the End
of Home output function is activated. This output is deactivated if the drive is rebooted, an
encoder fault occurs, the device is powered down, or a home is reinitiated.
At Velocity
This output function is active whenever the motor is at the peak commanded velocity of a
home, jog or index. It activates when the acceleration ramp completes and deactivates when
the deceleration ramp begins.
Brake
The Brake output function must be used to control the motor holding brake. If the Brake
output function is off, the brake is mechanically engaged. When the brake is engaged, the
diagnostic display on the front of the drive will display a b.
Drive OK
This output function is active whenever no fault condition exists. Travel limits and the Drive
Enable have no effect on this output function.
End of Home
This output function is activated when a home cycle is completed successfully (Home Limit
distance not hit). When this output function is activated, the Absolute Position Valid output
function is activated. This output function is deactivated when any Index, Home or Jog is
initiated.
End of Chaining Count
This output function will activate when the index chain count is complete or the index chain
has repeated itself the specified number of times. This output function will remain active until
another chain is started.
End of Index
This output function is activated when any index is completed. This output function is
deactivated when any Home, Jog or Index is initiated.
64
Operational Overview
End of Index Motion
This output function will activate when the index motion stops (prior to dwell). It will remain
active until another index is initiated or the next index in the chain begins. If two indexes are
chained together without a dwell in between (dwell at default of 0 ms), then this output
function will be active for 400 s.
End of Index Count
This output function will activate when an index repeats itself the number of times specified
in the index count parameter. It will remain active until the next index is initiated. If "Repeat
Forever" is selected for the index count, this function will never activate.
Fault
This output function is active whenever a drive fault condition exists.
Foldback Active
This output function is active when the drive is limiting motor current. If the RMS Foldback
value exceeds 100 percent of the continuous rating, the current foldback circuit will limit the
current delivered to the motor to 80 percent of the continuous rating.
Home Limit Distance Hit
This output function indicates that no home reference was sensed during the move to the
Home Limit Distance.
In + and In - Motion
This output function is activated whenever the velocity is greater than the In Motion Velocity
parameter in the positive or negative direction. The default value for the In Motion Velocity
parameter is 10 RPM. Hysteresis is used to avoid a high frequency toggling of this output
function. This function is deactivated when the motor velocity slows to less than 1/2 of the In
Motion Velocity parameter.
Index in Position
At the end of an index this output is activated when the position feedback is within a specified
window of distance from the position command for a specific amount of time.
To implement this function the user must set up an "index in position" window and time
(found in the Position tab). After the index command is complete, the output will not become
active until the position feedback is within the "index in position" window for the amount of
time specified by "index in position" time.
Registration Limit Distance Hit
This output function will activate if a registration index travels the full limit distance without
seeing a registration sensor or torque level (depending on which was selected).
Shunt Active
This is a real time indicator of the internal shunt activity.
65
66
Setting Up Parameters
Setup Tab
The setup tab is displayed as the default each time you open a Configuration Window.
Figure 54:
Identification Group
Name
Enter a 24 character alpha/numeric name for the device you are currently setting up.
Assigning a unique name for each device in your system allows you to quickly identify a
device when downloading, editing and troubleshooting. All keyboard characters are valid.
67
Configuration Group
Drive Type
Select the drive model for the system you are currently setting up. PowerTools FM software
will only display the motor models that are compatible with the drive you selected and any
user defined motors.
Motor Type
Select the motor you wish to use. PowerTools FM software will only display the motor
models that are compatible with the drive you selected and any user defined motors unless
Show All Motors is selected.
Selecting the wrong motor type can cause poor performance and may even damage the
motor and/or drive.
Line Voltage
EN
E Series Only
Line Voltage specifies the applied power and adjusts the internal gains to compensate
for it. This parameter has two choices 115 Vac and 230 Vac. If the Line Voltage is set
to 230 Vac when the actual applied voltage is 115 Vac, the motor will be slightly less
responsive to commands and load disturbances.
The Line voltage must never be set to 115 Vac if the applied voltage is actually 230 Vac.
This can cause drive instability and failure.
68
Setting Up Parameters
Encoder Scaling
This feature allows you to change the drive encoder output resolution in increments of 1 line
per revolution up to the density of the encoder in the motor. If the Encoder Output Scaling
parameter is set to a value higher than the motor encoder density, the drive encoder output
density will equal that of the motor encoder. The default is to the motor encoder density.
Figure 55:
CW Rotation
69
Figure 56:
Units Name
Select the type of units to be used throughout the configuration for all Position/Distance
parameters. The default units are revs.
Units Scaling
This will specify the number of user units in 1.0000 motor revolution. This parameter also
determines the resolution of distance/position parameters for the entire configuration. The
number of decimal places specified here sets the maximum resolution.
For example, If the user has a leadscrew with a 0.5" lead and wishes to perform indexes of
0.025", the Units Scaling must be set to 0.500. By specifying three digits after the decimal
place, the user will be able to enter the three digits necessary for the index distance.
Velocity Units
This will specify the number of digits after the decimal place to be used in all Velocity
parameters.
70
Setting Up Parameters
Acceleration Units
This will specify the number of digits after the decimal place to be used in all Acceleration/
Deceleration parameters.
Time Scale
Select either minute or second as the time scale for the configuration. The default time scale
is minutes. If the selected time scale is seconds, then the velocity units will appear as user
units/sec. If the selected time scale is minutes, the velocity units will appear as
user units/minute.
If the selected time scale is seconds, then the accel/decel units will appear as user units/sec2.
If the selected time scale is minutes, the accel/decel units will appear as
msec/(1000 (user units)/min) or msec/(k (user units)/min). Therefore, for accel/decel units,
the default is msec/kRPM (the same as previous versions of the Ei drive and FM-2 module).
71
Inputs Tab
This tab is divided into two windows. The Input Functions window, on the left side,
displays the input functions available, the function polarity and the always active state. The
Input Lines window, on the right side, displays the twelve input lines, the debounce value
and input function assignments.
Figure 57:
Inputs Tab
Active State
The active state of each input function is displayed next to the output function. See the Active
Off parameter below.
Always Active
The setting for Always Active is displayed next to each input function. See Always Active
below.
72
Setting Up Parameters
of the line numbers to assign the function. This list box would normally be used when a mouse
is not available to navigate the software. Assigning the input functions can also be
accomplished by dragging the Input Function and dropping it onto an Input line.
73
Outputs Tab
This tab is divided into two windows. The Output Functions window, on the left side,
displays the available output functions. The Output Lines window, on the right side,
displays the seven output lines, the line Active State (On or Off) and the output function
assignments.
Figure 58:
Outputs Tab
Note
For wiring information, refer to the Installation section of the EN Drives Installation
Manual (P/N 400501-02), or the Epsilon Eb and EN Drives Reference Manual (P/N
400501-01).
74
Setting Up Parameters
Jog Tab
This tab allows you to enable and define jog velocity, acceleration and deceleration.
Figure 59:
Jog Tab
75
Jog Velocity
This parameter specifies the velocity used for jogging with the Jog + or Jog - input functions.
Acceleration
This parameter specifies the acceleration value to be used during the jog. The acceleration
units are defined by the Time Scale parameter on the User Units tab.
Deceleration
This parameter specifies the deceleration value to be used during the jog. The deceleration
units are defined by the Time Scale parameter on the User Units tab.
76
Setting Up Parameters
Home Tab
This tab allows you to enable and define the home function.
Figure 60:
Home Tab
77
Chaining Group
Chain to Index
When the check box is selected, the device will then start the index shown in the text box after
the home cycle is complete.
Velocity
This parameter specifies the velocity used for homing. Use a positive value to make the drive
home in the positive direction and a negative value to make the drive home in the negative
direction.
Acceleration
This parameter specifies the acceleration value to be used during the home. The acceleration
units are defined by the Time Scale parameter on the User Units tab.
Deceleration
This parameter specifies the deceleration value to be used during the home. The deceleration
units are defined by the Time Scale parameter on the User Units tab.
78
Setting Up Parameters
Limit Distance
This parameter places an upper limit on the distance the motor will travel during the home.
In situations where the reference position indicator (sensor or marker) is not seen, this
parameter limits the total distance the motor will move.
79
Indexes Tab
This tab allows you to enable, define or assign the various indexes.
Figure 61:
Indexes Tab
Index Number
The device supports up to 16 indexes (0 - 15). Enter the index number you want to modify or
assign.
Index Type
Absolute
Absolute indexes are used in applications where the motor must travel to a specific position,
regardless of where the motor is when the index is initiated.
Incremental
An incremental index will move the motor a specified distance in the + or - direction
regardless of the starting position. The direction of the incremental index motion is
determined by the sign (+ or -) of the Index Distance parameter.
80
Setting Up Parameters
Registration
A Registration Index runs at the specified velocity until a registration sensor or torque level
is seen or until it reaches the Registration Limit Distance. If a Registration Sensor is seen, then
the index runs an additional specified Registration Offset distance. If Registration Indexes are
compounded, then Index ends a either Limit Dist or End of Registration offset. It will then
start the next index at the ending velocity.
Rotary Plus and Rotary Minus
Rotary Plus and Rotary Minus type indexes are typically used in applications which use rotary
rollover. If Rotary Rollover is enabled on the User Units Tab, a Rotary Plus index will always
move in the positive direction and a Rotary Minus index will always move in the negative
direction. These indexes are forced to run in a specific direction regardless of the starting
point. If Rotary Rollover is not enabled, these indexes will function like Absolute indexes.
Distance/Position/Limit Distance
This parameter changes from Distance to Position depending on whether you have chosen
Absolute, Incremental or Registration as the Index Type. The maximum distance/position/
limit distance value supported is +/- 214,748.3648 user units.
Velocity
The Velocity parameter specifies the velocity used for the index. The velocity parameter is
unsigned and must be greater than zero.
Acceleration
The Acceleration parameter specifies the acceleration value to be used during the index. The
acceleration is specified in units of ms/(k(user unit)/min) or user units/sec2, depending on the
time base parameter from the User Units Tab.
Deceleration
The Deceleration parameter specifies the deceleration value to be used during the index. The
deceleration is specified in units of ms/(k(user unit)/min) or user units/sec2, depending on the
time base parameter from the User Units Tab.
Dwell Time
Time in ms between indexes. The dwell starts at the end of the commanded motion of the
index, and the output line End of Index is turned on at the end of the dwell time. Default is 0
ms. Upper limit is 65,535 seconds.
Index Count
This parameter specifies how many times in a row this index is to run before proceeding on
to the next index. If repeat forever is chosen, the index will repeat continuously until a stop
81
Registration Tab
The registration index parameters are set on this tab. The signal for the registration mark can
come from one of four sources: Registration Sensor 1, Registration Sensor 2, Torque Level
1, or Torque Level 2.
The Offset can either be Calculated by PowerTools FM or Specified by the user in user units.
If Calculated is selected, the motor will stop at the specified deceleration ramp. If Specified
is selected, the motor will come to a stop the specified offset distance away from the
registration mark. If the Specified offset is less than the Calculated offset, the motor will stop
at the programmed deceleration ramp and then back up to the specified distance from the
registration mark. The Specified offset is a signed parameter; if the index direction is
negative, the specified offset parameter should also be negative.
Calculations Tab
This displays various index calculations, such as index distance, index time, acceleration,
deceleration and at velocity results.
Start Position
When an Absolute Index is selected, the Start Position of the index can be set to provide
index calculations from a non-zero position. The Start Position is defaulted to zero. The
Start Position parameter is not available using an Incremental Index.
Chain Tab
Multiple indexes can be chained together so that they run sequentially. As each index is
configured, this tab allows for no chaining or end of the chain (stop), continue to the next
index (start next index), or wait for a Run Index Input signal and continue to next index (wait
for run ...). Which index is to be run next is specified in the Index Next text box. The default
chain setting is Stop.
82
Setting Up Parameters
Figure 62:
Compound Indexes
This chaining instruction is used to initiate an index which has no deceleration ramp. The
index accelerates up to speed and runs at speed until the specified distance is reached. The
program then moves on to the next index. It smoothly transitions into the second index
without stopping. The second index then ramps to its pre-configured velocity. Multiple
indexes can be compounded to create a complex velocity profile. The last index in a
complex profile must have a deceleration ramp.
Compound indexes are accomplished by selecting the Compound into option button
located on the Chaining tab under the corresponding index.
83
84
Figure 63:
Index 0
Figure 64:
Index 1
Figure 65:
Setting Up Parameters
Tuning Tab
All parameters on the Tuning tab are related to the load on the motor and application
requirements.
The load on the motor is specified by two parameters: Inertia Ratio and Friction. Typical
application requirements are specified by the response adjustment and Feedforward Gains.
Position Error Integral is provided to compensate for systems with high friction or vertical
loads. Low Pass Filter is provided to filter machine resonance that are present is some
applications.
