Infranor SMT-BD2 User Manual

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SMT-BD2

DIGITAL SERVO DRIVE

FOR SINUSOIDAL

BRUSHLESS AC MOTORS

SMT-BD2

WARNING !

This is a manual describing a series of servo amplifiers having output capability suitable for driving AC brushless servo motors equipped with an encoder only or an encoder plus Hall effect sensors for the position feedback. This manual may be used in conjunction with appropriate and referenced drawings pertaining to the various specific models.

Maintenance procedures should be attempted only by highly skilled technicians (EN 60 204.1 standard) using proper test equipment.

The conformity with the standards and the "CE" approval are only valid if the items are installed according to the recommendations of the racks and amplifiers manuals.

Any contact with electrical parts, even after power down, may involve physical damage.

Wait for at least 5 minutes after power down before handling the amplifiers (a residual voltage of several hundreds of Volts may remain during a few minutes).

INFRANOR drives are conceived to be best protected against electrostatic discharges. However, some components are particularly sensitive and may be damaged. Before handling the drives and, particularly, before any contact with the connectors, the user himself must be earthed. Place or store the drives on conducting or electrostatically neutral areas but not on plastic areas, carpeting or insulation material that may be electrostatically loaded.

INFRANOR does not assume any responsibility for any physical or material damage due to improper handling or wrong descriptions of the ordered items.

Infranor reserves the right to change any information contained in this manual without notice.

Any intervention on the items, which is not specified in the manual, will immediately cancel the warranty.

This manual is a translation of the original document and does not commit INFRANOR's responsibility. The french manual is the only reference document.

SMT-BD2

CONTENTS............................................................................................................................................. 5

CHAPTER 1 - GENERAL DESCRIPTION ............................................................................................. 7

1 - INTRODUCTION............................................................................................................................. 7

2 - GENERAL DESCRIPTION.............................................................................................................. 7

3 - REFERENCE TO THE STANDARDS............................................................................................. 8

4 - REFERENCE TO OTHER DOCUMENTS....................................................................................... 8

CHAPTER 2 – SPECIFICATIONS.......................................................................................................... 9

1 - TECHNICAL SPECIFICATIONS..................................................................................................... 9

1.1 - Current ratings for the 220 VAC amplifier version.................................................................... 9

1.2 - Current ratings for the 400 VAC amplifier version.................................................................. 10

1.3 - Other specifications................................................................................................................ 11

2 - BLOCK DIAGRAM.........................................................................................................................13

3 - MAIN PROTECTIONS .................................................................................................................. 14

3.1 - Displayed protections............................................................................................................. 14

3.2 - Fuse protection....................................................................................................................... 15

CHAPTER 3 - INPUTS - OUTPUTS.................................................................................................... 16

1 - CONNECTORS LOCATION......................................................................................................... 16

1.1 - RACK connectors................................................................................................................... 16

1.2 - Amplifier connectors............................................................................................................... 16

2 - X5 SERIAL LINK CONNECTOR (SUB D 9 POINTS MALE)............................................................... 16

3 - X1 ENCODER FEEDBACK CONNECTOR (SUB D 15 POINTS FEMALE)......................................... 17

3.1 - X1 connector for TTL incremental encoder configuration...................................................... 17

3.2 - X1 connector for TTL incremental encoder & HES configuration.......................................... 18

3.3 - X1 connector for absolute single turn Sin/Cos encoder configuration................................... 19

3.4 - X1 connector for other sin/cos encoder configurations.......................................................... 20

4 - X4 COMMAND CONNECTOR (SUB D 25 POINTS MALE)................................................................ 21

4.1 - Specification of the analog inputs / outputs............................................................................ 22

4.2 - Specification of the logic inputs / outputs...............................................................................23

5 - X2 POSITION OUTPUT CONNECTOR (SUB D 25 POINTS FEMALE).............................................. 24

Specification of the TTL encoder output.........................................................................................24

CHAPTER 4 - CONNECTIONS............................................................................................................ 25

1 - CONNECTION DIAGRAMS.......................................................................................................... 25

1.1 - Rack power supply and motor connection............................................................................. 25

1.2 - Amplifier i/o connections......................................................................................................... 25

1.3 - RS-232 serial link connection................................................................................................. 27

2 - WIRING (ACCORDING TO CEI 801 AND EN 55011 STANDARDS) ....................................................... 28

2.1 - GND wiring and grounding..................................................................................................... 28

2.2 - Motor and sensors cables ...................................................................................................... 28

2.3 - Input command and serial link cables.................................................................................... 28

3 - 360° SHIELD ON THE CONNECTORS ........................................................................................ 29

CHAPTER 5 - ADJUSTABLE FUNCTIONS ........................................................................................ 30

1 - HARDWARE ADJUSTMENTS...................................................................................................... 30

2 - ADJUSTABLE PARAMETERS ..................................................................................................... 33

CHAPTER 6 - COMMISSIONING......................................................................................................... 34

1 - CHECKING THE AMPLIFIER CONFIGURATION........................................................................ 34

1.1 - Standard amplifier configuration............................................................................................. 34

1. 2 - Encoder configuration............................................................................................................ 34

Contents

SMT-BD2

1. 3 - Hall Effect Sensors configuration...........................................................................................35

1. 4 - Motor thermal sensor configuration.......................................................................................35

1.5 - Current loops adjustments......................................................................................................36

2 - PUTTING INTO OPERATION ....................................................................................................... 38

3 - AMPLIFIER COMMISSIONING AND ADJUSTMENT...................................................................38

3.1 - Amplifier setup........................................................................................................................38

3.2 - Motor Hall Effect Sensors adjustment .................................................................................... 39

3.3 - Absolute single turn Sin/Cos encoder adjustment.................................................................. 39

3.4 - Amplifier parameter setting.....................................................................................................40

3.5 - Amplifier auto-tuning with an unbalanced load...................................................................... 40

3.6 - Saving of the amplifier parameters......................................................................................... 41

3.7 - Motor phasing at power up.....................................................................................................41

3.8 - Parameters adjustment to a linear motor ...............................................................................42

CHAPTER 7 – FAULT FINDING...........................................................................................................43

1 - SYSTEM FAULT............................................................................................................................43

2 - STORED FAULTS.........................................................................................................................43

2.1 - "BUSY" fault........................................................................................................................... 43

2.2 - "EEPROM" fault......................................................................................................................44

2.3 - "°C MOTOR" fault...................................................................................................................44

2.4 - "UNDERVOLT." fault .............................................................................................................. 44

2.5 - "°C AMPLIFIER" fault..............................................................................................................44

2.6 - "POWER STAGE" fault...........................................................................................................44

2.7 - "HES" fault .............................................................................................................................. 44

2.8 - "ENCODER" fault.................................................................................................................... 45

2.9 - "COUNTING" fault ..................................................................................................................46

2.10 - "I2t" fault ................................................................................................................................47

2.11 - "TRACKING" fault.................................................................................................................47

2.12 - "ADC" fault............................................................................................................................47

3 - OPERATING PROBLEMS.............................................................................................................48

3.1 - Motor supplied, but no torque................................................................................................. 48

3.2 - Motor does not move..............................................................................................................48

3.3 - Shaft locked, eratic oscillations or rotation at maximum speed..............................................48

3.4 - Discontinuous motor rotation with zero torque positions.......................................................48

3.5 - Motor drift with analog input command at zero speed............................................................ 48

3.6 - Loud crackling noise in the motor at standstill........................................................................ 48

3.7 - Loud noise in the motor at standstill and when running.........................................................48

3.8 - Position control not possible with the NC ............................................................................... 48

4 - SERVICE AND MAINTENANCE ................................................................................................... 49

CHAPTER 8 - APPENDIX..................................................................................................................... 50

1 - USE OF THE LIMIT SWITCHES & "CVO" INPUTS......................................................................50

2 - USE OF THE "AMP. READY" & "POWER READY" OUTPUTS.................................................... 50

3 - SPEED FOLLOWING ERROR PROTECTION .............................................................................50

4 - I

T PROTECTION.......................................................................................................................... 51

4.1 - Current limitation in Fusing mode........................................................................................... 51

4.2 - Current limitation in Limiting mode ......................................................................................... 52

5 - COGGING COMPENSATION OPTION ........................................................................................ 52

5.1 - Amplifier configuration ............................................................................................................ 52

5.2 - cogging compensation setup for rotating motors ...................................................................53

5.3 - cogging compensation setup for linear motors....................................................................... 53

6 - AMPLIFIER TYPES.......................................................................................................................54

Contents

SMT-BD2

Chapter 1 - General description

1 - INTRODUCTION

Series SMT-BD2 digital servo modules are sinusoidal PWM power amplifiers that provide speed and torque/force control for AC brushless motors equipped with encoder only or encoder with Hall Effect Sensors (HES) for the position feedback. The speed or torque/force input command is a +/-10 V analog signal voltage.

The SMT-BD2 digital servo drive is 220 VAC or 400 VAC main operated. The SMT-BD2 plug-in system with 400 VAC power supply is available as a multiaxis version that can receive up to three axes in a standard 19" rack including the power supply. The SMT-BD2 plug-in system with 220 VAC power supply is available as a single-axis block version or as a multiaxis version that can receive up to six axes in a standard 19" rack including the power supply.

2 - GENERAL DESCRIPTION

Series SMT-BD2 amplifiers have their own DC/DC converter to provide the appropriate supply voltage (+5 V, +15 V, -15V). The source supply voltage for the logic board is the auxiliary 310 VDC supply voltage. The auxiliary supply voltage allows to have the position output signals still available when the power supply voltage is turned off.

Each module is packaged as a 6 U "double Eurocard":

- one power board with IGBT transistors

- one logic board with DSP (Digital Signal Processing).

The SMT-BD2 amplifier directly controls the motor torque/force and speed by means of the information provided by an encoder feedback device. The sinusoidal current commutation based on encoder feedback provides smooth motor torque/force control.

The SMT-BD2 amplifier can be configurated for various encoder types feedback. The appropriate encoder input configuration is selectable by jumpers.

- With an incremental encoder only, a motor phasing procedure must be executed at each amplifier power up before the motor enabling.

- With an incremental encoder + HES feedback from the motor, the motor phasing procedure is no more necessary and the servo motor can immediately be enabled after the amplifier power up.

- With an absolute single turn SinCos encoder feedback from the motor (Heidenhain ERN 1085 or compatible), the servo motor can also immediately be enabled after the amplifier power up.

The motor speed or torque/force input command is a +/-10 V analog voltage. The motor position output is available as two A and B encoder type channels in quadrature, and one Z marker pulse per revolution via RS422 line drivers. The ratio between the number of pulses on the motor encoder and the number of pulses on the SMT- BD2 amplifier encoder output is programmable.

The amplifier faults are displayed on the front panel and can also be read via the serial link.

All control parameters are programmable by means of the serial link and saved in an EEPROM. The autoconfiguration and auto-tuning functions allow an easy and quick commissioning of the amplifier.

The Visual Drive Setup software, which is IBM-PC compatible with the WINDOWS® operating system, allows the clear display and easy modification of all amplifier parameters. The Visual Drive Setup software also includes a digitizing oscilloscope function that is particularly useful for the drive commissioning and maintenance.

Chapter 1 - General description

SMT-BD2

3 - REFERENCE TO THE STANDARDS

The 220 VAC version of the SMT-BD2 amplifiers operating in the BF rack, which is equipped with the mains filter BF-35 or 70, has been approved for its conformity with the Electromagnetic Compatibility standards: EN 55011, Group 1, Class A regarding the conducted and radiated radioelectric disturbances, CEI 801 - 2 - 3 - 4 regarding the immunity.

The 220 VAC version of the SMT-BD2 amplifiers operating in the single axis BM20 A – BMM05F – BMM05AF, which is equipped with appropriate mains filter (FN 612-20/06 or FN 356-16/06) has been approved for its conformity with the Electromagnetic Compatibility standards: EN 55011, Group 1, Class A regarding the conducted and radiated radioelectric disturbances, CEI 801 - 2 - 3 – 4 regarding the immunity.