Figure 66:
Tuning Tab
Load Group
Inertia Ratio
Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50.0. If the exact
inertia is unknown, a conservative approximate value should be used. If you enter an inertia
value higher than the actual inertia, the resultant motor response will tend to be more
oscillatory.
Friction
This parameter is characterized in terms of the rate of friction increase per 100 motor RPM.
If estimated, always use a conservative (less than or equal to actual) estimate. If the friction
85
Tuning Group
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hertz. In general,
it affects how quickly the drive will respond to commands, load disturbances and velocity
corrections. A good value to start with (the default) is 50 Hz. The maximum value
recommended is 80 Hz.
Time Constant
Position Error Integral is a control term which can be used to compensate for the continuous
torque required to hold a vertical load against gravity. It is also useful in applications which
have high friction.
It also helps maintain accurate command execution during steady state or low frequency
torque disturbances (typically less than 10 Hz) or when holding a non-counterbalanced
vertical load in position.
The adjustment parameter is Position Error Integral Time Constant which is available in the
Tuning Tabs of PowerTools FM. This parameter determines how quickly the drive will
attempt to eliminate the following error. The time constant is in milliseconds and defines how
long it will take to decrease the following error by 63%. (3 time constants will reduce the
following error by 96%). The range for this parameter is 5 to 500 milliseconds. In certain
circumstances the value actually used by the drive will be greater than the value specified in
PowerTools FM because the minimum allowed time constant value is a function of the
Response parameter. The formula is Min. Time Constant = 1000/Response. For example,
with Response set to 50, the minimum time constant value is 1000/50 = 20 msec. A higher
time constant value will minimize instability with more compliant loads such as long drive
shafts, or spring loads. A lower time constant setting will increase the response and will
stiffen the system.
86
Setting Up Parameters
Friction parameter is less than the actual friction, velocity error will be reduced but not
eliminated.
Position Tab
This tab allows you to enable and define the Following Error Limit and view feedback
parameters. Feedback values are only enabled if the device is on-line with your PC.
Figure 67:
87
Limits Group
Following Error Check Box
Select this check box to enable or clear the check box to disable the Following Error Limit.
Following Error
The Following Error is the difference between the Position Command and the Position
Feedback. It is positive when the Position Command is greater than the Position Feedback. If
the absolute value of the following error exceeds the value you enter here, the drive will
generate a Following Error Fault (F). All accumulated Following Error will be cleared when
the drive is disabled.
The Following Error Limit is specified in user units.
In Position Time
This is the amount of time in seconds that commanded motion must be complete and the
following error must be less than the In Position Window for the In Posn output to activate.
If set to zero (default), then InPosn will activate as soon as motion stops and the following
error is less than the In Position Window parameter.
In Position Window
The absolute value of the Following Error must be less than or equal to this value at the end
of an index in order for the Index InPosn Output to activate. This window is set in units
specified in the User Units Tab.
88
Setting Up Parameters
Actual Group
Position Command
This is the commanded position generated by the device. This is set to zero when the Absolute
Position Valid output function is activated. The Position Command is specified in user units.
Following Error
The Following Error is the difference between the Position Command and the Position
Feedback. It is positive when the Position Command is greater than the Position Feedback.
Following Error is specified in user units.
Encoder Position
The motor position in encoder counts since power up when the value was set to zero. This is
a signed 32 bit value. This is set to zero when the Absolute Position Valid output function is
activated.
Position Feedback
This is the feedback position of the motor. It is set to zero when the Absolute Position Valid
output function is activated. Position Feedback is specified in user units.
89
Velocity Tab
This tab allows you to set the drive limits, and if you are on-line, view the velocity feedback
parameters.
Figure 68:
Limits Group
Overspeed Velocity
This parameter specifies the maximum allowable speed. If the Velocity Feedback exceeds
either the drives internal overspeed fault limit or the value of the Overspeed Velocity, an
Overspeed Fault will be generated. The internal overspeed fault limit is equal to 150 percent
of the Motor Maximum Operating Speed.
Stop Deceleration
The value you enter here defines the rate of velocity change to zero speed when a Stop input
function is activated.
90
Setting Up Parameters
Trigger Group
In Motion Velocity
This parameter sets the activation point for both the In + Motion and In - Motion output
functions. The output function will deactivate when the motor velocity slows to half of this
value.
Actual Group
All parameters in this group are only available when on-line with the drive.
Analog Command
The drive is in Analog Velocity mode this parameter gives the current velocity commanded
due to the Analog input function.
Velocity Command
The Velocity Command is the actual command received by the velocity loop.
Velocity Feedback
This parameter is the actual feedback motor velocity.
91
Torque Tab
This tab allows you to edit the Torque Limit and view the torque parameters.
Figure 69:
Note
The Torque Limit value takes effect only when the Torque Limit Enable input function is
active.
These parameters are continuously updated while on-line with the drive.
Actual Group
Torque Command
This parameter returns the torque command value before it is limited. The torque command
may be limited by either the Torque Limit (if the Torque Limit Enable input function is
active) or Current Foldback.
Torque Limit
This value is the level which the Torque Command will be limited to when the Torque Limit
input function is active. To make the Torque Limit always active, set the Torque Limit Input
Function to be Always Active.
92
Setting Up Parameters
Foldback RMS
This parameter accurately models the thermal heating and cooling of the drive and motor.
When it reaches 100 percent, current foldback will be activated.
Analog Tab
This tab displays the setup and feedback data for the two Analog Outputs.
Figure 70:
93
Offset
Each analog diagnostic output channel includes a programmable Analog Output Offset. This
feature allows you to zoom in to a desired range effectively increasing the resolution. The
units of this parameter is dependent upon the Analog Output Source selection.
Scale
Each analog diagnostic output channel includes a programmable Analog Output Scale. This
feature allows you to zoom in to a desired range effectively increasing the resolution. The
units of this parameter is dependent upon the Analog Output Source selection.
Feedback
This is a display of the real time status of the two analog outputs in volts. It is only available
when you are on-line with a device.
94
Setting Up Parameters
Figure 71:
Inputs Group
Lines Window
This feature shows the various Input Lines and whether they are active. The line is active if
the circle next to the line is green or lit.
Active State
The active state is shown for each input line.
Forced
The forced state is shown for each input line
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
95
Expand/Collapse Button
This button expands or collapses the hierarchy of the Inputs window. An expanded view
shows the relationship between functions and lines. A collapsed view shows only lines or
functions.
Figure 72:
If the function or line is currently active, the LED to the left of the function or line name
will be green.
Note
When a function or line is active, the state of the LED associated with the function or line
is dependent on how the Always Active, Forced On or Off and Active Off controls
are used.
96
Setting Up Parameters
Outputs Group
Lines Window
This feature shows the various Output Lines and whether they are active. The line is active if
the circle next to the line is green or lit-up.
Active State
The active state is displayed for each output line.
Forced
The forced state is displayed for each output line.
Note
The forced state of input and output lines are not saved to NVM and will be lost when the
drive is powered down.
Expand/Collapse Button
This button expands or collapses the hierarchy of the Outputs window. An expanded view
shows the relationship between functions and lines. A collapsed view shows only lines or
functions (see figure 73).
97
Figure 73:
If the function or line is currently active, the LED to the left of the function or line name
will be green.
Note
When a function or line is active, the state of the LED associated with the function or line
is dependent on how the Always Active, Forced On or Off and Active Off controls
are used.
Status Tab
This tab displays the drive status in real time and is only available when you are on-line with
a drive. The information in this tab is divided into five categories: Position, Velocity, Torque,
Drive Status and Time.
98
Setting Up Parameters
Figure 74:
Note
The information in this tab is for diagnostics purposes only and cannot be changed from
within this tab.
Position Group
Position Command
This is the commanded position generated by the device. This is set to zero when the Absolute
Position Valid output function is activated.
Following Error
The Following Error is the difference between the Position Command and the Position
Feedback. It is positive when the Position Command is greater than the Position Feedback.
Encoder Position
The motor position in encoder counts since power up when the value was set to zero. This is
a signed 32 bit value. This is set to zero when the Absolute Position Valid output function is
activated.
Position Feedback
This is set to zero when the Absolute Position Valid output function is activated.
99
Velocity Group
Velocity Command
The Velocity Command is the actual command received by the velocity loop.
Velocity Feedback
This parameter is the actual feedback motor velocity in RPMs.
Torque Group
Torque Command
This parameter returns the torque command value before it is limited. The torque command
may be limited by either the Torque Limit (if the Torque Limit Enable input function is
active) or current foldback.
Actual Command
This is the sum of all torque commands applied in summation mode.
EN
E Series Only
This parameter models the thermal utilization of the heatsink by the power stage. It
determines the amount of thermal capacity available for the Regen Shunt Resistor. A
display of 10 percent heatsink capacity remaining for use by the shunt resistor. When this
value reaches 100 percent or higher, no capacity is left for the shunt resistor and a shunt
resistor and a shunt fault will occur as soon as the shunt is activated.
100
Setting Up Parameters
Segment Display
Character currently being displayed by the diagnostic display on the front of the drive.
Bus Voltage
Epsilon Only
Displays the actual measured voltage on the DC power bus.
Firmware Revision
Displays the revision of the firmware in the drive you are currently on-line with.
Serial Number
Displays the serial number of the drive with which you are currently on-line.
FM Serial Number
Displays the serial number of the FM-2 Module with which you are currently on-line. This
does not apply to Epsilon drives.
Time Group
Total Power Up Time
Total amount of times the drive has been powered up since leaving the factory.
Power Up Count
Number of times the drive has been powered up since leaving the factory.
Power Up Time
Amount of time the drive has been powered up since last power up.
View Active Faults Button
Pushing this button displays the Active Drive Faults dialog box. From this dialog box you can
reset any resettable active faults by clicking the Reset Faults button.
Figure 75:
101
History Tab
This tab displays a complete fault history of your device including a Fault Log window and
a Fault Count window.
Figure 76:
Note
The fault log and fault counts cannot be cleared.
102
Setting Up Parameters
Note
The fault log and fault counts cannot be cleared.
Advanced Tab
This tab is reserved for very infrequently used parameters that sometimes need to be adjusted
to solve tricky application problems. This tab is not normally visible and it is only rarely
necessary. If any parameter in this tab is not at default, then the tab will automatically be
enabled when starting PowerTools FM.
EN
E Series Only
Drive Ambient Temperature is a parameter which will let the drive know the air
temperature around the drive heat sink while the system is under normal operating
conditions. If the actual ambient temperature is higher than 40 C (104 F), setting the
Drive Ambient Temperature parameter to the actual temperature will help to protect the
drive by activating the Shunt Fault at an appropriate time.
Figure 77:
Epsilon Only
This parameters default setting is enabled. When enabled, the drive will detect a low DC
bus at 60 Vdc and will log a Low DC Bus Fault if a power down is not completed after
the low DC bus is detected. Clearing this check box will disable the Low DC Bus Voltage
103
Figure 78:
Graph Tab
The Graph tab is only available when on-line. The Graphing function in the drive makes use
of an internal high speed data capture. After this capture is Armed, the capture will begin
to fill a rolling buffer with the data as specified by Channel 1 - Channel 4. Once triggered, the
data capture will fill the rest of the allocated memory. After the buffers are completely filled
and the trigger activated, the Upload and Plot button may be used to upload data which will
be displayed in a graphical format.
The User may trigger by entering a trigger level for one of the four channels or using the
manual trigger button.
104
Setting Up Parameters
Figure 79:
Data Capture
The Data Capture group box includes initiate, stop, and graph commands for the graphical
monitor.
The Run command button commands the drive to begin a high speed data capture of the
parameters as selected in each of the four data channels. After the Run command button is
activated the buffer will fill up to the trigger offset while the words Filling Buffer appear
indicating this graph state. Once the trigger offset level is reached the words Waiting
Trigger will appear next to the Graph State indicating that graphical monitor is now ready to
be triggered based on the trigger level selected. The Run command button may be activated
by the letter R on the keyboard.
The Stop command button will stop the high speed data log after it has been initiated and
clear out the buffer that this data was previously stored in. The Stop command button may
be activated by the letter S on the keyboard.
The Upload/Plot command button will upload captured data from the drive and display this
data on a graph. The user should wait for the Graph State to read Triggered before the data
is uploaded
105
Timing
The Timing Group Box includes parameters which control the size, accuracy, and duration of
the capture and upload. These parameters may be changed using the slider bars but the drive
must be updated or downloaded to in order for these changes to take affect.
Sample Rate
The Sample rate slider gives the user control of time spacing for the captured data. To give
the user a better idea of what this number means, the total number of samples and total capture
time is displayed on the bottom of the Timing group box.
Trigger Offset
This slider corresponds to the number of samples that will be included on the graph display
and data capture prior to the actual trigger. If the Trigger offset slider is completely to the left
(min samples), the data capture and graphing will start at the trigger location. If the slider is
completely to the right (max samples) the graph will capture data until the trigger point.
Data
The Data Group Box is used to select which parameters will be graphed as well as which
parameter will be used as the data trigger. If a change is made to any parameters within the
Data Group Box, this change must be sent to the drive via a download or update
command in PowerTools FM.
Channel 1 - 4
Channel 1 through Channel 4 give the user options for parameter display. If parameters with
the same units are mapped on adjacent channels then the graphical display will show these
two parameters overlapped on the same x/y axis. If it is desirable to have two adjacent
Channels mapped to separate axis on the graph then the selection (none) should be used on
the channel in between these two parameters.
Trigger
Selecting the trigger option button to the right of the channel will cause the graphical capture
to trigger the capture off of that Channel. The Trigger Level text box on the bottom of the
display will change units to accommodate the selected channels user units. This trigger level
may be changed at any time but the change must be sent to the drive via the update or
download button. If a manual trigger is desired, set the channel to None and select the
106
Setting Up Parameters
corresponding trigger option button. If no trigger is selected the capture will begin when
Run is clicked and end at the end of the Sample Rate.
Figure 80:
Graphical Plot
107
108
Devices mounted to the enclosure mounting plate, which depend on their mounting
surfaces for grounding, must have the paint removed from their mounting surfaces and the
mating area on the mounting plate to ensure a good ground. See the, Achieving Low
Impedance Connections section for more information.
109
AC line filter input and output wires and cables should be shielded, and all shields must
be grounded to the enclosure.
A good rule to follow when specifying conductors for high frequency applications is to use a
metal strap with a length to width ratio that is less than 3:1.
110
AC Line Filters
The AC line filters used during Control Techniques compliance testing are listed below.
These filters are capable of supplying the drive input power to the specified drive under
maximum output power conditions.
Epsilon
Schaffner Part #
Rating
FN2070-10/06
960307-01
10 A, 240 V, 1
FS5278-16/08
960305-01
FS5278-16/08
960305-01
Ei-202, Ei-203
16 A, 240 V, 1
Ei-205
Alternately, Control Techniques has also seen good results with the following line filters:
Drive
Part #
Rating
Corcom 20EQ1
20 A, 240 V, 1
Ei-202
Schaffner FN 2070-6-06
6 A, 240 V, 1
It is critical that you keep the filter inputs routed away from any electrical noise sources
or shield them to prevent noise from being induced into them and carried out of the
enclosure.
EMC criteria can be met in installations where multiple drives are supplied through a
single filter, however, it is the installers responsibility to verify EMC compliance.
The filter characteristics of most three phase line filters will suffer if the phase to phase
loading is unbalanced.
111
Figure 81:
Shielded Cable
Grommet
Kit Part #
Conduit
Dimension Hole
Size
Motor Cable, 16 Ga
CMDS
CGS-050
1/2" pipe
7/8"
Motor Cable, 12 Ga
CMMS
CGS-050
1/2" pipe
7/8"
Feedback Cable
CFOS
CGS-050
1/2" pipe
7/8"
CMDF
CGS-050
1/2" pipe
7/8"
CMMF
CGS-075
3/4" pipe
1 1/16"
Cable Type
112
CFCF, CFOF
CGS-063
3/4" pipe
1 1/16"
ENCO
CGS-038
1/2" pipe
7/8"
user supplied
user supplied
Inside Enclosure
Outside Enclosure
O-Ring seals against outside of enclosure
to meet IP68 (comparable to NEMA 6)
Spring Contacts
Cable Shielding
Cable Jacket
Cable Type
Motor Cable, 16 Ga
Cable Model
CMDS
CGS-047
CMMS
CGS-069
1.125 or 1 1/8"
4X12SS
CGS-069
1.125 or 1 1/8"
CMLS
CGS-098
1.5 or 1 1/2"
CFOS
CGS-047
0.8125 or 13/16"
MGFS
CGS-047
0.8125 or 13/16"
CMDF
CGS-047
0.8125 or 13/16"
4X16SF
CGS-047
0.8125 or 13/16"
CMMF
CGS-069
1.125 or 1 1/8"
4X12SF
CGS-069
1.125 or 1 1/8"
CFCF
CGS-069
1.125 or 1 1/8"
Motor Cable, 12 Ga
Motor Cable, 8 Ga
Feedback Cable
External Encoder
CFOF
CGS-069
1.125 or 1 1/8"
MGFF
CGS-069
1.125 or 1 1/8"
ENCO
CGS-047
0.8125 or 13/16"
113
Figure 82:
Environmental Considerations
If the installation environment contains atmospheric contaminants such as moisture, oils,
conductive dust, chemical contaminants and metallic particles, you must protect the drive
from these by mounting it in a protective enclosure typically rated NEMA 12.
If the ambient temperature inside the enclosure will exceed 40 C (104 F), you may require
forced air cooling depending on the RMS loading.
Note
It is necessary to maintain the drive surround air ambient temperature at 40 C (104 F)
[50 C (122 F) with derating of 3% per degree above 40 C(104 F)] or below to maintain
the drive UL ratings.
The amount of cooling depends on the size of the enclosure, the thermal transfer of the
enclosure to the ambient air and the amount of power being dissipated inside the enclosure.
Consult your enclosure manufacturer for assistance with determining cooling requirements.
114
Wiring Notes
To avoid problems associated with EMI (electromagnetic interference), you should route
high power lines (AC input power and motor power) away from low power lines (encoder
feedback, serial communications, etc.).
If a neutral wire (not the same as Earth Ground) is supplied from the building distribution
panel, it should never be bonded with PE wire in the enclosure.
You should consider future troubleshooting and repair when installing all wiring. All
wiring should be either color coded and/or tagged with industrial wire tabs.
As a general rule, the minimum cable bend radius is ten times the cable outer diameter.
All wiring and cables, stationary and moving, must be protected from abrasion.
Ensure that full metal to metal surface contact is made between the enclosure ground lug
and the metal enclosure, not simply through the mounting bolt and threads.
All inductive coils must be suppressed with appropriate devices, such as diodes or
resistor/capacitor (RC) networks.
Mechanical Installation
Drive Mounting
Drives must be back mounted vertically on a metal surface such as a NEMA enclosure. A
minimum spacing of two inches must be maintained above and below the drive and one-half
inch from the heatsink for ventilation. Additional space may be necessary for wiring and
cable connections.
For drive dimensions, weights and mounting specifications, see the Specifications section.
Motor Mounting
Motors should be mounted firmly to a metal mounting surface to ensure maximum heat
transfer for maximum power output and to provide a good ground.
For motor dimensions, weights and mounting specifications, see the Specifications section.
115
Electrical Installation
Eb-203
1
2
3
4
5
6
7
8
C
9
10
11
12
13
14
15
16
C
AXIMA 4000
J1
EN-214
L1
L2
Status
PE
RESET
BU S
Com 2
Com 1
Inputs
MOTOR
SERIAL
A.P.S.
J2
Axis 3
S
T
Axis 4
Axis 1
Axis 2
Axis 3
+
24 V
-
Axis 4
J3
+ Enable
- Drives
Axis 1
Outputs
1
2
3
4
5
6
7
8
9
10
11
12
I/O
Watchdog
Output
Axis 2
J 5
J 6
Encoder 1
Output
Figure 83:
116
The Protective Earth (PE) wire connection is mandatory for human safety and proper
operation. This connection must not be fused or interrupted by any means. Failure to
follow proper PE wiring can cause death or serious injury.
Epsilon Only
The Ei-202, Ei-203 and Ei-205 drives require 90 to 264 Vac single phase power. An
Epsilon drive can be connected to any pair of power phases on a 1 or 3 power source
that is grounded as shown in the following diagrams.
The input power range of the Epsilon drives can be extended to 42 to 264 Vac with the
Low DC Bus fault disabled.
Note
The maximum voltage applied to the drive terminals must not exceed 264 Vac phase to
phase and phase to PE ground. This can be accomplished by referencing the AC supply
to earth ground.
117
Figure 84:
Figure 85:
118
Figure 86:
Figure 87:
Figure 88:
119
Figure 89:
Transformer Sizing
If your application requires a transformer, use the following table for sizing the KVA rating.
The values in the table are based on worst case power usage and can be considered a
conservative recommendation. You can down-size the values only if the peak power usage is
less than the transformer continuous power rating. Other factors that may influence the
required KVA rating are high transformer ambient temperatures [>40 C (>104 F)] and drive
operation near the maximum speeds.
Drive/Motor Combination
Ei-202 or Ei-203/NT-207
1.0
Ei-202/NT-212
1.2
Ei-203/NT-212
1.7
Ei-203/MG-316
1.7
Ei-205/NT-212
1.7
Ei-205/MG-316
2.3
Ei-205/MG-340
3.0
At speeds near the maximum operating speed, transformer output voltage drop may become
a critical issue for proper operation. Typically, higher KVA transformers have lower voltage
drop due to lower impedance.
120
Drive Model
Recommended Minimum
AC/PE Line Wire Gauge
Ei-202
6 LPN Amp
16 AWG
Ei-203
8 LPN Amp
16 AWG
Ei-205
12 LPN Amp
16 AWG
The Protective Earth (PE) wire connection is mandatory for human safety and proper
operation. This connection must not be fused or interrupted by any means. Failure to
follow proper PE wiring can cause death or serious injury.
Drive Model
Input Voltage
(Vac)
Frequency
(Hz)
Input Current
(A RMS) at Full Drive Output
Current
Ei-202
240 / 1
47 - 63
4.3
140 (2 ms)
20 (2 ms)
Ei-203
240 / 1
47 - 63
6.5
140 (2 ms)
20 (2 ms)
Ei-205
240 / 1
47 - 63
10.8
140 (5 ms)
30 (2 ms)
This inrush current specification assumes the drive has been powered off for at least eight
minutes at 40 C (104 F) ambient or five minutes at 25 C (77 F) ambient. If this amount of
time has not elapsed since power off, the inrush current will be higher.
121
Front View
Ei-202
J1
L1
L2
RESET
BUS
PE
MOTOR
SERIAL
A.P.S.
J2
S
T
I/O
J3
J5
J6
Figure 90:
122
Current
Inrush Current
18-30 Vdc
0.5 A maximum
0.7 A peak
(0.4 A maximum
0.6 A peak if external
encoder is not used)
Using the APS supply input to power the drive logic and motor encoder allows the drive bus
to operate at DC voltages below 42 Vac (60 Vdc bus). The drive will operate down to 12 Vdc
on the bus (10 Vac on L1 and L2). However the low DC bus monitoring must be disabled to
prevent faults at these low DC bus voltage levels. This can be done with PowerTools FM
software on the Advanced tab in Detailed Setup mode.
Do not wire AC line into the APS input. Doing so will damage the drive.
Do not open the APS jumper access panel until at least six minutes after the main AC
power has been removed from the L1 and L2 terminals.
Note
Connecting 24V common on the APS to chassis ground reduces offset voltage in Analog
Diagnostic Outputs.
123
Side View
Front View
Ei-202
J1
L1
L2
RESET
BUS
PE
MOTOR
SERIAL
A.P.S.
J2
S
T
I/O
J3
J5
J6
Figure 91:
Single point PE
ground
(recommended)
Enabling APS power is done by sliding open the access panel on the side of the drive. Then
move the jumper into the APS position using needle nose pliers as shown in the figure above.
Use static control procedures when handling the jumper inside the drive case.
The APS input is isolated from all other circuits on the Epsilon drive including the DC bus,
logic and I/O. This permits you to use one common 24 Vdc power supply for multiple drives
without concern for ground loops and noise coupling between drives. The APS connection
will generate some high frequency ripple (.25 A at 80 Mhz) on the APS power lines. This may
disturb sensitive equipment that shares the same power supply.
124
Do not open the APS jumper access panel until at least six minutes after the main AC
power has been removed from the L1 and L2 terminals.
Note
Connecting 24 V common on the APS to chassis ground reduces offset voltage in Analog
Diagnostic Outputs.
Front View
Front View
Ei-202
Ei-202
J1
J1
L1
L2
PE
BUS
L2
PE
RESET
RESET
BUS
L1
MOTOR
J2
S
T
J3
I/O
I/O
J3
A.P.S.
SERIAL
A.P.S.
J2
SERIAL
MOTOR
J5
J5
J6
Figure 92:
J6
125
Front View
Ei-202
J1
L1
Motor Power
Connection
L2
RESET
BUS
PE
MOTOR
SERIAL
A.P.S.
J2
Brown
Red
Blue
Green/Yellow
Shield
I/O
J3
J5
J6
Important: PE ground
should connect to drive
and motor only. Nothing
should be connected
between these devices.
R
S
T
Ground
Connector Shell
Figure 93:
Note
The motor ground wire and shields must be run all the way back to the amplifier terminal
and must not be connected to any other conductor, shield or ground.