The 400 VAC version of the SMT-BD2 amplifiers operating in the BF-400 rack, which is equipped with the mains filter F400-35 or 70, has been approved for its conformity with the Electromagnetic Compatibility standards: EN 55011, Group 1, Class A regarding the conducted and radiated radioelectric disturbances, CEI 801 - 2 - 3 - 4 regarding the immunity.

Standard to be applied to the electrical equipments of industrial machines: EN 60204.1.

The SMT-BD2 amplifiers have been "CE" marked since year 2000.

4 - REFERENCE TO OTHER DOCUMENTS

♦ BF-400 rack – for the use of the 400 VAC amplifier version in a multiaxis rack. ♦ BF rack – for the use of the 220VAC amplifier version in a multiaxis rack. ♦ BM20A/BMM05F/05AF single-axis rack – for the use of the 220 VAC amplifier version in a single-axis rack.

Chapter 1 – General description

SMT-BD2

Chapter 2 – Specifications

1 - TECHNICAL SPECIFICATIONS

1.1

- CURRENT RATINGS FOR THE 220 VAC AMPLIFIER VERSION

Operating voltage DC bus 310 VDC (270 VDC < DC bus < 340 VDC max.) Auxiliary supply voltage 310 VDC ( 200 VDC < Uaux < 340 VDC max.) Motor terminal to terminal output voltage 200 Vrms for 310 VDC bus

Authorized output currents for current pulse mode operation (I2t protection in fusing mode)

AMPLIFIER

(Vrms) 1 s WITHOUT

SMT-BD2 - 220/04 240 4,4 2 SMT-BD2 - 220/08 240 8,8 4 SMT-BD2 - 220/12 240 13,8 6 SMT-BD2 - 220/17 240 17,7 8,5 SMT-BD2 - 220/30 240 30,8 10 12 15 SMT-BD2 - 220/30r 240 30,8 10 15 SMT-BD2 - 220/45 240 48,6 10 15 20 SMT-BD2 - 220/45r 240 48,6 10 20 23 SMT-BD2 - 220/60 240 61 10 19 25 SMT-BD2 - 220/60r 240 61 12 26 30 SMT-BD2 - 220/70 240 70 25 30 35 SMT-BD2 - 220/100 240 100 25 30 35

Authorized output currents for continuous current mode operation (I

AMPLIFIER TYPE

(Vrms) 1 s WITHOUT

SMT-BD2 - 220/04 240 4,4 2 SMT-BD2 - 220/08 240 8,8 4 SMT-BD2 - 220/12 240 13,8 6 SMT-BD2 - 220/17 240 17,7 8,5 8,5 SMT-BD2 - 220/30 240 30,8 8,5 12 15 SMT-BD2 - 220/30r 240 30,8 10 15 SMT-BD2 - 220/45 240 48,6 8,5 15 18 SMT-BD2 - 220/45r 240 48,6 10 20 23 SMT-BD2 - 220/60 240 61 8,5 17 20 SMT-BD2 - 220/60r 240 61 12 26 30 SMT-BD2 - 220/70 240 70 17 30 35 SMT-BD2 - 220/100 240 100 25 30 35

* Maximum ambient temperature = + 40° C, fan 1 = 56 l/s, fan 2 = 90 l/s.

Note

: The SMT-BD2-X/Xr amplifier types are equipped with an additional heatsink in order to improve the heat

dissipation and increase their rated current. The width of these amplifier types is then 18 TE instead of 12 TE.

Minimum inductance between phases 1 mH

U rated Imax (Arms)

Urated Imax (Arms)

Max. authorized rated current (Arms)

of the amplifier

FAN TYPE

FAN*

t protection in limiting mode)

Max. authorized continuous current (Arms) of

FAN*

the amplifier

FAN TYPE

Chapter 2 - Specifications

SMT-BD2

Conformity with the standards: CE approval - EMC standards with multiaxis power supply configuration Immunity: CEI standards 801- 2 - 3 - 4 BF rack and mains filter BF-35 or 70, Conducted and radiated disturbances: EN 55011, or SMTB.M 20 A single-axis rack and BF 35 filter. Group 1, class A "360°" shields; equipotentiality according to the - Electrical standards for industrial machines: wiring rules. EN 60204.1: - Insulator: 1500 VAC/1 min.

- Leakage current > 3 mA (EMI filters)

Temperature range * storage - 20°C to + 70°C * operation 5°C to +40°C From 40°C on, the rated currents must be reduced of 3 %/°C. Max. temperature: 50°C

1.2-C

URRENT RATINGS FOR THE 400 VAC AMPLIFIER VERSION

Operating voltage DC bus 565 VDC (480 VDC < DC bus < 685 VDC max.) Auxiliary supply voltage 310 VDC ( 200 VDC < Uaux < 340 VDC max.) Motor terminal to terminal output voltage 380Vrms for 565 VDC bus

Authorized output currents for current pulse mode operation (I

t protection in fusing mode)

AMPLIFIER

(Vrms) 1 s WITHOUT

U rated

Imax (Arms)

Max. authorized rated current

(Arms) of the amplifier

FAN TYPE

FAN*

SMT-BD2 - 400/15 400 15.5 5 7.5 SMT-BD2 - 400/30 400 30 8 15 SMT-BD2 - 400/45 400 48 10 19 SMT-BD2 - 400/60 400 60 not used 28

Authorized output currents for continuous current mode operation (I

t protection in limiting mode)

AMPLIFIER TYPE

(Vrms) 1 s WITHOUT

U rated

Imax (Arms)

Max. authorized continuous

current (Arms) of the amplifier

FAN TYPE

FAN*

SMT-BD2 - 400/15 400 15.5 not used 5 SMT-BD2 - 400/30 400 30 not used 10 SMT-BD2 - 400/45 400 48 not used 15 SMT-BD2 - 400/60 400 60 not used 23

* Maximum ambient temperature = + 40° C, fan 2 = 90 l/s.

Minimum inductance between phases 2 mH

Conformity with the standards: CE approval - EMC standards with multiaxis power supply configuration Immunity: CEI standards 801- 2 - 3 - 4 BF-400 rack and mains filter F400-35 or 70. Conducted and radiated disturbances: EN 55011, "360°" shields; equipotentiality according to the Group 1, class A wiring rules. - Electrical standards for industrial machines: EN 60204.1: - Insulator: 2500 VDC/1 min.

- Leakage current > 3 mA (EMI filters without condensators)

Temperature range * storage - 20°C to + 70°C * operation 5°C to +40°C From 40°C on, the rated currents must be reduced of 3 %/°C. Max. temperature: 50°C

Chapter 2 – Specifications

SMT-BD2

1.3 - OTHER SPECIFICATIONS

PWM switching frequency 10 KHz

Current regulator (PI) Adjusted to motor

Current loop bandwidth Cut-off frequency for 45° phase shift > 1 KHz

Internal current limitation Maximum current range : 20 % to 100 % of Imax Rated current range : 20 % to 50 % of Imax Imax = amplifier current rating

Analog current limitation input 0 V to 10 V, resolution = 12 bits 100 % to 0 % of the Maximum current value Maximum current available if not connected

Analog speed command input ±10 V, standard resolution = 12 bits Resolution = 16 bits optional

Motor accel/decel ramp range From 0 to 30 s between zero speed and max. speed

Speed regulator P, PI or PI Anti-wind-up system of the integrator Adjustable digital gains Antiresonance filter

Speed loop bandwidth Cut-off frequency for 45° phase shift Selectable : 50 Hz, 75 Hz or 100 Hz (see Note 1)

Speed range 2048 : 1 with 12 bit input command 32768 : 1 with 16 bit input command

Max. motor speed Adjustable from 100 rpm to 25000 rpm (see Note 2)

Hall sensors input Selectable by jumpers : 120° or 60° HES type 5 V or 15 V supply voltage HES sequence error detection

Sampling period = 0,5 ms

Note 1 :

The maximum speed loop bandwidth value not only depends on the amplifier specification but also on the feedback encoder resolution and the motor mechanical load. The lower the encoder resolution, the lower the servo loop gains and the servo loop bandwidth, to avoid any motor noise due to signal quantization effect. The mechanical load backlashes and elasticity can also limit the servo loop gains and bandwidth to avoid mechanical resonances. The optimal servo loop gain value for a given application can be automatically calculated by using the amplifier Auto-tuning procedure.

Note 2 :

The Max. motor speed value not only depends on the motor specification but also on the encoder specification. Both following conditions must be answered for taking into account the maximum encoder pulse frequency value : Max. motor speed (rpm) < 60 x 10 Max. motor speed (rpm) < 60 x Encoder pulse frequency limit (Hz) / Number of encoder pulses per revolution.For example with the ROD426 (Heidenhain) series encoder, the pulse frequency limit value is 300 KHz. So, a motor equipped with a ROD426 encoder having a resolution of 5000 ppr cannot exceed 3600 rpm.

Chapter 2 - Specifications

/ Number of encoder pulses per revolution

SMT-BD2

Encoder input Selectable by jumpers :

Quadrature TTL A & B with Z marker pulse RS 422 line receiver maximum pulses frequency: 1 MHz Resolution: 500 to 10

ppr (as from EPROM version 7.1C)

Incremental Sin/Cos encoder Heidenhain 1 Vcc Sin/Cos type or compatible Maximum signal frequency: 500 KHz Resolution: 10

to 106 ppr

Absolute single turn Sin/Cos encoder Heidenhain ERN 1085 or compatible resolution: 2048 ppr

Encoder output Quadrature TTL A & B with Z marker pulse RS 422 line driver Programmable encoder division ratio output resolution / input resolution : 1, 1/2, 1/4, 1/8

Logic inputs Optoisolated inputs, positive logic, response time = 0.5 ms:

•Enable/Disable: ENABLE

•Limit switch +: FC+

•Limit switch - : FC-

•Current command: CI

•Stop & Phasing command: CV0 Amplifier fault reset: RESET

Logic outputs Relay contact Umax = 50 V, Imax = 100 mA, Pmax = 10 W

• "Power ready": closed if power OK

• "Amp ready": closed if amplifier OK

• "Phasing OK": closed if motor phasing OK ( incremental encoder without HES)

• "Idyn": open if I

t warning threshold is reached

Monitor outputs 2 channels ANout1 & ANout2 +/-10 V full scale, 12 bit resolution Programmable output signals on the digitizing oscilloscope Channel 1 and Channel 2 : current ref (IDC), current mes (ID,IQ,IMES,I2t), speed ref (CV), speed mes (GT)

Error display LEDs on front panel and diagnostic via serial link

Parameter setting Serial link RS232 in standard or RS422 optional

Automatic functions Motor parameters adjustment (Auto-phasing) Regulator gains adjustment (Auto-tuning) Offset compensation on analog input CV

Altitude 1000 m

Moisture < 50 % at 40°C and < 90 % at 20°C no condensation (EN 60204.1 standard)

Cooling Natural convection or forced air, according to the rated

current (see current tables, chapter 2, § 1.1 and 1.2)

Chapter 2 – Specifications

SMT-BD2

2 - BLOCK DIAGRAM

The SMT-BD2 servo module block diagram is presented below.

A B

A B Z

ILIM

Encoder

input

Encoder

divider

Speed

ramping

Serial

link

Drive

protections

Speed Ref

+5 V

+15 V

-15 V

Speed

Pulses

counter

Speed

controller

Drive

parameters

Supply

voltages

Position

Current Ref

310 V DC

Vector

control

Current

limitation

Current Mes

Current

loops

PWM

power stage



Motor phases

Aux. supply

Power

supply

U V

PR

The PR8 and PR10 connectors are not accessible for direct wiring; they are plugged on the BM20A single-axis rack or on the multiaxes BF rack according to the SMT-BD2 amplifier housing (see chapter 3).