126
Figure 94:
127
Bottom View
Output #3
17
16
34
33
32
31
Drive Enable
I/O Supply
I/O Supply
I/O Common
I/O Common
J5
Single point
PE ground.
Figure 95:
A2
A1
Customer
supplied drive
enable contact
C
B
A
K1
14
1 Amp
Fuse
11
Relay:
EMC #BRM-1
Red +
- +
J1
L1
L2
BUS
RESET
MOTOR
A.P.S.
SERIAL
S
T
I/O
J3
J6
Figure 96:
128
Connected to
grounded
mounting panel.
PE
J5
Motor
24 VDC
Ei-202
J2
Internal
to Motor
2 Amp
Fuse
Ei-202
J1
L1
L2
RESET
BUS
PE
MOTOR
SERIAL
A.P.S.
J2
S
T
I/O
J3
J5
J6
Figure 97:
The I/O connector is a 26-pin male connector on the front of the drive. Control Techniques
offers a low profile interface plug and cable (EIO-xxx) for connections.
129
Figure 98:
Note
If loads are applied to the same output signal on both Command Connector and I/O
Connector, the sum total current loading must be limited to 150 mA per output signal.
130
Color Code
RED/BRN
BRN/RED
BLK/BLU
BLU/BLK
WHT/ORG
ORG/WHT
PUR/BLU
BLU/PUR
RED/BLU
BLU/RED
BLK/GRN
GRN/BLK
BLK/BRN
BRN/BLK
PUR/ORG
ORG/PUR
BLK/RED
RED/BLK
PUR/GRN
GRN/PUR
YEL/BLU
BLU/YEL
YEL/BRN
BRN/YEL
PUR/BRN
BRN/PUR
PUR/GRY
GRY/PUR
WHT/BLU
BLU/WHT
WHT/RED
RED/WHT
WHT/GRN
GRN/WHT
YEL/GRY
GRY/YEL
Drain Wires
Figure 99:
Input I/O 1
Input I/O 2
Input I/O 3
Input I/O 4
RS-485+
21
RS-485-
11
12
16
17
Output I/O 3
18
Output I/O 2
19
Output I/O 1
23
24
25
39
27
41
34 24 V I/O
32 O V I/O
33 24 V I/O
31 O V I/O
37
38
40
26
131
Function
Pin Numbers
Electrical Characteristics
1, 2, 3, 4, 16
Outputs
17, 18, 19
I/O Supply
33, 34
10 - 30 Vdc @ 1 A maximum
I/O Common
31, 32
I/O return
11
Encoder Common 0 V
12
Encoder Out
Diagnostic Output
43, 44
29
RS 485
6, 21
+15 out
28
Command Cables
The CMDO, CMDX and CDRO cables are all command cables that plug into the Command
Connector.
The CMDO and CMDX cables both use the same straight connector style, same color code
and carry the full complement of signals available from the Command Connector. The
difference is the CMDO cable has a male connector on one end with open wires on the other
while the CMDX cable has male connectors on both ends.
For information about CMDO-XXX and CMDX-XXX (18 pair cable) cable wire colors, see
the Specifications section.
Note
Some CMDO and CMDX cables may have White/Yellow and Yellow/White wires in
place of the White/Orange and Orange/White shown in the figure above (pins 6 and 21).
The CMDX cable has the identical signal pinout and wire colors, but has a 44-pin connector
on each end.
The CDRO cable includes only the most commonly used signals to reduce the cable outer
dimension and has a connector at only one end. The 45 degree connector design used on the
CDRO cable also reduces the spacing requirement below the drive.
For information about the CDRO-XXX (13 pair cable) cable wire colors the Specifications
section.
132
Note
Encoder outputs meet RS-422 driver specifications and can drive up to 10 RS-422 signal
receivers. The default encoder output resolution is 2048 lines per motor revolution. This
resolution is adjustable in one line per revolution increments with PowerTools FM
software. The range is between 200 and the actual motor encoder density.
Note: If the external controller does not have an internal terminating
resistor R1, R2, and R3 must be mounted within 6 inches of J5. A 120
Ohm resistor is recommended to high frequency encoders (over 250
kHZ) or cables longer than 25 feet. If encoder signals are multi-dropped,
termination resistors are required only at the last drop point. Do not
terminate at more than one point.
External
Controller
Encoder
Input
Figure 100:
Figure 101:
133
Serial Communications
Serial communications with the drive is provided through the female DB-9 connector located
on the front of the drive. The serial interface is either three wire non-isolated RS-232C or two
wire non-isolated RS-485. RS-485 is also available through the 44-pin Command Connector.
Figure 102:
When connecting the serial port of your PC to the serial port of the drive, verify that your
PCs ground is the same as the drive PE ground. Failure to do so can result in damage to
your PC and/or your drive.
134
Note
Communication errors can usually be avoided by powering the computer or host device
off of a convenience outlet that is mounted in the enclosure and whose neutral and ground
are wired to the same single ended point ground that the drives and controllers are using.
This is sometimes beneficial even with battery powered computers.
Noise pick-up on an unused RS-232 input at J4 pin 2 can in extreme cases interfere with RS485 communications. When using RS-485 communications it may be necessary to connect J4
pin 2 to J4 pin 5 to avoid communication errors.
Do Not use a standard 9 pin RS-232 serial cable or null modem cable at J4. Use a TIA or
equivalent that connects only pins 2, 3, 5 and the shield at the backshell or pin 1.
MODBUS Communications
The drives serial communication protocol is Modbus RTU slave with a 32 bit data extension.
The Modbus protocol is available on most operator interface panels and PLCs.
Serial Communications Specifications
Max baud rate
19.2k
Start bit
Stop bit
Parity
none
Data
Control Techniques Motion Interface panels are supplied with a Modbus master
communications driver.
135
Multi-Drop Communications
The RS-485 option (pins 4 and 9) is provided for multi-drop configurations of up to 32 drives.
Control Techniques provides a special multi-drop serial cable which allows you to easily
connect two or more drives.
Ei-202
L1
BUS
L2
PE
RESET
L2
PE
BUS
L2
PE
RESET
SERIAL
A.P.S.
MOTOR
J2
S
J2
A.P.S.
MOTOR
+
R
SERIAL
BUS
RESET
MOTOR
SERIAL
A.P.S.
J2
J1
J1
L1
TERM-H
Ei-202
Ei-202
J1
L1
S
T
TERM-T
J3
136
J6
DDS-XXX
Serial Cables
Note:
The terminating resistor packs, TERM-H
and TERM-T, should be installed on the
first (TERM-H) and last (TERM-T) drive in
the string if the total cable length is over
50 feet.
Figure 103:
I/O
I/O
I/O
J5
TIA-XXX
Serial Cable
J3
J3
J5
J6
J5
J6
TIA Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RX (232)
TX (232)
Ground
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
1
2
3
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
0V
+5
576
Ohm
485 +
120
Ohm
485 -
120
Ohm
Computer
Computer Serial
Port
576
Ohm
TERM-H
TERM-T
TIA Cable
DDS Cable
DDS Cable
Figure 104:
137
138
Do not attach or detach the FM-2 Module when power is applied to the drive.
Continue pressing the FM
against the drive until the
latch clicks into the slot
on the top of the drive.
Grip the FM
firmly on
each side.
Figure 105:
139
Grip the FM 1
on each side
of the LCD.
Figure 106:
Electrical Installation
Input/Output Wiring
The FM-2 Module is equipped with eight optically isolated input lines and four optically
isolated output lines. They are designed to operate from a +10 to 30 Vdc source. All inputs
and outputs are configured as sourcing. You are responsible for choosing a load that will limit
each output current to less than 200 mA.
The input lines, output lines and I/O power connectors are on removable terminal blocks. 18
to 24 AWG stranded wire is recommended.
A single power supply can be used to power the I/O on both the EN drive and the FM-2
Module, however, it must be wired to both the drive and the FM-2 Module because I/O power
is not passed through the connector on the back of the FM-2 Module. Alternatively, separate
power supplies can be used to power the I/O on the drive and the FM-2 Module, as long as
they share a common ground.
140
FM-2
2.8k
Figure 107:
141
Note
Some CMDO cables may have White/Yellow and Yellow/White wires in place of the
White/Orange and Orange/White shown in the figure above (pins 6 and 21).
Function
Inputs and Drive Enable
Pin Numbers
1, 2, 3, 4, 16
Electrical Characteristics
10-30 Volts (On) 0-3 Volts (Off) optically isolated
Outputs
17, 18, 19
I/O Supply
33, 34
I/O Common
31, 32
I/O return
Pulse Inputs
Differential
20, 36
Single-ended
25, 26, 27,
39, 40, 41
Encoder Supply
11
Encoder Common
12
Encoder Out
Analog In
14, 15
Diagnostic Output
43, 44
29
RS 485
6, 21
+15 out
28
Command Cables
The CMDO, CMDX and CDRO cables are all command cables that plug into the J5 command
connector. See the Specifications chapter for cable drawings and diagrams.
The CMDO and CMDX cables both use the same straight connector style, same color code
and carry the full complement of signals available from the J5 connector. The difference is
the CMDO cable has a male connector on one end with open wires on the other while the
CMDX cable has male connectors on both ends.
The CDRO cable includes only the most commonly used signals to reduce the cable O.D. and
has a connector at only one end. The 45 degree connector design used on the CDRO cable
reduces the enclosure depth requirement from 12 inches to 10 inches.
142
Serial Communications
Serial communications with the EN drive and the FM-2 Module is provided through the
female DB-9 connector (J4) located on the front of the drive. The serial interface is either
three wire non-isolated RS-232C or two wire non-isolated RS-485. RS-485 is also available
through the 44 pin command connector (J5).
Figure 108:
When connecting the serial port of your PC to the serial port of the drive, verify that your
PCs ground is the same as the drive PE ground. Failure to do so can result in damage to
your PC and/or your drive.
Note
Communication errors can usually be avoided by powering the computer or host device
off of a convenience outlet that is mounted in the enclosure and whose neutral and ground
are wired to the same single ended point ground that the drives and controllers are using.
This is sometimes beneficial even with battery powered computers.
143
MODBUS Communications
The drives serial communication protocol is Modbus RTU slave with a 32 bit data extension.
The Modbus protocol is available on most operator interface panels and PLCs.
Serial Communications Specifications
Max baud rate
19.2k
Start bit
Stop bit
Parity
none
Data
Control Techniques Motion Interface panels are supplied with a Modbus master
communications driver.
Multi-Drop Communications
The RS-485 option (pins 4 and 9) is provided for multi-drop configurations of up to 32 drives.
Control Techniques provides a special multi-drop serial cable which allows you to easily
connect two or more drives.
EN-214
Figure 109:
144
EN-214
EN-214
TIA Cable
DDS Cable
DDS Cable
TERM-T
TERM-H
RX (232)
TX (232)
Ground
1
2
3
4
5
6
1
2
1
2
1
2
1
2
3
4
5
6
3
4
5
6
3
4
5
6
3
4
5
6
1
2
3
4
5
6
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
7
8
9
Drive
Serial Port
Drive
Serial Port
Drive
Serial Port
0V
+5
576
Ohm
485 +
120
Ohm
485 -
120
Ohm
Computer
Computer Serial
Port
TERM-H
TIA Cable
576
Ohm
TERM-T
DDS Cable
DDS Cable
Figure 110:
145
146
Quick Start
Off-line Setup
Note
Generally, on-line setup is used when editing parameters in a device. Off-line setup
editing is usually only done when not connected to a device.
Figure 111:
When the New dialog box appears, select the drive setup selection and press the OK button.
A new Configuration Window will be displayed.
Figure 112:
147
Figure 113:
Setup Tab
Enter an identifying name for the drive you are setting up. You can use up to 24 alphanumeric characters.
2.
Enter the Target Drive Address(es) to which you wish to download the setup
information. Unless you have changed the Modbus address of your device, leave this
parameter set to the default value of 1.
You may use commas (,) or spaces ( ) to separate individual drive addresses or you may
use hyphens (-) to include all the drive addresses within a range. For example, if you
wanted to download to devices 1, 3, 4, 5, 6, 7 and 9 you could enter the addresses like this:
1,3-7,9.
148
Click the down arrow of the Drive Type list box, then select the drive model for the
drive you are currently setting up.
Quick Start
2.
Click the down arrow of the Motor Type list box, then select the motor connected to
the drive you are setting up. PowerTools FM will only display the motor models that are
compatible with the Drive Type you selected.
3.
Click the down arrow of the Line Voltage list box and select the voltage (115 or 230)
that will be powering the drive (EN drive only).
Note
CW and CCW rotation is determined by viewing the motor from the shaft end.
Figure 114:
Note
You cannot assign functions or Debounce the Drive Enable input line.
149
Figure 115:
Inputs Tab
Assign an input by highlighting an input function in the Input Functions window and
select the desired input option button or drag the highlighted input function to the desired
input in the Input Lines window.