Chapter 2 - Specifications

SMT-BD2

3 - MAIN PROTECTIONS

ISPLAYED PROTECTIONS

3.1-D

PROTECTION ERROR DISPLAY LED*

Amplifier rated current overload I2 t . blinking display = I2t warning threshold is reached (Idyn output) . continuous display = I2t fault (amplifier inhibited in fusing mode) Encoder cable interruption Encoder

Encoder pulses counting error Counting

Power stage failure: Power stage . power supply overvoltage . internal overcurrent protection . short-circuit between phases . amplifier overtemperature (220/04 to 220/60 current ratings and 400 VAC amplifier range) Amplifier overtemperature °C Amp (only 220/70 and 220/100 current rating amplifiers) Power supply undervoltage Undervolt.

Motor overtemperature °C Motor

Hall Effect Sensors or Sin/Cos commutation channels error HES

Analog to Digital Conversion error ADC

Speed following error Tracking

Fault of the amplifier parameter storage EEPROM

Amplifier automatic procedure: Busy . blinking display = procedure operating . continuous display = operating error

* z = LED is unlit 5 = LED is lit.

All these faults are memory stored in the amplifier except for the "Undervolt." fault.

The reset of a stored fault can be made:

- by means of the RESET function in the Visual Drive Setup software

- via the fault RESET input (pin 13 of the X4 connector)

- by switching off the amplifier power supply.

5 z z z

z 5 z z

5 5

z 5

5 5

z z

5 z 5 z z 5 5 z 5 5 5 z

z z 5 z

5 z z 5 z z

z 5

5 z 5 5 5 5 5 5

Chapter 2 – Specifications

SMT-BD2

3.2 - FUSE PROTECTION

3.2.1 - Fuse protection for the 220 VAC amplifier version

F1 : Control of the average DC current of the power board supply (see Hardware adjustments in chapter 5, § 1). F2 : Control of the average DC current of the logic board supply (see Hardware adjustments in chapter 5, § 1).

AMPLIFIER TYPE F1 F2

Power Logic

SMTBD2-220/04 to 12 10 AT 1 A SMTBD2-220/17 and 30 15 AT 1 A SMTBD2-220/45 20 AT 1 A SMTBD2-220/60 20 AT 1 A SMTBD2-220/70 - 1 A SMTBD2-220/100 - 1 A

3.2.2 - Fuse protection for the 400 VAC amplifier version

F2 : Control of the average DC current of the logic board supply (see Hardware adjustments in chapter 5, § 1).

AMPLIFIER TYPE F2

Logic

SMT-BD2 - 400/15 1 A SMT-BD2 - 400/30 1 A SMT-BD2 - 400/45 1 A SMT-BD2 - 400/60 1 A

Chapter 2 - Specifications

SMT-BD2

Chapter 3 - Inputs - Outputs

1 - CONNECTORS LOCATION

- RACK CONNECTORS

1.1

For the 400 VAC amplifier version, see BF-400 RACK manual. For the 220 VAC amplifier version, see SMTB.M 20 A SINGLE-AXIS RACK manual or BF RACK manual.

1.2 - AMPLIFIER CONNECTORS

LED Faults display

X1 Encoder sensor

X5 Serial link

X2 Encoder output

X4 Command

BP Offset

2 - X5 SERIAL LINK CONNECTOR (Sub D 9 points male)

PIN FUNCTION REMARKS

5 0 Volt GND (shield connection if no "360°" connection possible on the connector) 3 TXD Transmit data RS-232 2 RXD Receive data RS-232 6 TXH Transmit data RS-422 7 TXL Transmit data RS-422 8 RXL Receive data RS-422 9 RXH Receive data RS-422

Chapter 3 – Inputs-outputs

SMT-BD2

3 - X1 ENCODER FEEDBACK CONNECTOR (Sub D 15 points female)

– X1 CONNECTOR FOR TTL INCREMENTAL ENCODER CONFIGURATION

3.1

The "TTL incremental encoder" configuration is selected according to the following COM and COD jumpers setting (see chapter 5, section 1: Hardware adjustments).

COD

COM

B5 B4

A wrong jumper configuration may damage the encoder

and amplifier electronics.

The corresponding X1 connector pin function is described below.

PIN FUNCTION REMARKS

1 Marker Z/ Differential input of the encoder marker pulse Z/ 9 Marker Z Differential input of the encoder marker pulse Z 2 Channel A/ Differential input of the encoder channel A/

10 Channel A Differential input of the encoder channel A

3 Channel B/ Differential input of the encoder channel B/

11 Channel B Differential input of the encoder channel B

5 +5V Encoder supply voltage (400 mA max. current)

4 GND Encoder supply GND 12 TC Motor thermal sensor input (10 mA max. load current) 13 GND Motor thermal sensor GND

6,7,8 reserved

14,15 reserved

Encoder input specification

SMT-BD2

COD B2 B1

ZM jumper configuration

Marker pulse enabled

Marker pulse disabled

Recommended driver: 26LS31

X1-9, 10, 11

X1-1, 2,3

200 Ω

+5 V

3,3 KΩ

200 Ω

COD jumpers configuration

+5 V

26LS32

Thermal sensor input specification

X1-12

X1-13

+15 V

PSTH-A

100 KΩ

100 nF

10 KΩ

+15 V

+5 V

PSTH-B

MN & OP jumpers configuration

MN OP

PTC thermal sensor

MN OP

NTC thermal sensor

SMT-BD2

Chapter 3 - Inputs - Outputs

SMT-BD2

3.2 – X1 CONNECTOR FOR TTL INCREMENTAL ENCODER & HES CONFIGURATION

The “ TTL incremental encoder & HES” configuration is selected according to the following COM and COD jumpers setting (see chapter 5, section 1: Hardware adjustments).

COD

B2 B1

60° HES type

COM

B2 B1

COD

COM

120° HES type

A wrong jumper configuration may damage the encoder and amplifier electronics.

The corresponding X1 connector pin function is described below.

PIN FUNCTION REMARKS

1 Marker Z/ Differential input of the encoder marker pulse Z/ 9 Marker Z Differential input of the encoder marker pulse Z 2 Channel A/ Differential input of the encoder channel A/

10 Channel A Differential input of the encoder channel A

3 Channel B/ Differential input of the encoder channel B/

11 Channel B Differential input of the encoder channel B

5 +5V Encoder supply voltage (400 mA max. current) 4 GND Encoder supply GND

14 HALL U Hall sensor input signal phase U

6 HALL V Hall sensor input signal phase V

7 HALL W Hall sensor input signal phase W 15 +15V Hall sensors supply voltage (50 mA max. current) 12 TC Motor thermal sensor input (10 mA max. load current) 13 GND Hall sensors/Thermal sensor GND

8 reserved

Encoder input specification

X1-9, 10, 11

X1-1, 2,3

200 Ω

+5 V

3,3 KΩ

200 Ω

COD jumpers configuration

+5 V

26LS32

SMT-BD2

B2 B1

ZM jumper configuration

COD

Marker pulse enabled

Marker pulse disabled

Recommended driver: 26LS31

Specification of the Hall sensors input

X1-6, 7, 14

X1-13

1 KΩ

1 nF

+5 V

COM jumpers configuration

10 KΩ

74HC14

COM

SMT-BD2

B5 B4 B3

120° HES

60° HES

Chapter 3 – Inputs-outputs

SMT-BD2

3.3 – X1 CONNECTOR FOR ABSOLUTE SINGLE TURN SIN/COS ENCODER CONFIGURATION

The “ Absolute single turn Sin/Cos encoder ” configuration (Heidenhain ERN 1085 or compatible) is selected according to the following COM and COD jumpers setting (see chapter 5, section 1: Hardware adjustments).

COD

The corresponding X1 connector pin function description is given below.

PIN FUNCTION REMARKS

1 Reference R/ Differential input of the Sin/Cos encoder reference pulse R/ 9 Reference R Differential input of the Sin/Cos encoder reference pulse R 2 Channel A/ Differential input of the Sin/Cos encoder channel A/

10 Channel A Differential input of the Sin/Cos encoder channel A

3 Channel B/ Differential input of the Sin/Cos encoder channel B/

11 Channel B Differential input of the Sin/Cos encoder channel B

6 Channel C/ Differential input of the Sin/Cos encoder channel C/

14 Channel C Differential input of the Sin/Cos encoder channel C

8 Channel D/ Differential input of the Sin/Cos encoder channel D/ 7 Channel D Differential input of the Sin/Cos encoder channel D 5 +5V Sin/Cos encoder supply voltage (400 mA max. current)

4 GND Sin/Cos encoder supply GND 12 TC Motor thermal sensor input (10 mA max. load current) 13 GND Motor thermal sensor GND 15 reserved

Specification of the Sin/Cos encoder channels

X1-9, 10, 11

X1-1, 2, 3

COM

B4 B3

120 Ω

10 KΩ

A wrong jumper configuration may damage the encoder and amplifier electronics.

100 KΩ

COD jumpers configuration

ZM jumper configuration

SMT-BD2

COD

B2 B1

100 KΩ

Specification of the Sin/Cos commutation channels

X1-14, 7

1 KΩ

X1-6, 8

10 KΩ

50 KΩ

Marker pulse enabled

Marker pulse disabled

SMT-BD2

COM jumpers configuration

COM

B5 B4

Chapter 3 - Inputs - Outputs

SMT-BD2

3.4 - X1 CONNECTOR FOR OTHER SIN/COS ENCODER CONFIGURATIONS

3.4.1 – X1 CONNECTOR FOR INCREMENTAL SIN/COS ENCODER CONFIGURATION

The “ Incremental Sin/Cos encoder ” configuration (Heidenhain 1Vcc Sin/Cos encoder or compatible) is selected according to the following COM and COD jumpers setting (see chapter 5, section 1: Hardware adjustments).

COD

COM

B4 B3

COM

A wrong jumper configuration may damage the

encoder and amplifier electronics.

B5 B4 B3

COD

COM

B5 B4 B3

COD

The corresponding X1 connector pin function description is given below.

PIN FUNCTION REMARKS

10 Channel A Differential input of the Sin/Cos encoder channel A

3 Channel B/ Differential input of the Sin/Cos encoder channel B/

11 Channel B Differential input of the Sin/Cos encoder channel B

5 +5V Sin/Cos encoder supply voltage (400 mA max. current)

4 GND Sin/Cos encoder supply GND 12 TC Motor thermal sensor input (10 mA max. load current) 13 GND Motor thermal sensor GND

6,7,8 Reserved

14,15 Reserved

The Sin/Cos channels specifications are given in section 3.3 of this chapter.

3.4.2 – X1 CONNECTOR FOR INCREMENTAL SIN/COS ENCODER & HES CONFIGURATION

The “ Incremental Sin/Cos encoder & HES” configuration (Heidenhain 1Vcc Sin/Cos encoder or compatible) is selected according to the following COM and COD jumpers setting (see chapter 5, section 1: Hardware

adjustments).

B2 B1

60° HES type

A wrong jumper configuration may damage the encoder and amplifier electronics.

120° HES type

The corresponding X1 connector pin function description is given below.

PIN FUNCTION REMARKS

1 Reference R/ Differential input of the Sin/Cos encoder reference pulse R/

9 Reference R Differential input of the Sin/Cos encoder reference pulse R

2 Channel A/ Differential input of the Sin/Cos encoder channel A/ 10 Channel A Differential input of the Sin/Cos encoder channel A

3 Channel B/ Differential input of the Sin/Cos encoder channel B/ 11 Channel B Differential input of the Sin/Cos encoder channel B

5 +5V Sin/Cos encoder supply voltage (400 mA max. current)

4 GND Sin/Cos encoder supply GND 14 HALL U Hall sensor input signal phase U

6 HALL V Hall sensor input signal phase V

7 HALL W Hall sensor input signal phase W 15 +15V Hall sensors supply voltage (50 mA max. current) 12 TC Motor thermal sensor input (10 mA max. load current) 13 GND Motor thermal sensor GND

8 Reserved

The Sin/Cos channels specifications are given in section 3.3 of this chapter. The Hall sensor inputs specifications are given in section 3.2 of this chapter.

Chapter 3 – Inputs-outputs

SMT-BD2

4 - X4 COMMAND CONNECTOR (Sub D 25 points male)

Pin Function I / O REMARKS

1 Limit switch + I Optoisolated input (I/O jumper open), positive logic (5V to 24V)

14 Limit switch - I Optoisolated input (I/O jumper open), positive logic (5V to 24V)

4 Current command CI I Optoisolated input (I/O jumper open), positive logic (5V to 24V) 7 Stop&Phasing command CV0 I Optoisolated input (I/O jumper open), positive logic (5V to 24V)

20 Enable/Disable I Optoisolated input (I/O jumper open), positive logic (5V to 24V)

23,24,25 0 Volt of optoisolated input I Optoisolated reference (I/O jumper open)

13 RESET I Amplifier reset via 0 V (contact between 13 and 12) 12 0 Volt of RESET input I

Current limitation input

17 16

10 ANout1 monitor O ± 10 V; resolution: 12 bits; load: 10 mA

11 0 Volt analog outputs Programmable output signals on the digitizing oscilloscope

18,19 Amplifier ready O Relay contact: closed if amplifier OK

5,6 Phasing OK O Relay contact: closed if motor phasing OK

8,9 Idyn warning O Relay contact: open if Idyn warning threshold is reached

21 + 15 V O 47 Ohms output impedance, 50 mA max. output current 22 - 15 V O 47 Ohms output impedance, 50 mA max. output current

0 Volt analog inputs

Input command CV +

Input command CV ± 10 V current input command with CI input active (full amplifier current rating Imax for 10 V)

2 ANout2 monitor O ± 10 V; resolution: 12 bits; load: 10 mA

Pmax = 10 W with Umax = 50 V or Imax = 100 mA

I I Current limitation 100 % to 0 % of the Maximum current value

for 0 V to 10 V (Maximum current available if not connected)

I I ± 10 V speed input command with CI input inactive

(Maximum speed value for 10 V)

Channel 1 and Channel 2: current ref (IDC), current mes (ID, IQ, IMES, I2t), speed ref (CV), speed mes (GT)

Overvoltage pulses protection by bidirectional TRANSIL

(in motor phasing configuration without HES)

Overvoltage pulses protection by bidirectional TRANSIL

Chapter 3 - Inputs - Outputs

SMT-BD2

4.1 - SPECIFICATION OF THE ANALOG INPUTS / OUTPUTS

22 nF

20 KΩ

SMT-BD2

X4-17 (CV+) X4-16 (CV-)

X4-3 (ILIM)

X4-15 (AGND)

10 KΩ

10 nF

10 KΩ

10 nF

10 KΩ

10 nF

10 KΩ

22 nF

20 KΩ

22 nF

SMT-BD2

1 KΩ

X4-10 (ANout1)

1 KΩ

X4-2 (ANout2)

X4-11 (AGND)

Chapter 3 – Inputs-outputs

SMT-BD2

4.2 - SPECIFICATION OF THE LOGIC INPUTS / OUTPUTS

5 V

SMT-BD2

X4-1, 4, 7, 14, 20

X4-23, 24, 25

4,1 KΩ

100 KΩ

I/O

TLP281

10 nF

I/O jumper open

When the I/O jumper is open, the 0 V of the optoisolated inputs (X4 pins 23,24,25) is not connected to the 0 V of the SMT-BD2 amplifier module (X4, pin 12).

X4-1, 4, 7, 14, 20

X4-23, 24, 25

4,1 KΩ

100 KΩ

I/O

5 V

TLP281

10 nF

SMT-BD2

I/O jumper closed

When the I/O jumper is closed, the 0 V of the optoisolated inputs (X4, pins 23, 24, 25) is connected to the 0 V of the SMT-BD2 amplifier module (X4, pin 12).

SMT-BD2

+15 V

PRME15015

BZW04P85B

X4-5, 8, 18

X4-6, 9, 19

Chapter 3 - Inputs - Outputs

SMT-BD2

5 - X2 POSITION OUTPUT CONNECTOR (Sub D 25 points female)

PIN FUNCTION I / O REMARKS

1 Marker Z/ O Differential output of the encoder marker pulse (5 V, 20 mA max.) 2 Marker Z O Differential output of the encoder marker pulse 3 Channel A/ O Differential output of the encoder channel A/ (5 V, 20 mA max.) 4 Channel A O Differential output of the encoder channel A 5 Channel B/ O Differential output of the encoder channel B/ (5 V, 20 mA max.)

6 Channel B O Differential output of the encoder channel B 7 & 25 0 V O 8 to 24 reserved

The programmable encoder ouput Division ratio (Output resolution / Input resolution) is only valid for the A and B channels. The Marker Z channel is not modified by this parameter value.

SPECIFICATION OF THE TTL ENCODER OUTPUT

SMT-BD2

Recommended receiver: 26LS32.

+5 V

X2-2, 4, 6

26LS31

X2-1, 3, 5

Chapter 3 – Inputs-outputs

SMT-BD2

Chapter 4 - Connections

1 - CONNECTION DIAGRAMS

- RACK POWER SUPPLY AND MOTOR CONNECTION

1.1

For the 400 VAC amplifier version, see BF-400 RACK manual. For the 220 VAC amplifier version, see BM20A SINGLE-AXIS RACK manual or BF RACK manual.

1.2 - AMPLIFIER I/O CONNECTIONS

1.2.1 - Amplifier connections with TTL encoder & HES motor feedback

B2 B1

SMT- BD2

COD

COM

3 9

1 5

B5 B4 B3

15 13

B4 B3

12 13

RACK

U V

GND GND

+5 V

GND

U V W

+15 V

GND

CONTROLLER

Encoder

input

DAC

output

Logic

I/Os

GND

CV+ CV-

GND

+24 V

ENABLE

CV0

AOK

PhOK

Idyn

A A/

B B/

+24 V I/O

FC+ FC-

4 3 6 5 2 1 7

17 16

1 14

20 7 4

18 5 8

19 6 9

ENCODER

A A/

B B/ Z

THERMAL

U V

HALL

EFFECT

SENSORS

SENSOR

MOTOR

0 V

0 V I/O

Reset

12 13

I/O

I/O jumper open

L2 L3

GND

POWER SUPPLY

The I/O jumper must be open for getting the X4 connector I/Os optoisolation : the I/O 0 V (X4, pins 23, 24, 25) is disconnected from the 0 V of the SMT-BD2 amplifier module.

Chapter 4 - Connections

SMT-BD2

1.2.2 - Amplifier connections with Absolute single turn Sin/Cos encoder feedback

B2 B1

SMT- BD2

COD

COM

B4 B3

3 9

7 8 5

CONTROLLER

Encoder

input

GND

A A/

B B/

4 3 6 5 2 1 7

ENCODER

A A/ B

B/ R R/

C C/ D D/

+5 V

SIN/COS

THERMAL

SENSOR

MOTOR

POWER

SUPPLY

DAC

output

Logic

I/Os

CV+

CV-

GND

+24 V

ENABLE

CV0

AOK

PhOK

Idyn

0 V

+24 V I/O

0 V I/O

FC+

FC-

Reset

14 20

I/O

I/O jumper open

RACK

GND GND

GND

The I/O jumper must be open for getting the X4 connector I/Os optoisolation : the I/O 0 V (X4, pins 23, 24, 25) is disconnected from the 0 V of the SMT-BD2 amplifier module.

Chapter 4 – Connections

SMT-BD2

– CONNEXION DES E/S DU VARIATEUR EN UTILISANT LA TENSION D’ALIMENTATION +15 V SUR LE CONNECTEUR

1.2.3

+15 V

FC+

FC-

ENABLE

CV0

PhOK

Idyn

4,7 kOhm

4,7kOhm

4,7 kOhm

SMT- BD2

GND

RAZ

I/O

Pont I/O fermé

Le pont des I/O doit être fermé pour que le 0 V des E/S (X4, pins 23, 24, 25) soit connecté au 0 V du module variateur SMT-BD2.

1.3 – CONNEXION DE LA LIAISON SERIE RS-232

Reprise de blindage sur 360°

Port série

RxD 2

TxD 3

GND 5

3 TxD

2 RxD

5 GND

SMT-BD2

Sub D 9 pts femelle

Sub D 9 pts mâle

Chapitre 4 – Connexions

SMT-BD2

2 - WIRING (according to CEI 801 and EN 55011 standards)

- GND WIRING AND GROUNDING

2.1

The reference potential is the earth (ground). Motors and sensors (encoder + HES) are grounded via their housing. If a potential reference is existing, like a main chassis or a cabinet, with a low impedance between the various elements, it should be used to connect ALL references to it and also connect this reference to the earth (ground).

Long reference potential connections are suitable ONLY if these connections have an impedance < 0,1 Ω. Cables with low potential should NEVER run in the proximity of power lines. Each conductor cable (carrying a potential) must be shielded. Several wires in the same sleeve must be twisted and shielded.

According to the CEI 801 standard, the connectors must be metallic or metal plated and must have a 360° shield

connection.

2.2 - MOTOR AND SENSORS CABLES

Cable ends should have a metallic collar allowing a 360° shield connection. Motor cables must be shielded to avoid common mode effects. Encoder and HES cable must also be shielded.

2.3 - INPUT COMMAND AND SERIAL LINK CABLES

The analog input command signal CV requires a pair twisted and shielded cable. The shield must have a "360°" connection via metallic collars at both ends. If the shield is connected by means of a pig tail, it must be connected at one end to a 0 Volt pin of X4 on the amplifier side with a connection as short as possible.

The input command (CV) wiring must be made according to the polarity between the controller and the amplifier (CV on "diff high" of the controller). The logic 0 Volt is directly connected to the amplifier housing. The connection continuity is ensured by the fastening screws on the front panels. The amplifier 0 Volt and the controller 0 Volt

MUST be connected by means of a wire. The shield MUST NEVER be used as a conductor of the 0 Volt potential.

The serial link cable must also be shielded according to the above mentioned shielding recommendations.

Chapter 4 – Connections

SMT-BD2

3 - 360° SHIELD ON THE CONNECTORS

RULE : The shield must never be interrupted or corrupted over the whole cable length.

Self-sticking copper ribbon if necessary,

for increasing the shield diameter in order

to get it correctly tightened

under the clamp

Ground

Motor connector for

encoder and motor cables

W V

L2 U

Motor connector box

The cable can be soldered on the shield because the

connector box is metallic. This solution does not exactly meet

the EMC requirements but it is acceptable.

Metallic or metal plated plastic

360° shield ensured by

the tightening clamp

BF Rack

UV W

SMT-BM 20 A rack

SUB-D pin package

INFRANOR

amplifier

The fastening screws must

be tightened in order to ensure

the shield continuity on the

amplifier housing

SUB-D connector

NOTE : When the 360° shield is made by means of a clamp it is not necessary to additionally connect a wire on the shield connection pin of the SUB-D connector.

Chapter 4 - Connections

SMT-BD2

Chapter 5 - Adjustable functions

1 - HARDWARE ADJUSTMENTS

All the hardware adjustments of the SMT-BD2 amplifier module are presented on the following diagrams.

Current loops (power board)

X2 X5 X1

I/O

Inputs 0 V

reference

Motor thermal

sensor type

16 bit ADC (option)

01656C

+5 V supply

RS-422 (option)

Serial link selection:

B=RS-232 (standard)

C=RS-422 (option)

PSTH

A B C D

Motor thermal

sensor adjustment

B C

Parameters

EEPROM

"Undervolt." fault

inhibition

Encoder signal

Firmware memory

COD

Encoder marker pulse

disable/enable

CT/BD2 (option)

COM

Commutation signal

Power fuse

(power board)

Only for the

range

220 V

Logic fuse

(power board)

234

Drive address selection

PR3

234

PR8

For amplifier types 220/04 to 220/60 and 400/15 to 400/60 VAC range

Chapter 5 – Adjustable functions

SMT-BD2

PU CA C14 RA

CA C14 RA

A and B OPEN: with auxiliary supply

A and B CLOSED: without auxiliary supply

PR3

Power board adjustment for amplifier types 220/70 A and 220/100 A

CA C14 RA

Chapter 5 - Adjustable functions

SMT-BD2

Braking resistor

Braking resistor jumper

for 220/04w to 220/17w

Braking resistor jumper

for 220/30w to 220/60 w

SMT-BM 20 A single-axis rack: Braking resistor jumper closed. BF-rack: Braking resistor jumper open.