2.
To unassign an input function from an input line, select the desired input function from
the Input Functions window, then select the Unassigned option button or drag the
highlighted input assignment back to the Input Functions window.
2.
Click the Active Off check box. The Active State column in the Input Functions
window will automatically update to the current setup.
150
1.
2.
Click the Always Active check box. The Active State column in the Input Functions
window will automatically update to the current setup.
Quick Start
Figure 116:
Outputs Tab
2.
To unassign an output function from an output line, select the desired output function
from the Output Functions window, then select the Unassigned option button or drag
the highlighted output assignment back to the Output Functions window.
2.
Click the Active Off check box. The Active State column in the Output Functions
window will automatically update to the current setup.
151
Figure 117:
Before initiating jogging motion, enter the jog related parameters as described below.
1.
The Jog Velocity parameter specifies the velocity used for jogging when the Jog Fast
input function is not active.
2.
The Jog Fast Velocity parameter specifies the velocity used for jogging when the Jog
Fast input function is active.
3.
The Acceleration parameter specifies the acceleration value to be used during jogging.
4.
The Deceleration parameter specifies the deceleration value to be used during jogging.
152
Quick Start
Figure 118:
1.
The Home Reference parameter determines how the home reference position is
established. The parameter can have one of three different values: Sensor, Marker,
Sensor and Marker.
When the Home Reference is Sensor the going active edge of the Home Sensor
input function is used to establish the reference position.
When the Home Reference is Marker the rising edge of the motor encoders marker
channel is used to establish the reference position.
When the Home Reference is Sensor and Marker the reference position is
established using the first marker rising edge after the Home Sensor input function
goes active.
2.
The Velocity parameter specifies the velocity used for homing. Use a positive value to
search for home in the positive direction and a negative value to search for home in the
negative direction.
3.
The Acceleration parameter specifies the acceleration value to be used during the home.
4.
The Deceleration parameter specifies the deceleration value to be used during the home.
5.
The Home Offset parameter designates the location of the home position in the machine
coordinate system relative to the home reference. During the homing routine, after the
home reference is detected, the device moves the motor to the home offset position. This
153
After the motor reaches the home offset position, the End of Home Position value is put
into the command and feedback positions.
7.
The Home Limit Distance check box enables the Home Limit Distance parameter. If this
flag is not set, there is no limit to the distance the drive will travel during the home
routine.
8.
The Home Limit Distance parameter places an upper limit on the distance the motor will
travel during the home. In situations where the reference position indicator (sensor or
marker) is not seen, this parameter limits the total distance the motor will move.
9.
Select either the Back off before homing or Go forward to next sensor option button in
the If On Sensor ... group. This determines the operation of the system if the Home
Sensor input function is On when the home is initiated.
Figure 119:
154
1.
2.
Select the index type. Absolute indexes travel to specific absolute positions. Incremental
indexes move the axis a specific distance from its current position.
Quick Start
3.
The Distance/Position parameter specifies the distance the index will travel (incremental
index) or the absolute position the index will move to (absolute index).
4.
The Velocity parameter specifies the velocity used for the index. The velocity parameter
can not be negative.
5.
The Acceleration parameter specifies the acceleration value to be used during the index.
6.
The Deceleration parameter specifies the deceleration value to be used during the index.
On-line Setup
These steps assume you have already created a configuration file. If you have already
downloaded the configuration file, go to Step 3. If you have not yet created the configuration
file, go to Off-line Setup Step 1. Do Steps 1 through 7 in the previous section, Off-line
Setup, before establishing communications.
Note
Generally, on-line setup is used when editing parameters in a device. Off-line setup
editing is usually only done when not connected to a device.
2.
3.
Select the Configure Serial Port option on the Modbus Setup screen. The
Communications Setup dialog box below will be displayed.
Figure 120:
155
Select the Com port you will be using on your PC and baud rate.
5.
Click the OK button on the Communications Setup Dialog box and on the Modbus Setup
screens.
Note
The default baud rate for all drives is 19200.
Note
To download to more than one device, all drive models and motor models must be the
same and any FM modules attached to the EN drives must all be of the same model and
firmware revision.
Click the Download button at the bottom of the Configuration Window (or click the
Download icon in the toolbar).
PowerTools FM will establish communications and transfer all the information in the current
Configuration Window to the device(s) you select in the Download window.
Note
Downloading will automatically clear an Invalid Configuration fault (U fault).
156
Quick Start
Figure 121:
Figure 122:
From this dialog box select the device(s) you wish to upload into a Configuration Window.
You can only select non-grayed items. The list box is updated at regular intervals. Please
allow time when connecting and disconnecting devices to the system. Click the OK button to
begin the upload.
157
Figure 123:
Control Panel
I/O powered.
2.
Connections installed.
3.
4.
5.
Jog the axis with the Control Panel or Jog +/Jog - input functions.
6.
Initiate a Home.
7.
Initiate an Index.
158
Quick Start
159
160
Tuning Procedures
The drive uses closed loop controllers to control the position and velocity Travel Limit of the
attached motor. These position and velocity controllers and the associated tuning parameters
are in effect when the drive is in velocity or pulse mode and have no effect when the drive is
in Torque mode.
Many closed loop controllers require tuning using individual user-specified proportional,
integral and derivative (PID) gains which require skilled tweaking to optimize. The
combination of these gains along with the drive gain, motor gain, and motor inertia, define
the system bandwidth. The overall system bandwidth is usually unknown at the end of the
tweaking process. The drive closes the control loops for the user using a state-space pole
placement technique. Using this method, the drives position control can be simply and
accurately tuned. The overall systems bandwidth can be defined by a single user-specified
value (Response).
The drives default settings are designed to work in applications with up to a 10:1 load to
motor inertia mismatch. Most applications can operate with this default setting.
Some applications may have performance requirements which are not attainable with the
factory settings. For these applications a set of measurable parameters can be specified which
will set up the internal control functions to optimize the drive performance. The parameters
include Inertia Ratio, Friction, Response and Line Voltage. All the values needed for
optimization are real world values that can be determined by calculation or some method
of dynamic measurement.
161
Tuning Procedure
Once the initial setup has been completed, you can run the system to determine if the level of
tuning is adequate for the application. A drive can be tuned basically to four levels.
No Tuning
Basic Level
Intermediate Level
Each level is slightly more involved than the previous one requiring you to enter more
information. If your system needs optimization, we recommend that you start with the Basic
Level, then determine if further tuning is needed based on axis performance.
The setup procedures explained here assume that you are using PowerTools FM software or
an FM-P.
Initial Settings
Set the drive tuning parameters as follows:
Inertia Ratio = 0
Friction = 0
Response = 50
Feedforwards = Disabled
Tuning steps
If your Inertia Ratio is greater than 10 times the motor inertia, go directly to the Intermediate
Level tuning.
No Tuning
No tuning will be required in most applications where the load inertia is 10 times the motor
inertia or less.
Basic Level
Adjust Response to obtain the best performance.
Intermediate Level
162
1.
2.
Tuning Procedures
3.
Enter the inertia value calculated into the Inertia Ratio parameter.
4.
Set the Line Voltage to the applied voltage (default is 230 Vac).
5.
6.
7.
2.
3.
4.
5.
6.
The inertia of the system up to the motor shaft should be calculated using CT-Size software
or some other inertia calculating software. Under perfect mechanical conditions, entering this
number into the Inertia parameter will produce a well-matched system tuning. Because
most systems include mechanics that are less than ideal, a number less than the inertia
parameter will need to be used to avoid bandwidth issues or buzzing of the motor.
163
Figure 124:
Figure 125:
2.
The Response is normally the next adjustment when tuning. For best performance the
Response should be lower with a higher inertia mismatch (>10:1) and higher with a lower
inertia mismatch.
This is because most higher inertia systems have torsional compliance in the frequency range
of interest. Torsional compliance is specially noticed in a jaw type coupling with a rubber
164
Tuning Procedures
spider, or if there is a long drive shaft, the Response should be decreased. The highest
recommended Response with High Performance Gains enabled is 100 Hz.
The next step in tuning the system to its optimal level is to move the response of the system
up to the point of the desired system rigidity. A standard way of accomplishing this is to
slowly increase the response of the system until the system becomes unstable (an audible
noise will emit from the motor in the form of a buzz or hum). To verify stability at varying
loads, this process should be completed with the smallest load on the motor shaft. Once a state
of instability is reached back the response off by 20% to insure stable operation for years to
come.
Figure 126:
3.
The difference in motion when this parameter is disabled and enabled can be observed in the
following graphs. The first graph shows motion with the position error integral turned off.
The second graph shows motion with the position error integral enabled and the time constant
set for 20ms. Note the settling time difference of the two indexes.
165
Figure 127:
PEI = off
Figure 128:
PEI = on
Feedforwards gain can be enabled if the performance requirements are very demanding.
However, when using them make sure the Inertia Ratio and Friction values are an accurate
representation of the load. Otherwise, the system performance can actually be degraded or
stability will suffer. Enabling Feedforwards makes the system less tolerant of inertia or
friction variations during operation.
Tuning Parameters
Inertia Ratio
Inertia Ratio specifies the load to motor inertia ratio and has a range of 0.0 to 50.0. A value
of 1.0 specifies that load inertia equals the motor inertia (1:1 load to motor inertia). The drives
166
Tuning Procedures
can control up to a 10:1 inertia mismatch with the default Inertia Ratio value of 0.0. Inertial
mismatches of over 50:1 are possible if response is reduced.
The Inertia Ratio value is used to set the internal gains in the velocity and position loops,
including feedforward compensation if enabled.
To calculate the Inertia Ratio value, divide the load inertia reflected to the motor by the motor
inertia of the motor. Include the motor brake as a load where applicable. The resulting value
should be entered as the Inertia Ratio parameter.
IR =
RLI
MI
Where:
IR = Inertia Ratio
RLI = Reflected Load Inertia (lb-in-sec2)
MI = Motor Inertia (lb-in- sec2)
If the exact inertia is unknown, a conservative approximate value should be used. If you enter
an inertia value higher than the actual inertia, the resultant motor response will tend to be
more oscillatory.
If you enter an inertia value lower than the actual inertia, but is between 10 and 90 percent of
the actual, the drive will tend to be more sluggish than optimum but will usually operate
satisfactorily. If the value you enter is less than 10 percent of the actual inertia, the drive will
have a low frequency oscillation at speed.
There are three guidelines for defining the inertia ratio:
1.
2.
If the inertia of the machines varies or there is uncertainty in the estimate, use the lowest
value for inertia.
3.
The machine system bandwidth is reduced if the inertia estimate is low. Consequently a
low inertia estimate can sometimes add a level of robustness.
Friction
In the drive, this is a viscous friction parameter, characterized in terms of the rate of friction
increase per 100 motor RPM. The range is 0.00 to 100.00 in units of percent continuous
torque of the specified motor/drive combination. The Friction value can either be estimated
or measured. For most servo drives viscous friction is 0.
167
Response
The Response adjusts the velocity loop bandwidth with a range of 1 to 500 Hz. In general, it
affects how quickly the drive will respond to commands, load disturbances and velocity
corrections.
Note
The drives position velocity loop is designed to be a second order system with a gain of
one, a natural frequency specified in the Response scroll box, and a damping factor of 0.8.
If the drives bandwidth is defined to be the -3dB point of the response, the idealized
bandwidth of the system is approximately 2.2 times greater than the natural frequency.
For example:
When the Response is set to 50, the idealized bandwidth is 110 Hz.
Note
When using an external position controller, High Performance Gains should not be
enabled.
Feedforwards
Feedforward gains are essentially open loop gains that generate torque commands based on
the commanded velocity, accel/decel and the known load parameters (Inertia Ratio and
Friction). Using the feedforwards reduces velocity error during steady state and reduces
overshoot during ramping. This is because the Feedforwards do not wait for error to build up
to generate current commands.
Feedforwards should be disabled unless the absolute maximum performance is required from
the system. Using them reduces the forgiveness of the servo loop and can create instability if
168
Tuning Procedures
the actual inertia and/or friction of the machine varies greatly during operation or if the Inertia
Ratio or Friction parameters are not correct.
The internal feedforward velocity and acceleration gains are calculated by using the Inertia
Ratio and Friction parameters. The feedforward acceleration gain is calculated from the
Inertia Ratio parameter and the feedforward velocity gain is calculated from the Friction
parameter.
When Feedforwards are enabled, the accuracy of the Inertia Ratio and Friction parameters is
very important. If the Inertia Ratio parameter is larger than the actual inertia, the result would
be a significant velocity overshoot during ramping. If the Inertia parameter is smaller than the
actual inertia, velocity error during ramping will be reduced but not eliminated. If the Friction
parameter is greater than the actual friction, it may result in velocity error or instability. If the
Friction parameter is less than the actual friction, velocity error will be reduced by not
eliminated.