NOTE: This braking resistor system selection is only available on « w » referenced amplifiers.

Braking system selection on SMT-BD2-220/04w to 220/60w

Chapter 5 – Adjustable functions

SMT-BD2

2 – ADJUSTABLE PARAMETERS

The SMT-BD2 serial link connector (X5) must be connected to the serial interface of a PC for the parameter setting operation. The Visual Drive Setup software, which is IBM-PC compatible with the WINDOWS® operating system, allows the clear display and easy modification of all amplifier parameters.

Please see Web site www.infranor.fr

Minimum requirements for the PC Processor : Pentium Operating system : WINDOWS 95/98, WINDOWS NT Graphics adapter : Windows compatible, colour SVGA with resolution 800x600 or 1024x768 Drives : 3.5” disk drive hard disk with 6 MB free space Main memory : at least 8 MB Interface : One free serial interface (COM1, COM2, COM3 or COM4)

for downloading the Visual Drive Setup software.

Chapter 5 - Adjustable functions

SMT-BD2

Chapter 6 - Commissioning

1 - CHECKING THE AMPLIFIER CONFIGURATION

- STANDARD AMPLIFIER CONFIGURATION

1.1

The standard SMT-BD2 amplifier configuration is given below. See chapter 5, section 1 "Hardware

adjustments" for the jumpers location.

* Inputs 0 V reference jumper I/O is open (optoisolated inputs)

* Current loops adjustment jumpers in position B2 (medium gain)

* Motor temperature sensor jumper in position MN (PTC sensor type)

* Undervolt fault inhibition jumper in position JK ("Undervolt." fault enabled)

* Serial link communication jumper in position B (RS-232 protocol)

* Drive address selection jumpers in position OFF (address 0 selected)

* Encoder signal jumpers COD in position B1 (TTL incremental encoder configuration)

* Encoder marker pulse jumper in position ZM (encoder marker pulse enabled)

* Commutation signal jumpers COM in position B3 (incremental encoder configuration without HES)

During the machine adjustments, some drive connection or parameter setting errors may involve dangerous axis movements. It is the user's responsibility to take all necessary steps in order to

reduce the risk due to uncontrolled axis movements during the operator's presence in the concerned area.

1. 2 - ENCODER CONFIGURATION

If the motor is equipped with a "TTL incremental encoder", select the following COD and COM jumpers setting.

COD

B2 B1

If the motor is equipped with a "Sin/Cos incremental encoder", select the following COD and COM jumpers setting.

COD

If the motor is equipped with an "Absolute single turn Sin/Cos encoder" (Heidenhain ERN 1085 or compatible), select the following COD and COM jumpers setting.

COD

B2 B1

COM

B4 B3

Chapter 6 – Commissioning

SMT-BD2

1. 3 - HALL EFFECT SENSORS CONFIGURATION

If the motor is equipped with Hall Effect Sensors devices (HES), select the following COM jumpers setting according to the HES type (60° or 120°).

COM

B5 B4 B3

COM

B4 B3

60° HES type

120° HES type

If the motor is not equipped with Hall Effect Sensors devices, the following COM jumpers setting must be selected. In this case a motor phasing procedure must be executed at each amplifier power up.

COM

B5 B4 B3

1. 4 - MOTOR THERMAL SENSOR CONFIGURATION

Select the right MN or OP jumper setting according to the motor thermal sensor type (PTC or NTC).

1.4.1 - PTC thermal sensor

On motors equipped with a PTC thermal sensor (triggering on high impedance), the amplifier configuration is the following: MN jumper closed and OP jumper open. The triggering threshold adjustment for the PTC thermal sensor is made by means of the PSTH components, as described below : PSTH-D = 14,3 kΩ; PSTH-B = 28 kΩ; PSTH-A = 3 x RPTC (120°C) in kΩ. RPTC (120°C) = ohmic value of the PTC thermal sensor resistor at 120°C; the default adjustment is RPTC (120°C) # 3 kΩ with PSTH-A = 10 kΩ.

1.4.2 - NTC thermal sensor

On motors equipped with a NTC thermal sensor (triggering on low impedance), the amplifier configuration is the following: OP jumper closed and MN jumper open. The triggering threshold adjustment for the NTC thermal sensor is made by means of the PSTH components, as described below: PSTH-D = 14,3 kΩ; PSTH-B = 28 kΩ; PSTH-A = 3 x RNTC (120°C) in kΩ. RNTC (120°C) = ohmic value of the NTC thermal sensor resistor at 120°C; the default adjustment is RNTC (120°C) # 3 kΩ with PSTH-A = 10 kΩ.

Chapter 6 - Commissioning

SMT-BD2

1.5 - CURRENT LOOPS ADJUSTMENTS

1.5.1 - Current loops adjustments for the 400 VAC amplifier version

Select the right current loops jumpers setting (B1, B2 or B3 position) according to motor and amplifier specifications.

For the 400VAC version of the BL MAVILOR motor series, the current loops adjustments are made according to following selection table.

AMPLIFIER

MOTOR

BL 113 B2 BL 114 B2 BL 115 B2 B1 BL 141 B1 B1 BL 142 B2 B1 BL 143 B1 B1 B1 BL 144 B1 B1 B1 BL 191 B3 B3 BL 192 B3 B3

For other motors the adjustment of the current loops according to the amplifier current rating and to the inductance between the motor terminals is made as follows:

15 A and 30 A amplifier current ratings Calculation of G = 0.8 x Amplifier current rating (A) x Inductance between phases (mH), If G < 60, current loop jumpers (x3) on B3 position, If 60 < G < 100, current loop jumpers (x3) on B2 position, If G > 100, current loop jumpers (x3) on B1 position.

45 A and 60 A amplifier current ratings Calculation of G = 0.8 x Amplifier current rating (A) x Inductance between phases (mH), If G < 100, current loop jumpers (x3) on B3 position, If 100 < G < 250, current loop jumpers (x3) on B2 position, If G > 250, current loop jumpers (x3) on B1 position.

15 A 30 A 45 A 60A

Chapter 6 – Commissioning

SMT-BD2

1.5.2 - Current loops adjustments for the 220 VAC amplifier version

Select the right current loops jumpers setting (B1, B2 or B3 position) according to motor and amplifier specifications.

For the BL and MA MAVILOR motor series, the current loops adjustments are made according to following selection table.

AMPLIFIER

MOTOR

MA 3 B1 MA 6 B1 B1 MA 10 B2 B1 B1 B1 MA 20 B2 B1 B1 B1 B1 B1 MA 30 B2 B2 B2 B1 B1 MA 45 B2 B2 B1 B1 B1 MA 55 B2 B2 B2 B1 BL 55-3 B1 BL 55-5 B1 BL 71 B2 BL 72 B2 B1 B1 BL 73 B2 B1 B1 BL 74 B2 B1 B1 BL 111 B1 B1 BL 112 B2 B2 B1 B2 BL 113 B3 B3 B2 B2 B2 BL 114 B3 B3 B2 B2 BL 115 B3 B3 B2 B2 B2 BL 141 B2 B2 B2 B1 B1 BL 142 B3 B3 B2 B2 B1 BL 143 B3 B2 B2 B1 B1 B1 BL 144 B2 B2 B2 B1 B1 B1

For other motors the adjustment of the current loops according to the amplifier current rating and to the inductance between the motor terminals is made as follows:

4 A, 8 A, 12 A and 17 A amplifier current ratings Calculation of G = 1,4 x Amplifier current rating (A) x Inductance between phases (mH), If G < 60, current loop jumpers (x3) on B3 position, If 60 < G < 100, current loop jumpers (x3) on B2 position, If G > 100, current loop jumpers (x3) on B1 position.

30 A, 45 A, 60 A, 70 A and 100 A amplifier current ratings Calculation of G = 1,4 x Amplifier current rating (A) x Inductance between phases (mH), If G < 100, current loop jumpers (x3) on B3 position, If 100 < G < 250, current loop jumpers (x3) on B2 position, If G > 250, current loop jumpers (x3) on B1 position.

4 A 8 A 12 A 17 A 30 A 45 A 60 A 70 A 100 A

Chapter 6 - Commissioning

SMT-BD2

2 - PUTTING INTO OPERATION

The "Enable" input must be open and the analog input command CV open or short-circuited (X4 connector can be disconnected).

Test the auxiliary supply voltage :

Rated value = 230 Vrms single-phase. Maximum value (must never be exceeded) = 260 Vrms, all mains variation tolerances included.

Switch on the auxillary supply. The green ON Led must be lit and the UNDERVOLT error must be displayed.

Test the power supply voltage :

- For the 220 VAC amplifier version: Rated value = 230 Vrms between phases.

Maximum value (must never be exceeded) = 260 Vrms, all mains variation tolerances included.

- For the 400 VAC amplifier version: Rated value = 400 Vrms between phases. Maximum value (must never be exceeded) = 480 Vrms, all mains variation tolerances included.

Switch on the power supply. The UNDERVOLT error Leds must be unlit. The braking resistor must remain cold.

Check that the amplifiers front panel screws are correctly fastened on the rack.

CAUTION ! This resistor is under high voltage

3 - AMPLIFIER COMMISSIONING AND ADJUSTMENT

- AMPLIFIER SETUP

3.1

Connect the encoder feedback cable between the motor and the amplifier X1 connector.

Connect the X4 command connector : the Enable input must be open, the FC+ and FC- limit switches inputs must be connected and closed, and the analog input command CV must be open or short-circuited.

Connect the serial link RS 232 between the PC and the amplifier X5 connector.

Switch on the PC and the monitor and then start the WINDOWS® interface.

Start the Visual Drive Setup software installation and follow the instructions.

Turn on the SMT-BD2 amplifier and start the Visual Drive Setup software.

If the message "No serial communication found" appears on the screen, click on OK and check following points before connecting again the Visual Drive Setup software:

- the amplifier is on (green LED ON must be lit),

- the amplifier and the PC are correctly connected via the RS 232 link,

- the software configuration (Com. port and Baudrate) is correct.

The Connect and Disconnect commands in the Setup menu allow to change the serial link connection from one amplifier to the other without leaving the Visual Drive Setup software.

The amplifier command cables (input command, serial link, encoder, HES) as well as the power cables must be connected and disconnected with the amplifier turned off.

Chapter 6 – Commissioning

SMT-BD2

3.2 - MOTOR HALL EFFECT SENSORS ADJUSTMENT

If the motor is using Hall Effect Sensors, check that the COM jumpers setting is correct according to the motor HES type (60° or 120°).

Check that the ENABLE input is disabled and the amplifier turned on.

If the “ HES ” error is displayed, turn off the amplifier and check the following points before turning it on again:

♦ The HES are correctly wired on the amplifier X1 connector (if 60° type HES are used, check the different

HES signals wiring combinations to find the right wiring order).

♦ The commutation signal jumpers COM are correctly set according to the HES type. ♦ The HES supply voltage value is correct.

Move the motor manually over one revolution, or one pole pitch for a linear motor.

If the “ HES ” error is displayed turn off the amplifier and check the following points before turning it on again:

♦ The HES are correctly wired on the amplifier X1 connector (if 60° type HES are used, check the different

HES signals wiring combinations to find the right wiring order).

♦ The commutation signal jumpers COM are correctly set according to the HES type. ♦ The HES supply voltage value is correct. ♦ The Motor encoder resolution parameter value is correct.

If the motor HES are not working correctly, select the following COM jumpers setting to run the motor without the HES devices.

COM

In this case a motor phasing procedure must be executed at each amplifier power up.

B4 B3

3.3 - ABSOLUTE SINGLE TURN SIN/COS ENCODER ADJUSTMENT

If the motor is using an absolute single turn Sin/Cos encoder (Heidenhain ERN 1085 or compatible), check that the COD and COM jumpers setting are correct.

Check that the ENABLE input is disabled and the amplifier turned on, and move the motor manually over one revolution.

If the “ HES ” error is displayed, turn off the amplifier and check the following points before turning it on again:

♦ The Sin/Cos encoder commutation channels are correctly wired on the amplifier X1 connector. ♦ The commutation signal jumpers COM are correctly set. ♦ The Sin/Cos encoder supply voltage value is correct. ♦ The Motor encoder resolution parameter value is correct.

Chapter 6 - Commissioning

SMT-BD2

3.4 - AMPLIFIER PARAMETER SETTING

Select Software control mode and switch on the Off position.

Select the motor to be used in the Motor list and check the Motor encoder resolution value, the Speed limit and the Current limits according to the motor and amplifier specifications.

Select Fusing mode for the I

If the “incremental encoder" configuration without HES is selected, check that the free motor

If the motor used is not on the Motor list , proceed as described below :

♦ Enter the servo motor Encoder resolution value. ♦ Adjust the Speed limit according to the motor and encoder specifications. ♦ Adjust the Current limits according to the motor and amplifier specifications. ♦ Uncouple the motor from the mechanical load and check that the free motor movement over 1 revolution, or

1 pole pitch for linear motors, is not dangerous for the operator. Then execute the Auto-phasing procedure.

♦ Calculate the Current phase lead value (this parameter is especially useful for motors with a low inductance

and running at high speeds).

Select the Encoder output resolution.

In case of loud noise in the motor at standstill and when running, check the rigidity of the transmission between motor and load (backlashes and elasticities in gears and couplings). If necessary, renew the Auto-tuning procedure by selecting a lower bandwidth (Bandwidth = Medium or Low). If the problem remains, renew the

Auto-tuning procedure by activating the Antiresonance filter.

Test the motor running in both directions with a low digital speed reference value. If required, adjust with more accuracy the speed loop response stability by means of the Stability gain buttons or by means of the adjustable gain values.

Short-circuit the "CV" input of the X4 connector or enter a zero speed input command in the NC, if you want to compensate the offset of the whole amplifier + NC system. Then execute the Offset compensation procedure or activate the Offset button on the amplifier front panel.

movement over 1 revolution, or 1 pole pitch for linear motors, is not dangerous for the operator. Then execute the motor phasing procedure (see section 3.7 of this chapter).

Couple the motor to the load ; in the case of an axis with an unbalanced load (constant torque due to the gravity effect on a vertical axis), see paragraph 3.5 of this chapter. Check that the free motor movement over 1 revolution, or 1 pole pitch for linear motors, is not dangerous for the operator and the machine. Select the most apropriate filter and bandwidth; then execute the Auto-tuning procedure.

The Auto-tuning procedure should be executed in Software control mode and Off position selected. If the Auto-tuning procedure must be executed with the drive controlled by the analog input command CV, the value of the analog input command MUST be set at 0 Volt. It is the user's responsibility to take all necessary steps in order to reduce the risk due to uncontrolled axis movements during the Auto-tuning procedure.

t protection during all commissioning phases.

3.5 - AMPLIFIER AUTO-TUNING WITH AN UNBALANCED LOAD

Select Software control mode and switch on the OFF position.

Execute a first Auto-tuning procedure with the motor uncoupled from its mechanical load in order to initialize the gain values before coupling the motor to the load again.

Select the current limitation in Limiting mode and select a PI or PI and the motor brake are correctly operating before starting the Auto-tuning procedure.

In the case of an axis with an unbalanced load (constant torque due to the gravity effect on a vertical axis), the “incremental encoder ” configuration without HES is not valid because the motor phasing procedure at power up cannot be executed.

speed regulator. Check that the limit switches

Chapter 6 – Commissioning

SMT-BD2

Move the shaft with a low digital speed reference value up to a maintaining position (far enough from the axis limit switches) where a free movement over 1 revolution, or 1 pole pitch for linear motors, is not dangerous for operator and machine. Then execute the Auto-tuning procedure with the motor enabled at its maintaining position (digital speed reference input set at 0). In case of loud noise in the motor at standstill and when running, check the rigidity of the transmission between motor and load (backlashes and elasticities in gears and couplings). If necessary, renew the Auto-tuning procedure by selecting a lower bandwidth (Bandwidth = Medium or Low). If the problem remains, renew the Auto-tuning procedure by activating the Antiresonance filter.

During the Auto-tuning procedure execution with an unbalanced load (constant torque due to the gravity effect on a vertical axis), a wrong operation may involve dangerous axis movements. It is the user's

responsibility to take all necessary steps in order to reduce the risk due to uncontrolled axis movements during the operator's presence in the concerned area.

Go back to the motor standstill position before switching on the OFF position.

3.6 - SAVING OF THE AMPLIFIER PARAMETERS

Save all parameters in the amplifier EEPROM by means of the Save parameter to EEPROM procedure.

3.7 - MOTOR PHASING AT POWER UP

In the “incremental encoder ” configuration without HES, the motor phasing procedure must be executed according to the following diagram at each amplifier power up:

AMP. READY

X4-18, 19

POWER

READY

ENABLE

X4-20

CV0

X4-7

PHASING OK

X4-5, 6

Power up

End power up

Ready

Start phasing

Phasing

End phasing

Stopped

Start running

Running

In the case of an axis with an unbalanced load (constant torque due to the gravity effect on a vertical axis), the motor phasing procedure is not valid. The motor must be equipped with an incremental

encoder + HES or an absolute single-turn Sin/Cos encoder.

Chapter 6 - Commissioning

SMT-BD2

3.8 – PARAMETERS ADJUSTMENT TO A LINEAR MOTOR

The Motor encoder resolution parameter is calculated as described below:

S N S N S N

Motor magnets

Motor encoder resolution = 1000 x

The motor Maximum speed parameter value in rpm is calculated according to following formula:

Maximum speed (rpm) = 60 x x Maximum motor speed (m/s)

The linear speed value in m/s is calculated according to following formula:

Linear speed (m/s) = x X

1 encoder signal pitch = 4 counting increments

Motor pole pitch (mm)

Motor speed (rpm)

Pole pitch

Motor pole pitch (mm)

Encoder signal pitch (µm)

1000

Motor pole pitch (mm)

1000

Chapter 6 – Commissioning

SMT-BD2

Chapter 7 – Fault finding

1 - SYSTEM FAULT

If the red SYS led is lit when the amplifier is on, the logic board is off duty.

 Check that the EPROM firmware memory is correctly plugged on the amplifier.  Check for the possible presence of any conducting dust that may involve short-circuits on the amplifier logic

board.

2 - STORED FAULTS

If a fault occurs on the amplifier, it can generate the detection of several other faults which are only a consequence of the original one. In order to simplify the diagnostic and the maintainance, the faults are displayed and processed with the priority described below. For safety reasons, the power must be turned off before cancelling some faults that require the handling of the amplifier or the connectors.

2.1 - "BUSY" FAULT

 If the BUSY fault is continuously displayed after power on, the auto-test procedure has failed and the control

board is not operating correctly.

 If the BUSY fault is continuously displayed after the starting of the motor phasing procedure by CVO at power

up (“incremental encoder ” configuration without HES) , the procedure has failed because of an external cause and the calculated phase value is wrong. Check that the Motor encoder resolution parameter value is correct. Check that the Motor parameters (Pole pairs and Phase order) values are correct. Check that the ENABLE input is activated. Check that the limit switches inputs are not activated. Check that the motor is not locked and the shaft movement is free during the procedure execution.

 If the BUSY fault is continuously displayed after the execution of the Auto-phasing procedure, the procedure

has failed because of an external cause and the calculated parameters are wrong. Check that the Motor encoder resolution parameter value is correct. Check that the ENABLE input is activated. Check that the limit switches inputs are not activated . Check that the motor is unloaded and the shaft movement is free during the procedure execution.

 If the BUSY fault is continuously displayed after the execution of the Auto-tuning procedure, the procedure

has failed because of an external cause and the calculated parameters are wrong. Check that the ENABLE input is activated. Check that the limit switches inputs are not activated. Check that the motor shaft movement is free during the procedure execution.

 If the BUSY fault is continuously displayed after the execution of the Offset compensation procedure, the

offset is exceeding +/- 0.3 Volts. Check for the voltage value on the analog speed input command CV during the procedure execution. Check that the input command wiring between controller and amplifier answers the requirements of chapter 4 (CV at diff. low of the NC and 0 Volt cable).

 If the BUSY fault is continuously displayed after the execution of the Cogging torque acquisition procedure

(for rotating motors), the procedure has failed because of an external cause and the cogging acquisition is not valid. Check that the ENABLE input is activated. Check that the CI and CV0 inputs are not activated. Check that the limit switches inputs are not activated. Check that the encoder is providing one marker pulse per motor revolution. Check that the motor is unloaded and the shaft movement is free during the procedure execution. Check that the motor current value corresponding to the cogging torque effect is lower than 5% of the amplifier current rating.

 If the BUSY fault is continuously displayed after the execution of the Linear Cogging acquisition procedure

(for linear motors), the procedure has failed because of an external cause and the cogging acquisition is not valid. Check that the ENABLE input is activated. Check that the CI and CV0 inputs are not activated. Check that the positive and negative motor travel limit switches are operating correctly. Check that the encoder is providing one marker pulse over the entire motor travel. Check that the motor is unloaded and the displacement is free during the procedure execution. Check that the motor current value corresponding to the cogging force effect is lower than 5% of the amplifier current rating. Check that the motor travel distance (from the negative to the positive limit switch) is less than 4000000 encoder counting increments.

Chapter 7 - Fault finding

SMT-BD2

2.2 - "EEPROM" FAULT

 Check for the presence of the EEPROM and check its correct orientation and mounting.

 If the fault remains, the EEPROM is not correctly initialized (CHECKSUM error) or is not compatible with the

amplifier software. In this case, if the EEPROM fault is reset and if then the Save parameters to EEPROM procedure is executed, the EEPROM is automatically reinitialized with the amplifier default parameters.

2.3 - "°C MOTOR" FAULT

 If the fault occurs when starting the amplifier:

- Check the configuration of the MN and OP jumpers with regard to the type of thermal sensor used in the motor.

- Check the connection between thermal sensor and amplifier on the front panel connector X1.

 If the fault occurs during the operation:

- Check the motor temperature value and look for the reason of the motor overheating (mechanical overload, duty cycle too high, ...)

2.4 - "UNDERVOLT." FAULT

 If the fault occurs when starting the amplifier:

- Check that the power supply is on.

 If the fault occurs during the operation:

- Check that the power supply connections are correct

- Check that the power supply voltage value is correct

2.5 - "°C AMPLIFIER" FAULT

Check that the fan and the heatsink configurations are correct with regard of the required rated current (see

current table, Chapter 2, section 1).

Remark : This fault is only valid on amplifiers with current ratings 220/70 and 220/100.

2.6 - "POWER STAGE" FAULT

 If the fault occurs when starting the amplifier:

- Check the DC bus voltage and the terminal voltage of the power transformer secundary :

For the 220VAC version of the amplifier DC bus < 370 VDC and V secundary < 260 VAC For the 400VAC version of the amplifier DC bus < 800 VDC and V secundary < 480 VAC

 If the fault occurs during the operation:

- Check the braking system operation during the deceleration phases is correct,

- Check the sizing of the braking resistor with regard to the deceleration phases.

- Check for no short-circuit in the motor wiring and at the motor terminals.

- For amplifiers with 220/04 to 220/60 current ratings and 400 VAC range, check that the fan and the heatsink configuration is correct with regard to the required rated current (see current table, Chapter 2,

section 1).

2.7 - "HES" FAULT

For the "incremental encoder & HES" configuration:

 Check that the HES are correctly wired on the amplifier X1 connector (with 60° type HES you must check the

different wiring combinations to found the right wiring order).

 Check that the commutation signal jumpers COM are correctly set according to the HES type.  Check for the correct HES supply voltage value.  Check for the correct Motor encoder resolution parameter value.  Check that the HES-amplifier-motor ground connections and shield answer the requirements of chapter 4.