Feedforwards can be enabled in any operating mode, however, in certain modes they do not
function. These modes are described in table below.
Operating Mode
Vel FF
Analog Velocity
No
Yes
Preset Velocity
Yes
Yes
Pulse/Position
No
No
Summation
No
Yes
Line Voltage
Line Voltage specifies the applied power and adjusts the internal gains to compensate for it.
This parameter has two choices 115 Vac and 230 Vac. If the Line Voltage is set to 230 Vac
when the actual applied voltage is 115 Vac, the motor will be slightly less responsive to
commands and load disturbances.
The Line Voltage must never be set to 115 Vac if the applied voltage is actually 230 Vac.
This can cause drive instability and failure.
169
Note
If you have an application which exerts a constant unidirectional loading throughout the
travel such as in a vertical axis, the inertia tests must be performed in both directions to
cancel out the unidirectional loading effect.
Setting
Friction
0.00
Inertia Ratio
Response
500/Inertia Ratio
Disabled
Feedforwards
Disabled
Line voltage
Actual Applied
170
If your application has a very limited range of motion, it is recommended that you use a
position controller to produce the acceleration ramps and to prevent exceeding the axis
range of motion.
The accel and decel ramp should be aggressive enough to require at least 20 percent of
continuous motor torque. The higher the torque used during the ramp, the more accurate
the final result will be.
With ramps that take less than 1/2 second to accelerate, read the Diagnostic Analog
Outputs with an oscilloscope to measure the Torque Feedback.
Tuning Procedures
With ramps that take 1/2 second or longer to accelerate, read the Torque Command
parameter on the Motor tab of PowerTools FM or with the Watch Window.
To best determine the inertia, use both acceleration and deceleration torque values. The
difference allows you to drop the constant friction out of the final calculation.
If your application exerts a constant unidirectional loading throughout the travel such
as in a vertical axis, the inertia test profiles must be performed in both directions to cancel
out the unidirectional loading effect.
The Torque Command Limited and Velocity Feedback parameters can be measured using
the drives Analog Outputs, PowerTools FM software or an FM-P.
An oscilloscope will be needed for systems with limited travel moves and rapidly changing
signals of torque and velocity.
Inertia Measurement Procedure:
Note
The test profile will need to be run a number of times in order to get a good sample of data.
1.
2.
Note the Torque Command Limited value during acceleration and deceleration.
3.
For horizontal loads or counterbalanced vertical loads use the following formula:
IR =
(R Vm (Ta+ Td))
1
2000
Where:
IR = Inertia Ratio
R = ramp in ms/kRPM
Ta = (unsigned) percent continuous torque required during acceleration ramping (0
- 300)
Td = (unsigned) percent continuous torque required during deceleration ramping (0
- 300)
Vm = motor constant value from Table 18 below
For un-counter balanced vertical loads use the following formula:
IR =
Where:
171
Conversion Formula:
6
10
MPK =
(RPSS 60)
Where:
MPK = accel ramp in ms/kRPM
RPSS = accel ramp in revolutions per second2
Motor
Drive
Vm
Percent Continuous/volt
(default scaled Torque
Command)
MG-205
4.77
30
600
MG-208
5.11
30
600
3.17
30
600
600
EN-204
MG-316
NT-320
4.3
30
MG-316
3.17
30
600
MG-340
3.14
30
600
MG-455
2.44
30
600
5.16
30
600
NT-330
6.87
30
600
NT-345
6.72
30
600
NT-355
5.97
30
600
NT-320
172
EN-208
Tuning Procedures
Motor
Drive
Vm
Percent Continuous/volt
(default scaled Torque
Command)
MG-455
2.44
30
600
MG-490
1.85
30
600
1.69
30
600
NT-345
6.72
30
600
NT-355
5.97
30
600
NT-207
7.16
30
600
NT-212
9.22
30
600
MG-205
5.00
30
600
MG-208
6.47
30
600
NT-207
7.16
30
600
NT-212
12.40
30
600
MG-4120
EN-214
Ei-202
MG-205
5.00
30
600
MG-208
Ei-203
8.25
30
600
MG-316
15.68
30
600
173
174
Status
Description
Disabled
Ready
Indexing
Jogging
Homing
Torque Mode
175
Status
Description
Velocity Mode
Pulse Mode
RMS Foldback
Stall Foldback
(EN drive only)
Ready to Run
Fault Codes
A number of diagnostic and fault detection circuits are incorporated to protect the drive. Some
faults, like high DC bus and amplifier or motor over temperature, can be reset with the Reset
button on the front of the drive or the Reset input function. Other faults, such as encoder
faults, can only be reset by cycling power Off (wait until the diagnostics display turns
Off), then power On.
The drive accurately tracks motor position during fault conditions. For example, if there is a
Low DC Bus fault where the power stage is disabled, the drive will continue to track the
motors position provided the logic power is not interrupted.
176
Fault
Action to Reset
Bridge Disabled
Flash Invalid
Yes
Drive Overtemp
(Epsilon drive only)
Yes
Power Up Test
Cycle Power
Yes
NVM Invalid
Yes
Invalid Configuration
Yes
Power Module
Yes
High DC Bus
Yes
Low DC Bus
Yes
Encoder State
Cycle Power
Yes
Encoder Hardware
Cycle Power
Yes
177
Fault
Action to Reset
Bridge Disabled
Motor Overtemp
Yes
Yes
Overspeed
Yes
Yes
Auto
No
All On
Yes
Fault Descriptions
Flash Invalid
This fault indicates that the firmware checksum has failed. Use the Tools|Program Flash
menu item from PowerTools FM to reprogram/upgrade the firmware stored in flash memory.
If this problem persists, call Control Techniques. A common cause would be an interrupted
F/W Flash upgrade (cable disconnected in the middle of an upgrade process).
Drive Overtemp
Indicates the drive IGBT temperature has reached 100C (212F).
Power Up Test
This fault indicates that the power-up self-test has failed. This fault cannot be reset with the
reset command or reset button.
178
Epsilon Only
If this occurs call Technical Support at Control Techniques.
EN
E Series Only
The FM was not on this drive during its previous power-up and it is not known if the setup
data in the FM matches the drive and motor to which the FM is now attached.
This can also happen when a FM is removed from a drive and the drive is powered-up.
To reset the fault, create or open a configuration file with the correct drive and motor
selections and download the configuration to the FM or drive. If you are certain that the
setup data in the FM or drive matches the system configuration, press and hold the EN
drives Reset button for 10 seconds (until the fault is cleared).
Damage may occur to the drive, motor or both if the fault is cleared using the Reset button
when the setup data in the FM does not match the current drive and motor.
Power Module
This fault is generated when a power stage over-temperature, over-current or loss of power
stage logic supply occurs. This can be the result of a motor short to ground, a short in the
motor windings, a motor cable short or the failure of a switching transistor.
It can also occur if the drive enable input is cycled Off and On rapidly (>10 Hz).
High DC Bus
This fault will occur whenever the voltage on the DC bus exceeds 440 Vdc. The most likely
cause of this fault would be an open shunt fuse, a high AC line condition or an application
that requires an external shunt (e.g., a large load with rapid deceleration).
179
EN
E Series Only
This fault is generated when RMS shunt power dissipation is greater than the design rating
of the internal shunt.
Overspeed
This fault occurs when the actual motor speed exceeds the Overspeed Velocity Limit
parameter. This parameter can be accessed with PowerTools FM software.
Max Following Error
This fault is generated when the following error exceeds the following error limit (default
following error limit is 0.2 revs). With PowerTools FM you can change the Following Error
Limit value or disable it on the Position tab.
180
Channel #2
Analog GND
Channel #1
EN Drive
Figure 129:
181
Figure 130:
182
Drive Faults
The Active Drive Faults dialog box is automatically displayed whenever a fault occurs. The
two options in this dialog box are Reset Faults and Ignore Faults.
Figure 131:
Resetting Faults
Some drive faults are automatically reset when the fault condition is cleared. Others require
drive power to be cycled or the drive to be rebooted to be cleared. If you wish to continue
working in the PowerTools FM software without resetting the fault, click the Ignore Fault
button.
To reset faults that can be reset with the Reset Faults button, simply click the Reset Faults
button in the Drive Faults Detected dialog box or push the Reset button on the front of the
drive where the fault occurred.
183
Watch Window
This feature allows you to customize a window to monitor drive parameters which you select
from a complete list of drive parameters. From this window you can watch the parameters you
selected in real time. This feature is only available when you are on-line with the drive.
Note
You cannot change the values of the parameters while they are being displayed in the
Watch Window. The parameter in the setup screens will look like they have been changed
when they actually have not.
Note
It is normal to have the Watch Window show up with the three motor parameters already
selected. If you do not need to view them, simply push the Clear All button and select the
parameters you wish to view.
Figure 132:
Watch Window
Note
Parameters selected and displayed in the Watch Window cannot be updated from the tabs.
To update a parameter, delete it from the Watch Window selection.
The Watch Window is accessed by selecting Watch Drive Parameters from the Tools menu
or by clicking on the Watch Window icon on the toolbar.
The Watch Window will automatically appear as soon as you select a parameter from the
Select Drive Parameters dialog box. After you have selected the parameters you wish to
watch, click the Close button. The Select Drive Parameters dialog box will close and the
Watch Window will remain open.
184
Figure 133:
185
Figure 134:
The View Motor Parameters window is accessed by selecting View Motor Parameters from
the Tools menu.
Control Panel
PowerTools FM software is capable of monitoring the performance of the drive. The Control
Panel allows the user to jog, index or home the drive with the click of a button. This tool helps
reduce the time required to setup and simplifies diagnostics.
Figure 135:
Keyboard Commands
Key
SPACEBAR
Action
Activate the control with the focus to allow keyboard-based Jog. Index and
Homing control. Jogging stops when the spacebar is released.
ESC
TAB
Moves focus to next control. The order of movement is generally from left to
right and from top to bottom.
SHIFT+TAB
Moves focus to preceding control. The order of movement is generally from right
to left and from top to bottom.
Error Messages
PowerTools FM will pop-up an error message box to alert you to any errors it encounters.
These message boxes will describe the error and offer a possible solution.
186
Cause
Solution
See message.
Yes/No.
Communication error.
No device selected.
187
188
Commutation Basics
To properly commutate the motor, the drive must know the electrical angle (the angle
between the motor magnetic field and stator coils; R, S and T). At power-up, the drive
determines the starting electrical angle from the U, V and W commutation tracks. After this
is determined, the U, V and W commutation tracks are ignored and the commutation is
entirely based on the A and B incremental channels. The number of U, V and W cycles must
match the number of poles in the motor but they do not have to be aligned with the motor
poles in any particular way.
The U, V and W tracks have a fairly coarse resolution, therefore, on power-up, the
commutation accuracy is limited to 30 electrical degrees from optimum. When the Z
channel is seen by the drive, the commutation angle is gradually shifted to the optimum
position as defined by the Motor Encoder Marker Angle parameter. This shift is accomplished
in about one second whether the motor is rotating or not.
Tools Required:
Coupling method between the drill motor and the test motor.
Terminal strip (18 position suggested) to conveniently connect the motor power and
encoder wires during testing.
Method to securely hold the motor during operation (a vise or large C-clamp).
Procedure
The steps required to assemble a servo system consisting of a drive, and a non-ControlTechniques motor are listed below:
189
Determine if your motor is compatible with the drive by verifying its characteristics.
There are a number of restrictions such as encoder line density and motor pole count that
must be considered. Most of these parameters are commonly found on a motor data sheet
and some may have to be determined by testing.
It is important that the encoder used have a repeatable Z channel angle with reference to
one of the commutation channels. This is especially the case if you will be using the same
encoder on several motors and you wish to use the same setup file on them all. Otherwise
you will need to generate a motor file for each individual motor/encoder.
2.
Design and assemble the cabling and interface circuitry required to connect the motor
and drive. Motor and feedback cables must be properly shielded and grounded.
3.
Determine the encoder alignment. In order to commutate a motor correctly the angular
relationship of the encoder commutation tracks and the marker pulse with respect to the
R, S and T windings in the stator must be known.
4.
Enter the motor/encoder data into the MOTOR.DDF file. This data is then read by the
PowerTools FM software when setting up the drive.
5.
Test your system to verify that the servo system is working correctly.
2.
You can select any of the three motor terminals and call it R. In this procedure we will
choose terminal A.
The rotation of the motor will generate dangerous voltages and currents on the motor
phase leads. Make sure the wires and connections are properly insulated.
190
3.
Connect the scope to read VCA and VBA. VCA and VBA are measured by putting the
probe ground clips on A and the scope probes on C and B.
4.
Rotate the motor CCW (i.e., rotate the shaft counter-clockwise as you face the shaft end
of the motor).
Figure 136:
5.
Look at the phase-to-phase voltages VCA and VBA. There are two possibilities. If VCA
leads VBA, then assign B to S and C to T. If VCA leads VBA, then assign B to T and C
to S. These relationships are summarized in the figure below.