For the "Absolute single turn Sin/Cos encoder" configuration:

Chapter 7 – Fault finding

SMT-BD2

 Check that the Sin/Cos encoder commutation channels are correctly wired on the amplifier X1 connector.  Check that the commutation signal jumpers COM are correctly set.  Check for the correct Sin/Cos encoder supply voltage value.  Check for the correct Sin/Cos encoder C channel and D channel signal amplitude value.  Check that the Motor encoder resolution parameter value is correct.  Check that the encoder-amplifier-motor ground connections and shield answer the requirements of

chapter 4.

2.8 - "ENCODER" FAULT

For the “incremental encoder" configuration:

 Check the encoder supply connection on the amplifier connector X1.  Check that the encoder signal jumpers COD are correctly set.  Check the encoder A channel, B channel and marker pulse connections on the amplifier connector X1.

If the motor encoder is not providing a marker pulse channel output, the amplifier marker pulse channel must be disabled in order to cancel the "Encoder" fault. In this case the encoder marker pulse jumper ZM must be set in the disabled position as described below.

Encoder marker pulse enabled

For the “ Absolute single turn Sin/Cos encoder” configuration:

 Check the encoder supply connection on the amplifier connector X1.  Check that the encoder signal jumpers COD are correctly set.  Check the encoder A channel and B channel connections on the amplifier connector X1.

When the amplifier marker pulse channel input is disabled, the encoder counting protection is disabled (see section 2.9 "Counting" fault). In this case an incorrect encoder pulses counting can involve uncontrolled motor movements that may be dangerous for operator and machine.

Encoder marker pulse disabled

Chapter 7 - Fault finding

SMT-BD2

2.9 - "COUNTING" FAULT

For the "TTL incermental encoder" configuration:

 Check that the encoder signal jumpers COD are correctly set (position B1).  Check for the correct encoder supply voltage value  Check for the correct encoder-amplifier-motor ground and shield connections with regard to the

recommendations of chapter 4.

 Check for the correct encoder A channel, B channel and Z marker signal waveforms

Forward direction

Reverse direction

 Check that the following condition are answered for taking into account the maximum value of the encoder

pulse frequency at the maximum motor speed value : Max. motor speed (rpm) < 60 x 10

/ Number of encoder pulses per revolution

Max. motor speed (rpm) < 60 x Encoder pulse frequency limit (Hz) / Number of encoder pulses per revolution

 Check that the Motor encoder resolution parameter value is correct.

 Check that the number of encoder pulses between two successive Z marker pulses is an entire multiple of the

Motor encoder resolution value. If this condition is not fulfilled, the encoder counting protection must be disabled in order to cancel the "Counting" fault. The encoder counting protection can be disabled by disabling the encoder marker pulse by means of the ZM jumper (see section 2.8 "Encoder fault").

The encoder counting protection is checking that the encoder pulses count value between two successive Z marker pulses is an entire multiple of the Motor encoder resolution value. When the encoder counting protection has been disabled, the amplifier is only checking that the encoder pulses frequency is lower than 1.5 times the maximum encoder frequency. The maximum encoder frequency is calculated into the amplifier according to the Motor encoder resolution parameter value and the Maximum speed parameter value. In this case, encoder pulse noise at a frequency lower than 1.5 times the maximum encoder frequency may involve uncontrolled motor movements that may be dangerous for operator and machine.

Chapter 7 – Fault finding

SMT-BD2

For the Sin/Cos encoder" configuration:

 Check that the encoder signal jumpers COD are correctly set (position B2)  Check for the correct encoder supply voltage value  Check for the correct encoder-amplifier-motor ground and shield connections with regard to the

recommendations of chapter 4.

 Check for the correct encoder A channel, B channel and R reference signal waveforms.

A/ B

R R/

Forward direction Reverse direction

 Check for the correct Motor encoder resolution parameter value.

 Check that the number of encoder pulses between two successive R reference signals is an entire multiple of

the Motor encoder resolution value. If this condition is not fulfilled, the encoder counting protection must be disabled in order to cancel the "Counting" fault. The encoder counting protection can be inhibited by disabling the encoder reference channel by means of the ZM jumper (see section 2.8 "Encoder fault").

2.10 - "I

 Check the rated current value required with regard to the current table (see chapter 2, section 1).  Check the amplifier rated current defined in the Rated current parameter with regard to the current required

The encoder counting protection is checking that the encoder pulse count value between two successive R encoder counting protection has been disabled, the amplifier is only checking that the encoder pulse frequency is lower than 1.5 times the maximum encoder frequency. The maximum encoder frequency is calculated into the amplifier according to the Motor encoder resolution parameter value and the Maximum speed parameter value. In this case, encoder pulse noise at a frequency lower than 1.5 times the maximum encoder frequency can involve uncontrolled motor movements that may be dangerous for operator and machine.

T" FAULT

for the operation cycle.

reference signals is an entire multiple of the Motor encoder resolution value. When the

2.11 - "TRACKING" FAULT

Check that the Speed following error threshold parameter value is compatible with the required amplifier operating cycle (speed profile and speed loop adjustments). If necessary, increase the Speed following error

threshold parameter value.

2.12 - "ADC" FAULT

 On SMT-BD2/b amplifiers equipped with the 16 bit ADC option, check for the correct orientation and the

correct mounting of the 16 bit ADC component.

 Check that the input command wiring between controller and amplifier corresponds to the recommendations

of chapter 4, and repeat the Offset compensation procedure.

 If the fault still remains, the amplifier control board is not operating correctly.

Chapter 7 - Fault finding

SMT-BD2

3 - OPERATING PROBLEMS

- MOTOR SUPPLIED, BUT NO TORQUE

3.1

 Check the Maximum current and Rated current parameters.  Check that the current limitation input (X4 pin 3) is not activated.  Check that the amplifier is not operating in torque mode (X4 pin 4 active) with zero input command or with

CV0 input activated.

3.2 - MOTOR DOES NOT MOVE

 Check that the amplifier is on.  Check that the power supply is on.  Check the amplifier fuses (F1 and F2) and the motor connection.  Check the wiring of the signals FC+, FC- and ENABLE.

3.3 - SHAFT LOCKED, ERATIC OSCILLATIONS OR ROTATION AT MAXIMUM SPEED

 Check that the Pulse input mode is disabled in the Advanced functions menu.  Check the encoder wiring on the X1 connector and the mechanical mounting of the encoder on the motor.  Check the value of the Motor parameters parameter in the Advanced Functions menu and repeat the

Auto-phasing procedure, with unloaded motor.

3.4 - DISCONTINUOUS MOTOR ROTATION WITH ZERO TORQUE POSITIONS

Check the connection of the 3 phase cables between motor and amplifier.

3.5 - MOTOR DRIFT WITH ANALOG INPUT COMMAND AT ZERO SPEED

 Check that the input command wiring between the controller and the amplifier corresponds to the

recommendations of chapter 4 (CV at diff. low of the NC and 0 Volt cable).

 Check the offset compensation and, if necessary, execute the Offset compensation procedure.

3.6 - LOUD CRACKLING NOISE IN THE MOTOR AT STANDSTILL

 Check that the motor-amplifier-controller ground connections correspond to the recommendations of chapter

 Check that the speed input command wiring between controller and amplifier corresponds to the

recommendations of chapter 4 and check the shield connection of the encoder cable.

3.7 - LOUD NOISE IN THE MOTOR AT STANDSTILL AND WHEN RUNNING

 Check the rigidity of the mechanical transmission chain between motor and load (backlash and elasticity in

the gearboxes and couplings).

 Execute the Auto-tuning procedure again by choosing a lower bandwidth (Medium or Low).  If the problem remains, renew the Auto-tuning procedure by activating the Antiresonance filter.

3.8 - POSITION CONTROL NOT POSSIBLE WITH THE NC

 Check for the presence of the A, B and Z signals on the amplifier X2 connector by turning manually the motor

shaft and check the wiring between NC and amplifier.

 Check for the correct Maximum speed and Encoder output resolution parameters.  Check for the counting direction of the NC with regard to the sign of the speed input command. If there is a

reversal, use the function Reverse Movement to get a correct operation.

Chapter 7 – Fault finding

SMT-BD2

4 - SERVICE AND MAINTENANCE

When exchanging an amplifier on a machine, proceed as follows:

- Check that the new amplifier has the same hardware configuration as the old one,

- Plug in the parameter EEPROM (or a copy of it) of the old amplifier on the new one,

- Apply a zero speed input command and start the offset compensation procedure by means of the Offset button on the amplifier front panel.

The new amplifier is configurated like the old one.

Chapter 7 - Fault finding

SMT-BD2

Chapter 8 - Appendix

1 - USE OF THE LIMIT SWITCHES & "CVO" INPUTS

During the amplifier operation in speed mode (CI input inactive) the enabling of the CV0 input immediately stops the motor. The motor is decelerating according to the Accel/decel time parameter value. The motor is maintained at standstill while the CV0 input is activated. During the amplifier operation in torque mode (CI input activated) the enabling of the CV0 input sets the current reference at 0. The current reference is maintained at 0 while the CV0 input is activated.

During the amplifier operation in speed mode (CI input inactive) or in torque mode (CI input active), the enabling of the FC+ limit switch stops any motor displacement in the positive direction and the enabling of the FC- limit switch stops any motor displacement in the negative direction. The motor is decelerating with the amplifier

Maximum current value in order to get the shortest possible braking time.

2 - USE OF THE "AMP. READY" & "POWER READY" OUTPUTS

When an amplifier fault is released, the AMP. READY output is immediatly disabled (contact is open). After elimination of the error source, the amplifier can be reset via pins 12 and 13 of the X4 connector.

If the position initialization reference must be kept when a stored fault is released on the amplifier and the power supply turned off, it is necessary to have an auxiliary supply for the logic board which is independent from the power supply. In this case, the JK and KL jumpers of the logic board allow to inhibit or to release the "Undervolt." fault when the amplifier is turned on.

JK jumper closed and KL jumper open configuration : If the auxiliary supply is turned on before the main power supply, the "Undervolt." fault is displayed and can hide a fault of lower priority. The AMP READY and POWER READY outputs are both inactive (contact is open) until the power supply in on.

JK jumper open and KL jumper closed configuration : The "Undervolt." fault is inhibited when turning on the auxiliary supply before switching on the main power supply. The AMP READY output is then active and POWER READY remains inactive (contact open) until the main power supply is on.

Positive and negative directions depend on the encoder wiring and on the motor wiring. So, before mounting and wiring the limit switches, it is recommended to find the positive and negative directions of the motor.

3 - SPEED FOLLOWING ERROR PROTECTION

During the amplifier operation in speed mode (ENABLE input active and CI input inactive), when the speed controller error reaches the following error threshold value, the “Tracking” fault is released and the amplifier is disabled. The Speed following error threshold parameter value must be adjusted at its minimum value according to the operating cycle in order to detect any uncontrolled motor movements that may be dangerous for operator and machine.

Speed following error protection is inactive during the Auto-phasing and the Auto-tuning procedures. When the amplifier is operating in torque mode (CI input active), the speed following

error protection is also inactive.

Chapter 8 – Appendix

SMT-BD2

4 – I2t PROTECTION

– CURRENT LIMITATION IN FUSING MODE

4.1

When the amplifier RMS current (I the I2t error display is blinking on the amplifier front panel. If the RMS current (I2t) has not dropped below 85 % of the Rated current within 1 second, the I and the blinking I2t error display are both cancelled).

When the amplifier RMS current (I current at this value.

The amplifier current limitation diagram in an extreme case (motor overload or locked shaft) is shown below.

Maximum current

Rated current

t) reaches 85 % of the Rated current, the Idyn signal output is activated and

t fault is released and the amplifier is disabled (otherwise, the Idyn signal

t) reaches the Rated current value, the I2t protection limits the amplifier

Amplifier current

t1 = Idyn signal activation t2 = current limitation

t3 = I

t fault

1 second

Time

t1 t2 t3

The maximum current duration before the release of the Idyn signal depends on the value of the Rated current and Maximum current parameters. This value is calculated as follows:

T dyn (second) = t1 - t0 = 3.3 x [ Rated current (%) / Maximum current (%) ] 2

The maximum current duration before the limitation at the rated current also depends on the value of the Rated current and Maximum current parameters. This value is calculated as follows:

T max (second) = t2 - t0 = 4 x [ Rated current (%) / Maximum current (%) ]

NOTE 1 The above formulas are valid as long as the Maximum current / Rated current ratio is higher than 3/2. When the Maximum current / Rated current ratio is close to 1, the calculated values of Tdyn and Tmax are quite below the real values. For example when Maximum current / Rated current = 1.2, the measured Tdyn = 3.4 seconds and the measured Tmax = 4.4 seconds. When the Maximum current / Rated current ratio is equal to

t protection is no more disabling the amplifier but the current is limited at the Rated current value.