191
Figure 137:
Note
For the remainder of this procedure we will refer to the motor terminals using the Control
Techniques designations R, S and T.
192
Figure 138:
Note
The maximum current available out of the drive encoder +5 volt supply connection is 250
mA.
193
Figure 139:
I capacity min: 1 mA
194
Determine whether your encoder has all the required signals to operate with a drive.
Some encoders, for example, do not provide a marker pulse or the marker pulse may not
have a fixed phase relationship to the commutation tracks.
2.
Determine the mapping from the motor encoder signals to the drive. To help with this
second step we have provided a description of the required characteristics of the A, B, Z,
U, V and W encoder signals.
The signal relationships of A, B, U, V and W required by the drive are shown in the phase
plots below. For clarity the time scale against which A and B are plotted is different from that
which U, V and W are plotted. Note that A leads B and U leads V and V leads W.
Plots like these are obtained by powering the encoder then rotating the motor while observing
the signals on an oscilloscope. It is important to note which direction of motor rotation (CW
or CCW) generates the phasing shown in the figures below.
Figure 140:
Figure 141:
If the signal phasing in the figure above is obtained by rotating the motor -, the Motor Encoder
Reference Motion is defined as - and the Motor Encoder Reference Motion parameter is set
to 0. If the signal phasing in the figure above is obtained by rotating the motor +, then the
195
Note
It is important that all the encoder phases match the phase plot in the figure above. (i.e.,
A leads B, U leads V and V leads W. No particular phase relationship is required between
the A and B pair and the U, V, W signals.
Drive signal names are relatively standard. Your encoder signals may be named differently
or they may have the same names but the signals may be functionally different. You must
determine the proper encoder signal mapping to correctly wire your encoder to a drive.
Encoder signals are used for commutation. Incorrectly wired encoder signals can cause
damage to the drive.
Be careful when using the drive encoder power supply for testing a motor. Shorting the
5V drives encoder power supply will blow an internal fuse which can only be replaced at
the factory.
196
Figure 142:
Oscilloscope Connections
197
Figure 143:
180
EUA = 90 + tu
t1
Where:
EUA = Motor Encoder U Angle
If EUA is >360 subtract 360.
Next, use the oscilloscope to examine the phase relationship between Z and VTS. Use Figure
76 to determine the electrical angle at the rising edge Z. This is the Encoder Marker Electrical
Angle.
198
180
EMA = 90 + tz
t1
Where:
EMA = Motor Encoder Marker Angle
If EMA is >360 subtract 360.
Many encoders are designed so that the encoder marker pulse occurs a specified number of
electrical degrees from the rising edge of U. You could obtain this value from the encoder
specification sheet however, to minimize errors in conversion, you should make this
measurement.
If you cannot obtain a stable angle measurement between U or Z and VTS, check the encoder
to verify it has the proper cycles per revolution for your motors pole count.
CW Reference Rotation
If the reference motion for the encoder is CW (i.e., Encoder Reference Motion parameter will
be set to 1), rotate the motor in the CW direction. Using an oscilloscope, look at the phase
relationship between the rising edge of U and negative peak of VTS. Use the figure below to
determine the electrical angle at the rising edge of U. Determine the marker electrical angle
in a similar manner.
199
Figure 144:
In Figure 76 the electrical angle decreases from left to right and the positive peak of VTS
occurs at zero degrees electrical. In Figure 77 the electrical angle increases from left to right
and the negative peak of VTS occurs at zero degrees electrical. Note that with a CW reference
rotation the negative peak of VTS is at zero electrical degrees and the electrical angle
decreases from left to right.
Note
If you cannot obtain a stable angle measurement between U or Z and VTS, check the
encoder to verify it has the proper cycles per revolution for your motors pole count.
200
201
Note
Verify that you are seeing the rising edge of the U channel in the encoder reference
direction by twisting the motor shaft CCW by hand while the DC current is applied and
verifying that U goes high when the shaft is rotated in the encoder reference direction.
Motor Ke
In this test you will be measuring the AC voltage generated by the motor or the CEMF
(Counter Electro-Motive Force). This measurement requires an AC voltmeter that can
accurately read sine waves of any frequency and some way to determine the motor speed at
the time of the measurement, such as a photo tachometer or an oscilloscope.
1.
Connect the volt meter across any two of the motor power leads.
2.
Set the volt meter to read VAC at its highest range. You can usually expect to read about
20 to 300 VAC.
3.
4.
Note
When using an oscilloscope, use the following formula to determine the motor velocity in
RPM.
RPM =
202
60
Seconds/Re volutions
Ke = 1000
VRMS
RPM
Attach a scope probe to the R winding referenced to the S winding and one to the encoder
Z channel referenced to the encoder power supply 0 volt.
2.
Connect S winding to the encoder power supply 0 volt wire thereby connecting the scope
ground clips together.
3.
4.
Note
If you are using an electric drill to rotate the motor, the drills name plate should specify
the maximum RPM.
5.
Adjust the horizontal time base until at least two Z channel pulses are visible.
6.
Count the number of full cycles of the Motor waveform you see between the rising edges
of the Z pulses.
7.
203
Header
The header includes the revision and serial number information along with a count of how
many special motor definitions are included in the particular file. Standard Control
Techniques motors will not appear in this file because their data is hard coded into the drives
memory.
Revision
This parameter is fixed and is set by the PowerTools FM revision during installation.
Serial
This parameter defines the format of the .ddf file. Do not change this parameter.
Beta
This parameter is not used and should be set to 0.
NameCount
The NameCount parameter defines the number of motor sections contained in the .ddf file. If
four motor sections exist, this parameter should be set equal to 4 which will cause PowerTools
FM to recognize only the first four (4) motor definitions in the file.
Motor Data
The motor data section contains the names and parameters of one or more user defined
motors.
MotorID is used for each motor to mark the beginning of a new user defined motor definition.
The format is [MotorXX] where XX is the ID number starting with zero and incrementing by
one.
204
205
DDF Identifier
motorPoles
encoderLines
encoderMarker
encoderU
encoderRef
Motor Inertia
rotorInertia
Motor KE
motorKE
Motor Resistance
phaseResistance
Motor Inductance
phaseInductance
peakCurrent
continuousCurrent
maxOperatingSpeed
206
207
Start PowerTools FM and either open an existing file or start a new file off-line.
Note
PowerTools FM will not allow you to select a Motor Type or Drive Type while online with a drive.
208
From the Motor Type list box on the EZ Setup tab (or from the Motor tab if you are in
Detailed Setup view) select your motor from the list of motors.
When you select a new motor, PowerTools FM will display the Motor Parameters dialog
box. In most cases you will want to select the default option which sets the Full Scale
Velocity parameter to the value you entered into the MOTOR.DDF file.
Figure 145:
3.
4.
5.
Note
For safety reasons, it is a good idea to double check that the key motor parameters below
have been specified correctly.
Motor Ke
Motor Resistance
Motor Inductance
209
The motor may run away during this test. Make sure it is securely fastened and that there
is nothing connected to the motor shaft.
At a certain point in the test it will be necessary to manually rotate the motor through an
integral number of revolutions. This can only be done if the motor shaft and housing are
marked in some way so that the motor can be aligned to a specific position. A disk or pulley
can be installed during that portion of the test to make this alignment more precise.
The four tests are Rotation test, Torque test, Commutation test and Velocity test. Each test
builds on the last. It is important to perform the tests in the order given.
Note
Do not attempt to perform a test if you were not able to get the proceeding test to work.
Rotation Test
This test verifies that the encoder has been correctly interfaced to the drive.
Figure 146:
Note
This test assumes that you have completed Step 6: Configuring the Drive on page 287.
210
1.
2.
While on-line with the drive, select the Status tab. Find the Position Feedback parameter
and note its value.
3.
Mark the motor shaft and the motor face. This is your reference starting point.
Manually rotate the motor CW one revolution as accurately as you can. Verify that the
Position Feedback increased by one revolution. This verifies that the A and B encoder
signals are wired correctly and the Motor Encoder Reference Motion parameter is
correct.
5.
Manually rotate the motor as accurately as you can, CW 20 revolutions. The Position
Feedback should increase by exactly 20 revs. If the change has some significant
fractional part (20.5 for example) the Motor Encoder Lines Per Revolution parameter is
probably wrong.
6.
Select View Motor Parameters from the Tools menu. Note the value of the
Commutation Track Angle parameter. This parameter is obtained directly from the state
of the U, V and W commutation tracks.
7.
Slowly rotate the motor clockwise. The Commutation Track Angle should increase in 60
degree steps and will roll over to 0 at 360. If it does not change, there is a fundamental
problem with the U, V and W encoder signals. If it decreases or changes erratically there
is either a problem with the Motor Encoder Reference Motion parameter or the phasing
of U, V and W.
8.
9.
Power-down the drive and wait for the status display to go blank and then power the drive
up again.
10. Re-establish communications with the drive by selecting the Upload button.
11. Select View Motor Parameters from the Tools menu. Note the value of the
Commutation Angle Correction parameter. Its value should be zero until the motor
encoder Z channel is detected. Rotate the motor through one or more complete
revolutions until the Z channel is detected.
12. The value should now have a non-zero value between 40 degrees. If the parameter is
still zero, the drive is probably not seeing the marker pulse.
To confirm this repeat Steps 7-9 several times with different motor shaft starting
locations. If the absolute value of the parameter is greater than 40, there is either a problem
with the phasing of U, V and W or an inconsistency in the encoder alignment parameters.
Torque Test
The purpose of this test is to enable the drive in Torque mode and verify that a positive
command produces CW torque.
1.
Use PowerTools FM to select Torque mode and set Full Scale Torque to 5 percent. Then
click the Update button to download the changes to the drive.
211
Move to the Analog tab and find the Analog Input parameter.
3.
Using your simulator adjust the analog command until the value of this parameter is
approximately 0 volts.
4.
Enable the drive. It should not move. If the drive faults at this point you most likely have
a wiring problem (see Step 1: Motor Wiring).
5.
Gradually increase the analog command voltage. The motor should start moving with a
voltage level somewhere between 2 and 5 volts. Verify that the direction of motion is
CW.
6.
The Encoder Lines Per Revolution parameter has been specified incorrectly
The motor terminals have been mis-identified (see Step 1: Motor Wiring).
2.
3.
4.
5.
Select View Motor Parameters from the Tools menu so you can monitor the
Commutation Voltage.
6.
Spin the motor clockwise 500 to 1000 RPM, then counter-clockwise at the same speed.
The Commutation Voltage should be <10 percent. If the Commutation Voltage is higher
than 10 percent, the Motor Encoder Marker Angle was incorrectly specified and should
be re-tested.
212
Reset the Torque Limit and the Torque Limit Enable input function to their previous
settings.
Velocity Test
1.
2.
Select Velocity Analog mode and set Full Scale Velocity parameter to 12 RPM.
3.
4.
Enable the drive. Find the Velocity Command Analog parameter on the Status tab.
Adjust the analog command until this parameter reads exactly 6 RPM. The motor should
be moving at 6 RPM. If the system got through the Torque test, the motor should not runaway at this point. If it does, go back and repeat the Torque test.
5.
Confirm that the motor velocity is really 6 RPM by confirming that it takes 10 seconds
to make one revolution. If this is not the case, the problem may be that both the motor
poles and the encoder line density are off by the same factor.
6.
Reduce the analog command voltage to zero volts and disable the drive.
213
214
Ei-203
J1
L1
L2
RESET
BU S
PE
MOTOR
SERIAL
A.P.S.
J2
S
T
I/ O
J3
J5
J6
215
EN Drive
EN-214
OIT-EN-232-XXX
or
OIT-EN-485-XXX
OIT-PC-232-XXX
and D9P-D9P adapter
Serial Cable, DDS-XXX,
EN Drive to Drive
(J4 to J4)
216
STI-EIO Interface
The STI-EIO interface, see figure 147, allows access to all digital input and output signals.
The STI-EIO board mounts directly to the Epsilon drives Input/Output Connection (J3) and
away from any high voltage wiring.
Figure 147:
Note
Shield connection points are connected to the shell of the 44-pin D connector on the
STI-EIO.
The STI-EIO wire range is #18 to 24 AWG stranded insulated wire.
Note
Wiring should be done with consideration for future troubleshooting and repair. All
wiring should be either color coded and/or tagged with industrial wire tabs. Low voltage
wiring should be routed away from high voltage wiring.
217
Figure 148:
Dimensions of ECI-44
Note
Shield connection points are connected to the shell of the 44-pin D connector on the
ECI-44.
Use tie wraps to provide a strain relief and a ground connection at the shield connection
points.
If you do not wish to use the DIN rail mounting hardware, the ECI-44 can be disassembled
and the mounting clips removed.
The ECI-44 wire range is #18 to 24 AWG stranded insulated wire.
Note
Wiring should be done with consideration for future troubleshooting and repair. All
wiring should be either color coded and/or tagged with industrial wire tabs. Low voltage
wiring should be routed away from high voltage wiring.
218
Command Connector
on Drive (J5)
Screw Terminals
on ECI-44
Ext Encoder
Supply Output
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
Do Not Connect
20
EN V+
NC2
NC1
(Connector shell
and strain relief
points)
Figure 149:
219
220
Specifications
Epsilon Ei Specifications
Epsilon Series
Power Requirements
Standard Range:
90 - 264 Vac, 1 , 47 - 63 Hz
Extended Range: (Requires Auxiliary Power Supply (APS)
42-264 Vac, 1 , 47 - 63 Hz
Switching Frequency
10 kHz
Efficiency - Drive
Drive: IP20
MG motors: IP65
NT motors: IP65/IP54
Molded motor and feedback cables: IP65
Serial Interface
RS-232 / RS-485
Internal RS-232 to RS-485 converter
Modbus protocol with 32 bit data extension
9600 or 19.2 k baud
Analog command: 10 Vdc 14 bit, 100 kohm impedance, differential
Control Inputs
Digital inputs: (12) 10-30 Vdc, 2.8 kohm impedance; current sourcing
signal compatible (active high); max input response time is 500 s;
optically isolated
Input debounce: 0-2000 ms
Diagnostic analog outputs: (2) 10 Vdc (single ended, 20 mA max)
10 bit software selectable output signals
Control Outputs
Digital outputs: (7) 10-30 Vdc 150 mA max, current sourcing, (active
high) optically isolated: Input debounce: Programmable range, 0 to
200 ms
Motor temp sensor (analog): 0 to +5 Vdc (single ended), 10 Kohm
impedance
221
Pulse Mode
Single ended - 1 MHz per channel; 50% duty cycle (4 MHz count in
quadrature)
Ratio Capabilities: 20 to 163,840,000 PPR
Input Device = AM26C32
Vdiff = 0.1 - 0.2 V
V common mode max = +/- 7 V
Input impedance each input to 0 V = 12 - 17 kohm
Differential line driver, RS-422 and TTL compatible
Scalable in one line increment resolution up to 2048 lines/rev of the
motor (MG and NT)
222
Cooling Method
Specifications
Epsilon Series
Ambient temperature range for rated output: O to 40 C (32 to
104 F)
Maximum ambient operating temperature: 40 to 50 C (104 to 122
F) with power derating of 3%/ C
Rated altitude: 1000 m (3,280 feet)
Environmental
Vibration: 10 - 2000 Hz at 2g
Humidity requirement: 10 - 95% non-condensing
Storage temperature: -25 to 75 C (-13 to 167 F)
Temperature:
Operation in ambient temperature over 50 C (122 F) not
recommended.
Drive output power must be derated by 3%/C between 40 to 50 C
(104 to 122 F)
Derating
UL listed
Canadian UL listed
CE Mark: Low voltage directive; EMC directive
Accessory Specifications
Amplifier Weights
Ei-202
Ei-203
Ei-205
Continuous
Peak
Ei-202
1.8
3.6
Ei-203
3.0
6.0
Ei-205
5.0
10.0
FM-2 Specifications
Power consumption: 5 W from EN drive power supply.
Function
Electrical Characteristics
Inputs
Outputs
223
Drive Model
Dimension B*
(shown in
inches/mm)
Ei-202
2.10 [53.3]
.45 [11.4]
Ei-203
2.10 [53.3]
.45 [11.4]
Ei-205
3.56 [90.42]
.7 [17.78]
5.21
[132.3]
5.39
[136.9]
5.96
[151.4]
0.5 [13]
side clearance
for heatsink
1.20
[30.5]
1.81
[46.1]
0.20
[5.1]
A*
0.22
[5.6]
1.04
[26.4]
3.00
[76.2]
TIA Cable
& C0422
7.75
[196.9]
8.27
[210.1]
7.15
[181.6]
DDS
DDS, Term-H, Term-T
EIO Cable
0.19
[4.8]
3.50
[88.9]
Cable
Clearance
224
1.84
[46.7]
1.85
[46.9]
0.75
[19.05]
B*
1.20
[30.5]
0.56
[14.2]
Specifications
225
Figure 150:
226
Specifications
EN-204
EN-208
EN-214
Max
speed
RPM
Max
Accel
Rate
ms/
krpm
(no
load)
Encoder
resolution
lines/rev
Motor
Ke
VRMS/
krpm
Motor
Kt
lb-in/
ARMS
(Nm/
ARMS)
0.000084
(0.095)
5000
0.770
2048
28.3
4.1
(0.46)
0.64
(0.48)
0.000144
(0.163)
5000
0.650
2048
28.3
4.1
(0.46)
41.9
(4.73)
1.00
(0.75)
0.000498
(0.562)
4000
1.130
2048
37.6
5.5
(0.62)
18.6
(2.10)
55.8
(6.31)
1.00
(0.75)
0.000498
(0.562)
4000
0.910
2048
37.6
5.5
(0.62)
MGM-340
48
(5.65)
133.0
(15.0)
2.00
(1.49)
0.00125
(1.414)
3000
1.090
2048
55.0
8.0
(0.90)
MGE/M-455
68
(7.68)
139.1
(15.72)
2.46
(1.83)
0.00338
(3.819)
3000
2.680
2048
60.0
8.8
(0.99)
MGE/M-455
68
(7.68)
201.0
(22.71)
2.46
(1.83)
0.00338
(3.819)
3000
1.890
2048
60.0
8.8
(0.99)
MGE/M-490
100
(11.30)
208.0
(23.50)
3.75
(2.79)
0.00648
(7.319)
3000
3.380
2048
58.9
8.6
(0.97)
MGE/M-4120
132
(14.92)
257.0
(29.03)
5.30
(3.95)
0.00938
(10.593)
3000
4.290
2048
71.8
10.5
(1.19)
MG-205
5
(0.56)
13.5
(1.53)
0.31
(0.23)
0.000084
(0.95)
5000
0.70
2048
28.3
4.1
(0.46)
MG-208
6.7
(0.76)
13.2
(1.49)
0.53
(0.4)
0.000144
(0.163)
5000
1.19
2048
28.3
4.1
(0.46)
NT-207
7.3
(0.82)
15.2
(1.72)
0.45
(0.34)
0.000094
(0.1063)
5000
0.53
2048
35
5.124
(0.58)
NT-212
9.2
(1.04)
18
(2.03)
0.71
(0.53)
0.000164
(0.185)
5000
0.93
2048
34.7
5.08
(0.57)
MG-205
5
(0.56)
15.0
(1.69)
0.31
(0.23)
0.000084
(0.95)
5000
0.59
2048
28.3
4.1
(0.46)
MG-208
9.1
(1.03)
20
(2.26)
0.58
(0.43)
0.000144
(0.163)
5000
0.72
2048
28.3
4.1
(0.46)
MG-316
15.8
(1.79)
31.8
(3.59)
1.0
(0.75)
0.000498
(0.562)
4000
1.78
2048
37.6
5.5
(0.62)
NT-212
12.5
(1.41)
27
(3.05)
0.8
(0.6)
0.000164
(0.185)
5000
0.56
2048
34.7
5.08
(0.57)
Motor
Cont.
Torque
lb-in
(Nm)
Peak
Torque
lb-in
(Nm)
Power
HP @
Rated
Speed
(kWatts)
Inertia
lb-in-sec2
(kg-cm2)
MGE-205
5.2
(0.59)
15.6
(1.76)
0.38
(0.28)
MGE-208
9.1
(1.03)
27.3
(3.09)
MGE-316
18.6
(2.10)
MGE-316
Ei-202
Ei-203
227
Holding
Torque
lb-in
(Nm)
Added Inertia
lb-in-sec2
(kg-cm2)
Added
Weight
lb (kg)
Coil Voltage
(Vdc)
Coil Current
(A)
Mechanical
Disengagement
Time
Mechanical
Engagement
Time
MGE-2XXCB
10
(1.13)
0.000025
(0.0282)
1.8
(0.55)
24 (10%)
0.48 (10%)
25 ms
40 ms
MGE-316CB
MGM-340CB
50
(5.6)
0.00015
(0.1693)
2.4
(1.1)
24 (10%)
0.52 (10%)
100 ms
250 ms
MGE/M-455CB
MG-490CB
MG-4120CB
220
(24.9)
0.000412
(0.4652)
5.8
(2.6)
24 (10%)
0.88 (10%)
100 ms
250 ms
Motor Weights
228
Motor
Weight
lb (kg)
without Brake
Weight
lb (kg)
with Brake
MGE-205
3.0 (1.36)
N/A
MGE-208
4.0 (1.8)
5.8 (2.6)
MGE-316
8.3 (3.8)
10.7 (4.9)
MGE/M-340
14.6 (6.6)
17.0 (7.7)
MGE/M-455
18.5 (8.4)
24.3 (11.0)
MGE/M-490
27.0 (12.3)
32.8 (14.9)
MGE/M-4120
38.0 (17.3)
43.8 (19.9)
NT-207
3 (1.36)
N/A
NT-212
4 (1.81)
N/A
Specifications
Axial/Radial Loading
Motor
Max Radial
Load (lb)
Max. Axial
Load (lb)
MGE-205
20
15
MGE-208
20
15
MGE-316
40
25
MGM-340
40
25
MGE/M-455
100
50
MGE/M-490
100
50
MGE/M-4120
100
50
IP Ratings
Motor
Rating
MG (all)
IP65
NT-207
IP65
IP54
NT-212
IP65
IP54
Encoder Specifications
Motor
Density
Output Type
Output
Frequency
Output Signals
Power Supply
MG and NT
2048 lines/rev
RS422 differential
driver
A, B, Z, Comm U,
Comm W, Comm V
and all complements
229
Power Dissipation
In general, the drive power stages are 90 to 95 percent efficient depending on the actual point
of the torque speed curve the drive is operating. Logic power losses on the EN drive is 11 W
minimum to 21 W depending on external loading such as FM modules and input voltages.
Logic power loses on the Epsilon drive with normal loads to 15 W with additional loads such
as external encoder and low input voltage (<22 Vdc on APS or 120 Vac on AC input).
The values shown in the table below represent the typical dissipation that could occur with
the drive/motor combination specified at maximum output power.
Drive Model
Total
Power Losses
(Watts)
EN-204 / MG-205
30
52
EN-204 / MG-208
50
72
EN-204 / MG-316
82
104
160
182
EN-208 / MG-455
200
222
EN-214 / MG-490
300
322
EN-214 / MG-4120
430
452
Ei-202 / MG-205
25
36
Ei-202 / NT-207
25
36
Ei-202 / NT-212
30
41
EN-208 / MG-340
19
Ei-203 / NT-207
30
41
30
41
11
Ei-203 / MG-208
230
Ei-203 / NT-212
40
51
Ei-203 / MG-316
40
51
Ei-202 / NT-208
30
41
Specifications
TPL =
TRMS Vmax
+ Pld + Psr
1500
Where:
TPL = Total power losses (Watts)
TRMS = RMS torque for the application (lb-in)
Vmax = Maximum motor speed in application (RPM)
Pld = Logic Power Losses Drive (Watts)
Psr = Shunt Regulation Losses (Watts)-(RSR-2 losses
or equivalent)
Note
TRMS * Vmax / 1500 = Power Stage Dissipation = Pp
A more accurate calculation would include even more specifics such as actual torque
delivered at each speed plus actual shunt regulator usage. For help in calculating these, please
contact the Application Department at Control Techniques with your system profiles and
loads.
231
6 x 6 x .25
10 x 10 x .375
MG-4120
12 x 16 x .5
Speed torque curves are based on 230 Vac (3 on EN-214) drive operation.
.4 WITH %.
3PEED 20-
3PEED 20-
LB
IN
.M
LB IN
.M
4ORQUE
.4
WITH %.
3PEED 20-
3PEED 20-
4ORQUE
.4 WITH %.
LB
IN
.M
4ORQUE
232
.4 WITH %.
LB IN
.M
4ORQUE
Specifications
.4 WITH %.
.4 WITH %.
3PEED 20-
3PEED 20-
LB
IN
.M
LB IN
.M
4ORQUE
.4 WITH %.
.4 WITH %.
3PEED 20-
3PEED 20-
4ORQUE
LB
IN
LB IN
.M
.M
4ORQUE
4ORQUE
3PEED 20-
3PEED 20-
LB
IN
.M
LB IN
.M
4ORQUE
4ORQUE
233
3PEED 20-
3PEED 20-
LB IN
.M
LB IN
.M
4ORQUE
4ORQUE
3PEED 20-
3PEED 20-
LB
IN
LB IN
.M
.M
4ORQUE
3PEED 20-
3PEED 20-
4ORQUE
LB
IN
.M