1, the I

NOTE 2 The amplifier I “ Channel ” menu. The I

t signal can be displayed on the digitizing oscilloscope by selecting the "I2t" signal in the

t signal threshold values according to the I2t protection mode described above are

calculated in the following manner :

Idyn signal activation threshold (%) = [Rated current (%)] Current limitation threshold (%) = [Rated current (%)]

/ 50

/ 70

The corresponding amplifier RMS current value can be calculated according to following formula :

Amplifier RMS current (%) = [I

t signal value (%) x 50]

1/2

In Fusing mode, the amplifier Rated current value must be adjusted lower or equal to the Maximum authorized rated current of the amplifier (see Chapter 2, section 1).

Chapter 8 - Appendix

SMT-BD2

4.2 - CURRENT LIMITATION IN LIMITING MODE

When the amplifier RMS current (I the I2t error display is blinking on the amplifier front panel. When the RMS current (I2t) drops below 85 % of the Rated current, the Idyn signal and the blinking I

When the amplifier RMS current (I2t) reaches the Rated current value, the I2t protection limits the amplifier current at this value.

The amplifier current limitation diagram in an extreme case (motor overload or locked shaft) is shown below.

Maximum current

Rated current

t) reaches 85 % of the Rated current, the Idyn signal output is activated and

t error display are both cancelled.

Amplifier current

t1 = Idyn signal t2 = current limitation

Time

t1 t2

The maximum current duration before the release of the Idyn signal output (t1 - t0) and before limitation at the rated current (t2 - t0) is calculated the same way as for the Fusing mode.

The I

t signal threshold values and the amplifier RMS current value on the digitizing oscilloscope, are also

calculated the same way as for the Fusing mode.

In Limiting mode, the amplifier Rated current value must be adjusted lower or equal to the

Maximum authorized continuous current of the amplifier (see Chapter 2, section 1).

5 - COGGING COMPENSATION OPTION

The cogging torque in brushless permanent magnet rotating motors or the cogging force in brushless permanent magnet linear motors result from the interaction between the permanent magnets and the winding frame slots. This disturbance is due to the difference of reluctance between the copper of the windings and the iron of the slots. For a given motor, the cogging can be easily evaluated by simply moving the motor manually when the amplifier is disabled. The Cogging compensation option available in the SMT-BD2 amplifier allows to cancel the motor cogging effects for specific applications where torque accuracy or force accuracy higher than 1 % are required.

5.1 - AMPLIFIER CONFIGURATION

The cogging compensation option for both rotating and linear motors is available from the 6.1 version of the amplifier firmware memory and the 1.04 version of the Visual Drive Setup software.

Check for the presence of the CT/BD2 memory mounted on the amplifier logic board (see Chapter 5, section 1

Hardware adjustments).

Check that the encoder marker pulse channel is enabled (ZM jumper in enabled position).

Chapter 8 – Appendix

SMT-BD2

5.2 – COGGING COMPENSATION SETUP FOR ROTATING MOTORS

Cogging torque compensation is only valid on brushless rotating motors equipped with an encoder providing one marker pulse per motor revolution.

Start the amplifier commissioning and adjustment as described in chapter 6.

Uncouple the motor from the load in order to avoid any external disturbance on the shaft during the cogging torque acquisition procedure.

Select the PI

Execute the Cogging torque acquisition procedure. This procedure is taking a few minutes because the motor is moving at low speed over 1 or 2 revolutions in both directions. The acquired cogging torque value is automatically stored in the amplifier CT/BD2 memory during the procedure execution.

For checking the cogging torque compensation effects on the motor shaft, proceed as described below :

Switch the amplifier in torque control mode by activating the CI input (X4 connector, pin 4) and short-circuit or open the analog command input CV (X4 connector, pins 15, 16 and 17).

Execute the Offset compensation procedure.

Check manually for the reduction of the cogging torque effects, by moving the motor shaft when the Cogging compensation command is activated and the amplifier enabled. If some resistant points do remain over one complete motor shaft revolution, renew the acquisition procedure.

Switch off the amplifier and couple the motor to the load.

Switch on the amplifier again, enable the Cogging compensation command and execute the Save parameters

to EEPROM procedure.

controller and the High Bandwidth, then execute the Auto-tuning procedure.

The motor shaft must not be disturbed during the cogging torque acquisition procedure.

At the amplifier power up the cogging torque compensation is only effective after the detection of the first encoder marker pulse.

When changing either the motor, the encoder or the amplifier, the cogging torque acquisition procedure must be renewed.

5.3 – COGGING COMPENSATION SETUP FOR LINEAR MOTORS

Cogging force compensation is only valid on brushless linear motors equipped with an encoder providing only one marker pulse over the entire motor travel. The motor must also be equipped with positive and negative travel limit switches connected on the X4 connector (FC+ and FC- inputs). The

maximum motor travel distance (from the negative to the positive limit switch) is limited at 4000000 encoder counting increments. The CT/BD2 memory can store up to 8000 cogging compensation points; so the cogging compensation pitch is equal to the motor travel distance value divided by 8000.

Start the amplifier commissioning and adjustment as described in chapter 6. Check that the motor positive and negative travel limit switches are operating correctly.

In the case of a motor with an unbalanced load (constant force due to the gravity effect on a non horizontal axis), the cogging compensation will include the gravity force. In this case the cogging

compensation is only valid if the motor current value corresponding to the gravity force effect is lower than 5% of the amplifier current rating.

Chapter 8 - Appendix

SMT-BD2

Select the PI

Execute the Linear cogging acquisition procedure. This procedure is taking a few minutes because the motor is moving at low speed from one travel limit switch to the other in both directions. The acquired cogging force value is automatically stored in the amplifier CT/BD2 memory during the procedure execution.

For checking the cogging force compensation effects on the motor shaft, proceed as described below :

Switch the amplifier in force control mode by activating the CI input (X4 connector, pin 4) and short-circuit or open the analog command input CV (X4 connector, pins 15, 16 and 17).

Execute the Offset compensation procedure.

Check manually for the reduction of the cogging force effects, by moving the motor when the Cogging compensation command is activated and the amplifier enabled. If some resistant points do remain over one complete motor travel, renew the acquisition procedure.

Switch off the amplifier. Then switch on the amplifier again, enable the Cogging compensation command and execute the Save parameters to EEPROM procedure.

controller and the High Bandwidth, then execute the Auto-tuning procedure.

The motor must not be disturbed during the cogging force acquisition procedure.

At the amplifier power up the cogging force compensation is only effective after the detection of the encoder marker pulse.

When changing either the motor, the encoder or the amplifier, the cogging force acquisition procedure must be renewed.

6 - AMPLIFIER TYPES

SMT-BD2 / _ _ - _ / _ _ / _ - T - _ _

Serial link : 1 = RS 232 / 2 = RS 422

Analog input : a = 12 bit / b = 16 bit

Amplifier voltage rating: 220 VAC or 400 VAC

Amplifier current rating: 4 A to 100 A (220 VAC) or 15 A to 60 A (400 VAC)

r = Additional heatsink for 220 VAC amplifiers (total width = 18 TE)

w = Braking resistor for 220 VAC amplifiers (single-axis rack)

BS = Synchronous motor

CT = Cogging torque compensation

Chapter 8 – Appendix

Infranor SMT-BD2 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Contents

Chapter 1 - General description

1 - INTRODUCTION

2 - GENERAL DESCRIPTION

3 - REFERENCE TO THE STANDARDS

4 - REFERENCE TO OTHER DOCUMENTS

Chapter 2 – Specifications

1 - TECHNICAL SPECIFICATIONS

- CURRENT RATINGS FOR THE 220 VAC AMPLIFIER VERSION

1.3 - OTHER SPECIFICATIONS

2 - BLOCK DIAGRAM

3 - MAIN PROTECTIONS

3.2 - FUSE PROTECTION

3.2.1 - Fuse protection for the 220 VAC amplifier version

3.2.2 - Fuse protection for the 400 VAC amplifier version

Chapter 3 - Inputs - Outputs

1 - CONNECTORS LOCATION

- RACK CONNECTORS

1.2 - AMPLIFIER CONNECTORS

2 - X5 SERIAL LINK CONNECTOR (Sub D 9 points male)

3 - X1 ENCODER FEEDBACK CONNECTOR (Sub D 15 points female)

3.4 - X1 CONNECTOR FOR OTHER SIN/COS ENCODER CONFIGURATIONS

4 - X4 COMMAND CONNECTOR (Sub D 25 points male)

4.1 - SPECIFICATION OF THE ANALOG INPUTS / OUTPUTS

4.2 - SPECIFICATION OF THE LOGIC INPUTS / OUTPUTS

5 - X2 POSITION OUTPUT CONNECTOR (Sub D 25 points female)

Chapter 4 - Connections

1 - CONNECTION DIAGRAMS

- RACK POWER SUPPLY AND MOTOR CONNECTION

1.2 - AMPLIFIER I/O CONNECTIONS

1.2.1 - Amplifier connections with TTL encoder & HES motor feedback

1.2.2 - Amplifier connections with Absolute single turn Sin/Cos encoder feedback

2 - WIRING (according to CEI 801 and EN 55011 standards)

- GND WIRING AND GROUNDING

2.2 - MOTOR AND SENSORS CABLES

2.3 - INPUT COMMAND AND SERIAL LINK CABLES

3 - 360° SHIELD ON THE CONNECTORS

Chapter 5 - Adjustable functions

1 - HARDWARE ADJUSTMENTS

2 – ADJUSTABLE PARAMETERS

Chapter 6 - Commissioning

1 - CHECKING THE AMPLIFIER CONFIGURATION

- STANDARD AMPLIFIER CONFIGURATION

1. 2 - ENCODER CONFIGURATION

1. 3 - HALL EFFECT SENSORS CONFIGURATION

1. 4 - MOTOR THERMAL SENSOR CONFIGURATION

1.4.1 - PTC thermal sensor

1.4.2 - NTC thermal sensor

1.5 - CURRENT LOOPS ADJUSTMENTS

1.5.1 - Current loops adjustments for the 400 VAC amplifier version

1.5.2 - Current loops adjustments for the 220 VAC amplifier version

2 - PUTTING INTO OPERATION

3 - AMPLIFIER COMMISSIONING AND ADJUSTMENT

- AMPLIFIER SETUP

3.2 - MOTOR HALL EFFECT SENSORS ADJUSTMENT

3.3 - ABSOLUTE SINGLE TURN SIN/COS ENCODER ADJUSTMENT

3.4 - AMPLIFIER PARAMETER SETTING

3.5 - AMPLIFIER AUTO-TUNING WITH AN UNBALANCED LOAD

3.6 - SAVING OF THE AMPLIFIER PARAMETERS

3.7 - MOTOR PHASING AT POWER UP

3.8 – PARAMETERS ADJUSTMENT TO A LINEAR MOTOR

Chapter 7 – Fault finding

1 - SYSTEM FAULT

2 - STORED FAULTS

2.1 - "BUSY" FAULT

2.2 - "EEPROM" FAULT

2.3 - "°C MOTOR" FAULT

2.4 - "UNDERVOLT." FAULT

2.5 - "°C AMPLIFIER" FAULT

2.6 - "POWER STAGE" FAULT

2.7 - "HES" FAULT

2.8 - "ENCODER" FAULT

2.9 - "COUNTING" FAULT

2.11 - "TRACKING" FAULT

2.12 - "ADC" FAULT

3 - OPERATING PROBLEMS